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DODGE JOURNEY 2009-2010

Service Repair Manual

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

2009 ACCESSORIES AND EQUIPMENT Body - Journey

DESCRIPTION VEHICLE IDENTIFICATION Throughout this part, references to the Chrysler Corporation vehicle family identification code are used when describing a procedure that is unique to that vehicle. Refer to Vehicle Data/Vehicle Information/Vehicle Identification Number - Description . If a procedure is common to all vehicles covered in this article, no reference will be made to a vehicle family code.

WARNING WARNINGS WARNINGS

Disconnect the battery negative cable when servicing electrical components that are live when the ignition is OFF. Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, or potentially serious or fatal injury. Use an OSHA approved breathing filter when spraying paint or solvents in a confined area. Serious or fatal injury can result. Avoid prolonged skin contact with petroleum or alcohol-based cleaning solvents. Serious or fatal injury can result. Do not stand under a hoisted vehicle that is not properly supported on safety stands. Serious or fatal injury can result. Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Serious or fatal injury can result. SAFETY PRECAUTIONS

Disconnect the battery negative cable from servicing electrical components that are live when the ignition is OFF. When holes must be drilled or punched in an inner body panel, verify depth of space to the outer body panel, electrical wiring, or other components. Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the user Monday, June 04, 2012 9:23:57 9:23:47 AM

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repair area. Always have a fire extinguisher ready for use when welding. Do not use harsh alkaline-based cleaning solvents on painted or upholstered surfaces.

DIAGNOSIS AND TESTING WATER LEAKS Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away from the actual leak point, making leak detection difficult. All body sealing points should be water tight in normal wet-driving conditions. Water flowing downward from the front of the vehicle should not enter the passenger or luggage compartment. Moving sealing surfaces will not always seal water tight under all conditions. At times, side glass or door seals will allow water to enter the passenger compartment during high pressure washing or hard driving rain (severe) conditions. Overcompensating on door or glass adjustments to stop a water leak that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort. After completing a repair, water test vehicle to verify leak has stopped before returning vehicle to use. VISUAL INSPECTION BEFORE WATER LEAK TESTS

Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate part for proper procedures. WATER LEAK TESTS

WARNING: Do not use electric shop lights or tools in water test area. Serious or fatal injury can result. When the conditions causing a water leak have been determined, simulate the conditions as closely as possible. z

z

z

If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an open-ended garden hose. If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable velocity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions. If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist the right side of the vehicle. For hoisting recommendations. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .

WATER LEAK DETECTION user Monday, June 04, 2012 9:23:47 AM

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To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose cannot be positioned without being held, have someone help do the water test. Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears, find the highest point of the water track or drop. The highest point usually will show the point of entry. After leak point has been found, repair the leak and water test to verify that the leak has stopped. Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water may splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become apparent after accelerating, stopping, turning, or when on an incline. MIRROR INSPECTION METHOD

When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be used to deflect light to a limited-access area to assist in locating a leak point. BRIGHT LIGHT LEAK TEST METHOD

Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If necessary, have a helper direct a drop light over the suspected leak areas around the luggage compartment. If light is visible through a normally sealed location, water could enter through the opening. PRESSURIZED LEAK TEST METHOD

When a water leak into the passenger compartment cannot be detected by water testing, pressurize the passenger compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all doors and windows, start engine, and set heater control to high blower in HEAT position. If engine can not be started, connect a charger to the battery to ensure adequate voltage to the blower. With interior pressurized, apply dish detergent solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with spray device or soft bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point could be at that location. WIND NOISE Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal airtight under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger compartment during high cross winds. Over compensating door or glass adjustments to stop wind noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort. After a repair procedure has been performed, test vehicle to verify noise has stopped before returning vehicle to use. VISUAL INSPECTION BEFORE TESTS

Verify that floor and body plugs are in place and body components are aligned and sealed. If component user Monday, June 04, 2012 9:23:47 AM

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alignment or sealing is necessary, refer to the appropriate part for proper procedures. ROAD TESTING WIND NOISE

1. Drive the vehicle to verify the general location of the wind noise. 2. Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of tape is applied, remove tape, locate, and repair defect. POSSIBLE CAUSE OF WIND NOISE z z z z z

Moldings standing away from body surface can catch wind and whistle. Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds. Misaligned movable components. Missing or improperly installed plugs in pillars. Weld burn through holes.

STANDARD PROCEDURE BODY LUBRICATION Lubrication Requirements

Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers , liftgate, tailgate, sliding doors and hood hinges, should be lubricated periodically with a lithium based grease such as Mopar ® Spray White Lube to ensure quiet, easy operation and to protect against rust and wear. Prior to the application of any lubricant, wipe the parts clean, to remove dust and grit. After lubricating, excess oil and grease should be removed. Particular attention should also be given to hood latching components to make sure they function properly. When performing other underhood services, clean and lubricate the hood latch release mechanism and safety catch. The external lock cylinders should be lubricated twice a year, preferably in the fall and spring. Apply a small amount of a high quality lubricant such as Mopar ® Lock Cylinder Lubricant directly into the lock cylinder. Lubricant Application Door Lock Cylinders

1. Apply a small amount of lubricant directly into the lock cylinder. 2. Apply a small amount of lubricant to the key. 3. Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position. NOTE:

Do not add more lubricant.

4. Cycle the lock cylinder mechanism several times to allow the lubricant to flow throughout the cylinder. user Monday, June 04, 2012 9:23:47 AM

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5. Wipe all lubricant from exterior of lock cylinder and key. All Other Body Mechanisms

1. Clean component as described above. 2. Apply specified lubricant to all pivoting and sliding contact areas of component. Lubricant Usage

Engine Oil z z z

door hinges - hinge pin and pivot contact areas hood hinges - pivot points liftgate hinges

Mopar ® Spray White Lube or Equivalent z z z z z z z z

door check straps liftgate latches liftgate prop pivots ash receiver fuel filler door remote control latch mechanism parking brake mechanism sliding seat tracks liftgate latch

Mopar ® Multipurpose Grease or Equivalent z

all other hood mechanisms

Mopar ® Lock Cylinder Lubricant or Equivalent z z

door lock cylinders liftgate lock cylinder

BUZZ, SQUEAKS AND RATTLES Buzz, Squeaks and Rattles (BSR's) may be caused by any one or more of the following and may be corrected as indicated: z z z

Loose fasteners should be tightened to specifications. Damaged or missing clips should be replaced. Damaged trim panels should be replaced.

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z

Incorrectly installed trim panels should be reinstalled properly.

Many BSR complaints such as loose trim, can be serviced using various tapes or lubricants. Tapes including foam, flock and anti-squeak, can be used to eliminate noises caused by metal, plastic and vinyl components. Long life lubricants and greases can also be used on a variety of components. Refer to the BUZZ, SQUEAKS AND RATTLES table for materials and usage. BUZZ, SQUEAKS AND RATTLES ITEM FEATURES ITCH AND An abrasion resistant material SQUEAK TAPE thin enough to conform to most irregular surfaces. Stops most itches and squeaks. BLACK NYLON FLOCK

Nylon Flock with an aggressive acrylic adhesive. Provides for cushioning and compression fit, also isolates components. Water-resistant.

HIGH DENSITY URETHANE FOAM

Tear resistant, highly resilient and durable.

OPEN CELL FOAM TAPE

Soft foam conforms to irregular surfaces.

CLOSED CELL LOW DENSITY FOAM TAPE

Soft, conformable. Waterresistant.

NYE® GREASE 880

Long life.

KRYTOX® OIL

Long life. Will not dry out or harm plastics or rubber.

KRYTOX® GREASE

Long life. Will not dry out or harm plastics or rubber.

APPLICATIONS Between metal and metal, metal and plastic, metal and vinyl, vinyl and plastic. Interior. Examples: Trim panels and bezels. Between metal and metal, metal and plastic, vinyl and plastic. Examples: Pull cups, bezels, clips, ducts, top cover to glass, cowl panel. Between metal and metal, metal and plastic. Waterresistant. Examples: I/P, heavy metal rattles, isolating brackets. Wire harness and connector wrap. Examples: Seals, gasket, wiring, heat ducts. Wherever bulk is needed. Prevents closing flutters and rattles when applied to door watershield. Examples: Door, I/P. Suspensions. Examples: Strut bushings, sway bars. When access is not possible, oil will migrate to condition. Vinyl, rubber, plastic, metal. Examples: Convertible top bushings, pull cups trim panel inserts. Vinyl, rubber, plastic, metal, glass.

SERVICE TEMP -40° to 107° C (-40° to 225° F)

-40° to 82° C (-40° to 180° F)

-40° to 82° C (-40° to 180° F)

-40° to 82° C (-40° to 180° F) -40° to 82° C (-40° to 180° F)

-40° to 200° C (-40° to 390° F) -34° to 205° C (-30° to 400° F)

-34° to 205° C (-30° to 400° F)

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Examples: Weatherstrips, backlight and windshield moldings. PLASTIC BODY PANEL REPAIR There are many different types of plastics used in today's automotive environment. We group plastics in three different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion promoter for repair. These types of plastic are used extensively on Chrysler Motors vehicles. Always follow repair material manufacturer's plastic identification and repair procedures. Rigid Plastics:

Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and Polycarbonates. Semi-Rigid Plastics:

Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels. Flexible Plastics:

Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers. Repair Procedure:

The repair procedure for all three categories of plastics is basically the same. The one difference is the material used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic repair. Adhesion Promoter/Surface Modifier:

Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics that require the use of adhesion promoter/surface modifiers. Always follow repair material manufacturer's plastic identification and repair procedures. SAFETY PRECAUTION AND WARNINGS

WARNING:

z

z

z

Eye protection should be used when servicing components. Personal injury can result. Use an OSHA approved breathing mask when mixing epoxy, grinding, and spraying paint or solvents in a confined area. Personal injury can result. Avoid prolonged skin contact with resin, petroleum, or alcohol based solvents. Personal injury can result.

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z

NOTE:

z

z

Do not venture under a hoisted vehicle that is not properly supported on safety stands. Personal injury can result.

When holes must be drilled or cut in body panels, verify locations of internal body components and electrical wiring. Damage to vehicle can result. Do not use abrasive chemicals or compounds on undamaged painted surfaces around repair areas. Damage to finish can result.

RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES

CODE ASA ABS ABS/PC ABS/PVC BMC EMA METTON MPPO PA PET PBT/PPO PBTP

FAMILY NAME Acrylonitrile Styrene Acrylite Acrylonitrile Butadiene Styrene ABS/PC Alloy ABS/PV Alloy Bulk Molding Compound Ehtylene Methyl Acrylate/Ionomer Metton Modified Polyphenylene Oxide Polyamid Thermoplastic Polyester PBT/PPO Alloy Polybutylene Therepthalate

PBTP/EEBC Polybutylene Therepthalate/EEBC Alloy PC Polycarbonate PC/ABS PPO

PC/ABS Alloy Polyphenylene Oxide

PPO/PA PR/FV

Polyphenylene/Polyamid Fiberglass Reinforced Plastic Polystyrene

PS

COMMON TRADE NAME TYPICAL APPLICATION Lurans Consoles, Grilles Terluran

"A" Pillars, Consoles, Grilles

Pulse, Proloy, Bayblend Proloy, Pulse, Lustran, Cyclovin BMC Surlyn, EMA, Ionomer

Doors, Instrument Panels Door Panels, Grilles, Trim

Metton

Grilles, Kick Panels, Running Boards Spoiler Assembly

MPPO Zytel, Vydyne, PA, Minlon Rynite Germax PBT, PBTP, Pocan, Valox

Fender Extensions Bumper Guards, Pads

PPO/PA, GTX 910 Fiberglass, FV, PR/FV

Fenders, Quarter Panels Trim Claddings Wheel Covers, Fenders, Grilles Fascias, Rocker Panel, Moldings Tail Light Lenses, I/P Trim, Valance Panels Doors, Instrument Panels Interior Trim, Door Panels, Splash Shields, Steering Column Shroud Fenders, Quarter Panels Body Panels

Lustrex, Styron, PS

Door Panels, Dash Panels

Bexloy, "M", PBTP/EEBC Lexan, Merlon, Calibre, Makrolon PC Germax, Bay Blends, Pulse Azdel, Hostalen, Marlex, Prfax, Noryl, GTX, PPO

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RTM SMC TMC UP

Resin Transfer Molding Compound Sheet Molded Compound Transfer Molding Compound Unsaturated Polyester (Thermosetting)

EEBC

Ether/Ester Blocked CoPolymer EEBC/PBTP EEBC/Polybutylene Terepthalate EMPP Ethylene Modified Polypropylene EPDM Ethylene/Propropylene Diene Monomer EPM Ethylene/Propropylene CoPolymer MPU Foam Polyurethane PE Polyethylene

RTM

Body Panels

SMC TMC

Body Panels Grilles

SMC, BMC, TMC, ZMC, IMC, XSMC, UP EEBC

Grille Opening Panel, Liftgates, Flareside Fenders, Fender Extensions Bumpers

EEBC, PBTP, BEXLOY

Bumper, Rocker Panels

EMPP

Bumper Covers

EPDM, Nordel, Vistalon

Bumpers

EPM

Fenders

MPU Alathon, Dylan, Lupolen, Marlex Noryl, Azdel, Marlox, Dylon, Pravex

Spoilers -

PP

Polypropylene (Blends)

PP/EPDM PUR PUR/PC PVC

PP/EPDM Alloy Polyurethane PUR/PC Alloy Polyvinyl Chloride

PP/EPDM Colonels, PUR, PU Texin Apex, Geon, Vinylite

RIM

RIM, Bayflex

TPE TPO

Reaction Injected Molded Polyurethane Reinforced Reaction Injected Molded Thermo Polyethylene Thermopolyolefin

TPP TPU

Thermo-Polypropylene Thermopolyurethane,

RRIM

PUR, RRIM TPE, Hytrel, Bexloy-V Polytrope, Renflex, Santoprene, Visaflex, ETA, Apex, TPO, Shields, Claddings TPP TPU, Hytrel, Texin, Estane

Inner Fender, Spoilers, Kick Panels, A-Pillars, Door Panels, B-Pillars, Quarter Panels, Sport Bar Trim, Liftgate Trim, Decklid Trim Scuff Plates, Kick Panels, Consoles Spoilers, Grilles Fascias, Bumpers Bumpers Body Moldings, Wire Insulation, Steering Wheels Front Fascias, Modular Windows Fascias, Body Panels, Body Trims Fascias, Bumpers, Claddings Bumpers, End Caps, Telcar, Rubber, Strips, Sight, Interior B-Pillar Bumpers Bumpers, Body Side,

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Polyester

Moldings, Fenders, Fascias

PANEL SECTIONING

If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel. To bond two plastic panels together, a reinforcement must overlap both panels. The panels must be "V'd" at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag. When bonding plastic panels, Follow repair material manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured. The assembly can be held 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 necessary and, as a final step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair. PANEL REINFORCEMENT

Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing. Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semirigid or flexible repair materials should be used for semi-rigid or flexible backing reinforcement. Open meshed fiberglass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall tape used, the stronger the repair. Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar 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 desirable 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. It is recommended that sharp edges be avoided because the joint may show through after the panel is refinished. z

z

z

Panel repair for both flexible and rigid panels are basically the same. The primary difference between flexible panel repair and rigid panel repair is in the adhesive materials used. 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 damage part to its original strength and appearance without exceeding the value of the replacement part. When plastic repairs are required, it is recommended that the part be left on the vehicle when ever possible. That will save time, and the panel will remain stationary during the repair. Misalignment can

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cause stress in the repair areas and can result in future failure. VISUAL INSPECTION

Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors, and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may require partial removal of interior trim or inner panels. Identify the type of repair: Puncture or Crack - Damage that has penetrated completely through the panel. Damage is confined to one general area; a panel section is not required. However, a backer panel, open fiberglass tape, or matted material must be bonded from behind. PANEL SURFACE PREPARATION

If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area 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. Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20 degrees to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas. PANEL PATCH FABRICATIONS

A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following operation if required: 1. Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required. 2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area. 3. Apply a liberal coat of adhesive over the reinforcement mesh. If necessary apply a second or third coat of adhesive and mesh after first coat has cured. The thickness of the patch should be the same as the repair area. 4. After patch has cured, peel waxed paper or plastic from the back of the patch. 5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength. PANEL PATCH INSTALLATION user Monday, June 04, 2012 9:23:47 AM

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Make a paper or cardboard pattern the size and shape of the cutout hole in the panel. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces. Using the pattern as a guide, cut the patch to size. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper. Mix enough adhesive to cover one side of all support squares. Apply adhesive to cover one side of all support squares. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares. Position patch in cutout against support squares and adjust patch until the gap is equal along all sides. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch. Apply a coat of adhesive to the exposed ends of the support squares. Install screws to hold the patch to support squares. Tighten screws until patch surface is flush with panel surface. Allow adhesive to cure, and remove all screws. Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch. With compressed air, blow dust from around patch. Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch. Mix enough adhesive to cover the entire patch area. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair.

PATCHED PANEL SURFACING

After patch panel is installed, the patch area can be finished using the same methods as finishing other types of body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required. HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together user Monday, June 04, 2012 9:23:47 AM

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and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel.

SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION Front Seat Track To Floor Pan Bolts Front Seat Inboard Pivot Bolt Front Seat Recliner To Seat Cushion Frame Front Seat Track To Cushion Frame Bolts Front Seat Back Front Seat Back Recliner To Seat Back Front Seat Belt Buckle Anchor Nut Front Seat Belt Retractor Bolt Front Seat Belt Buckle Anchor Bolt Front Door Striker Front Door Pin Assembly JS27 Front Door Carrier Plate Front Door Hinge To Door Nuts Front Door Latch Striker Front Seat Rear Outboard Seat Track To Floor Pan Bolts Hood Hinge Bolts Hood Latch Bolts Decklid Latch Striker Rear Door Glass To Regulator Bolt Rear Door Carrier Plate Fasteners Rear Door Exterior Handle Rear Door Latch Striker Rear Door Nuts To Hinge Rear Door Latch Striker Rear Door Glass Run Fastener To Division Post Rear Door Hinge

N.m 61 40 12 12 45 12 40 38 40 15 8 6 28 28 28 15 28 22 9 8 7 20 13 28 6 28

Ft. Lbs. 45 30 9 9 34 9 29 28 29 49 20 20 20 11 20 16 62 15 20 21

In. Lbs. 133 71 97 70 115 53 -

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Rear Seat Back Outer Bracket Nuts Sunroof Module To Roof Panel

61 11

45 -

100

SPECIAL TOOLS BODY

Fig. 1: Trim Stick C-4755 Courtesy of CHRYSLER LLC

Fig. 2: Remover, Moldings C-4829-A Courtesy of CHRYSLER LLC

Fig. 3: Remover, Outer Door Belt Molding 9093 Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:47 AM

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DECKLID/HATCH/LIFTGATE/TAILGATE HANDLE, EXTERIOR, LIFTGATE Removal REMOVAL

Fig. 4: Liftgate Handle Rear Mounting Nut Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Remove the liftgate trim panel. See Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Removal. Remove the liftgate handle rear mounting nut. Place the liftgate in the closed position. Remove the mounting fasteners on the front of the liftgate handle. Disconnect the liftgate handle latch cable. Disconnect the electrical connectors and remove the liftgate handle.

Installation INSTALLATION

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Fig. 5: Liftgate Handle Rear Mounting Nut Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Connect the liftgate handle latch cable. Connect electrical connectors and seat the liftgate handle into position. Install the front liftgate handle fasteners. Place the liftgate in the up position. Install the rear liftgate handle fastener. Install the liftgate trim panel. See Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Installation.

HINGE, LIFTGATE Removal REMOVAL

NOTE:

It is not necessary to remove the liftgate to replace one or both hinges. The hinges can be replaced one at a time.

NOTE:

A suitable body sealant should be used when removing or moving the hinges.

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Fig. 6: Upper Hinge Bolts Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Place the liftgate in the full up position. Support liftgate on a suitable lifting device. Using a trim stick C-4755 or equivalent, remove the upper rear headliner trim. Mark outline of hinge on the inside of liftgate to aid in installation. Remove the upper hinge bolts (1).

Fig. 7: Lower Hinge Bolts Courtesy of CHRYSLER LLC 6. Remove the lower hinge bolts (1). user Monday, June 04, 2012 9:23:47 AM

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7. Remove hinge from vehicle. Installation INSTALLATION

Fig. 8: Lower Hinge Bolts Courtesy of CHRYSLER LLC 1. Position hinge to the vehicle. 2. Install the lower hinge bolts (1). Tighten the hinge bolts to 28 N.m (21 ft. lbs.).

Fig. 9: Upper Hinge Bolts Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:47 AM

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3. 4. 5. 6.

Align the hinge to the previously made markings. Install the upper hinge bolts (1). Tighten the hinge bolts to 28 N.m (21 ft. lbs.). Install the upper rear headliner trim. Close the liftgate and verify proper operation. See Body/Decklid/Hatch/Liftgate/Tailgate/LIFTGATE Adjustments.

LATCH, LIFTGATE Removal REMOVAL

Fig. 10: Liftgate Latch Cable Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove the liftgate trim panel. See Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Removal. Disconnect the electrical connector (2) from the latch (3). Disconnect the liftgate latch cable (1). Lower the liftgate to mid position and remove the latch mounting bolts. Remove the liftgate latch from the vehicle.

Installation INSTALLATION

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Fig. 11: Liftgate Latch Cable Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Position the liftgate latch to the liftgate. Install the mounting fasteners. Tighten the bolts to 28 N.m (21 ft. lbs.). Connect the liftgate latch cable. Connect the electrical connector to the latch. Install the liftgate trim panel. See Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Installation. Close the liftgate and verify proper operation. See Body/Decklid/Hatch/Liftgate/Tailgate/LIFTGATE Adjustments.

LIFTGATE Removal REMOVAL

WARNING: Do not disconnect the support rod cylinders with the liftgate closed. The support rod pistons are operated by high pressure gas. This pressure could cause damage and/or personal injury if they are removed while the pistons are compressed.

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Fig. 12: Lower Hinge Bolts Courtesy of CHRYSLER LLC 1. Open and support the liftgate. 2. Using a trim stick C-4755 or equivalent, remove the upper rear headliner trim. 3. Remove the support cylinders from the liftgate. See Body/Decklid/Hatch/Liftgate/Tailgate/PROP, Gas - Removal. 4. Disconnect the wire harnesses and the washer hose. 5. Using a grease pencil or equivalent, mark the hinge location. 6. Remove the liftgate to body fasteners (1) and remove liftgate from vehicle. Installation INSTALLATION

NOTE:

A suitable body sealant should be used when removing or moving the hinges.

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Fig. 13: Lower Hinge Bolts Courtesy of CHRYSLER LLC 1. Position the liftgate onto the vehicle using the reference marks made during the Removal procedure and install the body fasteners (1). 2. Tighten the bolts to 28 N.m (21 ft. lbs.). 3. Connect the wire harness and washer hose. 4. Install the support struts. See Body/Decklid/Hatch/Liftgate/Tailgate/PROP, Gas - Installation. 5. Install the upper rear headliner trim. 6. Close the liftgate and verify proper operation. See Body/Decklid/Hatch/Liftgate/Tailgate/LIFTGATE Adjustments. Adjustments ADJUSTMENTS

NOTE:

The position of the liftgate can be adjusted upward or downward by the use of slots in the hinge. An inward or outward adjustment is achieved by use of slots in the body. If an inward or outward adjustment is needed, use a body sealer on the hinge to body mating surface.

In/out

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Fig. 14: Lower Hinge Bolts Courtesy of CHRYSLER LLC 1. Using a trim stick C-4755 or equivalent, remove the upper rear headliner trim. 2. For the upper lift gate adjustments, loosen the six hinge to header bolts (1) and adjust to specifications. See Body/Body Structure/Gap and Flush - Specifications 3. Tighten the hinge bolts to 28 N.m (21 ft. lbs.).

Fig. 15: Striker Screws Courtesy of CHRYSLER LLC 4. For the lower lift gate adjustments, loosen the striker screws (1) and adjust to specifications. See Body/Body Structure/Gap and Flush - Specifications user Monday, June 04, 2012 9:23:47 AM

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5. Tighten the striker screws to 28 N.m (21 ft. lbs.). 6. Position the upper rear headliner trim and seat fully. Up/Down and Left/Right

Fig. 16: Upper Hinge Bolts Courtesy of CHRYSLER LLC 1. Loosen the hinge to liftgate bolts (2).

Fig. 17: Striker Screws Courtesy of CHRYSLER LLC 2. Loosen the striker screws (1). user Monday, June 04, 2012 9:23:47 AM

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3. Adjust the liftgate up/down position and tighten the hinge bolts to 28 N.m (21 ft. lbs.). See Body/Body Structure/Gap and Flush - Specifications 4. Confirm the lower liftgate in/out position and tighten the striker screws to 28 N.m (21 ft. lbs.). PANEL, TRIM, LIFTGATE Removal REMOVAL

1. Remove the left and right side trim panels. 2. Using a trim stick C-4829A or equivalent, separate the push-pin fasteners and remove the upper trim panel. 3. Remove the two lower screws. 4. Remove the lower trim panel and disconnect the electrical connector. Installation INSTALLATION

1. 2. 3. 4.

Connect the electrical connector and install the lower trim panel. Install the two lower screws. Install the left and right side trim panels. Position the upper trim into place and seat the push pin fasteners fully.

PROP, GAS, LIFTGATE Removal REMOVAL

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Fig. 18: SUPPORT CYLINDER REMOVAL Courtesy of CHRYSLER LLC 1. Open liftgate. 2. Using a small flat bladed tool or equivalent, release the retaining clips while pulling the ball socket away from the ball stud.

Fig. 19: SUPPORT CYLINDER RETAINING CLIP Courtesy of CHRYSLER LLC 3. Remove the gas prop-rod lock caps. 4. Remove the support cylinder. user Monday, June 04, 2012 9:23:47 AM

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Installation INSTALLATION

Fig. 20: SUPPORT CYLINDER RETAINING CLIP Courtesy of CHRYSLER LLC 1. Make sure the retaining clips are seated into the ball socket (2) fully. 2. Install the support cylinder over the ball studs with the thin end connected to the liftgate and the retaining clips snapping into place. STRIKER, LIFTGATE LATCH Removal REMOVAL

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Fig. 21: Striker Screws Courtesy of CHRYSLER LLC 1. Open the liftgate. 2. Remove screws attaching liftgate striker to floor pan (1) and remove the striker. Installation INSTALLATION

Fig. 22: Striker Screws Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:47 AM

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1. Install the striker (2) and install the bolts (1). 2. Tighten the bolts to 28 N.m (21 ft. lbs.). 3. Adjust the striker if needed. See Body/Decklid/Hatch/Liftgate/Tailgate/STRIKER - Adjustments. Adjustments ADJUSTMENT

1. Using a grease pencil or equivalent, mark the position of the striker to aid in adjustment. 2. Loosen the striker bolts. 3. Change the striker position to adjust the lower liftgate gap and flush measurement. See Body/Body Structure/Gap and Flush - Specifications 4. Tighten the bolts to 28 N.m (21 ft. lbs.).

DOOR - FRONT DOOR Removal REMOVAL

1. 2. 3. 4.

Open and support door on a suitable lifting device. Mark hinges attachment locations with a grease pencil or other suitable device to aid installation. Disengage wire connector at hinge A-pillar. Remove the nuts attaching the door to the door hinges and remove the door from the vehicle.

Installation INSTALLATION

1. Position door onto the door hinges and install the nuts. Tighten nuts to 13 N.m (115 in.lbs.) 2. Connect wire connector at hinge pillar. 3. Verify door fit and operation. Adjust the door for flushness and parallel gaps as necessary. See Body/Door - Front/DOOR - Adjustments. Adjustments ADJUSTMENTS-FRONT DOOR

1. 2. 3. 4.

Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. See Body/Body Structure/Gap and Flush - Specifications. If door needs to be adjusted Fore/Aft loosen A-pillar to hinge bolts. If door needs to be adjusted In/Out loosen door to hinge nuts.

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5. If in/out alignment can not be achieved, it may be necessary to enlarge (drill) the hinge/door flange holes to 12.5 mm (1/2 inch) maximum. 6. This may allow extra movement to achieve the proper alignment. 7. Remove door and hinge as necessary. GLASS, DOOR Removal REMOVAL

Fig. 23: Door Trim Panel & Window Switches Courtesy of CHRYSLER LLC 1. Remove door trim panel and re-install the window switches, if equipped. See Body/Door Front/PANEL, Door Trim - Removal 2. Remove the interior window trim molding. See Body/Door - Front/MOLDING - Removal 3. Remove the door speaker. Refer to Electrical - Audio and Video/Audio and Video/SPEAKER Removal 4. Drill a hole large enough to get a small punch through into the carrier plate (3). 5. Lower glass to approximately mid position and line up the glass lift plates (1) with the holes (2 and 3). 6. Using a punch or equivalent, press tabs releasing glass from window regulator (2 and 3).

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Fig. 24: GLASS HOLES Courtesy of CHRYSLER LLC 7. Remove glass from channel. 8. Raise glass (1) upward and out of the opening at top of door. Installation INSTALLATION

Fig. 25: Glass Holes Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:47 AM

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1. 2. 3. 4.

Lower glass (1) down and in the opening at top of door. Slide glass downward making sure the glass holes properly lock into snaps (1). Install the interior window trim molding. See Body/Door - Front/MOLDING - Installation Install the door speaker. Refer to Electrical - Audio and Video/Audio and Video/SPEAKER Installation 5. Install door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. HANDLE, EXTERIOR Removal REMOVAL

Fig. 26: DOOR HANDLE Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Place the door glass in the full up position. Remove door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. Disconnect latch rods. Remove fasteners (2) attaching door handle (1) to outer door panel. Remove outside door handle from door.

Installation INSTALLATION

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Fig. 27: DOOR HANDLE Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Insert tip of handle (1) towards front of door through handle opening in door outer. Pull handle at rear as if to open to swing handle into opening. Install fasteners (2) into sheet metal and into rear side of door handle. Tighten to 7 N.m (62 in. lbs.) Install door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. Verify door handle operation. Adjust door latch as necessary. See Body/Door - Front/LATCH, Door Adjustments.

HANDLE, INTERIOR Removal REMOVAL

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Fig. 28: Door Handle Cable Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove trim panel from door. See Body/Door - Front/PANEL, Door Trim - Removal Remove mounting fastener (1). Remove the interior door handle from door module. Disconnect the door handle cable (2).

Installation INSTALLATION

Fig. 29: Door Handle Cable user Monday, June 04, 2012 9:23:48 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Connect the interior handle cable (2) to the handle. Position the handle to the door module ensuring that the handle is aligned correctly. Install the mounting fastener (1). Install the door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation.

HINGE, DOOR Removal REMOVAL

Fig. 30: Hinge Courtesy of CHRYSLER LLC 1. Remove front door from vehicle. See Body/Door - Front/DOOR - Removal 2. Transfer door to bench. 3. Mark position of upper hinge (3) and lower hinge (4) on the upper A-pillar and lower A-pillar with a grease pencil or other suitable device to ease installation. 4. Remove bolts attaching hinge to door the upper A-pillar and lower A-pillar frame and remove the hinge. Installation INSTALLATION

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Fig. 31: Hinge Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

If necessary, paint new door hinge prior to installation. Loosely install bolts attaching hinge to lower A-pillar. Align hinges to marks made previously and tighten all bolts. Tighten bolts to 28 N.m (21 ft. lbs.) torque. Install the front door. See Body/Door - Front/DOOR - Installation. Verify door fit and operation. Adjust door hinge for proper door alignment, if necessary. See Body/Door - Front/DOOR - Adjustments.

LATCH, DOOR Removal REMOVAL

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Fig. 32: Latch Cable & Rods Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove the door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. Remove the door module. See Body/Door - Front/PLATE, Carrier - Removal. Remove the latch assembly from the rear of the door module by disengaging the clips. Disconnect the latch cable (1) and rods (2) from the latch assembly.

Installation INSTALLATION

CAUTION: Do not close door before adjusting the door latch. Door may fail to reopen.

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Fig. 33: Latch Cable & Rods Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Position the latch assembly to the door module. Connect the latch cable (1) and rods (2) to the latch assembly. Snap the latch assembly into place onto the door module. Install the door module. See Body/Door - Front/PLATE, Carrier - Installation. Install the door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation.

Adjustments ADJUSTMENTS

1. Insert a suitable Allen wrench through the elongated slot in door end frame and loosen bolt 1/2 to one full turn. 2. Cycle outside door handle twice. 3. Tighten adjusting screw. 4. Verify latch operation. MOLDING, INTERIOR WINDOW TRIM Removal REMOVAL

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Fig. 34: Push-Pin Style Retainers From Interior Window Trim Molding Courtesy of CHRYSLER LLC 1. Remove the door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. 2. Remove the push-pin style retainers (2) from the front and rear of the interior window trim molding (3). 3. Remove the molding from the vehicle. Installation INSTALLATION

Fig. 35: Push-Pin Style Retainers From Interior Window Trim Molding Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. Position the interior window trim molding (3) to the door (1). 2. Install the push-pin style fasteners (2) to the front and rear of the molding. 3. Install the door trim panel. MOLDING, OUTER BELT Removal REMOVAL

Fig. 36: Front Door Belt Molding Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Lower the window to the full down position. Remove the front door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. Remove the rear mounting fastener. Remove the front door belt molding (1) by carefully pulling up on the molding and remove from the front door (4).

Installation INSTALLATION

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Fig. 37: Front Door Belt Molding Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the front door belt molding (1) to the front door (4). Install the rear mounting fastener. Install the front door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. Verify proper window operation.

PANEL, DOOR TRIM Removal REMOVAL

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Fig. 38: Trim Panel On Door Courtesy of CHRYSLER LLC 1. Remove pull handle screw. 2. Remove screw from inside door handle. 3. Remove the power window controls. Refer to Electrical - Power Systems/Power Windows/SWITCH, Power Window - Removal . 4. Using trim stick C-4755, pry trim panel from door (1). 5. Transfer trim panel (2) to bench Installation INSTALLATION

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Fig. 39: Trim Panel On Door Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Position door trim panel near to door. Raise trim panel such that the backside of trim edge can be engaged with inner belt molding. Press downward on top edge of trim panel while rotating bottom edge of panel towards door. Position the locators at the top of the backside of the trim panel into the corresponding sheet metal holes ensuring fit. Install the screw to the interior handle cover. Install the screw to the pull handle. Snap screw covers closed. Install the power window controls. Refer to Electrical - Power Systems/Power Windows/SWITCH, Power Window - Installation . Close door window.

PLATE, CARRIER Removal REMOVAL

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Fig. 40: Door Module & Door Latch Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8.

Remove the door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. Remove the front door window. See Body/Door - Front/GLASS, Door - Removal. Disconnect the electrical connectors on the door module and the door latch assembly. Remove the wiring harness from the door module. Disconnect the exterior door handle connecting rods. Remove the door latch fasteners (1). Remove the door module mounting fasteners (4). Carefully remove the door module (3) by raising the front and lowering the rear of the door module while pulling away from the door.

Installation INSTALLATION

Fig. 41: Door Module & Door Latch Assembly Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. 2. 3. 4. 5. 6. 7. 8.

Position the door module (3) into the door (2). Install the door module mounting fasteners (4). Install the door latch fasteners (1). Connect the exterior door handle connecting rods. Install the wiring harness to the door module and connect all electrical connectors. Install the front door window. See Body/Door - Front/GLASS, Door - Installation. Install the door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. Verify latch adjustments and adjust as necessary. See Body/Door - Front/LATCH, Door Adjustments.

REGULATOR, WINDOW Removal REMOVAL

Fig. 42: Regulator Mounting Fasteners Courtesy of CHRYSLER LLC 1. Remove door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. 2. Remove the door module assembly. See Body/Door - Front/PLATE, Carrier - Removal. 3. Remove the power window lift motor. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Removal . 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Installation INSTALLATION

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Fig. 43: Regulator Mounting Fasteners Courtesy of CHRYSLER LLC 1. Position regulator on door module assembly and install mounting fasteners. 2. Install the power window motor. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Installation . 3. Install the door module assembly. See Body/Door - Front/PLATE, Carrier - Installation. 4. Install door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. STRIKER, DOOR LATCH Removal REMOVAL

NOTE:

Be sure to check for any shims between door latch striker and B-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation.

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Fig. 44: Latch Striker Courtesy of CHRYSLER LLC 1. Mark outline of door latch striker on B-pillar to aid in installation. 2. Remove mounting fasteners attaching door latch striker to B-pillar. 3. Remove latch striker from vehicle. Installation INSTALLATION

Fig. 45: Latch Striker Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. 2. 3. 4. 5.

Position door latch striker and any shims on vehicle. Loosely install mounting fasteners attaching latch striker to B-pillar. Align latch striker to marks on B-pillar made previously. Tighten all fasteners. Verify door fit and operation. Adjust door latch striker as necessary. See Body/Door - Front/LATCH, Door - Adjustments.

DOORS - REAR DOOR, REAR Removal REMOVAL

Fig. 46: Door Fasteners Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Open and support door on a suitable lifting device. Mark hinges attachment locations with a grease pencil or other suitable device to aid installation. Disengage wire connector at hinge B-pillar. Remove the nuts attaching the door to the door hinges and remove the door from the vehicle.

Installation INSTALLATION

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Fig. 47: DOOR FASTENERS Courtesy of CHRYSLER LLC 1. Position door onto the door hinges and install the nuts. Tighten nuts to 13 N.m (115 in.lbs.) 2. Connect wire connector at hinge pillar. 3. Verify door fit and operation. Adjust the door for flushness and parallel gaps as necessary. See Body/Door - Front/DOOR - Adjustments. Adjustments REAR DOOR

1. 2. 3. 4. 5.

Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. See Body/Body Structure/Gap and Flush - Specifications. If door needs to be adjusted Fore/Aft loosen B-pillar to hinge bolts. If door needs to be adjusted In/Out loosen door to hinge nuts. If door alignment can not be achieved, it maybe necessary to enlarge (drill) the hinge flange holes to 12.5 mm (1/2 inch). 6. This may allow extra movement to achieve the proper alignment. 7. Remove door and hinge as necessary.

GLASS, DOOR Removal REMOVAL

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Fig. 48: Glass Lift Plates Courtesy of CHRYSLER LLC 1. Remove door trim panel and re-install the window switches, if equipped. See Body/Doors Rear/PANEL, Rear Door Trim - Removal 2. Remove the interior window trim molding. See Body/Doors - Rear/MOLDING - Removal 3. Remove the door speaker. Refer to Electrical - Audio and Video/Audio and Video/SPEAKER Removal 4. Drill a hole large enough to get a small punch through into the carrier plate (2). 5. Lower glass to approximately mid position and line up the glass lift plates (4) with the holes (1 and 2). 6. Using a punch or equivalent, press tabs releasing glass from window regulator (1 and 2). 7. Remove glass from channel by rotating the front of the glass up 90° and carefully pulling the glass up and out of the door. Installation INSTALLATION

1. With the front of the glass in the up position, carefully lower the glass into the door. 2. Slowly rotate the front of the glass downward 90° as the glass is being lowered into the glass run channels, making sure the glass is seated properly into the window weatherstrips. 3. Slide glass downward make sure the glass holes properly lock into snaps. 4. Install the interior window trim molding. See Body/Doors - Rear/MOLDING - Installation 5. Install the door speaker. Refer to Electrical - Audio and Video/Audio and Video/SPEAKER Installation 6. Install door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation HANDLE, EXTERIOR user Monday, June 04, 2012 9:23:48 AM

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Removal REMOVAL

1. 2. 3. 4. 5.

Move the glass to the full up position. Remove the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. Disconnect the link rod from the door handle. Remove the mounting fasteners. Remove the handle from the door.

Installation INSTALLATION

1. 2. 3. 4. 5.

Place the door handle into position in the door. Install the mounting fasteners. Connect the link rod to the door handle. Install the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation. Verify proper operation.

HANDLE, INTERIOR Removal REMOVAL

1. 2. 3. 4.

Remove the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. Remove the mounting fastener. Disconnect the door handle cable from the interior handle. Remove the handle.

Installation INSTALLATION

1. 2. 3. 4. 5.

Connect the interior door handle cable. Align the handle to the door module assembly. Install the mounting fastener. Install the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation. Verify proper operation.

HINGE, DOOR Removal user Monday, June 04, 2012 9:23:48 AM

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REMOVAL

Fig. 49: Door Fasteners Courtesy of CHRYSLER LLC 1. Remove the door. See Body/Doors - Rear/DOOR, Rear - Removal. 2. Mark hinge attachment locations with a grease pencil or other suitable device on the B-pillar. 3. Remove the nuts and remove the hinges. Installation INSTALLATION

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Fig. 50: Door Fasteners Courtesy of CHRYSLER LLC NOTE: 1. 2. 3. 4.

If necessary, paint new door hinge prior to installation.

Loosely install bolts attaching hinge to lower B-pillar. Align hinge to marks made previously and tighten bolts and nuts to 28 N.m (20 ft. lbs.). Install the rear door. See Body/Doors - Rear/DOOR, Rear - Installation. Verify door fit and operation. Adjust door hinge for proper door alignment, as necessary. See Body/Doors - Rear/DOOR, Rear - Adjustments.

LATCH, DOOR Removal REMOVAL

Fig. 51: Latch Cable & Rods Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. Remove the door module assembly. Remove the latch assembly from the rear of the door module by disengaging the clips. Disconnect the latch cable and rods from the latch assembly.

Installation INSTALLATION

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Fig. 52: Latch Cable & Rods Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Position the latch assembly to the door module. Connect the latch cable and rods to the latch assembly. Snap the latch assembly into place onto the door module. Install the door module. Install the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation. Verify proper operation and adjust as necessary. See Body/Doors - Rear/LATCH, Door - Adjustments.

Adjustments ADJUSTMENTS

1. Insert a suitable Allen wrench through the elongated slot in door end frame and loosen bolt 1/2 to one full turn. 2. Cycle outside door handle twice. 3. Tighten adjusting screw. 4. Verify latch operation. MOLDING, INTERIOR WINDOW TRIM Removal REMOVAL

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Fig. 53: Interior Window Trim Molding Courtesy of CHRYSLER LLC 1. Remove the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. 2. Remove the push-pin style retainers (3) from the front and rear of the interior window trim molding (2). 3. Remove the window trim molding from the rear door (1). Installation INSTALLATION

Fig. 54: Interior Window Trim Molding Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. Position the interior window trim molding (2) to the door (1). 2. Install the push-pin style fasteners (3) to the front and rear of the molding. 3. Install the door trim panel. MOLDING, OUTER BELT Removal REMOVAL

Fig. 55: Front Door Belt Molding Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Lower the window to the full down position. Remove the rear door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. Remove the front and rear mounting fasteners. Remove the rear door belt molding (2) by carefully pulling up on the molding and remove from the rear door (3).

Installation INSTALLATION

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Fig. 56: Front Door Belt Molding Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the rear door belt molding (2) to the rear door (3). Install the front and rear mounting fasteners. Install the rear door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation. Verify proper window operation.

PANEL, REAR DOOR TRIM Removal REMOVAL

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Fig. 57: Trim Panel From Door Assembly Courtesy of CHRYSLER LLC 1. Remove fastener located in pull handle. 2. Remove fastener near inside door handle. 3. Using trim stick C-4755 or equivalent, gently pry upward on door trim panel (1) disengaging trim panel from door run. 4. Disconnect the power window switch if equipped. 5. Remove trim panel from door assembly. Installation INSTALLATION

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Fig. 58: Trim Panel From Door Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install trim panel (1) to door assembly. Connect the power window switch if equipped. Install fastener located in pull handle. Install fastener near inside door handle.

PLATE, CARRIER Removal REMOVAL

Fig. 59: Door Module & Door Latch Assembly Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. 2. 3. 4. 5. 6. 7. 8.

Remove the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. Remove the rear door window. See Body/Doors - Rear/GLASS, Door - Removal. Disconnect the electrical connectors on the door module and the door latch assembly. Remove the wiring harness from the door module. Disconnect the exterior door handle connecting rods. Remove the door latch fasteners (1). Remove the door module mounting fasteners (4). Carefully remove the door module (3) by raising the front and lowering the rear of the door module while pulling away from the door.

Installation INSTALLATION

Fig. 60: Door Module & Door Latch Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8.

Position the door module (3) into the door (2). Install the door module mounting fasteners (4). Install the door latch fasteners (1). Connect the exterior door handle connecting rods. Install the wiring harness to the door module and connect all electrical connectors. Install the rear door window. See Body/Doors - Rear/GLASS, Door - Installation. Install the door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Installation. Verify latch adjustments and adjust as necessary. See Body/Door - Front/LATCH, Door Adjustments.

REGULATOR, WINDOW Removal user Monday, June 04, 2012 9:23:48 AM

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REMOVAL

1. Remove door trim panel. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. 2. Remove the door module assembly. See Body/Doors - Rear/PANEL, Rear Door Trim - Removal. 3. Remove the power window lift motor. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Removal 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Installation INSTALLATION

1. Install regulator to door module assembly. 2. Install the regulator mounting fasteners. 3. Install the power window lift motor. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Removal . 4. Install the door module assembly. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Removal . 5. Install door trim panel. Refer to Electrical - Power Systems/Power Windows/MOTOR, Window Regulator - Removal . 6. Verify Proper operation of the window. STRIKER, DOOR LATCH Removal REMOVAL

NOTE:

Be sure to check for any shims between door latch striker and C-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation.

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Fig. 61: Latch Striker Courtesy of CHRYSLER LLC 1. Mark outline of door latch striker on C-pillar. 2. Remove bolts attaching door latch striker to C-pillar. 3. Remove door latch striker from vehicle. Installation INSTALLATION

Fig. 62: Latch Striker Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. 2. 3. 4.

Position door latch striker and any shims on vehicle. Loosely install screws attaching latch striker to C-pillar. Align latch striker to marks on C-pillar and tighten bolts to 20 N.m (14.8 ft. lbs.). Verify door fit and operation. Adjust door latch striker as necessary. See Body/Doors - Rear/LATCH, Door - Adjustments

EXTERIOR BRACE, WHEELHOUSE Removal REMOVAL

1. Open the hood.

Fig. 63: COWL TOP SCREEN Courtesy of CHRYSLER LLC 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

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Fig. 64: COWL SCREEN Courtesy of CHRYSLER LLC 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3).

Fig. 65: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 5. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 6. Remove the wheelhouse brace (2). Installation user Monday, June 04, 2012 9:23:48 AM

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INSTALLATION

Fig. 66: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 1. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Fig. 67: COWL SCREEN Courtesy of CHRYSLER LLC 2. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in user Monday, June 04, 2012 9:23:48 AM

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place. 3. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Installation

Fig. 68: COWL TOP SCREEN Courtesy of CHRYSLER LLC 4. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). CLADDING, BODY Removal REMOVAL

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Fig. 69: Body Cladding Courtesy of CHRYSLER LLC 1. Molding, Roof 2. Tape, C-pillar Molding 3. Tape, B-pillar Rear Molding 4. Tape, B-pillar Front Molding

5. Tape, A-pillar Molding 6. Applique, Exterior Mirror 7. Molding, Front Window Belt 8. Molding, Rear Window Belt

1. Warm the effected adhesive type molding and body metal to approximately 38°C (100°F) using a suitable heat lamp or heat gun. 2. Pull stick-on molding from painted surface. Installation INSTALLATION

1. Clean body surface with MOPAR® Super Kleen solvent or equivalent. Wipe surface dry with lint free cloth. 2. Remove protective cover from tape on back of molding. Apply molding to body below the masking tape guide. 3. Remove masking tape guide and firmly press molding to body surface to assure adhesion. COVER, COWL PANEL, INNER Removal REMOVAL

1. Open the hood. user Monday, June 04, 2012 9:23:48 AM

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Fig. 70: COWL TOP SCREEN Courtesy of CHRYSLER LLC 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

Fig. 71: COWL SCREEN Courtesy of CHRYSLER LLC 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. user Monday, June 04, 2012 9:23:48 AM

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5. Remove the cowl screen (3). Installation INSTALLATION

Fig. 72: COWL SCREEN Courtesy of CHRYSLER LLC 1. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 2. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Installation

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Fig. 73: COWL TOP SCREEN Courtesy of CHRYSLER LLC 3. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). COVER, COWL PANEL, OUTER Removal REMOVAL

1. Open the hood.

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Fig. 74: COWL TOP SCREEN Courtesy of CHRYSLER LLC 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). 3. Remove the cowl top screen (3). Installation INSTALLATION

Fig. 75: COWL TOP SCREEN Courtesy of CHRYSLER LLC 1. Position the cowl top screen (3). 2. Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). DOOR, FUEL FILL Removal REMOVAL

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Fig. 76: FUEL FILLER DOOR Courtesy of CHRYSLER LLC 1. Open fuel filler door (2). 2. Remove the two Torx screws (1). 3. Remove fuel filler door (2) from vehicle. Installation INSTALLATION

Fig. 77: FUEL FILLER DOOR Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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1. Place fuel filler door (2) into position. 2. Install the two Torx screws (1). 3. Ensure that door operates properly. FENDER, FRONT Removal REMOVAL

1. Remove fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Removal 2. Remove headlamp assembly. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/UNIT, Front Lamp - Removal . 3. Remove inner splash shield. See Body/Exterior/SHIELD, Splash - Removal.

Fig. 78: FENDER DOG LEG TO BODY Courtesy of CHRYSLER LLC 4. Remove fender (2) dogleg to body fastener (1).

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Fig. 79: FENDER SUPPORT BRACKET Courtesy of CHRYSLER LLC 5. Remove fender brace (1). 6. Remove fender fastener to lower rocker panel.

Fig. 80: UPPER FENDER FASTENERS Courtesy of CHRYSLER LLC 7. Remove fasteners attaching fender to upper rail. 8. Remove fender from vehicle. Installation user Monday, June 04, 2012 9:23:48 AM

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INSTALLATION

1. Place fender in position on vehicle.

Fig. 81: UPPER FENDER FASTENERS Courtesy of CHRYSLER LLC 2. From inside engine compartment, start the center upper rail bolt. Install all the fasteners (1) attaching fender to upper rail and tighten.

Fig. 82: FENDER DOG LEG TO BODY Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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3. Install fender to lower cowl panel bolt. 4. Install fender to rocker panel bolt. 5. Place fascia into position.

Fig. 83: FENDER SUPPORT BRACKET Courtesy of CHRYSLER LLC 6. Install fender to fascia brace (1) fastener. 7. Install inner splash shields. See Body/Exterior/SHIELD, Splash - Installation. 8. Install headlamp assembly. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/UNIT, Front Lamp - Installation . 9. Check fender for flush and gap. 10. Continue to install fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Installation . GRILLE Description DESCRIPTION

The grille is removed as part of the front fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front Removal . MIRROR, OUTSIDE REARVIEW Removal REMOVAL

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Fig. 84: Rearview Outside Mirror Courtesy of CHRYSLER LLC 1. Remove the door trim panel. See Body/Door - Front/PANEL, Door Trim - Removal. 2. Remove the interior window trim molding as necessary to gain access to the mounting fasteners. See Body/Door - Front/MOLDING - Removal. 3. Disconnect power window mirror motor wire connector, if so equipped. 4. Disconnect manual mirror adjuster from side mirror cover, if so equipped. 5. Remove nuts attaching side view mirror to mirror flag. 6. Remove side view mirror from vehicle. Installation INSTALLATION

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Fig. 85: Rearview Outside Mirror Courtesy of CHRYSLER LLC 1. Feed power mirror wire harness through hole in mirror flag and seat grommet. Do not pull on wire harness to seat grommet, if so equipped. 2. Position side view mirror to vehicle. 3. Install nuts attaching side view mirror to mirror flag. 4. Engage push in fastener attaching power mirror wire connector to inner door panel, if so equipped. 5. Engage power mirror motor wire connector. 6. Install the interior window trim molding. 7. Install door trim panel. See Body/Door - Front/PANEL, Door Trim - Installation. MIRROR, OUTSIDE REARVIEW, GLASS Removal REMOVAL

WARNING: Always wear eye and hand protection when servicing the mirror assembly. Failure to observe these warnings may result in personal injury from broken glass. 1. Carefully pull/pry the broken glass holder from the mirror assembly. 2. Disconnect the heated mirror electrical connectors from the terminals on the mirror glass holder, if equipped. Installation INSTALLATION user

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CAUTION: It is important to make sure the motor is square to the glass holder (attaching fingers) prior to glass holder attachment, otherwise the glass holder could be installed incorrectly causing poor retention and possible repeat failure. 1. Position the new mirror glass holder to the mirror assembly. NOTE:

Position the mirror glass holder so that the moisture drain hole on the mirror glass holder assembly is facing downward.

2. Align the mirror glass holder's attaching fingers to the mirror motor housing. NOTE:

Ensure that the protective rubber cover of the mirror motor housing is positioned correctly around the bottom of the fingers area.

3. Using one hand, firmly press the mirror glass holder assembly into place while at the same time supporting the housing assembly from the backside with the other hand. NOTE:

Pressure must be applied equally over the center portion of the mirror to engage the mirror glass holder's attaching fingers to the corresponding fingers on the housing assembly. One or more clicks may be heard when finger engagement takes place.

4. Verify retention of the mirror glass holder assembly by gently pulling outward on the mirror glass holder. NAMEPLATE Removal REMOVAL

NOTE:

Exterior nameplates are attached to body panels with adhesive tape.

1. Apply a length of masking tape on the body, parallel to the top edge of the nameplate to use as a guide, if necessary. 2. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun. Do not exceed 52°C (120°F) when heating emblem. 3. Insert a plastic trim stick or a hard wood wedge behind the emblem to separate the adhesive backing from the body. 4. Clean adhesive residue from body with MOPAR® Super Kleen solvent or equivalent. Installation INSTALLATION

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1. 2. 3. 4.

Remove carrier from adhesive tape on back of emblem. Position emblem properly on body. Press emblem firmly to body with palm of hand. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52°C (120°F) when heating emblem.

RACK, LUGGAGE Removal REMOVAL

1. 2. 3. 4.

Remove the luggage rack crossbars. Remove the front and rear covers of the luggage rack rails. Remove the mounting fasteners. Carefully remove the luggage rack rails from the top of the vehicle.

Installation INSTALLATION

1. 2. 3. 4.

Carefully install the luggage rack rails to the top of the vehicle. Install the mounting fasteners. Install the front and rear covers of the luggage rack rails. Install the luggage rack crossbars.

SHIELD, SPLASH, FRONT WHEELHOUSE Removal REMOVAL

NOTE: 1. 2. 3. 4.

The front splash shields are a two piece assembly.

Remove the appropriate front wheel. Refer to Tires and Wheels - Removal Remove push pins. Remove fasteners. Remove splash shield from wheel well.

Installation INSTALLATION

1. Place splash shield up to wheelhouse opening. user Monday, June 04, 2012 9:23:48 AM

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2. Install push pins. 3. Install fasteners. 4. Install the front wheel. Refer to Tires and Wheels - Installation . SHIELD, SPLASH, REAR WHEELHOUSE Removal REMOVAL

1. 2. 3. 4.

Remove the appropriate rear wheel. Refer to Tires and Wheels - Removal . Remove push pins. Remove fasteners. Remove splash shield from wheel well.

Installation INSTALLATION

1. 2. 3. 4.

Place splash shield up to wheelhouse opening. Install push pins. Install fasteners. Install the rear wheel. Refer to Tires and Wheels - Installation .

HOOD CABLE, HOOD RELEASE Removal REMOVAL

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Fig. 86: Hood Release Handle Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove left front cowl trim panel. Remove screws (2) attaching hood release handle (1) to inner cowl panel. Disconnect the hood release cable from the latch handle. Disengage rubber grommet at lower dash panel. Disengage push-in fastener (3) attaching hood release cable (4) to dash panel.

Fig. 87: Hood Release Cable Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:48 AM

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6. Remove hood latch. See Body/Hood/LATCH, Hood - Removal. 7. Release clips (2) attaching hood release cable to left inner frame rail. 8. Remove hood release cable (1) from vehicle. Installation INSTALLATION

Fig. 88: Hood Release Handle Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Route hood release cable (4) through hole in lower dash panel and along inner frame rail. Engage rubber grommet to lower dash panel. Engage push-in fastener (3) attaching hood release cable to lower dash panel. Install screws attaching hood release cable handle (1) to inner cowl panel. Tighten screws (2) to 1.8 N.m (16 in. lbs.) torque. Install left front cowl trim panel.

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Fig. 89: Hood Release Cable Courtesy of CHRYSLER LLC 7. Engage hood release cable into clips (2) along inner frame rail. 8. Install hood latch. See Body/Hood/LATCH, Hood - Installation. HINGE, HOOD Removal REMOVAL

Fig. 90: Bolts Attaching Hood Hinge To Load Beam Inner user Monday, June 04, 2012 9:23:48 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Support hood on the side that requires hinge replacement. Mark hinge attachment locations with a grease pencil or other suitable device to aid installation. Remove cowl cover. See Body/Exterior/COVER, Cowl Panel - Removal. Remove bolts attaching hood to hinge. Remove bolts attaching hood hinge to load beam inner and remove hinge from vehicle.

Installation INSTALLATION

Fig. 91: Bolts Attaching Hood Hinge To Load Beam Inner Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7.

If necessary, paint new hinge before installation. Place hinge in position on vehicle. Install bolts to attach hood hinge to load beam inner. Install bolts to attach hood to hinge. Align all marks and secure bolts. Tighten bolts to 28 N.m (20 ft. lbs.) torque. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. 8. Install cowl cover. See Body/Exterior/COVER, Cowl Panel - Installation. 9. Verify hood latch operation. Adjust as necessary. HOOD user Monday, June 04, 2012 9:23:48 AM

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Removal REMOVAL

Fig. 92: Bolts Attaching Hood Hinge To Load Beam Inner Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Open hood (2). Mark outline of hinges on inside of hood to aid installation. Disconnect under hood lamp wire connector to engine compartment wire harness if equipped. Disconnect windshield washer hose from hood. Remove the top bolts attaching hood to hinge and loosen the bottom fasteners (1) until they can be removed by hand. 6. With assistance from a helper at the opposite side of the vehicle to support the hood, remove bottom fasteners attaching hood to hinge. 7. Remove the hood from the vehicle. 8. Transfer parts as necessary. Installation INSTALLATION

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Fig. 93: Bolts Attaching Hood Hinge To Load Beam Inner Courtesy of CHRYSLER LLC 1. 2. 3. 4.

With assistance from a helper, place hood (2) in position on vehicle. Install bottom fasteners (1) to attach hood to hinge finger tight. Install top fasteners to attach hood to hinge finger tight. Position bolts at outline marks and tighten bolts (3) to 20 N.m (15 ft. lbs.). The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. 5. Connect under hood lamp wire connector to engine compartment wire harness, if equipped. 6. Route and connect windshield washer hose to hood. 7. Verify hood latch operation and alignment. Adjust as necessary. LATCH, HOOD Removal REMOVAL

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Fig. 94: Latch Courtesy of CHRYSLER LLC 1. Release hood latch and open hood. 2. Support hood on prop rod. 3. Mark outline of hood latch on radiator support crossmember with a grease pencil or other suitable device to aid installation. 4. Remove nuts (1) attaching hood latch to upper radiator support crossmember. 5. Remove hood latch from vehicle. 6. Disengage remote release cable (2) from hood latch. See Body/Hood/CABLE, Hood Release - Removal Installation INSTALLATION

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Fig. 95: Latch Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Engage remote release cable into hood latch. Position hood latch on vehicle. Install nuts attaching hood latch onto upper radiator support crossmember. Tighten nut to 28 N.m (20 ft.lbs.) torque. Verify operation. Adjust as necessary.

INSTRUMENT PANEL BEZEL, INSTRUMENT CLUSTER Removal REMOVAL

1. Remove the left instrument panel air outlet. Refer to Heating and Air Conditioning/Distribution/OUTLET, Air - Removal . 2. Using a trim stick special tool C-4755 or equivalent, disengage clips holding the cluster bezel to instrument panel. 3. Remove cluster bezel from vehicle. Installation INSTALLATION

1. Position the cluster bezel in place and align the spring retainers with the instrument panel. 2. Hand tap cluster bezel in place ensuring proper seat. 3. Install the left instrument panel air outlet. Refer to Heating and Air Conditioning/Distribution/OUTLET, Air - Installation . BEZEL, INSTRUMENT PANEL, CENTER Removal REMOVAL

1. Using a trim stick special tool C-4755 or equivalent, disengage clips holding the center bezel to instrument panel. 2. Remove center bezel from vehicle. Installation INSTALLATION

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1. Position the center bezel in place and align the spring retainers with the instrument panel. 2. Hand tap center bezel in place ensuring proper seat. BIN, INSTRUMENT PANEL, BEVERAGE COOLER Removal REMOVAL

Fig. 96: Storage Bin Door Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Open the storage bin (3) door. Remove the interior liner. Remove the air outlet. Refer to Heating and Air Conditioning/Distribution/OUTLET, Air - Removal . Carefully remove the cooling vent inside the storage bin. Remove the cooling hose attached to vent. Using a trim stick special tool C-4755 or equivalent, disengage clips holding the storage bin to instrument panel. 7. Remove the storage bin from the vehicle.

Installation INSTALLATION

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Fig. 97: Storage Bin Door Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Install the storage bin (3) from the vehicle. Engage clips securing the storage bin to instrument panel. Install the cooling hose to vent. Install the cooling vent inside the storage bin. Install the air outlet. Refer to Heating and Air Conditioning/Distribution/OUTLET, Air - Removal . Install the interior liner.

BIN, INSTRUMENT PANEL, LOWER Removal REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Remove the center console. See Body/Interior/CONSOLE, Center - Removal. 3. Remove the push-pin retainers by pressing the center inward to release then prying the retainer out of the storage bin. 4. Remove the lower storage bin from the vehicle. Installation INSTALLATION

1. 2. 3. 4.

Install the lower storage bin to the vehicle. Install the push-pin retainers. Install the center console. See Body/Interior/CONSOLE, Center - Installation. Connect the battery negative cable.

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CAP, INSTRUMENT PANEL END Removal REMOVAL

Fig. 98: Clips Holding End Cover Courtesy of CHRYSLER LLC 1. Open front door. 2. Using a trim stick special tool C-4755 or equivalent, disengage clips holding end cover (2) to instrument panel. Installation INSTALLATION

Fig. 99: Clips Holding End Cover Courtesy of CHRYSLER LLC 1. Position end cover (2) over retaining slots and firmly snap into place. user Monday, June 04, 2012 9:23:49 AM

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2. Close front door. COVER, STEERING COLUMN OPENING Removal REMOVAL

1. Using trim stick C-4755 or equivalent, pry steering column cover disengaging tabs. 2. Remove steering column cover from instrument panel. Installation INSTALLATION

1. Place steering column cover in position. 2. Firmly press steering column cover into place engaging clips ensuring proper seat. GLOVE BOX, INSTRUMENT PANEL Removal REMOVAL

1. 2. 3. 4.

Open glove box. Push in on sides of glove box bin and lower door. Pivot glove box downward and disengage hinge hooks from instrument panel. Remove glove box.

Installation INSTALLATION

1. 2. 3. 4.

Place glove box in position. Engage hinge hooks into instrument panel and pivot glove box upward. Push in sides of glove box bin and snap glove box assembly into instrument panel. Close glove box door.

GRILLE, DEFROSTER Removal REMOVAL

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Fig. 100: Defroster Grille Courtesy of CHRYSLER LLC 1. Remove the left and right A-pillar trim panels. See Body/Interior/PANEL, A-Pillar Trim - Removal. 2. Using trim stick C4755 or equivalent, pry up on defroster grille disengaging clips. 3. Remove defroster grille from vehicle. Installation INSTALLATION

Fig. 101: Defroster Grille Courtesy of CHRYSLER LLC 1. Position the defroster grille in place and align the spring retainers with the instrument panel. 2. Hand tap defroster grille in place ensuring proper seat. 3. Install the left and right A-pillar trim panels. See Body/Interior/PANEL, A-Pillar Trim - Installation. KNEEBLOCKER user Monday, June 04, 2012 9:23:49 AM

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Removal REMOVAL

Fig. 102: Identifying Steering Column Cover Reinforcement Courtesy of CHRYSLER LLC 1. Remove the steering column cover. See Body/Instrument Panel/COVER, Steering Column Opening Removal. 2. Remove mounting fasteners. 3. Remove knee bolster from instrument panel. Installation INSTALLATION

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Fig. 103: Identifying Steering Column Cover Reinforcement Courtesy of CHRYSLER LLC 1. Place knee bolster into position. 2. Install the mounting fasteners. 3. Install the steering column cover. See Body/Instrument Panel/COVER, Steering Column Opening Installation. LATCH, GLOVE BOX DOOR Removal REMOVAL

1. Open the glove box. 2. Remove the three glove box latch screws. 3. Separate the latch from the glove box assembly. Installation INSTALLATION

1. Install the latch onto the glove box assembly. 2. Install the glove box latch screws. 3. Close glove box door. PAD, INSTRUMENT PANEL Removal REMOVAL

Fig. 104: Storage Bin Door user Monday, June 04, 2012 9:23:49 AM

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Courtesy of CHRYSLER LLC 1. Remove the A-pillar trim panels. 2. Remove the defroster grille. See Body/Instrument Panel/GRILLE, Defroster - Removal. 3. Remove the lower instrument panel storage bin. See Body/Instrument Panel/BIN, Instrument Panel Removal. 4. Remove the instrument panel end caps using a trim stick or equivalent. 5. Remove the glove box by pressing the sides of the glove box and pull down on the glove box. 6. Remove the steering column. Refer to Steering/Column - Removal . 7. Remove the instrument panel center bezel using a trim stick or equivalent. 8. Remove the knee bolster. See Body/Instrument Panel/KNEEBLOCKER - Removal. 9. Remove the instrument cluster. Refer to Electrical/Instrument Cluster - Removal . 10. Remove the radio fasteners. 11. Disconnect the electrical connectors and remove from the instrument panel. 12. Remove the beverage cooler storage bin. See Body/Instrument Panel/BIN, Instrument Panel Removal. 13. Remove the passenger air bag and mounting fasteners. Refer to Restraints/AIR BAG, Passenger Removal . 14. Remove the top pad mounting fasteners.

Fig. 105: Fasteners Located At Bottom Of Glove Box Opening Courtesy of CHRYSLER LLC 15. Remove the fasteners (1) located at the bottom of the glove box opening. 16. Remove the fasteners that secure the defrost ducts to the top pad.

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Fig. 106: Mounting Fasteners At Center Of Instrumental Panel Courtesy of CHRYSLER LLC 17. Remove the mounting fasteners (1) at the center of the IP above the radio mounting area.

Fig. 107: Mounting Fasteners At End Caps Of Instrument Panel Courtesy of CHRYSLER LLC 18. Remove the mounting fasteners at the end caps of the instrument panel. 19. Remove the top pad from the instrument panel assembly. Installation INSTALLATION

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Fig. 108: Storage Bin Door Courtesy of CHRYSLER LLC 1. Install the top pad to the instrument panel assembly.

Fig. 109: Mounting Fasteners At End Caps Of Instrument Panel Courtesy of CHRYSLER LLC 2. Install the mounting fasteners at the end caps of the instrument panel.

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Fig. 110: Mounting Fasteners At Center Of Instrumental Panel Courtesy of CHRYSLER LLC 3. Install the mounting fasteners (1) at the center of the IP above the radio mounting area. 4. Install the fasteners that secure the defrost ducts to the top pad.

Fig. 111: Fasteners Located At Bottom Of Glove Box Opening Courtesy of CHRYSLER LLC 5. Install the fasteners (1) located at the bottom of the glove box opening. 6. Install the top pad mounting fasteners. 7. Install the passenger air bag and mounting fasteners. Refer to Restraints/AIR BAG, Passenger Installation . 8. Install the beverage cooler storage bin. See Body/Instrument Panel/BIN, Instrument Panel Installation. user Monday, June 04, 2012 9:23:49 AM

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9. 10. 11. 12. 13. 14. 15. 16.

Connect the electrical connectors and install the radio to the instrument panel. Install the radio fasteners. Install the instrument cluster. Refer to Electrical/Instrument Cluster - Installation . Install the knee bolster. See Body/Instrument Panel/KNEEBLOCKER - Installation. Install the left and right cowl trim panels. Install the glove. Install the instrument panel end caps using a trim stick or equivalent. Install the lower instrument panel storage bin. See Body/Instrument Panel/BIN, Instrument Panel Installation 17. Install the defroster grille. See Body/Instrument Panel/GRILLE, Defroster - Installation. 18. Install the A-pillar trim panels. 19. Connect the battery negative cable. PANEL, INSTRUMENT Removal REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE:

LHD model shown in illustrations. RHD model similar.

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Fig. 112: Electrical Connectors Located At Left & Right A-Pillar Courtesy of CHRYSLER LLC NOTE:

Left side shown. Right side similar.

1. Disconnect and isolate the negative battery cable. 2. Remove the A-pillar trim panels. See Body/Interior/PANEL, A-Pillar Trim - Removal. 3. Disconnect the electrical connectors located at the left and right A-pillar.

Fig. 113: Defroster Grille Courtesy of CHRYSLER LLC 4. Using Trim Stick C-4755 or equivalent, disengage the clips that secure the defroster grille (1) to the top of the instrument panel and remove the grille.

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Fig. 114: Storage Bin Door Courtesy of CHRYSLER LLC 5. Using Trim Stick C-4755 or equivalent, disengage the clips that secure the steering column cover (5) to the instrument panel (2) and remove the cover. 6. Remove the steering column. Refer to Steering/Column - Removal . 7. Using Trim Stick C-4755 or equivalent, disengage the clips that secure the instrument panel center bezel (1) to the instrument panel and remove the center bezel. 8. Remove the glove box (3). 9. Remove the nut (4) that secures the instrument panel to the stud located near the blower motor.

Fig. 115: Front Door Sill Scuff Plates Courtesy of CHRYSLER LLC NOTE:

Left side shown. Right side similar.

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10. Using trim stick C-4755 or equivalent, disengage the clips (2) that secure the left and right front door sill scuff plates (1) to the door sills (3) and remove the scuff plates.

Fig. 116: Cowl Trim Panels Courtesy of CHRYSLER LLC NOTE:

Right side shown. Left side similar.

11. Using Trim Stick C-4755 or equivalent, disengage the clips (4) that secure the left and right cowl trim panels (1) to the door sills (2) and cowl (3) and remove the trim panels.

Fig. 117: Instrument Panel Electrical Connectors Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:49 AM

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12. Disconnect the instrument panel electrical connectors. 13. Disconnect the HVAC electrical connectors.

Fig. 118: Windshield Fence Nuts & Bolts Courtesy of CHRYSLER LLC 14. Remove the windshield fence nuts (1) and bolts (2).

Fig. 119: Clips Holding End Cover Courtesy of CHRYSLER LLC NOTE:

Right side shown. Left side similar.

15. Remove the center floor console. See Body/Interior/CONSOLE, Center - Removal. 16. Remove the lower instrument panel storage bin. See Body/Instrument Panel/BIN, Instrument Panel Removal. 17. Remove the two lower instrument panel bolts (3). 18. Using Trim Stick C-4755 or equivalent, remove the left and right end caps (2). 19. Remove the two bolts (1) located on each end of the instrument panel and remove the panel from the user Monday, June 04, 2012 9:23:49 AM

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vehicle. Installation INSTALLATION

NOTE:

LHD model shown in illustrations. RHD model similar.

Fig. 120: Clips Holding End Cover Courtesy of CHRYSLER LLC NOTE:

Right side shown. Left side similar.

1. Position the instrument panel into the vehicle and engage the alignment pins located on each end of the panel to the body. 2. Install the two bolts (1) to each end of the instrument panel. Tighten the bolts to 21 N.m (15 ft. lbs.). 3. Install the left and right end caps (2). Make sure the retaining clips are fully engaged. 4. Install the two lower instrument panel bolts (3). Tighten the bolts to 21 N.m (15 ft. lbs.). 5. Install the lower instrument panel storage bin. See Body/Instrument Panel/BIN, Instrument Panel Installation. 6. Install the center floor console. See Body/Interior/CONSOLE, Center - Installation.

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Fig. 121: Windshield Fence Nuts & Bolts Courtesy of CHRYSLER LLC 7. Install the windshield fence nuts (1) and bolts (2). Tighten the nuts and bolts securely.

Fig. 122: Instrument Panel Electrical Connectors Courtesy of CHRYSLER LLC 8. Connect the instrument panel electrical connectors. 9. Connect the HVAC electrical connectors.

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Fig. 123: Cowl Trim Panels Courtesy of CHRYSLER LLC NOTE:

Right side shown. Left side similar.

10. Install the left and right cowl trim panels (1) to the door sills (2) and cowl (3). Make sure the retaining clips (4) are fully engaged.

Fig. 124: Front Door Sill Scuff Plates Courtesy of CHRYSLER LLC NOTE:

Left side shown. Right side similar.

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11. Install the left and right front door sill scuff plates (1) to the door sills (3). Make sure the retaining clips (2) are fully engaged.

Fig. 125: Storage Bin Door Courtesy of CHRYSLER LLC 12. Install the nut (4) that secures the instrument panel (2) to the stud located near the blower motor. Tighten the nut securely 13. Install the glove box (3). 14. Install the instrument panel center bezel (1). Make sure the retaining clips are fully engaged. 15. Install the steering column. Refer to Steering/Column - Installation . 16. Install the steering column cover (5). Make sure the retaining clips are fully engaged.

Fig. 126: Defroster Grille Courtesy of CHRYSLER LLC 17. Install the defroster grille (1). Make sure the retaining clips are fully engaged.

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Fig. 127: Electrical Connectors Located At Left & Right A-Pillar Courtesy of CHRYSLER LLC NOTE:

Left side shown. Right side similar.

18. Connect the electrical connectors located at the left and right A-pillar. 19. Install the A-pillar trim panels. See Body/Interior/PANEL, A-Pillar Trim - Installation. 20. Reconnect the negative battery cable. PANEL, SILENCER, LOWER Removal REMOVAL

1. Remove closeout panels push pins fastening closeout panels to the bottom of the instrument panel assembly. 2. Remove closeout panels from instrument panel assembly. Installation INSTALLATION

1. Position closeout panels to the bottom of the instrument panel assembly. 2. Install push pins fastening closeout panels to instrument panel.

INTERIOR BIN, STORAGE, SECOND ROW user Monday, June 04, 2012 9:23:49 AM

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Removal REMOVAL

Fig. 128: Mounting Fasteners Securing Storage Bin To Floor Courtesy of CHRYSLER LLC 1. Open the lid to the second row storage bin and remove the inner liner. 2. Remove the mounting fasteners securing the storage bin to the floor. 3. Remove the storage bin from the vehicle. Installation INSTALLATION

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Fig. 129: Mounting Fasteners Securing Storage Bin To Floor Courtesy of CHRYSLER LLC 1. Place the storage bin into position in the vehicle. 2. Install the mounting fasteners that secure the storage bin to the floor. 3. Install the liner and close the lid. BIN, STORAGE, REAR Removal REMOVAL

Fig. 130: Storage Bin Liner Courtesy of CHRYSLER LLC 1. Remove the carpet (1) covering the storage bin. user Monday, June 04, 2012 9:23:49 AM

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2. Remove the storage bin liner (3). 3. Remove the mounting fasteners (4). 4. Remove the storage bin (5) from the vehicle. Installation INSTALLATION

Fig. 131: Storage Bin Liner Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the storage bin (5) to the vehicle. Install the mounting fasteners (4). Install the storage bin liner (3). Install the carpet (1) covering the storage bin.

BOX, STORAGE, REAR Removal REMOVAL STORAGE BOX - 5 PASSENGER

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Fig. 132: Storage Box Mounting Fasteners Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove the mat covering the storage box. Remove the load floor assembly (3). Remove the storage box mounting fasteners (2). Remove the storage box (1) from the vehicle.

STORAGE BOX - 7 PASSENGER

Fig. 133: Storage Box Liner Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove the retainers on the seat back gap hider to the rear storage box. Open the storage bin lid. Remove the storage box liner (2), if equipped. Remove the storage box mounting fasteners (4). Remove the storage box (1) from the vehicle.

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Installation INSTALLATION STORAGE BOX - 5 PASSENGER

Fig. 134: Storage Box Mounting Fasteners Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the storage box (1) to the vehicle. Install the storage box mounting fasteners (2). Install the load floor assembly (3). Install the mat covering the storage box.

STORAGE BOX - 7 PASSENGER

Fig. 135: Storage Box Liner Courtesy of CHRYSLER LLC 1. Install the storage box (1) to the vehicle. user Monday, June 04, 2012 9:23:49 AM

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2. Install the storage box mounting fasteners (4). 3. Install the storage box liner (2). 4. Install the seat back gap hider retainers to the rear storage box. CARPET, FLOOR Removal REMOVAL

Fig. 136: Floor Carpet Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Remove door sill trim. See Body/Interior/PLATE, Scuff - Removal Remove front seats. See Body/Seats/SEAT - Removal. Remove the second row seats. See Body/Seats/SEAT - Removal Remove the third row seats, if equipped. See Body/Seats/SEAT - Removal. Remove B-pillar trim panels as necessary to clear carpet. Remove cowl trim panels. See Body/Interior/PANEL, Cowl Trim - Removal Remove center console. See Body/Interior/CONSOLE, Center - Removal Remove the rear storage bin. See Body/Interior/BIN, Storage - Removal. Remove the rear storage box. See Body/Interior/BOX, Storage - Removal. Pull carpet from behind brake pedal, accelerator pedal and remove the front left carpet (5). Pull carpet from behind the HVAC and remove the front right carpet (2). Remove the rear carpet from the vehicle (3).

Installation INSTALLATION

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Fig. 137: Floor Carpet Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Install the rear carpet to the vehicle (3). Install the front right carpet (2) and push the carpet behind the HVAC. Install the front left carpet (5) and push the carpet behind brake pedal and accelerator pedal. Install the rear storage box. See Body/Interior/BOX, Storage - Installation. Install the rear storage bin. See Body/Interior/BIN, Storage - Installation. Install center console. See Body/Interior/CONSOLE, Center - Installation. Install cowl trim panels. See Body/Interior/PANEL, Cowl Trim - Installation. Install B-pillar trim panels as necessary to clear carpet. Install the third row seats, if equipped. See Body/Seats/SEAT - Installation. Install the second row seats. See Body/Seats/SEAT - Installation. Install front seats. See Body/Seats/SEAT - Installation Install door sill trim. See Body/Interior/PLATE, Scuff - Installation.

CONSOLE, CENTER Removal REMOVAL

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Fig. 138: CENTER CONSOLE Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove the shifter bezel and shifter knob. Place the parking brake handle (6) in the up position. Remove the side mounting fasteners (1). Open the console lid (3) and remove the four mounting fasteners (2). Carefully pry up on the front of the center console until the retainers disengage from the instrument panel center console (5). 6. Disconnect the electrical connector (4) at the back of the center floor console. 7. Remove the center floor console from the vehicle. Installation INSTALLATION

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Fig. 139: CENTER CONSOLE Courtesy of CHRYSLER LLC 1. Install the center floor console into position to the vehicle. 2. Connect the electrical connector (4) at the back of the center floor console. 3. Carefully depress the front of the center console until the retainers engage to the instrument panel center console (5). 4. Install the four mounting fasteners (2) located in the storage bin area. 5. Install the side mounting fasteners (1). 6. Install the shifter bezel and shifter knob. 7. Lower the parking brake handle (6). HEADLINER Removal REMOVAL

NOTE:

Do not remove the headliner from the vehicle, unless replacing with a new headliner or it is absolutely necessary.

1. Remove the sun visors by removing the mounting fasteners and disconnect the electrical connector, if equipped. 2. Remove the sun visor support mounting fasteners and remove the support from the headliner. 3. Remove the A-pillar trim panel. See Body/Interior/PANEL, A-Pillar Trim - Removal. 4. Remove the B-pillar trim panel. See Body/Interior/PANEL, B-Pillar Trim - Removal. 5. Remove the C-pillar trim panel. See Body/Interior/PANEL, B-Pillar Trim - Removal user Monday, June 04, 2012 9:23:49 AM

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6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Remove the D-pillar trim panel. See Body/Interior/PANEL, D-Pillar Trim - Removal. Remove the overhead console. Refer to Electrical - Message Systems/Overhead Console - Removal . Remove the header trim panel by carefully pulling down on the trim disengaging the retainers. Remove the mounting fasteners and remove the grab handles and coat hooks. Remove the left quarter trim panel. See Body/Interior/PANEL, Quarter Trim - Removal. Remove the seat belt mounting bracket from the right D-pillar. Lower the first and second row seats as far as possible removing the headrests as necessary. Disconnect electrical connectors. Remove the push-pin retainers at the rear of the headliner. Carefully disengage retaining clips and lower headliner. With the help of an assistant(s), remove the headliner from the vehicle through the lift gate opening.

Installation INSTALLATION

1. With the help of an assistant(s), carefully install the headliner into the vehicle through the rear liftgate opening. Do not over flex the headliner and be carefully not to crack or mar the headliner. 2. Raise the headliner into position and engage the retainers. 3. Connect the electrical connectors. 4. Install the grab handles and coat hooks. Install the mounting fasteners. 5. Install the overhead console. Refer to Electrical - Message Systems/Overhead Console - Installation . 6. Install the D-pillar trim panel. See Body/Interior/PANEL, D-Pillar Trim - Installation. 7. Install the C-pillar trim panel. See Body/Interior/PANEL, C-Pillar Trim - Installation. 8. Install the B-pillar trim panel. See Body/Interior/PANEL, B-Pillar Trim - Installation. 9. Install the A-pillar trim panel. See Body/Interior/PANEL, A-Pillar Trim - Installation. 10. Install the quarter trim panel to the vehicle. See Body/Interior/PANEL, Quarter Trim - Installation. 11. Install the sun visor support and mounting fasteners. 12. Install the sun visors and mounting fasteners. HOUSING, SHIFTER Removal REMOVAL AUTOMATIC

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Fig. 140: Lower Cover Of Shift Knob - Automatic Courtesy of CHRYSLER LLC 1. Disengage the lower cover of the shift knob (1) to access set screw. 2. Remove set screw and remove shift knob. 3. Carefully pry up the shift bezel (2) and remove. MANUAL

Fig. 141: Lower Cover Of Shift Knob - Manual Courtesy of CHRYSLER LLC 1. Disengage the lower cover of the shift knob (4) to access set screw. user Monday, June 04, 2012 9:23:49 AM

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2. Remove set screw and remove shift knob. 3. Carefully pry up the shift bezel (3) and remove. 4. Carefully pry up on the shift boot (1) and remove from shift shaft (2). Installation INSTALLATION AUTOMATIC

Fig. 142: Lower Cover Of Shift Knob - Automatic Courtesy of CHRYSLER LLC 1. Install the shift bezel (2). 2. Remove set screw and remove shift knob (1). 3. Install the lower cover. MANUAL

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Fig. 143: Lower Cover Of Shift Knob - Manual Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the shift boot (1). Install the shift bezel (3). Install the shift knob (4) and install the set screw. Install the lower cover.

MIRROR, REARVIEW Removal REMOVAL

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Fig. 144: Inside Rearview Mirror Courtesy of CHRYSLER LLC 1. If the vehicle is equipped with either the electrochromic (automatic dimming) or the telematic (hands-free phone) mirror option, disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, disconnect the electrochromic mirror takeout and connector (1) and/or the telematic mirror takeout and connector (2) of the headliner wire harness from the connector receptacle on the back (windshield side) of the mirror housing (3).

Fig. 145: Removing/Installing Inside Rearview Mirror Courtesy of CHRYSLER LLC 3. Remove the set screw (3) that secures the rear view mirror (2) to the support bracket/button (1) on the inside of the windshield glass. 4. Slide the rear view mirror upward far enough to disengage it from the support bracket/button. user Monday, June 04, 2012 9:23:49 AM

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Installation MIRROR

Fig. 146: Removing/Installing Inside Rearview Mirror Courtesy of CHRYSLER LLC 1. Position and slide the rear view mirror (2) downward over the support bracket/button (1) on the inside of the windshield glass. 2. Install and tighten the set screw (3) that secures the rear view mirror to the support bracket/button. Tighten the screw to 2 N.m (17 in. lbs.).

Fig. 147: Inside Rearview Mirror Courtesy of CHRYSLER LLC 3. If the vehicle is so equipped, route the electrochromic (automatic dimming) mirror takeout and connector user Monday, June 04, 2012 9:23:49 AM

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(1) and/or the telematic (hands-free phone) mirror takeout and connector (2) of the headliner wire harness to the left of the mirror support bracket and reconnect it to the connector receptacle on the back (windshield side) of the mirror housing (3). 4. If the vehicle is equipped with either the electrochromic or the telematic mirror option, reconnect the battery negative cable. REAR VIEW MIRROR BUTTON

NOTE:

The rear view mirror button is permanently bonded to the inside of the windshield glass. If the button should become separated from the glass, it may be re-bonded using the following procedure. This procedure requires the use of a Rear View Mirror Adhesive kit that is available through Mopar® in single application packages that include a two-part adhesive and an accelerant with applicator.

1. Mark the proper position for the mirror button on the outside of the windshield glass with a wax pencil. The residual adhesive on the inside of the glass from the prior mirror button installation can be used as a guide. 2. Clean the button contact area on the inside of the glass. Use a mild powdered cleanser on a cloth saturated with rubbing alcohol. Finally, clean the glass with a paper towel dampened with alcohol. 3. Sand the bonding surface (the smaller side) of the support button with fine grit-sandpaper. Wipe the button surface clean with a paper towel. 4. Apply accelerant to the bonding surface of the button according to the following instructions: z Crush the accelerant vial to saturate the felt applicator. z Remove the paper sleeve. z Apply accelerant to the bonding surface of the button. z Allow the accelerant to dry for five minutes. z Do not touch the button bonding surface after the accelerant has been applied. 5. Apply adhesive accelerant to the button contact area on the inside of the windshield glass. Allow the accelerant to dry for one minute. Do not touch the button contact area of the glass after the accelerant has been applied. 6. Install the button according to the following instructions: z Apply one drop of adhesive at the center of the button contact area on the inside of the windshield glass. z Apply an even coat of adhesive to the bonding surface of the button. z Align the button with the marked position on the windshield glass. z Press and hold the button in place for at least one minute. NOTE:

Verify that the mirror button is correctly aligned, because the adhesive will cure rapidly.

7. Allow the adhesive to cure for 8-10 minutes. Remove any excess adhesive with an alcohol-dampened cloth. user Monday, June 04, 2012 9:23:49 AM

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8. Allow the adhesive to cure for an additional 8-10 minutes before reinstalling the mirror. PANEL, A-PILLAR TRIM Removal REMOVAL

CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether.

Fig. 148: Rosebud Retainer Courtesy of CHRYSLER LLC 1. Carefully pull the upper end of the trim away from the A-pillar far enough to disengage the rosebud retainer (6) and unfold the tether (2). 2. Using a screwdriver or equivalent, carefully disengage the tether clip (1) and slide from housing on the Apillar trim panel.

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Fig. 149: A-Pillar Trim Courtesy of CHRYSLER LLC 3. Carefully pull the bottom end of the trim away from the A-pillar to disengage the spring clip retainer. 4. Remove A-pillar trim from vehicle. Installation INSTALLATION

CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether.

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Fig. 150: A-Pillar Trim Courtesy of CHRYSLER LLC 1. Place A-pillar trim (1) into position. 2. Carefully push the bottom end of the trim onto the A-pillar to engage the spring clip retainer.

Fig. 151: Rosebud Retainer Courtesy of CHRYSLER LLC 3. Carefully slide the tether (2) into the housing on the A-pillar trim panel and engage the tether clip (1). 4. Carefully engage the rosebud retainer (6) and push the upper end of the trim to the A-pillar and engage the spring clip retainer. PANEL, B-PILLAR TRIM user Monday, June 04, 2012 9:23:49 AM

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Removal REMOVAL

Fig. 152: Front Door Sill Scuff Plates Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove sill trim panel. See Body/Interior/PLATE, Scuff - Removal Remove seat belt anchor. Refer to Restraints/RETRACTOR, Seat Belt - Removal Remove the lower B-pillar trim panel. Using trim stick C-4755, remove SRS airbag cover located at top of B-pillar.

Fig. 153: B-Pillar Trim user Monday, June 04, 2012 9:23:49 AM

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Courtesy of CHRYSLER LLC 5. Move seat belt adjuster all the way down exposing the B-pillar screw. Remove B-pillar screw. 6. Using trim stick C-4755, pry up B-pillar and route seat belt through B-pillar trim. Remove B-pillar bottom first and remove trim from B-pillar. Installation INSTALLATION

Fig. 154: B-Pillar Trim Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Insert top of B-pillar trim locator into position. Before hinging B-pillar upward into place, route seat belt anchor through seat belt adjuster opening. Fasten seat belt anchor to seat. Refer to Restraints/ADJUSTER, Seat Belt Turning Loop - Installation Hinge B-pillar trim downward, engaging clips ensuring proper seat. Install B-pillar screw into B-pillar.

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Fig. 155: Front Door Sill Scuff Plates Courtesy of CHRYSLER LLC 6. Snap SRS airbag anchor cover into place ensuring proper seat. 7. Install the lower B-pillar trim panel. 8. Install the sill trim panel. See Body/Interior/PLATE, Scuff - Installation. PANEL, C-PILLAR TRIM Removal REMOVAL

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Fig. 156: C-Pillar Trim Panel Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove the quarter trim panel. See Body/Interior/PANEL, Quarter Trim - Removal. Remove seat belt anchor bolt. Refer to Restraints/RETRACTOR, Seat Belt - Removal . Remove the access hole cover and remove the mounting fastener. Using trim stick C-4755, carefully pry the C-pillar out disengaging the retaining clips. Route seat belt through opening and remove C-pillar trim panel from vehicle.

Installation INSTALLATION

Fig. 157: C-Pillar Trim Panel Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Place upper C-pillar trim into position. Route seat belt through opening in C-Pillar Trim Firmly seat the retaining clips to the C-pillar. Install the mounting fastener and access hole cover. Install bolt attaching seat belt lower anchor to floor. Refer to Restraints/RETRACTOR, Seat Belt Installation . 6. Install quarter panel trim. See Body/Interior/PANEL, Quarter Trim - Installation. PANEL, COWL TRIM Removal user Monday, June 04, 2012 9:23:49 AM

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REMOVAL

Fig. 158: Cowl Trim Panels Courtesy of CHRYSLER LLC 1. Remove door sill trim panel. See Body/Interior/PLATE, Scuff - Removal. 2. Using trim stick C-4755, disengage cowl trim panel clips from the corresponding locations in the sheet metal. 3. Remove cowl trim panel from vehicle. Installation INSTALLATION

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Fig. 159: Cowl Trim Panels Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Ensure plastic retaining nut (3) is installed. Position cowl trim panel (1) to vehicle. Hand press cowl trim panel to corresponding holes in sheet metal. Install door sill trim panel. See Body/Interior/PLATE, Scuff - Installation.

PANEL, D-PILLAR TRIM Removal REMOVAL

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Fig. 160: D-Pillar Trim Panel Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove the rear header trim panel. Remove the access hole covers and remove the mounting fasteners. Using trim stick C-4755, carefully pry the D-pillar out disengaging the retaining clips. Remove the D-pillar from the vehicle.

Installation INSTALLATION

Fig. 161: D-Pillar Trim Panel user Monday, June 04, 2012 9:23:49 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Position the D-pillar into position. Firmly seat the retaining clips securing the D-pillar. Install mounting fasteners and access hole covers. Install the rear header trim panel.

PANEL, QUARTER TRIM Removal REMOVAL

Fig. 162: Quarter Trim Panel Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7.

Remove the second row seats. See Body/Seats/SEAT - Removal. Remove the third row seats, if equipped. See Body/Seats/SEAT - Removal Remove the storage box, if equipped. See Body/Interior/BOX, Storage - Removal. Remove the door sill plate. See Body/Interior/PLATE, Scuff - Removal. Remove the D-pillar trim panel. See Body/Interior/PANEL, D-Pillar Trim - Removal. Remove the mounting fasteners. Using trim stick C-4755, carefully pry the quarter trim panel out disengaging the retaining clips.

Installation INSTALLATION

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Fig. 163: Quarter Trim Panel Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7.

Install the quarter trim panel. Install the mounting fasteners. Install the door sill plate. See Body/Interior/PLATE, Scuff - Installation. Install the D-pillar trim panel. See Body/Interior/PANEL, D-Pillar Trim - Installation. Install the storage box, if equipped. See Body/Interior/BOX, Storage - Installation. Install the third row seats, if equipped. See Body/Seats/SEAT - Installation. Install the second row seats. See Body/Seats/SEAT - Installation.

PLATE, SCUFF, DOOR SILL Removal REMOVAL

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Fig. 164: Front Door Sill Scuff Plates Courtesy of CHRYSLER LLC 1. Using trim stick C-4755 disengage clips holding door sill scuff panel and to door sill. 2. Starting at forward end of door sill scuff panel, pull upward on sill scuff panel in order to disengage clips attaching sill scuff panel to door opening flange. 3. Remove door sill scuff panel from vehicle. Installation INSTALLATION

Fig. 165: Front Door Sill Scuff Plates user Monday, June 04, 2012 9:23:49 AM

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Courtesy of CHRYSLER LLC 1. Place door sill trim panel into position. 2. Ensure plastic retaining nut is installed. 3. Pushing downward on sill trim panel to engage tabs and attaching clips to the door sill. PLATE, SCUFF, LIFTGATE SILL Removal REMOVAL

Fig. 166: LIFTGATE SILL TRIM PANEL Courtesy of CHRYSLER LLC 1. Open the liftgate. 2. Using trim stick C-4755, carefully pry the liftgate sill plate out disengaging the retaining clips. 3. Remove the liftgate sill plate from the vehicle. Installation INSTALLATION

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Fig. 167: LIFTGATE SILL TRIM PANEL Courtesy of CHRYSLER LLC 1. Position the liftgate sill plate into the vehicle. 2. Firmly press the sill plate downward securing the retaining clips. 3. Close the liftgate. SUPPORT, VISOR Removal REMOVAL

1. Disengage sun visor from center support. 2. Remove mounting fasteners attaching support to roof header, 3. Remove support from vehicle. Installation INSTALLATION

1. Place support into position. 2. Install mounting fasteners attaching support to roof header, 3. Engage sun visor to center support. VISOR Removal user Monday, June 04, 2012 9:23:50 AM

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REMOVAL

Fig. 168: Sun Visor Courtesy of CHRYSLER LLC CAUTION: When removing or installing the screws (1), be certain to avoid any wiring or drain tube interference. 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). Installation INSTALLATION

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Fig. 169: Sun Visor Courtesy of CHRYSLER LLC CAUTION: When removing or installing the screws (1), be certain to avoid any wiring or drain tube interference. 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 N.m (20 in. lbs.).

PAINT SPECIFICATIONS PAINT CODES

EXTERIOR COLORS EXTERIOR COLOR Inferno Red Crystal Pearl Coat White Gold Metallic Clearcoat Deep Water Blue Pearl Coat Silver Steel Metallic Clearcoat Bright Silver Metallic Clearcoat Brilliant Black Crystal Pearl Coat Stone White Clearcoat

CHRYSLER CODE ARH HWL GBS DA4 WS2 AXR SW1

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INTERIOR COLORS INTERIOR COLOR V = Dark Slate Gray B = Dark Pebble Beige/Pastel Pebble Beige

CHRYSLER CODE DV KA

BASECOAT/CLEARCOAT FINISH Description DESCRIPTION

On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. FINESSE SANDING, BUFFING, AND POLISHING Description DESCRIPTION

Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing.If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. PAINT CODE Description DESCRIPTION

The paint code is identified on the Vehicle Safety Certification Label which is located on the drivers door shut face. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The codes listed in the Color Code Chart are used for manufacturing purposes. PAINT TOUCH-UP user Monday, June 04, 2012 9:23:50 AM

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Description DESCRIPTION

When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar® Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. For a description of the paint codes. See Body/Paint - Specifications. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. TOUCH UP PROCEDURE

1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar® Tar/Road Oil Remover, 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 surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in 4. Allow clear top coat to dry hard. If desired, 5 can be performed on clear top coat. WARNING: Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result.

SEATS, FRONT ADJUSTER, SEAT, FRONT Removal POWER ADJUSTER

NOTE: 1. 2. 3. 4.

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

Remove front seat from vehicle. See Body/Seats/SEAT - Removal. Remove the seat back from the seat cushion. See Body/Seats/SEAT BACK - Removal. Remove the seat cushion. See Body/Seats/COVER, Seat Cushion - Removal. Remove the seat wiring harness (37).

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5. Remove the STPS sensor (32), if equipped. 6. Remove the wiring bracket fastener (35) and bracket (33). MANUAL ADJUSTER

NOTE: 1. 2. 3. 4. 5. 6.

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

Remove the front seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the seat back. See Body/Seats/SEAT BACK - Removal. Remove the seat cushion. See Body/Seats/COVER, Seat Cushion - Removal. Remove the wiring harness (30) from the seat frame. Remove the STPS sensor (32). Remove the wiring bracket fastener (29) and bracket (28).

Installation POWER ADJUSTER

NOTE: 1. 2. 3. 4. 5. 6.

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

Install the wiring bracket fastener (35) and bracket (33). Install the STPS sensor (32), if equipped. Install the seat wiring harness (37). Install the seat cushion. See Body/Seats/COVER, Seat Cushion - Installation. Install the seat back to the seat cushion assembly. See Body/Seats/SEAT BACK - Installation. Install front seat to vehicle. See Body/Seats/SEAT - Installation.

MANUAL ADJUSTER

1. 2. 3. 4. 5. 6.

Install the wiring bracket (28) and fastener (29). Install the STPS sensor (32). Install the wiring harness (30) to the seat frame. Install the seat cushion. See Body/Seats/COVER, Seat Cushion - Installation. Install the seat back. See Body/Seats/SEAT BACK - Installation. Install the front seat to the vehicle. See Body/Seats/SEAT - Installation.

BIN, UNDER SEAT STORAGE Removal REMOVAL

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NOTE:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Refer to the fold flat passenger seat exploded view for illustration. See Body/Seats/SEAT - Description.

Remove the seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the seat side shields. See Body/Seats/SIDE SHIELDS, Seat Cushion - Removal. Remove the wiring harness (28) anchors from the seat bottom. Remove the anchors securing the recliner cable (19) from the seat bottom. Remove the seat cover and cushion. See Body/Seats/COVER, Seat Cushion - Removal. Fold the seat back forward completely. Remove the front biteline pad (41). Remove the inner left shield (21). Remove the inner right shield (33). Fully recline the seat back. Remove the storage bin (2) from the seat frame.

Installation INSTALLATION

NOTE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Refer to the fold flat passenger seat exploded view for illustration. See Body/Seats/SEAT - Description.

With the seat back fully reclined, install the storage bin (2) to the seat frame. Fold the seat back completely forward. Install the inner right shield (33). Install the inner left shield (21). Install the front biteline pad (41). Install the seat cushion and cover. See Body/Seats/COVER, Seat Cushion - Installation. Install the anchors securing the recliner cable (19) to the seat bottom. Install the wiring harness (28) anchors to the seat bottom. Install the seat side shields. See Body/Seats/SIDE SHIELDS, Seat Cushion - Installation. Install the seat into vehicle. See Body/Seats/SEAT - Installation.

COVER, SEAT BACK Removal REMOVAL

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

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NOTE:

All call outs are in reference to the Driver Power exploded view unless otherwise noted.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Remove the seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the seat back. See Body/Seats/SEAT BACK - Removal. Remove the lumbar handle cover (23). Remove the retaining fastener (22) and remove the handle (21). Remove the back panel from the seat back. See Body/Seats/PANEL, Seat Back - Removal. Remove the J-clips and pushpins on the seat back cover from the frame. Remove the side airbag (SAB) mounting nuts. Disconnect the SAB wiring connector. Remove the SAB from the seat cover. Remove the inner inboard shield (41). Remove the inner outboard shield (28). Remove the headrest guides (12). See Body/Seats/SLEEVE, Headrest - Removal. Starting from the bottom rear of the seat back, carefully pull seat cover off seat cushion to expose hog rings. 14. Cut hog rings and discard. 15. Remove the cover from the seat back assembly. 16. Remove the seat cushion foam, if required. Installation INSTALLATION

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

NOTE:

Do not reuse the recliner assembly attaching bolts.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Position cover on the top of seat back. Carefully roll cover down to the area that hog rings are to be installed. Install the side airbag (SAB) to the seat back cover. Connect the SAB wiring connector. Install the SAB mounting fasteners. Engage the J-clip retainers to the back frame assembly. Install hog rings. Roll cover downward. Engage the J-clip retainer to the seat frame. Install lumbar handle, if equipped. Install the seat back panel. See Body/Seats/PANEL, Seat Back - Installation

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12. 13. 14. 15.

Install headrest guides. See Body/Seats/SLEEVE, Headrest - Installation. Install seat back to seat cushion. See Body/Seats/SEAT BACK - Installation. Install the seat to the vehicle. See Body/Seats/SEAT - Installation. Check seat back and headrest operation.

COVER, SEAT CUSHION Removal REMOVAL

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

1. Remove seat from vehicle. See Body/Seats/SEAT - Removal 2. Remove the wiring harness from the seat pan.

Fig. 170: SEAT PAN FASTENERS Courtesy of CHRYSLER LLC 3. Remove four seat pan fasteners (1). 4. Remove the seat pan from the adjuster assembly. 5. Remove the J-clips securing the seat cover to the seat pan, if required.

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Fig. 171: HEATED SEAT ELEMENT Courtesy of CHRYSLER LLC 6. Starting at the rear of the seat cushion, carefully pull seat cover (3) down towards the front. 7. Cut and discard hog rings. 8. Remove the seat cover from the foam. Installation INSTALLATION

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

Fig. 172: HEATED SEAT ELEMENT Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:50 AM

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1. Install the heated seat element (2) to the seat cushion, if required. 2. Slide the seat cover (3) over the front of the cushion. 3. Install hog rings as the cover is slid over the cushion.

Fig. 173: SEAT PAN FASTENERS Courtesy of CHRYSLER LLC 4. 5. 6. 7. 8.

Place the seat cushion into position on the seat pan. Install the J-clips securing the seat cushion to the seat pan. Install the seat pan and cushion to the adjuster assembly. Install the mounting fasteners and torque to 12.5 N-m (9 ft. lbs.). Install the seat to the vehicle. See Body/Seats/SEAT - Installation.

PANEL, SEAT BACK, FRONT Removal REMOVAL FOLD FLAT SEAT

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Fig. 174: Seat Back Retainers Courtesy of CHRYSLER LLC 1. Carefully disengage the clip retainers (2) by pulling up on the bottom and sides of the back panel. 2. Slide the back panel up to disengage the side retainers (3). 3. While lifting the bottom of the panel, slide the panel down and remove from the seat back disengaging the upper retainers (1). NON-FOLD FLAT SEAT

Fig. 175: Non-Fold Flat Seat Retainers Courtesy of CHRYSLER LLC 1. Carefully pull the bottom and sides of the panel upwards to disenge the lower clip retainers (2). 2. While lifting the bottom of the back panel, disengage the upper retainers (1) and remove the panel from user Monday, June 04, 2012 9:23:50 AM

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the seat back. Installation INSTALLATION FOLD FLAT SEAT

Fig. 176: Seat Back Retainers Courtesy of CHRYSLER LLC 1. While lifting the bottom of the panel up, engage the upper retainers (1) to the seat back. 2. Engage the side retainers (3) to the seat and slide the back panel down into position. 3. Firmly seat the clip retainers (2) securing the back panel to the seat back. NON-FOLD FLAT SEAT

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Fig. 177: Non-Fold Flat Seat Retainers Courtesy of CHRYSLER LLC 1. While lifting the bottom of the back panel, engage the upper retainers (1) to the seat back. 2. Firmly seat the lower clip retainers (2) securing the back panel to the seat back. SEAT BACK, FRONT Removal REMOVAL

NOTE:

See Body/Seats/SEAT - Description for detailed exploded views.

NOTE:

All call outs are in reference to the Driver Power exploded view unless otherwise noted.

1. 2. 3. 4. 5. 6. 7.

Remove the seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the lift handle cover and mounting fasteners, if equipped. Remove the lift handle, if equipped. Carefully pry the side shield away from the recliner handle (26) and remove the retaining clip. Remove the recliner handle. Remove the rear fastener (31) from the outboard shield (25). Starting at the rear of the outboard shield, carefully pry the side shield until the retainers disengage and slide the shield forward to remove. 8. Remove the seat buckle bolt and buckle (40). 9. Remove the rear fastener (31) from the inboard shield (42). 10. Starting at the rear of the inboard shield, carefully pry the side shield until the retainers disengage and user Monday, June 04, 2012 9:23:50 AM

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slide the shield forward to remove. 11. Remove the airbag wiring harness (24) from the seat bottom, ensure the harness is completely removed from the bracket (26) and through recliner mechanism. 12. Remove the outboard and inboard seat back bolts (30). 13. Remove the seat back from the seat cushion assembly. Installation INSTALLATION

NOTE:

See Body/Seats/SEAT - Description for detailed exploded views.

NOTE:

All call outs are in reference to the Driver Power exploded view unless otherwise noted.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Install the seat back to the seat cushion assembly. Install the outboard and inboard seat back bolts and torque to 40 N-m (29 ft. lbs.). Install the airbag wiring harness to the seat bottom. Install the inboard shield. Install the rear fastener to the inboard shield. Install the seat buckle bolt and buckle. Tighten to 45 N-m (33 ft. lbs.). Install the outboard shield. Install the rear fastener to the outboard shield. Install the recliner handle retaining clip. Install the recliner handle. Install the lift handle, if equipped. Install the mounting fasteners and lift handle cover, if equipped. Install the seat to the vehicle. See Body/Seats/SEAT - Removal.

SEAT, FRONT Description DESCRIPTION

WARNING: Discard and replace the seat back bolts with new bolts when servicing. Installing used bolts may result in the loosening of the seat back bolts after repair. Failure to follow these instructions may result in serious or fatal injury.

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Fig. 178: Front Seat - Driver Power Courtesy of CHRYSLER LLC 1. HEADRES 2. CUSHION/COVER, SEAT BACK 3. BACK, HEATER PAD 4. SCREW 5. CLAMP BAND, FRONT 6. BRACKET, FRONT PAN 7. CUSHION PAN, FRONT 8. BRACKET, REAR PAN 9. SCREW 10. CLAMP BAND, REAR 11. BAG, ANTI-SQUEAK 12. GUIDES, HEADREST 13. FRAME, SEAT BACK 14. PANEL, BACK W/MAP POCKET 15. TREE CLIP, SUB PANEL 16. BASE, SUB PANEL 17. BRACKET, SIDE AIRBAG 18. PIN, PUSH

23. CAP, LUMBER HANDLE 24. HARNESS, AIRBAG WIRING 25. SHIELD, SIDE 26. HANDLE, RECLINER 27. COVER, SEAT BELT ANCHOR 28. FLANGE, OUTBOARD RETURN 29. SWITCH, POWER SEAT 30. SCREW 31. SCREW 32. SENSOR, STPS 33. BRACKET, WIRING 34. COVER, RISER 35. SCREW 36. ASSEMBLY, TRACK 37. HARNESS, WIRING 38. MODULE, HEATED SEAT 39. BUCKLE, SEAT (INTERNATIONAL) 40. BUCKLE, SEAT

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19. NUT, LOCK 20. AIRBAG, SIDE 21. HANDLE, LUMBER 22. SCREW

41. FLANGE, INNER RETURN 42. SHIELD, SIDE 43. CUSHION, HEATER PAD 44. CUSHION/COVER, SEAT

Fig. 179: Front Seat - Driver Manual Courtesy of CHRYSLER LLC 1. HEADREST 2. SCREW 3. CLAMP BAND, FRONT 4. BRACKET, FRONT PAN 5. CUSHION PAN, FRONT 6. BRACKET, REAR PAN 7. SCREW 8. CLAMP BAND, REAR 9. BAG, ANTI-SQUEAK 10. GUIDES, HEADREST 11. FRAME, SEAT BACK 12. BRACKET, SIDE AIRBAG 13. PIN, PUSH

21. HANDLE, RECLINER 22. COVER, SEAT BELT ANCHOR 23. HANDLE, LIFT 24. CAP, LIFT HANDLE 25. HARNESS, AIRBAG 26. SCREW 27. COVER, RISER 28. BRACKET, WIRING 29. SCREW 30. HARNESS, WIRING 31. ASSEMBLY, TRACK 32. SENSOR, STPS. 33. SCREW

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14. BASE, SUB PANEL 15. TREE CLIP, SUB PANEL 16. NUT, LOCK 17. AIRBAG, SIDE 18. FLANGE, OUTBOARD RETURN 19. BOLTS, SEAT BACK 20. SHIELD, SIDE

34. BUCKLE, SEAT (INTERNATIONAL) 35. BUCKLE, SEAT DOMESTIC 36. FLANGE, INNER RETURN 37. SHIELD, SIDE 38. CUSHION/COVER, SEAT 39. CUSHION/COVER, SEAT BACK -

Fig. 180: Front Seat - 2 Way Passenger-Fold Flat Courtesy of CHRYSLER LLC 1. HEADREST 2. BIN, STORAGE 3. BRACKET, FRONT MOUNTING 4. BOLT, PIVOT 5. FRAME, CUSHION 6. SCREW 7. BAG, ANTI-SQUEAK 8. HARNESS, AIRBAG WIRING 9. AIRBAG, SIDE 10. NUT, LOCK

22. BUCKLE, SEAT DOMESTIC 23. BUCKLE, SEAT INTERNATIONAL 24. SHIELD, SIDE INBOARD 25. SCREW 26. BRACKET, WIRING 27. COVER, RISER 28. HARNESS, WIRING 29. ASSEMBLY, TRACK 30. SENSOR, STPS 31. SCREW

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11. HANDLE, RECLINER 12. BRACKET, SIDE AIRBAG 13. PIN, PUSH 14. GUIDES, HEADREST 15. FRAME, SEAT BACK 16. ASSEMBLY, BACK PANEL 17. BASE, SUB PANEL 18. TREE CLIP, SUB PANEL 19. CABLE ASSEMBLY, FOLD FLAT 20. SHIELD, UPPER INBOARD 21. SHIELD, INNER LEFT

32. SCREW 33. SHIELD, INNER RIGHT 34. PLATE, WIRE 35. SHIELD, UPPER OUTBOARD 36. SHIELD, SIDE OUTBOARD 37. COVER, SEAT BELT ANCHOR 38. HEAT PAD, CUSHION 39. HEAT PAD, SEAT BACK 40. CUSHION/COVER, SEAT 41. PAD, FRONT BITELINE 42. CUSHION/COVER, SEAT BACK

Fig. 181: Front Seat - 2 Way Passenger Courtesy of CHRYSLER LLC 1. HEADREST 2. SCREW 3. CLAMP BAND, FRONT 4. BRACKET, FRONT PAN 5. CUSHION PAN, FRONT 6. CLAMP BAND, REAR

20. SCREW 21. SHIELD, INNER LEFT 22. SHIELD, SIDE INBOARD 23. BUCKLE, SEAT DOMESTIC 24. BUCKLE, SEAT INTERNATIONAL 25. SCREW

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7. BRACKET, REAR PAN 8. SCREW 9. HARNESS, AIRBAG WIRING 10. AIRBAG, SIDE 11. NUT, LOCK 12. BRACKET, SIDE AIRBAG 13. PIN, PUSH 14. GUIDES, HEADREST 15. FRAME, SEAT BACK 16. TREE CLIP, SUB PANEL 17. BASE, SUB PANEL 18. BAG, ANTI-SQUEAK 19. SCREW

26. BRACKET, WIRING 27. HARNESS, WIRING 28. COVER, RISER 29. ASSEMBLY, TRACK 30. SENSOR, STPS 31. SCREW 32. SHIELD, INNER RIGHT 33. HANDLE, RECLINER 34. COVER, SEAT BELT ANCHOR 35. SHIELD, SIDE OUTBOARD 36. CUSHION/COVER, SEAT 37. CUSHION/COVER, SEAT BACK -

Removal REMOVAL

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

NOTE: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove the headrest. Slide seat forward. Using a trim stick C-4755 or equivalent, remove the seat belt anchor trim. Remove both rear seat adjuster bolts. Remove seat belt anchor bolt attaching seat belt to seat. Slide seat rearward. Disconnect and isolate the negative battery cable. Remove both front seat adjuster bolts. Disconnect all electrical connectors. CAUTION: Caution should be taken not to handle seat by adjuster release bar when removing spring loaded seat from vehicle.

10. Remove front seat from vehicle. Installation INSTALLATION

CAUTION: Do not handle by seat adjuster release bar.

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NOTE:

Ensure that the seat tracks are rearward. Ensure the seat tracks on the right and left are in equal latch positions.

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

1. 2. 3. 4.

Place front seat in position in vehicle. Connect front seat wire harness connector to body harness connector. Install bolts to attach front of seat adjuster to the floor. Tighten bolts to 65 N.m (48 ft. lbs.). Slide seat forward and install bolts attaching rear of seat track to the floor. Tighten bolts to 65 N.m (48 ft. lbs.). 5. Install seat belt anchor bolt through seat belt and snap seat belt anchor cover to seat cover side shield. 6. Connect the battery negative cable. 7. Verify front seat operation. SIDE SHIELDS, SEAT CUSHION, FRONT Removal REMOVAL

NOTE:

See Body/Seats/SEAT - Description for detailed exploded views.

NOTE:

All call outs are in reference to the Driver Power exploded view unless otherwise noted.

1. 2. 3. 4. 5. 6. 7. 8.

Remove the seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the lift handle cover and mounting fasteners, if equipped. Remove the lift handle, if equipped. Remove the recliner handle retainer and handle. Remove the seat belt buckle bolt and buckle. Remove the rear fastener on the outboard shield. Remove the rear fastener on the inboard shield. Remove the appropriate side shield.

Installation INSTALLATION

NOTE:

See Body/Seats/SEAT - Description for detailed exploded views.

NOTE:

All call outs are in reference to the Driver Power exploded view unless otherwise noted.

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1. 2. 3. 4. 5. 6. 7. 8.

Install the side shield. Install the rear fastener on the inboard shield. Install the rear fastener on the outboard shield. Install the seat belt buckle bolt and buckle. Install the recliner handle retainer and handle. Install the lift handle, if equipped. Install the lift handle cover and mounting fasteners, if equipped. Install the seat to the vehicle. See Body/Seats/SEAT - Removal.

SLEEVE, HEADREST Removal REMOVAL

NOTE:

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

1. 2. 3. 4.

Remove the headrest. If equipped, remove the back panel (14) or unzip the seat back cover. Remove the J-clip from the bottom rear of the seat back. Squeeze the detents at the bottom of the headrest guides then lightly tap the headrest guides (12) until the retaining clips disengage from the seat frame. 5. Remove the headrest guides from the seat back. Installation INSTALLATION

NOTE: 1. 2. 3. 4. 5. 6.

See Body/Seats/SEAT - Description for a detailed exploded view of the seats.

Install the headrest guides to the seat back. Lightly tap the headrest guides (12) until the retaining clips engage the seat frame. Zip the seat back cover. Install the J-clip to the bottom rear of the seat back. Install the back panel (14), if equipped. Install the headrest.

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REMOVAL

1. 2. 3. 4. 5. 6.

Remove the seat cushion. See Body/Seats/COVER, Seat Cushion - Removal. Remove the rear plastic shield fasteners and shields. Remove the bottom plastic shield by carefully prying up on the shield until the retainers disengage. Remove the cables and cable assemblies. Remove the frame to adjuster fasteners and separate. Remove the adjuster latch mounting nuts and remove the latch.

Installation INSTALLATION

1. 2. 3. 4. 5. 6. 7.

Install the adjuster latch mounting nuts and install the latch. Position the frame to the adjuster assembly. Install the frame to adjuster fasteners. Tighten to 30 N-m (22 ft. lbs.). Install the cables and cable assemblies. Install the bottom plastic shield ensuring the retainers engage. Install the rear plastic shield shields and fasteners. Install the seat cushion and cover. See Body/Seats/COVER, Seat Cushion - Installation.

ARMREST, SECOND ROW Removal REMOVAL

1. Position the 40 split seat with back folded flat, to the full forward position. 2. Partially remove the armrest side shield and remove the mounting fastener. 3. With the armrest folded down, remove the two mounting fasteners located on the inside of the armrest bracket. 4. Remove the armrest from the vehicle. NOTE: 5. 6. 7. 8. 9.

Only perform the following steps if the cover or foam replacement is required.

Remove the armrest plastic cover, by carefully prying up until the retainers disengage. If equipped, remove the headrest. Remove the headrest sleeves, if equipped. Carefully pull the seat cover off of the armrest and remove the cover. Remove the foam as required.

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INSTALLATION

1. 2. 3. 4. 5. 6. 7.

Install the foam, if required. Carefully install the seat cover to the armrest. If equipped, install the headrest sleeves to the armrest. Install the headrest, if equipped. Install the armrest plastic cover, ensuring the retainers engage. Position the armrest to the vehicle. With the armrest folded down, install the two mounting fasteners located on the inside of the armrest bracket. Tighten to 40 N-m (29 ft. lbs.). 8. Install the outboard armrest mounting fastener. Tighten to 30 N-m (22 ft. lbs.). COVER, SEAT BACK Removal REMOVAL

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Remove the folding seat handle cover, mounting fasteners and handle from the seat back. Remove the seat belt trim, if required. Remove the headrest and headrest guides. Fold the seat back down flat. For the 60 split seat only, remove the seat belt anchor bolt. Remove the back panel from the seat back. See Body/Seats/PANEL, Seat Back - Removal. Release the seat cover clips from the seat back. Carefully pull the seat cover and foam away from the seat back frame. If required, feed the seat belt through the seat cover. Carefully pull the cover off of the foam, cutting any hog rings and discarding.

Installation INSTALLATION

1. 2. 3. 4. 5. 6. 7. 8.

Carefully install the cover to the foam, installing any hog rings. If required, feed the seat belt through the seat cover. Position the seat cover and foam to the seat back frame. Install the seat cover clips to the seat back. Install the seat back panel. See Body/Seats/PANEL, Seat Back - Installation. For the 60 split seat only, install the seat belt anchor bolt. Tighten to 49 N-m (36 ft. lbs.). Fold the seat back up. Install the headrest guides and headrest.

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9. Install the seat belt trim, if required. 10. Install the folding seat handle, mounting fasteners and cover to the seat back. COVER, SEAT CUSHION, SECOND ROW Removal REMOVAL

NOTE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Only the 40 split seat must be removed to replace the seat cushion.

For the 40 split seat only, remove the seat from the vehicle. See Body/Seats/SEAT - Removal. Remove the seat recliner handle cover and fastener. Remove the seat recliner handle. Remove the seat adjuster handle cover and fastener. Remove the seat adjuster handle. Remove the seat side shields. Remove the outboard seat bolt securing the seat cushion to the seat frame. For the 40 split seat only, remove the inboard seat cushion mounting fastener. Pull the release latch and push up on seat cushion to separate from the seat frame. Remove the cable assembly from the seat cushion. Remove the gas strut from the seat cushion, if equipped. Remove the cushion from the seat frame. Unzip the cover from the cushion. Carefully pull the seat cover off of the seat cushion, cutting any hog rings and discarding them, if required.

Installation INSTALLATION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Carefully pull the seat cover over the seat foam, installing any hog rings, if required. Zip the cover on to the foam. Install the cushion to the seat frame. Install the gas strut to the seat cushion, if equipped. Install the cable assembly to the seat cushion. Ensure the seat cushion is latched into the seat frame. Install the outboard seat bolt securing the seat cushion to the seat frame. Tighten to 30 N-m (22 ft. lbs.). Install the inboard seat bolt, if required. Install the seat side shields. Install the seat recliner handle.

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11. 12. 13. 14.

Install the seat recliner handle fastener and cover. Install the seat adjuster handle. Install the seat adjuster handle fastener and cover. Install the seat to the vehicle, if required. See Body/Seats/SEAT - Installation.

PANEL, SEAT BACK, SECOND ROW Removal REMOVAL

Fig. 182: Retainers On Seat Back Panels & Armrest Courtesy of CHRYSLER LLC 1. Note the locations (1) of the retainers on the seat back panels (3) and armrest (2).

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Fig. 183: Seat Back Panel Retainers Courtesy of CHRYSLER LLC CAUTION: Use care when removing the pushpins on the back panel from the seat back. Failure to do so will result in damage to the back panel. 2. Using a clip removal tool or equivalent, carefully disengage the retainers (2) that secure the seat back panel (1). 3. Remove the back panel from the seat. Installation INSTALLATION

Fig. 184: Seat Back Panel Retainers user Monday, June 04, 2012 9:23:50 AM

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Courtesy of CHRYSLER LLC 1. Place the back panel (1) into position on the seat. 2. Engage the retainers (2) that secure the back panel to the seat.

Fig. 185: Retainers On Seat Back Panels & Armrest Courtesy of CHRYSLER LLC 3. Press firmly on the retainer locations (1), as shown above, to ensure proper engagement. SEAT Description DESCRIPTION

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Fig. 186: Seat - 5 Passenger - 40% Seat Exploded View Courtesy of CHRYSLER LLC Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Cover, Headrest Foam, Headrest Sleeve, Headrest Screw Cover, Seat Back Shield, Seat Back Foam, Seat Back Frame, Seat Back Screw Cable, Recliner Release Nut, Lock Screw Shield, Upper Recliner LH Screw Cover, Release Handle Shield, Rear

Item 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Description Bumper Cover, Rear Track Spacer Assembly, Outboard Track Assembly, Inboard Track Shield, Cushion Latch Nut, Lock Bumper Screw Buckle, Seatbelt Shield, Lower Outer Screw Shield, Upper Recliner RH Screw Bumper Assembly, Lower Structure

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17 18 19 20 21 22 23 24 25 26

Handle, Recliner Screw Screw Screw Cover, Release Handle Cable, Track Release Frame, Seat Cushion Foam, Seat Cushion Cover, Seat Cushion Screw

43 44 45 46 47 48 49 50 51 -

Shield, Lower Recliner Nut, Plastic Nut, Lock Screw Shield, Upper Inner Assembly, Cushion Latch Screw Shield, Upper Seat Back Inner Sleeve, Headrest -

Fig. 187: Seat - 5 Passenger - 60% Seat Exploded View Courtesy of CHRYSLER LLC Item 1 2 3 4 5 6 7 8 9

Description Cover, Headrest Foam, Headrest Sleeve, Headrest Frame, Seat Back Bezel, Seat Belt Screw Cover, Striker Cover, Seat Back Shield, Seat Back

Item 41 42 43 44 45 46 47 48 49

Description Screw Sleeve, Headrest Frame, Seat Nut Nut Screw Nut Cushion, Bumper Buckle, Seat Belt

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10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Cover, Headrest Foam, Seat Back Foam, Headrest Strap, Release Sleeve, Headrest Sleeve, Headrest Nut Latch, Armrest Bracket, Armrest Pivot Screw Screw Nut Frame, Armrest Cover, Armrest Panel, Armrest Cover Foam, Armrest Cover, Pivot Bracket Screw Shield, Rear Screw Cover, Rear Track Assembly, Outboard Track Assembly, Inboard Track Retractor, Seat Belt Screw Cover, Inner Pivot Pin, Push Shield, Upper Recliner LH Screw Buckle, Seat Belt Screw

50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Screw Nut Cover, Lower Outer Cover, Upper Recliner Screw Bumper Screw Screw Screw Foam, Seat Cushion Cover, Seat Cushion Cable, Track Release Screw Cap, Handle Handle, Seat Adjust Shield, Lower Side Screw Frame, Seat Cushion Cap, Handle Handle, Recliner Shield, Upper Side Screw Cable, Recliner Release Pin, Push Screw Nut Cover, Lower Recliner Screw Screw Shield, Upper Seat Back Inner Sleeve, Headrest

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Fig. 188: Seat - 7 Passenger - 40% Seat Exploded View Courtesy of CHRYSLER LLC Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Cover, Headrest Sleeve, Headrest Sleeve, Headrest Frame, Seat Back Foam, Seat Back Cover, Seat Back Panel, Seat Back Cable, Release Screw Handle, Easy Entry Screw Cap, Handle Screw Cable, Release Shield, Lower RH Handle, Seat Adjust

Item 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

Description Spacer Bumper Screw Spring, Assist Sleeve, Headrest Cable, Release Shield, Upper Inner Screw Cover, Cushion Latch Cover, Lower Recliner Screw Buckle, Seat Belt Bumper Nut Nut Nut

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17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Screw Cable, Release Shield, Lower LH Handle, Recliner Screw Cap, Handle Screw Cap, Handle Screw Screw Cover, Rear Cable, Release Cover, Rear Track Track, Inboard Track, Outboard

48 49 50 51 52 53 54 55 56 57 58 59 60 61 -

Frame, Seat Cover, Lower Outer Cover, Seat Cushion Foam, Seat Cushion Strut, Gas Frame, Seat Cushion Screw Screw Cover, Upper Recliner Screw Screw Screw Shield, Upper Seat Back Inner Sleeve, Headrest -

Fig. 189: Seat - 7 Passenger - 60% Seat Exploded View Courtesy of CHRYSLER LLC Item 1 2 3

Description Cover, Headrest Sleeve, Headrest Cap, Handle

Item 46 47 48

Description Screw Cover, Inner Pivot Nut

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4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Screw Handle, Easy Entry Screw Cable, Release Frame, Seat Back Bezel, Seat Belt Screw Cover, Striker Screw Retractor, Seat Belt Foam, Seat Back Cover, Seat Back Shield, Seat Back Cover, Headrest Foam, Headrest Sleeve, Headrest Strap, Release Nut Latch, Armrest Bracket, Armrest Pivot Screw Nut Frame, Armrest Sleeve, Headrest Panel, Armrest Cover Cover, Armrest Foam, Armrest Screw Cover, Pivot Bracket Screw Screw Shield, Rear Track, Inboard Track, Outboard Cable, Release Cover, Rear Track Cable, Release Frame, Seat Pin, Push Shield, Upper Recliner LH Screw

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89

Screw Nut Cover, Lower Recliner Screw Pin, Push Cable, Release Screw Screw Nut Screw Shield, Upper Side Handle, Recliner Cap, Handle Screw Bumper Nut Cushion, Bumper Nut Screw Spring Sleeve, Headrest Buckle, Seat Belt Screw Cover, Lower Outer Cover, Cushion Latch Screw Cover, Upper Recliner Foam, Seat Cushion Cover, Seat Cushion Strut, Gas Cable, Release Screw Cap, Handle Handle, Seat Adjust Shield, Lower Side Screw Frame, Seat Cushion Screw Screw Shield, Upper Seat Back Inner Sleeve, Headrest

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Buckle, Seat Belt

90

Foam, Headrest

Removal REMOVAL

1. 2. 3. 4. 5.

Remove the headrest. Slide seat forward. Remove both rear seat adjuster bolts. Slide seat rearward. While pulling the release tab located under the seat, pull the seat up and remove the plastic covers to gain access to the front adjuster bolts. 6. Remove both front seat adjuster bolts. 7. Remove front seat from vehicle. Installation INSTALLATION

1. Place seat in position in vehicle. Make sure tracks are in time and locked in place. In time means that both tracks are in the same fore/aft position, same locking window on each track. 2. Install bolts to attach front of seat adjuster to the floor. Tighten bolts to 95 N.m (70 ft. lbs.). 3. Slide seat forward and then push back on the seat to ensure that both tracks are locked into position. Ensure tracks are still in time before tightening bolts and install bolts attaching rear of seat track to the floor. Tighten bolts to 95 N.m (70 ft. lbs.). 4. Verify seat operation. SEAT BACK, SECOND ROW Removal REMOVAL

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Fig. 190: Recliner Handle Cover & Mounting Fasteners Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Remove the recliner handle cover and mounting fasteners. Remove the recliner handle Remove the folding seat handle cover, mounting fasteners and handle, if equipped. Remove the outboard shield. Remove the headrest and headrest guides. Fold the seat flat and remove the seat back panel by carefully prying up on the panel until the retainers disengage. 7. For the 60 split seat only, remove the seat belt anchor mounting fastener. 8. Remove the seat cover clips and pull back to expose the inboard seat back mounting fasteners. NOTE:

On the 40 split seat, the inboard mounting fasteners are located on the outside of the seat back frame. On the 60 split seat, they are located on the inside of the seat back frame which will require the seat back cushion/cover to be removed. See Body/Seats/SEAT BACK - Removal.

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Fig. 191: SEAT BACK BOLTS Courtesy of CHRYSLER LLC 9. 10. 11. 12.

Remove the inboard seat back mounting fasteners. Remove the outboard seat back mounting fasteners. Remove the cable attachment from the back steel panel. Remove the seat back from the vehicle.

Installation INSTALLATION

Fig. 192: SEAT BACK BOLTS Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:50 AM

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1. 2. 3. 4. 5. 6. 7.

Position the seat back frame to the seat adjuster assembly. For the 40% seat back, install the inboard mounting fasteners. Tighten to 55 N-m (40 ft. lbs.). For the 40% seat back, install the outboard mounting fasteners. Tighten to 30 N-m (22 ft. lbs.). For the 60% seat back, install the inboard mounting fasteners. Tighten to 60 N-m (44 ft. lbs.). For the 60% seat back, install the outboard mounting fasteners. Tighten to 30 N-m (22 ft. lbs.). Install the seat back cushion/cover, if required. See Body/Seats/SEAT BACK - Installation. For the 60% seat back, place the seat belt and seat buckle into position. Tighten the mounting fastener to 49 N-m (36 ft. lbs.). 8. Install the cable attachment to the back steel panel.

Fig. 193: Recliner Handle Cover & Mounting Fasteners Courtesy of CHRYSLER LLC 9. 10. 11. 12. 13.

Install the outboard shield. Install the recliner handle Install the recliner handle mounting fasteners and cover. Install the folding seat handle, mounting fasteners and cover, if equipped. Install the headrest guides and headrest.

SEAT, CHILD Removal REMOVAL

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Fig. 194: Child Seat Courtesy of CHRYSLER LLC 1. COVER, BOOSTER SEAT FOAM 2. COVER, BOOSTER SEAT FOAM 3. FOAM, BOOSTER SEAT 4. SUPPORT BASE, BOOSTER SEAT 5. ASSEMBLY, BOOSTER SEAT 6. SCREW 7. STRAP, BOOSTER 8. BEZEL, PULL STRAP

9. ASSEMBLY, BOOSTER SEAT FOOT PLATE 10. SCREW 11. SCREW 12. FRONT SUPPORT, BOOSTER SEAT 13. SCREW 14. STRUT, GAS 15. FRAME, FOAM BOOSTER SEAT 16. PAD, FOAM

1. Remove the appropriate seat cushion and place on a bench. See Body/Seats/COVER, Seat Cushion Removal. 2. Unzip the seat cover. 3. Partially remove the seat cushion cover to gain access to the booster seat fasteners. 4. Remove the booster seat mounting fasteners. 5. Unlatch the booster seat and carefully place in the upright position. 6. Disengage the booster seat cover trim clips. 7. Remove the booster seat from the seat cushion. 8. If required, disengage the seat cover clips and carefully pull the booster seat cover off the foam. user Monday, June 04, 2012 9:23:50 AM

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Installation INSTALLATION

Fig. 195: Child Seat Courtesy of CHRYSLER LLC 1. COVER, BOOSTER SEAT FOAM 2. COVER, BOOSTER SEAT FOAM 3. FOAM, BOOSTER SEAT 4. SUPPORT BASE, BOOSTER SEAT 5. ASSEMBLY, BOOSTER SEAT 6. SCREW 7. STRAP, BOOSTER 8. BEZEL, PULL STRAP 1. 2. 3. 4. 5. 6. 7.

9. ASSEMBLY, BOOSTER SEAT FOOT PLATE 10. SCREW 11. SCREW 12. FRONT SUPPORT, BOOSTER SEAT 13. SCREW 14. STRUT, GAS 15. FRAME, FOAM BOOSTER SEAT 16. PAD, FOAM

If required, carefully pull the booster seat cover over the foam and engage the booster seat cover clips. Install the booster seat to the seat cushion. Engage the booster seat cover trim clips. Latch the booster seat. Install the booster seat mounting fasteners. Tighten to 13 N-m (10 ft. lbs.). Install the seat cushion cover. Zip the seat cover.

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8. Install the seat cushion. See Body/Seats/COVER, Seat Cushion - Installation.

SEATS, THIRD ROW COVER, SEAT CUSHION Removal REMOVAL

Fig. 196: Seat Cushion Cover Courtesy of CHRYSLER LLC 1. Remove the rear storage box. See Body/Interior/BOX, Storage - Removal. 2. Lift front edge of the third row seat until retainers (5) disengage. 3. With the help of an assistant, carefully pry up on the hooks (4) while the seat cushion is being pressed towards the seat back. 4. While lifting up on the hooks, pull the seat cushion out towards the front of the vehicle and remove the seat cushion. 5. Disengage J-clips from seat cushion. 6. Carefully remove the seat cover from the cushion, removing any hog rings and discarding. Installation INSTALLATION

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Fig. 197: Seat Cushion Cover Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7.

Carefully install the seat cover to the cushion, installing any hog rings required. Engage J-clips to seat cushion. Place the third row seat cushion (1) into position. Press the seat cushion back (2) and under the seat back. Ensure the seat retaining hooks (4) slide under the body side hooks. Firmly depress the front of the seat cushion down, ensuring that the seat retainers (5) engage. Install the rear storage box. See Body/Interior/BOX, Storage - Installation

SEAT BACK, THIRD ROW Removal REMOVAL

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Fig. 198: Front Seat Back Mounting Fasteners Courtesy of CHRYSLER LLC 1. Remove the seat cover and cushion. See Body/Seats/COVER, Seat Cushion - Removal. 2. Remove the retainers on the seat back gap hider from the rear storage box. 3. Remove the front seat back mounting fasteners (1).

Fig. 199: Rear Seat Back Mounting Fasteners Courtesy of CHRYSLER LLC 4. Remove the rear seat back mounting fasteners (1 and 2). 5. Remove the seat back from the vehicle. user Monday, June 04, 2012 9:23:50 AM

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Installation INSTALLATION

Fig. 200: Rear Seat Back Mounting Fasteners Courtesy of CHRYSLER LLC 1. Place the seat back into position in the vehicle. Make sure that the seat belts are position correctly. 2. Install the rear mounting fasteners (1 and 2). Tighten to 95 N.m (70 ft. lbs.).

Fig. 201: Front Seat Back Mounting Fasteners Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:50 AM

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3. Install the front mounting fasteners (1). Tighten to 95 N.m (70 ft. lbs.). 4. Install the retainers on the seat back gap hider to the rear storage box. 5. Install the seat cushion and cover. See Body/Seats/COVER, Seat Cushion - Installation.

STATIONARY GLASS WARNING WINDSHIELD SAFETY PRECAUTIONS

WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. z

z

z

z

z

z

Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. Chrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warrant will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. Be sure to refer to the urethane manufacturer's directions for curing time specifications, and do not use adhesive after its expiration date. Vapors that are emitted from the urethane adhesive or primer could cause personal injury. Use them in a well-ventilated area. Skin contact with urethane adhesive should be avoided. Personal injury may result. Always wear eye and hand protection when working with glass.

CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. GLASS, LIFTGATE Removal REMOVAL

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Fig. 202: ADHESIVE SEPARATION Courtesy of CHRYSLER LLC 1 - T-HANDLE 2 - WINDSHIELD ADHESIVE 3 - COUNTER SUPPORT 4 - CUTTING WIRE NOTE:

Windshield removal shown, backlight similar.

1. Before proceeding with the following repair procedure, review all warnings and cautions. See Body/Stationary Glass - Warning 2. Remove liftgate trim panels. See Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Removal 3. Remove rear window wiper arm, if equipped. Refer to Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Removal 4. Disconnect the heated backlight electrical connectors, if equipped. 5. Using a windshield cut-out wire or other suitable tool, separate the adhesive. 6. Carefully remove backlight. Installation INSTALLATION

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 user Monday, June 04, 2012 9:23:51 AM

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(if available) before installing backlight to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE:

The backlight fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the liftgate opening.

Glass Preparation - Installing A Previously Installed Backlight

Fig. 203: WINDSHIELD ADHESIVE PREPARATION Courtesy of CHRYSLER LLC 1 - WINDSHIELD 2 - SCRAPER 3 - OLD ADHESIVE 1. Before proceeding with the following repair procedure, review all warnings and cautions. See Body/Stationary Glass - Warning 2. Level old bead of backlight adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.

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Fig. 204: Spacers To Liftgate Frame & Backlight Courtesy of CHRYSLER LLC 3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 4. Install the lower spacers (2) to the backlight approximately 25 mm (1.0 in) from each side of the glass. NOTE:

Remove the lower spacers 2 hours after installation of the glass.

5. Position backlight in center of liftgate opening and resting on the side and lower spacers.

Fig. 205: WINDSHIELD POSITIONING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:51 AM

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1 - TAPE 2 - WINDSHIELD FRAME 6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE:

Windshield installation shown, backlight similar.

7. Verify the backlight gap is parallel to with the liftgate opening. 8. Cut tape with a sharp knife and remove backlight.

Fig. 206: WINDSHIELD PRIMER Courtesy of CHRYSLER LLC 1 - PRIMER 2 - WINDSHIELD SEAL NOTE:

Typical primer installation shown.

9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 10. Using a flash light, verify that glass primer is without damage. 11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed.

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Fig. 207: PRIMER INSTALLATION Courtesy of CHRYSLER LLC 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Backlight

Fig. 208: Spacers To Liftgate Frame & Backlight Courtesy of CHRYSLER LLC 1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 2. Install the lower spacers (2) to the backlight approximately 36 cm (1.0 in) from each side of the glass.

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NOTE:

Remove the lower spacers 2 hours after installation of the glass.

3. Position backlight in center of liftgate opening and resting on the side and lower spacers.

Fig. 209: WINDSHIELD POSITIONING Courtesy of CHRYSLER LLC 1 - TAPE 2 - WINDSHIELD FRAME 4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE:

Windshield installation shown, backlight similar.

5. Verify the backlight gap is parallel to with the liftgate opening. 6. Cut tape with a sharp knife and remove backlight.

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Fig. 210: WINDSHIELD PRIMER Courtesy of CHRYSLER LLC 1 - PRIMER 2 - WINDSHIELD SEAL NOTE:

Typical primer installation shown.

7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 8. Apply primer to gluing surface at backlight seal.

Fig. 211: PRIMER INSTALLATION Courtesy of CHRYSLER LLC 9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 10. Allow primer to air dry for at least 10 minutes. 11. Using a flash light, verify that glass primer is without damage. user Monday, June 04, 2012 9:23:51 AM

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Liftgate Opening Preparation

Fig. 212: WINDSHIELD OPENING PREPARATION Courtesy of CHRYSLER LLC 1 - OLD ADHESIVE 2 - SCRAPER 3 - WINDSHIELD OPENING NOTE:

Windshield opening shown, liftgate opening similar.

1. Clean and vacuum liftgate opening. 2. Level old bead of liftgate opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.

Fig. 213: WINDSHIELD OPENING PRIMER Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:51 AM

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1 - PRIMER 2 - WINDSHIELD OPENING NOTE:

Windshield opening shown, liftgate opening similar.

3. Clean and dry area of liftgate opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Backlight Installation

Fig. 214: WINDSHIELD ADHESIVE APPLICATION Courtesy of CHRYSLER LLC 1 - ADHESIVE BEAD 2 - WINDSHIELD SEAL 1. Apply bead of adhesive (1) with a triangular nozzle directly to the backlight seal starting at bottom in center of the backlight. CAUTION: Always apply bead of adhesive to the backlight. Always install the backlight within 5 minutes after applying adhesive.

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Fig. 215: BEAD DIMENSIONS Courtesy of CHRYSLER LLC 1 - ADHESIVE WIDTH 9.5 mm (0.375 in) 2 - ADHESIVE HEIGHT 12.7 mm (0.50 in) 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2).

Fig. 216: WINDSHIELD ADHESIVE OVERLAP Courtesy of CHRYSLER LLC 1 - ADHESIVE BEAD 2 - WINDSHIELD SEAL 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush.

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Fig. 217: Spacers To Liftgate Frame & Backlight Courtesy of CHRYSLER LLC 4. Lift backlight into place in the center of the liftgate opening and use the tape as a guide to aid installation of the backlight into the center of the cutout. 5. Carefully lay down the backlight and press on. CAUTION: It is no longer possible to move the backlight after installation. The backlight should never be pressed into place by more than one person, because the backlight 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 backlight to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install the rear wiper arm, if equipped. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper - Installation 7. Install the liftgate trim panels. GLASS, QUARTER Removal REMOVAL

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Fig. 218: ADHESIVE SEPARATION Courtesy of CHRYSLER LLC 1 - T-HANDLE 2 - WINDSHIELD ADHESIVE 3 - COUNTER SUPPORT 4 - CUTTING WIRE 1. Before proceeding with the following repair procedure, review all warnings and cautions. See Body/Stationary Glass - Warning. 2. Remove quarter panel trim. See Body/Interior/PANEL, Quarter Trim - Removal. NOTE:

Windshield removal shown, quarter glass similar.

3. Using a windshield cut-out wire (4) or other suitable tool, separate the adhesive (2). 4. Release the tabs and the tabs on the alignment pin and carefully remove the quarter glass. Installation INSTALLATION

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 quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. user Monday, June 04, 2012 9:23:51 AM

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NOTE:

The quarter glass fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected.

Glass Preparation - Installing A Previously Installed Quarter Glass

Fig. 219: WINDSHIELD ADHESIVE PREPARATION Courtesy of CHRYSLER LLC 1 - WINDSHIELD 2 - SCRAPER 3 - OLD ADHESIVE 1. Before proceeding with the following repair procedure, review all warnings and cautions. See Body/Stationary Glass - Warning 2. Level old bead of quarter glass adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.

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Fig. 220: WINDSHIELD PRIMER Courtesy of CHRYSLER LLC 1 - PRIMER 2 - WINDSHIELD SEAL NOTE:

Typical primer installation shown.

3. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 4. Using a flash light, verify that glass primer is without damage. 5. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 6. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.). NOTE:

Make sure the primer does not touch the locating pins and tabs.

7. Allow primer to air dry for at least 10 minutes. 8. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Quarter Glass

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Fig. 221: WINDSHIELD PRIMER Courtesy of CHRYSLER LLC 1 - PRIMER 2 - WINDSHIELD SEAL NOTE:

Typical primer installation shown.

1. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 2. Apply primer to gluing surface at quarter glass seal. 3. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (3). NOTE:

Make sure the primer does not touch the locating pins and tabs (2, 4).

4. Allow primer to air dry for at least 10 minutes. 5. Using a flash light, verify that glass primer is without damage. Quarter Glass Opening Preparation

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Fig. 222: WINDSHIELD OPENING PREPARATION Courtesy of CHRYSLER LLC 1 - OLD ADHESIVE 2 - SCRAPER 3 - WINDSHIELD OPENING NOTE:

Windshield opening shown, quarter glass opening similar.

1. Clean and vacuum quarter glass opening. 2. Level old bead of quarter glass opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive.

Fig. 223: WINDSHIELD OPENING PRIMER Courtesy of CHRYSLER LLC 1 - PRIMER user Monday, June 04, 2012 9:23:51 AM

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2 - WINDSHIELD OPENING NOTE:

Windshield opening shown, quarter glass opening similar.

3. Clean and dry area of quarter glass opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. NOTE:

Make sure the primer does not touch the locating pins and tabs.

5. Allow primer to air dry for at least 10 minutes. Quarter Glass Installation

Fig. 224: WINDSHIELD ADHESIVE APPLICATION Courtesy of CHRYSLER LLC 1 - ADHESIVE BEAD 2 - WINDSHIELD SEAL 1. Apply bead of adhesive (1) with a triangular nozzle directly to the quarter glass seal starting at bottom in center of the quarter glass. CAUTION: Always apply bead of adhesive to the quarter glass. Always install the quarter glass within 5 minutes after applying adhesive.

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Fig. 225: BEAD DIMENSIONS Courtesy of CHRYSLER LLC 1 - ADHESIVE WIDTH 9.5 mm (0.375 in) 2 - ADHESIVE HEIGHT 12.7 mm (0.50 in) 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2).

Fig. 226: WINDSHIELD ADHESIVE OVERLAP Courtesy of CHRYSLER LLC 1 - ADHESIVE BEAD 2 - WINDSHIELD SEAL 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift quarter glass into place in the center of the quarter glass opening and install over the alignment tabs and pin. 5. Carefully lay down the quarter glass and press on. CAUTION: It is no longer possible to move the quarter glass after installation. user Monday, June 04, 2012 9:23:51 AM

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The quarter glass should never be pressed into place by more than one person, because the quarter glass 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 quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install quarter panel trim. See Body/Interior/PANEL, Quarter Trim - Installation WINDSHIELD Description DESCRIPTION

The windshield is attached to the window frame (fence) with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the rubber seals are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and seals from the parts supplier. Removal REMOVAL

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Fig. 227: ADHESIVE SEPARATION Courtesy of CHRYSLER LLC 1. Before proceeding with the following repair procedure, review all warnings and cautions. See Body/Stationary Glass - Warning. 2. Remove the rear view mirror. See Body/Interior/MIRROR, Rearview - Removal. 3. Remove the cowl grille. See Body/Exterior/COVER, Cowl Panel - Removal CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 4. Using an assistant and a wire-type windshield cut-out tool (1, 3 and 4), cut and separate the urethane adhesive (2) securing the windshield to the windshield fence. 5. Carefully remove the windshield from the vehicle. 6. Remove molding from the sides of the windshield. Installation INSTALLATION

Fig. 228: Glass Adhesive Preparation Courtesy of CHRYSLER LLC WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the windshield. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. user Monday, June 04, 2012 9:23:51 AM

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1. If the windshield (1) is being reused, remove as much of the original urethane (3) as possible from the glass surface using a razor knife (2).

Fig. 229: WINDSHIELD OPENING PREPARATION Courtesy of CHRYSLER LLC CAUTION: To prevent corrosion, do not damage paint on windshield fence when removing original urethane. CAUTION: The windshield fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.039 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. CAUTION: Support spacers located near the cowl at the bottom of the windshield fence should be replaced with new spacers. Replace any missing or damaged spacers around the perimeter of the windshield fence. 2. Using a razor knife (2), level the original bead of urethane (1) on the windshield fence (3) to a thickness of approximately 1 mm (0.04 in.) and remove any damaged adhesive backed spacers. 3. Install new adhesive backed spacers along the windshield fence as required. 4. Install a new rubber seal along the sides of the windshield. 5. Using an assistant, position the windshield into the windshield opening and against the windshield fence and spacers. 6. Verify the windshield lays evenly against the fence at the top, bottom and sides of the opening. If not, the fence must be formed to the shape of the windshield. 7. Mark the windshield and the windshield fence with a grease pencil or pieces of masking tape to use as a reference for installation. user Monday, June 04, 2012 9:23:51 AM

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8. Using an assistant, remove the windshield from the windshield opening and place it on a suitable padded work surface.

Fig. 230: WINDSHIELD PRIMER Courtesy of CHRYSLER LLC WARNING: Do not use solvent based glass cleaners to clean the windshield before applying glass prep and primer or poor glass adhesion may result. 9. Clean the inside of the windshield with an ammonia based glass cleaner and a lint-free cloth. 10. Apply glass prep adhesion promoter 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 11. Apply glass primer 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 12. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the windshield. 13. Re-prime any area that is not fully and evenly primed.

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Fig. 231: WINDSHIELD OPENING PRIMER Courtesy of CHRYSLER LLC 14. Clean the windshield fence with an ammonia based glass cleaner and a lint-free cloth. 15. Apply pinch weld primer 15 mm (0.75 in.) wide (1) around the windshield fence (2). Allow at least three minutes drying time. 16. Using a flashlight, verify that the primer is completely and evenly installed along the windshield fence. 17. Re-prime any area that is not fully and evenly primed.

Fig. 232: WINDSHIELD ADHESIVE APPLICATION Courtesy of CHRYSLER LLC CAUTION: Always apply the bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying the adhesive. NOTE:

If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing

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new adhesive. 18. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive (1) with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass (2) starting at the bottom center of the windshield.

Fig. 233: WINDSHIELD ADHESIVE OVERLAP Courtesy of CHRYSLER LLC 19. Run the end of the adhesive bead (1) on the windshield (2) parallel to the start of the bead and smooth the ends flush. 20. Using an assistant, position the windshield over the windshield opening. 21. Using the grease pencil marks or tape as reference points, align the windshield to the windshield opening. 22. Carefully lower the windshield into the windshield opening. Guide the windshield and the rubber seals on the sides of the windshield into its proper location. CAUTION: It is not possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. 23. Push the windshield inward until the windshield comes into contact with the spacers ocated on each side and the bottom of the windshield fence. 24. Install the cowl grill. See Body/Exterior/COVER, Cowl Panel - Removal. 25. Install the rear view mirror onto the windshield. See Body/Interior/MIRROR, Rearview - Installation.

SUNROOF DESCRIPTION DESCRIPTION user Monday, June 04, 2012 9:23:51 AM

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Fig. 234: Exploded View Of Sunroof Courtesy of CHRYSLER LLC SUNROOF ASSEMBLY BREAKDOWN 1 - DRAIN TROUGH 2 - GLASS ASSEMBLY 3 - SUN SHADE 4 - WIND DEFLECTOR 5 - MOTOR

6 - MOTOR SCREWS (3) 3 N.m (26 in. lbs.) 7 - GLASS ASSEMBLY SCREWS (4) 3.5 N.m (31 in. lbs.) 8 - FRAME ASSEMBLY 9 - BRACKETS 10 - END CAPS

WARNING: Keep fingers and other body parts out of sunroof opening at all times.

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The sunroof features a power sliding glass panel and a sunshade which can be manually positioned anywhere along its travel, rearward of glass panel front edge. DIAGNOSIS AND TESTING WATER DRAINAGE AND WIND NOISE

The sliding glass panel is designed to seal water entry with a snug fit between the roof and the seal. The fit can be checked by inserting a piece of paper between the roof and the seal. The piece of paper should have some resistance when pulled out when the glass panel is in the closed position. The sunroof housing will drain off a minimum amount of water. Excessive wind noise could result if the gap clearances are exceeded. The sunroof glass panel may need to be adjusted. See Body/Sunroof/GLASS, Sunroof - Adjustments. Adequate drainage is provided by a drain trough in the sunroof housing which encircles the sliding glass panel and leads to drain hoses. If a wet headliner or other water leak complaints are encountered, before performing any adjustments, first ensure that the drainage system is not plugged or disconnected. Use a pint container to pour water into the sunroof housing drain trough. If water flow is restricted, use compressed air to blow out any material plugging the drain system. Retest system again. To further check for a disconnected drain hose: 1. Remove A-pillar trim, sun visors, and map lamps/mini console. 2. Lower headliner as necessary to gain access to sunroof housing drain tubes. See Body/Interior/HEADLINER - Removal. 3. Repair as necessary. 4. Install headliner. See Body/Interior/HEADLINER - Installation. DEFLECTOR, WIND Removal REMOVAL

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Fig. 235: Wind Deflector Spring Lock Courtesy of CHRYSLER LLC 1. Open the sunroof glass to the full open position. 2. Press the spring lock (1) with a small flat bladed tool and push the wind deflector (2) reward to release from the car top opening. 3. Repeat the previous step on the opposite side.

Fig. 236: Wind Deflector Springs Courtesy of CHRYSLER LLC 4. Rotate the wind deflector (1) up and release from the mounting hole (2) in the sunroof frame. Installation INSTALLATION

Fig. 237: Wind Deflector Springs user Monday, June 04, 2012 9:23:51 AM

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Courtesy of CHRYSLER LLC 1. Position the wind deflector springs (1) into the mounting holes (2) in the sunroof frame. 2. Rotate forward and down into position.

Fig. 238: Sliding Wind Deflector & Spring Forward Courtesy of CHRYSLER LLC 3. Slide the wind deflector and spring (1) forward under the car top lip and make sure the spring lock snaps into place (2) fully. GLASS, SUNROOF Removal REMOVAL

Fig. 239: GLASS PANEL Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:51 AM

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1. 2. 3. 4.

Slide sunshade rearward to the open position. Move the glass panel to the closed position. Remove the four glass panel screws (1). Lift off glass panel and remove from vehicle.

Installation INSTALLATION

Fig. 240: GLASS PANEL Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Position glass panel (2) on to mechanism lift arm. Start the four attaching screws (1). Center glass in opening by running a business card around the glass. Adjust glass panel. See Body/Sunroof/GLASS, Sunroof - Adjustments.

Adjustments GLASS PANEL

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Fig. 241: GLASS PANEL Courtesy of CHRYSLER LLC 1. Move the sunshade rearward to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Adjust the glass one corner at a time. a. Loosen four glass screws (1). b. Lift glass assembly and align the top of the glass panel to the top of the roof panel. c. Tighten screw to 3 N.m (26 in. lbs.). d. Repeat steps a. and b. for each corner of the glass panel. e. When properly adjusted, the front of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface and the rear edge of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface.

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Fig. 242: FRONT ADJUST Courtesy of CHRYSLER LLC NOTE:

When properly adjusted, the front of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface (2).

Fig. 243: REAR ADJUST Courtesy of CHRYSLER LLC NOTE:

When properly adjusted, the rear edge of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface (2).

4. Verify sunroof operation and alignment. Check fit and re-adjust as necessary. MOTOR, SUNROOF, WITH CONTROL UNIT Standard Procedure DRIVE MOTOR TEACH PROCEDURE REPLACEMENT DRIVE MOTOR

1. Press and hold the sunroof switch open until the sunroof glass fully opens, automatically reverses direction, and stops at a position just forward of the full open position. 2. Release sunroof switch. 3. Within five seconds of releasing sunroof switch, press and hold the sunroof switch open again until the sunroof glass closes, goes into vent position, and then finally stops in the closed position. 4. Release sunroof switch. Sunroof will now operate normally. user Monday, June 04, 2012 9:23:51 AM

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ORIGINAL DRIVE MOTOR

1. Press and hold sunroof switch open until the sunroof glass opens and stops. 2. Release sunroof switch. 3. Press and hold sunroof switch open once again for at least 10 seconds. After 10 seconds of pressing the switch open, the sunroof glass will automatically move and stop at a new location. 4. Release sunroof switch. 5. Within five seconds of releasing the sunroof switch, press and hold the switch open again until the sunroof glass closes, goes into vent position, and then finally stops in the closed position. 6. Release sunroof switch. The sunroof will now operate normally. Removal REMOVAL

Fig. 244: DRIVE MOTOR Courtesy of CHRYSLER LLC 1 - ELECTRICAL CONNECTOR 2 - MODULE ASSEMBLY 3 - DRIVE MOTOR 4 - MOUNTING SCREWS 1. Drop headliner to dash. See Body/Interior/HEADLINER - Removal 2. Disconnect the electrical connector (1). 3. Remove three motor assembly attaching screws (4) from bottom side of motor assembly (3) and remove motor assembly from the motor bracket. Installation INSTALLATION

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Fig. 245: LIFT ARM POSITIONING Courtesy of CHRYSLER LLC 1 - LIFTER ARM 2 - TROLLEY 3 - ALIGNMENT PIN 1. If sunroof was open when drive motor was removed, carefully move glass panel into closed position and remove glass panel. See Body/Sunroof/GLASS, Sunroof - Removal 2. Set lifter arm timing by manually sliding the mechanisms (1) in the track until timing holes in the trollies are aligned with the timing holes in the lifter arm cams (2) and insert pins (3) into the mechanisms to hold mechanisms in closed position.

Fig. 246: DRIVE MOTOR Courtesy of CHRYSLER LLC 1 - ELECTRICAL CONNECTOR user Monday, June 04, 2012 9:23:51 AM

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2 - MODULE ASSEMBLY 3 - DRIVE MOTOR 4 - MOUNTING SCREWS 3. Place motor (3) into position and install screws (4) attaching motor to bracket (2). 4. Tighten the screws (4) to 3 N.m (26 in. lbs.). 5. If sunroof glass panel was removed previously, remove the timing pins and install the sunroof glass panel. See Body/Sunroof/GLASS, Sunroof - Installation 6. Partially install the headliner and connect the sunroof wiring electrical connectors. See Body/Interior/HEADLINER - Installation 7. Temporarily install sunroof switch and perform the sunroof motor teach procedure. See Body/Sunroof/MOTOR, Sunroof - Standard Procedure 8. Test sunroof operation, adjust glass as necessary. See Body/Sunroof/GLASS, Sunroof - Adjustments 9. Raise headliner to roof. Complete the headliner installation. See Body/Interior/HEADLINER Installation SEAL, SUNROOF GLASS Removal REMOVAL

Fig. 247: GLASS SEAL Courtesy of CHRYSLER LLC 1. Remove sunroof glass panel. See Body/Sunroof/GLASS, Sunroof - Removal. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Installation INSTALLATION

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Fig. 248: GLASS SEAL Courtesy of CHRYSLER LLC NOTE:

Always position seal seam on center of the passenger side of glass panel.

1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel. See Body/Sunroof/GLASS, Sunroof - Installation. SUNROOF Removal REMOVAL

Fig. 249: BATTERY SYSTEM COMPONENTS Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:51 AM

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1. 2. 3. 4.

Move glass panel to fully closed position. Disconnect and isolate negative battery cable (4). Remove control switch. Refer to Electrical/Power Top/SWITCH, Sunroof - Removal . Drop headliner to seat. See Body/Interior/HEADLINER - Removal.

Fig. 250: ELECTRICAL CONNECTOR Courtesy of CHRYSLER LLC 5. Disconnect the electrical connector.

Fig. 251: Drain Tubes From Sunroof Housing Courtesy of CHRYSLER LLC 6. Disconnect drain tubes (2) from sunroof housing (1). user Monday, June 04, 2012 9:23:51 AM

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Fig. 252: Sunroof Module Assembly Courtesy of CHRYSLER LLC 7. 8. 9. 10. 11. 12. 13.

Remove two module side bracket (4) bolts (6) and loosen the six remaining fasteners (3). Remove the six (3) fasteners attaching sunroof module assembly (1) to roof panel. Remove the glass panel. See Body/Sunroof/GLASS, Sunroof - Removal. Remove the sunshade. See Body/Sunroof/SUNSHADE, Sunroof - Removal. Remove the drive motor. Refer to Electrical/Power Top/MOTOR, Sunroof - Removal . Remove the wire harness. Remove the trough guides. See Body/Sunroof/TROUGH, Sunroof - Removal

Installation INSTALLATION

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Fig. 253: Sunroof Module Assembly Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8.

Install the trough guides. See Body/Sunroof/TROUGH, Sunroof - Installation. Install the drive motor. Refer to Electrical/Power Top/MOTOR, Sunroof - Installation . Install the sunshade. See Body/Sunroof/SUNSHADE, Sunroof - Installation. Install the glass panel. See Body/Sunroof/GLASS, Sunroof - Installation. Raise rear end of sunroof module assembly (1) and guide into position and start the six fasteners (3). Visually line up the alignment guide holes (2) with the guide holes in the roof of the vehicle. Tighten the six fasteners (3) to 9 N.m (80 in. lbs.). Tighten the two side bracket fasteners (6) to 9 N.m (80 in. lbs.).

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Fig. 254: Drain Tubes From Sunroof Housing Courtesy of CHRYSLER LLC 9. Connect the drain tubes (2) to the assembly (1).

Fig. 255: ELECTRICAL CONNECTOR Courtesy of CHRYSLER LLC 10. 11. 12. 13.

Connect the electrical connector. Connect the battery negative cable. Test sunroof operation, adjust glass as necessary. See Body/Sunroof/GLASS, Sunroof - Adjustments. Partially install the headliner and connect the sunroof wiring electrical connectors. See Body/Interior/HEADLINER - Installation. 14. Temporarily install sunroof switch and perform the sunroof motor teach procedure. See Body/Sunroof/MOTOR, Sunroof - Standard Procedure.

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15. Install the headliner. See Body/Interior/HEADLINER - Installation. 16. Verify correct sunroof operation. SUNSHADE, SUNROOF Removal REMOVAL

Fig. 256: Front Center Of Sunshade Courtesy of CHRYSLER LLC 1. Remove the drain trough. See Body/Sunroof/TROUGH, Sunroof - Removal 2. Push up the front center of the sunshade (1) to pop out the front two feet.

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Fig. 257: Rotating Sunshade So That Other Feet Are Removed From Guide Track Courtesy of CHRYSLER LLC 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. Installation INSTALLATION

Fig. 258: Rotating Sunshade So Other Rear Foot Is In Track As Well As Other Feet On Same Side As First Foot Courtesy of CHRYSLER LLC 1. Verify the sunshade track is free of obstructions like the trim lace/ring. user Monday, June 04, 2012 9:23:51 AM

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2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot.

Fig. 259: Insertingmaining Two Feet Apply Force To Middle Front Of Sunshade Courtesy of CHRYSLER LLC 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain trough. See Body/Sunroof/TROUGH, Sunroof - Installation TROUGH, SUNROOF Removal REMOVAL

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Fig. 260: Trough Pins From Glass Lift Mechanisms Courtesy of CHRYSLER LLC 1. Remove the glass. See Body/Sunroof/GLASS, Sunroof - Removal. 2. Separate the trough pins (3) from the glass lift mechanisms (1).

Fig. 261: Guide Shoe Tab Courtesy of CHRYSLER LLC 3. Slide trough (1) to one side and push down on the center of the trough until the guide shoe tab (3) releases from the track (2). 4. Slide the trough in the opposite direction to release the other shoe and lift the trough out of the sunroof opening. user Monday, June 04, 2012 9:23:51 AM

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Installation INSTALLATION

Fig. 262: Guide Shoe Tab Courtesy of CHRYSLER LLC 1. Insert one of the trough guides (3) and guide shoe (2) into the track. 2. Push down on the center of the trough (1) to flatten it out and install the remaining trough guide (3) and guide shoe (2) into the track.

Fig. 263: Trough Pins From Glass Lift Mechanisms Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:51 AM

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3. Install the trough guide pins into the glass lift mechanism (3) and seat fully. 4. Install the glass. See Body/Sunroof/GLASS, Sunroof - Installation. TUBE, SUNROOF DRAIN Removal REMOVAL

Fig. 264: FRONT HOSE Courtesy of CHRYSLER LLC 1. Drop down the headliner as necessary to gain access to the drain hoses. See Body/Interior/HEADLINER - Removal. 2. Disconnect the front hoses (2) from the sunroof assembly (1). 3. Release the support clips (3) and disconnect the lower grommet and remove the hose.

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Fig. 265: Drain Tubes From Sunroof Housing Courtesy of CHRYSLER LLC 4. Disconnect the rear hoses (2) from the sunroof assembly (1) and release the support clips (3).

Fig. 266: Support Clips Courtesy of CHRYSLER LLC 5. Separate the remaining support clips (1). 6. Disconnect the grommet (2) from the body (3) and remove the rear hoses as necessary. user Monday, June 04, 2012 9:23:51 AM

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Installation INSTALLATION

Fig. 267: Support Clips Courtesy of CHRYSLER LLC 1. Install the rear hoses (4) and connect the grommets (2) to the body (3). 2. Connect the support clips (1).

Fig. 268: Drain Tubes From Sunroof Housing user Monday, June 04, 2012 9:23:51 AM

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Courtesy of CHRYSLER LLC 3. Route the hose as required and connect the remaining support clips (3). 4. Connect the hoses (2) to the sunroof assembly (1).

Fig. 269: FRONT HOSE Courtesy of CHRYSLER LLC 5. Connect the front hose lower grommet to the body. 6. Connect the front hose (2) to the sunroof assembly (1) and connect the support clips (3).

BODY STRUCTURE GAP AND FLUSH Specifications GAP AND FLUSH

INDEX DESCRIPTION BODY GAP AND FLUSH

FIGURE Fig. 270

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Fig. 270: GAP & FLUSH Courtesy of CHRYSLER LLC NOTE: z

All dimensions are in millimeters.

O/F = Over Flush

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z z z

U/F = Under Flush U/D = Up/Down F/A = Fore/Aft

DIMENSION

DESCRIPTION

GAP

1

Headlamp to Hood

8.0 +/- 2.0 Parallel within 1.5

2

Hood to Grille

8.0 +/- 2.0

3

Headlamp to Fender

2.0 +/- 1.5 Parallel within 2.0

Fender to Hood

4.0 +/- 1.5 Parallel within 1.5 Symmetrical within 1.5 LH to RH 4.5 @ 10mm From Rear

Fender O/F 1.0 +/- 1.5 Consistent within 1.5

4.0 +/- 1.5 Parallel within 1.5

Door U/F -1.6 +/- 1.5 Consistent within 1.5

3.2 +/- 1.0 Parallel within 1.0

Door U/F 0.5 +/- 1.0 Consistent within 1.0

4.0 +/- 1.5 Parallel within 1.5

0.0 +/- 1.5 Consistent within 1.5

4.0 +/- 1.5 Parallel within 1.5 4.25 +/- 1.5 Parallel within 1.0

Front Door O/F 1.0 +/-1.5 Consistent within 1.0 Fender O/F 1.0 +/- 1.5 Consistent within 1.5 Fascia U/F 1.0 +/- 1.0 Consistent within 1.5

4

5 6 7 8

Front AND Rear Door Header to Body Side Aperture Fuel Filler Door to Body Side Aperture Front Door to Rear Door (Above Belt) Front Door to Rear Door (Below Belt

9

Fender to Front Door

10

Fascia to Fender

11

Headlamp to Fascia

12

Headlamp to Grille

13

Grille to Fascia

Net to 1.0 2.0 +/- 2.0 Parallel within 2.0 2.0 +/- 2.0 Parallel within 2.0 2.0 +/- 2.0 Parallel within 2.0

FLUSH Headlamp U/F 2.5@Y= +/525 Headlamp U/F 3.5@Y=+/675 Consistent within 2.0 Grille U/F 1.8 +/- 2.0 Top: Headlamp U/F 2.0 @ Y = +/-725 2.5 @ Y = +/- 575 Side: Headlamp U/F 1.0 +/2.0 Consistent within 2.0

0.0 +/- 2.0 Consistent within 2.0 Lift Gate (Above Belt) U/F 2.0

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14

Body Side Aperture to Lift Gate

15

Lift Gate to Roof

16

Lift Gate to Body Side Aperture

6.2 +/- 1.5 Parallel within 1.5 6.2 +/- 1.5 Parallel within 1.5

17

Quarter Glass to Rear Door

4.0 +/- 2.0 Parallel within 2.0

18 19 20

Front AND Rear Door to Body Side Aperture Sill Rear Door to Body Side Aperture Fascia to Body Side Aperture

5.0 +/- 1.5 Parallel within 1.5

6.0 +/- 2.5 Parallel within 2.0 4.0 +/- 1.5 Parallel within 1.5 Net to 1.0

21

Body Side Aperture Tail Lamp to Fascia

2.0 +/- 2.0 Parallel within 2.0

22

Body Side Aperture Tail Lamp to Lift Gate

23

Lift Gate to Fascia

24

Lift Gate to Fascia

3.7 +/- 2.0 Parallel within 1.0 U/D 8.0 +/- 2.0 Parallel within 2.0 Cross/Car 4.2 +/- 1.5 Parallel within 2.0

Lift Gate (Below Belt U/F 1.0 +/- 1.5 Consistent within 1.5 Lift Gate U/F 2.0 +/- 1.5 Consistent within 1.5 Lift Gate U/F 2.0 +/- 1.5 Consistent within 1.5 Glass U/F 2.0 @ Z = 1150 Glass U/F 1.5 @ Z = 900 +/- 2.0 Consistent within 2.0 Rear Door O/F 1.0 +/- 1.5 Consistent within 1.5 Fascia U/F 1.0 +/- 1.0 Consistent within 1.5 Tail Lamp U/F 0.0 to 1.5 +/- 2.0 Consistent within 2.0 Lift Gate O/F 1.0 +/- 2.0 Consistent within 1.0 Liftgate U/F 1.0 +/- 1.5 Consistent within 2.0

OPENING DIMENSIONS Specifications BODY OPENING DIMENSIONS

INDEX DESCRIPTION ENGINE BOX WINDSHIELD FRONT DOOR REAR DOOR REAR QUARTER WINDOW LIFTGATE

FIGURE Fig. 271 Fig. 272 Fig. 273 Fig. 274 Fig. 275 Fig. 276

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LIFTGATE WINDOW

Fig. 277

Fig. 271: ENGINE BOX Courtesy of CHRYSLER LLC

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Fig. 272: WINDSHIELD Courtesy of CHRYSLER LLC

Fig. 273: FRONT DOOR Courtesy of CHRYSLER LLC

Fig. 274: REAR DOOR user Monday, June 04, 2012 9:23:52 AM

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Courtesy of CHRYSLER LLC

Fig. 275: REAR QUARTER WINDOW Courtesy of CHRYSLER LLC

Fig. 276: LIFTGATE Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:23:52 AM

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Fig. 277: LIFTGATE WINDOW Courtesy of CHRYSLER LLC SEALER LOCATIONS Specifications BODY SEALER LOCATIONS

INDEX DESCRIPTION APPLICATION METHODS COWL SIDE TO DASH PANEL DASH TO COWL COWL SIDE TO DASH PANEL DASH TO COWL STEERING BRACKET A-PILLAR FRONT FLOOR PAN TO DASH FRONT FLOOR PAN TO SILL INNER SILL SIDE SILL TO FLOOR PAN FRONT FLOOR TO STORAGE BINS FRONT FLOOR PAN TO REAR CROSSMEMBER MID FLOOR/REAR FLOOR PAN TO SIDEMEMBER MID FLOOR PAN TO 3RD ROW CROSSMEMBER

FIGURE Fig. 278 Fig. 279 Fig. 280 Fig. 281 Fig. 282 Fig. 283 Fig. 284 Fig. 285 Fig. 286 Fig. 287 Fig. 288 Fig. 289 Fig. 290 Fig. 291

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REAR SILL TO REAR FLOOR PAN REAR WHEEL HOUSE TO BODY SIDE APERTURE INNER INNER WHEELHOUSE TO INNER BODY SIDE APERTURE REAR WHEELHOUSE TO REAR FLOOR PAN 3RD ROW CROSSMEMBER TO REAR FLOOR PAN BODY SIDE APERTURE - LOWER FRONT DOOR OPENING BODY SIDE APERTURE - REAR REAR FLOOR PAN TO BODY SIDE APERTURE INNER STORAGE BIN REAR FLOOR UPPER CROSSMEMBER TO REAR FLOOR PAN BODY SIDE APERTURE TO ROOF PANEL UPPER LIFTGATE OPENING BODY SIDE APERTURE TO DRAIN CHANNEL BODY SIDE APERTURE TO TAIL LAMP HOUSING PANEL LIFTGATE DRAIN CHANNEL TO LOWER DECK ROOF TO LIFTGATE DRAIN CHANNEL

Fig. 292 Fig. 293 Fig. 294 Fig. 295 Fig. 296 Fig. 297 Fig. 298 Fig. 299 Fig. 300 Fig. 301 Fig. 302 Fig. 303 Fig. 304 Fig. 305 Fig. 306 Fig. 307

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Fig. 278: APPLICATION METHODS Courtesy of CHRYSLER LLC

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Fig. 279: COWL SIDE TO DASH PANEL Courtesy of CHRYSLER LLC

Fig. 280: DASH TO COWL Courtesy of CHRYSLER LLC

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Fig. 281: COWL SIDE TO DASH PANEL Courtesy of CHRYSLER LLC

Fig. 282: DASH TO COWL STEERING BRACKET Courtesy of CHRYSLER LLC

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Fig. 283: A-PILLAR Courtesy of CHRYSLER LLC

Fig. 284: FRONT FLOOR PAN TO DASH Courtesy of CHRYSLER LLC

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Fig. 285: FRONT FLOOR PAN TO SILL Courtesy of CHRYSLER LLC

Fig. 286: INNER SILL Courtesy of CHRYSLER LLC

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Fig. 287: SIDE SILL TO FLOOR PAN Courtesy of CHRYSLER LLC

Fig. 288: FRONT FLOOR TO STORAGE BINS Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 9:23:52 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

Fig. 289: FRONT FLOOR PAN TO REAR CROSSMEMBER Courtesy of CHRYSLER LLC

Fig. 290: MID FLOOR/REAR FLOOR PAN TO SIDEMEMBER Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

Fig. 291: MID FLOOR PAN TO 3RD ROW CROSSMEMBER Courtesy of CHRYSLER LLC

Fig. 292: REAR SILL TO REAR FLOOR PAN Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 9:23:52 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

Fig. 293: REAR WHEEL HOUSE TO BODY SIDE APERTURE INNER Courtesy of CHRYSLER LLC

Fig. 294: INNER WHEELHOUSE TO INNER BODY SIDE APERTURE Courtesy of CHRYSLER LLC

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Fig. 295: REAR WHEELHOUSE TO REAR FLOOR PAN Courtesy of CHRYSLER LLC

Fig. 296: 3RD ROW CROSSMEMBER TO REAR FLOOR PAN Courtesy of CHRYSLER LLC

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Page 251

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Fig. 297: BODY SIDE APERTURE - LOWER FRONT DOOR OPENING Courtesy of CHRYSLER LLC

Fig. 298: BODY SIDE APERTURE - REAR Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

Fig. 299: REAR FLOOR PAN TO BODY SIDE APERTURE INNER Courtesy of CHRYSLER LLC

Fig. 300: STORAGE BIN REAR FLOOR Courtesy of CHRYSLER LLC

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Fig. 301: UPPER CROSSMEMBER TO REAR FLOOR PAN Courtesy of CHRYSLER LLC

Fig. 302: BODY SIDE APERTURE TO ROOF PANEL Courtesy of CHRYSLER LLC

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Fig. 303: UPPER LIFTGATE OPENING Courtesy of CHRYSLER LLC

Fig. 304: BODY SIDE APERTURE TO DRAIN CHANNEL Courtesy of CHRYSLER LLC

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Fig. 305: BODY SIDE APERTURE TO TAIL LAMP HOUSING PANEL Courtesy of CHRYSLER LLC

Fig. 306: LIFTGATE DRAIN CHANNEL TO LOWER DECK Courtesy of CHRYSLER LLC

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Fig. 307: ROOF TO LIFTGATE DRAIN CHANNEL Courtesy of CHRYSLER LLC STRUCTURAL ADHESIVE LOCATIONS Specifications STRUCTURAL ADHESIVE LOCATIONS

INDEX DESCRIPTION COWL SIDE/ENGINE BOX LOAD BEAM COWL SIDE PANEL SIDEMEMBER (1 OF 2) SIDEMEMBER (2 OF 2) REAR FLOOR/BODY SIDE APERTURE REAR FLOOR/CROSSMEMBER LOWER LIFTGATE OPENING LOWER LIFTGATE OPENING CROSSMEMBER BODY SIDE APERTURE/UPPER LIFTGATE OPENING CROSSMEMBER BODY SIDE APERTURE/ROOF BOW (TYPICAL) BODY SIDE APERTURE/ROOF PANEL ROOF BOWS/ROOF PANEL

FIGURE Fig. 308 Fig. 309 Fig. 310 Fig. 311 Fig. 312 Fig. 313 Fig. 314 Fig. 315 Fig. 316 Fig. 317 Fig. 318 Fig. 319

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Fig. 308: COWL SIDE/ENGINE BOX Courtesy of CHRYSLER LLC

Fig. 309: LOAD BEAM Courtesy of CHRYSLER LLC

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Fig. 310: COWL SIDE PANEL Courtesy of CHRYSLER LLC

Fig. 311: SIDEMEMBER (1 OF 2) Courtesy of CHRYSLER LLC

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Fig. 312: SIDEMEMBER (2 OF 2) Courtesy of CHRYSLER LLC

Fig. 313: REAR FLOOR/BODY SIDE APERTURE Courtesy of CHRYSLER LLC

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Fig. 314: REAR FLOOR/CROSSMEMBER LOWER LIFTGATE OPENING Courtesy of CHRYSLER LLC

Fig. 315: LOWER LIFTGATE OPENING CROSSMEMBER Courtesy of CHRYSLER LLC

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Fig. 316: BODY SIDE APERTURE/UPPER LIFTGATE OPENING CROSSMEMBER Courtesy of CHRYSLER LLC

Fig. 317: BODY SIDE APERTURE/ROOF BOW (TYPICAL) Courtesy of CHRYSLER LLC

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Fig. 318: BODY SIDE APERTURE/ROOF PANEL Courtesy of CHRYSLER LLC

Fig. 319: ROOF BOWS/ROOF PANEL Courtesy of CHRYSLER LLC WELD LOCATIONS user Monday, June 04, 2012 9:23:52 AM

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Specifications WELD LOCATIONS

INDEX DESCRIPTION FRONT WHEELHOUSE (1 OF 6) FRONT WHEELHOUSE (2 OF 6) FRONT WHEELHOUSE (3 OF 6) FRONT WHEELHOUSE (4 OF 6) FRONT WHEELHOUSE (5 OF 6) FRONT WHEELHOUSE (6 OF 6) DASH (1 OF 3) DASH (2 OF 3) DASH (3 OF 3) PLENUM/COWL (1 OF 7) PLENUM/COWL (2 OF 7) PLENUM/COWL (3 OF 7) PLENUM/COWL (4 OF 7) PLENUM/COWL (5 OF 7) PLENUM/COWL (6 OF 7) PLENUM/COWL (7 OF 7) PLENUM/DASH (1 OF 2) PLENUM/DASH (2 OF 2) ENGINE BOX (1 OF 17) ENGINE BOX (2 OF 17) ENGINE BOX (3 OF 17) ENGINE BOX (4 OF 17) ENGINE BOX (5 OF 17) ENGINE BOX (6 OF 17) ENGINE BOX (7 OF 17) ENGINE BOX (8 OF 17) ENGINE BOX (9 OF 17) ENGINE BOX (10 OF 17) ENGINE BOX (11 OF 17) ENGINE BOX (12 OF 17) ENGINE BOX (13 OF 17) ENGINE BOX (14 OF 17) ENGINE BOX (15 OF 17) ENGINE BOX (16 OF 17) ENGINE BOX (17 OF 17) FRONT FLOOR (1 OF 7)

FIGURE Fig. 320 Fig. 321 Fig. 322 Fig. 323 Fig. 324 Fig. 325 Fig. 326 Fig. 327 Fig. 328 Fig. 329 Fig. 330 Fig. 331 Fig. 332 Fig. 333 Fig. 334 Fig. 335 Fig. 336 Fig. 337 Fig. 338 Fig. 339 Fig. 340 Fig. 341 Fig. 342 Fig. 343 Fig. 344 Fig. 345 Fig. 346 Fig. 347 Fig. 348 Fig. 349 Fig. 350 Fig. 351 Fig. 352 Fig. 353 Fig. 354 Fig. 355

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FRONT FLOOR (2 OF 7) FRONT FLOOR (3 OF 7) FRONT FLOOR (4 OF 7) FRONT FLOOR (5 OF 7) FRONT FLOOR (6 OF 7) FRONT FLOOR (7 OF 7) UNDERBODY (1 OF 5) UNDERBODY (2 OF 5) UNDERBODY (3 OF 5) UNDERBODY (4 OF 5) UNDERBODY (5 OF 5) UNDERBODY REAR (1 OF 4) UNDERBODY REAR (2 OF 4) UNDERBODY REAR (3 OF 4) UNDERBODY REAR (4 OF 4) MISCELLANEOUS BODY SIDEMEMBER (1 OF 16) SIDEMEMBER (2 OF 16) SIDEMEMBER (3 OF 16) SIDEMEMBER (4 OF 16) SIDEMEMBER (5 OF 16) SIDEMEMBER (6 OF 16) SIDEMEMBER (7 OF 16) SIDEMEMBER (8 OF 16) SIDEMEMBER (9 OF 16) SIDEMEMBER (10 OF 16) SIDEMEMBER (11 OF 16) SIDEMEMBER (12 OF 16) SIDEMEMBER (13 OF 16) SIDEMEMBER (14 OF 16) SIDEMEMBER (15 OF 16) SIDEMEMBER (16 OF 16) MISCELLANEOUS COWL/FLOOR (1 OF 3) MISCELLANEOUS COWL/FLOOR (2 OF 3) MISCELLANEOUS COWL/FLOOR (3 OF 3) UNDERBODY COMPLETE (1 OF 21) UNDERBODY COMPLETE (2 OF 21) UNDERBODY COMPLETE (3 OF 21) UNDERBODY COMPLETE (4 OF 21) UNDERBODY COMPLETE (5 OF 21) UNDERBODY COMPLETE (6 OF 21)

Fig. 356 Fig. 357 Fig. 358 Fig. 359 Fig. 360 Fig. 361 Fig. 362 Fig. 363 Fig. 364 Fig. 365 Fig. 366 Fig. 367 Fig. 368 Fig. 369 Fig. 370 Fig. 371 Fig. 372 Fig. 373 Fig. 374 Fig. 375 Fig. 376 Fig. 377 Fig. 378 Fig. 379 Fig. 380 Fig. 381 Fig. 382 Fig. 383 Fig. 384 Fig. 385 Fig. 386 Fig. 387 Fig. 388 Fig. 389 Fig. 390 Fig. 391 Fig. 392 Fig. 393 Fig. 394 Fig. 395 Fig. 396

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UNDERBODY COMPLETE (8 OF 21) UNDERBODY COMPLETE (9 OF 21) UNDERBODY COMPLETE (10 OF 21) UNDERBODY COMPLETE (11 OF 21) UNDERBODY COMPLETE (12 OF 21) UNDERBODY COMPLETE (13 OF 21) UNDERBODY COMPLETE (14 OF 21) UNDERBODY COMPLETE (15 OF 21) UNDERBODY COMPLETE (16 OF 21) UNDERBODY COMPLETE (17 OF 21) UNDERBODY COMPLETE (18 OF 21) 090 UNDERBODY COMPLETE (19 OF 21) UNDERBODY COMPLETE (20 OF 21) UNDERBODY COMPLETE (21 OF 21) BODY SIDE APERTURE (1 OF 14) BODY SIDE APERTURE (2 OF 14) BODY SIDE APERTURE (3 OF 14) BODY SIDE APERTURE (4 OF 14) BODY SIDE APERTURE (5 OF 14) BODY SIDE APERTURE (6 OF 14) BODY SIDE APERTURE (7 OF 14) BODY SIDE APERTURE (8 OF 14) BODY SIDE APERTURE (9 OF 14) BODY SIDE APERTURE (10 OF 14) BODY SIDE APERTURE (11 OF 14) BODY SIDE APERTURE (12 OF 14) BODY SIDE APERTURE (13 OF 14) BODY SIDE APERTURE (14 OF 14) BODY SIDE APERTURE COMPLETE (1 OF 18) BODY SIDE APERTURE COMPLETE (2 OF 18) BODY SIDE APERTURE COMPLETE (3 OF 18) BODY SIDE APERTURE COMPLETE (4 OF 18) BODY SIDE APERTURE COMPLETE (5 OF 18) BODY SIDE APERTURE COMPLETE (6 OF 18) BODY SIDE APERTURE COMPLETE (7 OF 18) BODY SIDE APERTURE COMPLETE (8 OF 18) BODY SIDE APERTURE COMPLETE (9 OF 18) BODY SIDE APERTURE COMPLETE (10 OF 18) BODY SIDE APERTURE COMPLETE (11 OF 18) BODY SIDE APERTURE COMPLETE (12 OF 18)

Fig. 397 Fig. 398 Fig. 399 Fig. 400 Fig. 401 Fig. 402 Fig. 403 Fig. 404 Fig. 405 Fig. 406 Fig. 407 Fig. 408 Fig. 409 Fig. 410 Fig. 411 Fig. 412 Fig. 413 Fig. 414 Fig. 415 Fig. 416 Fig. 417 Fig. 418 Fig. 419 Fig. 420 Fig. 421 Fig. 422 Fig. 423 Fig. 424 Fig. 425 Fig. 426 Fig. 427 Fig. 428 Fig. 429 Fig. 430 Fig. 431 Fig. 432 Fig. 433 Fig. 434 Fig. 435 Fig. 436 Fig. 437

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BODY SIDE APERTURE COMPLETE (14 OF 18) BODY SIDE APERTURE COMPLETE (15 OF 18) BODY SIDE APERTURE COMPLETE (16 OF 18) BODY SIDE APERTURE COMPLETE (17 OF 18) BODY SIDE APERTURE COMPLETE (18 OF 18) BODY IN WHITE (1 OF 6) BODY IN WHITE (2 OF 6) BODY IN WHITE (3 OF 6) BODY IN WHITE (4 OF 6) BODY IN WHITE (5 OF 6) BODY IN WHITE (6 OF 6) BODY IN WHITE COMPLETE (1 OF 6) BODY IN WHITE COMPLETE (2 OF 6) BODY IN WHITE COMPLETE (3 OF 6) BODY IN WHITE COMPLETE (4 OF 6) BODY IN WHITE COMPLETE (5 OF 6) BODY IN WHITE COMPLETE (6 OF 6) BODY IN WHITE COMPLETE W/ROOF (1 OF 10) BODY IN WHITE COMPLETE W/ROOF (2 OF 10) BODY IN WHITE COMPLETE W/ROOF (3 OF 10) BODY IN WHITE COMPLETE W/ROOF (4 OF 10) BODY IN WHITE COMPLETE W/ROOF (5 OF 10) BODY IN WHITE COMPLETE W/ROOF (6 OF 10) BODY IN WHITE COMPLETE W/ROOF (7 OF 10) BODY IN WHITE COMPLETE W/ROOF (8 OF 10) BODY IN WHITE COMPLETE W/ROOF (9 OF 10) BODY IN WHITE COMPLETE W/ROOF (10 OF 10)

Fig. 438 Fig. 439 Fig. 440 Fig. 441 Fig. 442 Fig. 443 Fig. 444 Fig. 445 Fig. 446 Fig. 447 Fig. 448 Fig. 449 Fig. 450 Fig. 451 Fig. 452 Fig. 453 Fig. 454 Fig. 455 Fig. 456 Fig. 457 Fig. 458 Fig. 459 Fig. 460 Fig. 461 Fig. 462 Fig. 463 Fig. 464 Fig. 465

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Fig. 320: FRONT WHEELHOUSE (1 OF 6) Courtesy of CHRYSLER LLC

Fig. 321: FRONT WHEELHOUSE (2 OF 6) Courtesy of CHRYSLER LLC

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Fig. 322: FRONT WHEELHOUSE (3 OF 6) Courtesy of CHRYSLER LLC

Fig. 323: FRONT WHEELHOUSE (4 OF 6) Courtesy of CHRYSLER LLC

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Fig. 324: FRONT WHEELHOUSE (5 OF 6) Courtesy of CHRYSLER LLC

Fig. 325: FRONT WHEELHOUSE (6 OF 6) Courtesy of CHRYSLER LLC

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Fig. 326: DASH (1 OF 3) Courtesy of CHRYSLER LLC

Fig. 327: DASH (2 OF 3) Courtesy of CHRYSLER LLC

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Fig. 328: DASH (3 OF 3) Courtesy of CHRYSLER LLC

Fig. 329: PLENUM/COWL (1 OF 7) Courtesy of CHRYSLER LLC

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Fig. 330: PLENUM/COWL (2 OF 7) Courtesy of CHRYSLER LLC

Fig. 331: PLENUM/COWL (3 OF 7) Courtesy of CHRYSLER LLC

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Fig. 332: PLENUM/COWL (4 OF 7) Courtesy of CHRYSLER LLC

Fig. 333: PLENUM/COWL (5 OF 7) Courtesy of CHRYSLER LLC

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Fig. 334: PLENUM/COWL (6 OF 7) Courtesy of CHRYSLER LLC

Fig. 335: PLENUM/COWL (7 OF 7) Courtesy of CHRYSLER LLC

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Fig. 336: PLENUM/DASH (1 OF 2) Courtesy of CHRYSLER LLC

Fig. 337: PLENUM/DASH (2 OF 2) Courtesy of CHRYSLER LLC

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Fig. 338: ENGINE BOX (1 OF 17) Courtesy of CHRYSLER LLC

Fig. 339: ENGINE BOX (2 OF 17) Courtesy of CHRYSLER LLC

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Fig. 340: ENGINE BOX (3 OF 17) Courtesy of CHRYSLER LLC

Fig. 341: ENGINE BOX (4 OF 17) Courtesy of CHRYSLER LLC

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Fig. 342: ENGINE BOX (5 OF 17) Courtesy of CHRYSLER LLC

Fig. 343: ENGINE BOX (6 OF 17) Courtesy of CHRYSLER LLC

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Fig. 344: ENGINE BOX (7 OF 17) Courtesy of CHRYSLER LLC

Fig. 345: ENGINE BOX (8 OF 17) Courtesy of CHRYSLER LLC

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Fig. 346: ENGINE BOX (9 OF 17) Courtesy of CHRYSLER LLC

Fig. 347: ENGINE BOX (10 OF 17) Courtesy of CHRYSLER LLC

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Fig. 348: ENGINE BOX (11 OF 17) Courtesy of CHRYSLER LLC

Fig. 349: ENGINE BOX (12 OF 17) Courtesy of CHRYSLER LLC

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Fig. 350: ENGINE BOX (13 OF 17) Courtesy of CHRYSLER LLC

Fig. 351: ENGINE BOX (14 OF 17) Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Body - Journey

Fig. 352: ENGINE BOX (15 OF 17) Courtesy of CHRYSLER LLC

Fig. 353: ENGINE BOX (16 OF 17) Courtesy of CHRYSLER LLC

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Fig. 354: ENGINE BOX (17 OF 17) Courtesy of CHRYSLER LLC

Fig. 355: FRONT FLOOR (1 OF 7) Courtesy of CHRYSLER LLC

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Fig. 356: FRONT FLOOR (2 OF 7) Courtesy of CHRYSLER LLC

Fig. 357: FRONT FLOOR (3 OF 7) Courtesy of CHRYSLER LLC

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Fig. 358: FRONT FLOOR (4 OF 7) Courtesy of CHRYSLER LLC

Fig. 359: FRONT FLOOR (5 OF 7) Courtesy of CHRYSLER LLC

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Fig. 360: FRONT FLOOR (6 OF 7) Courtesy of CHRYSLER LLC

Fig. 361: FRONT FLOOR (7 OF 7) Courtesy of CHRYSLER LLC

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Fig. 362: UNDERBODY (1 OF 5) Courtesy of CHRYSLER LLC

Fig. 363: UNDERBODY (2 OF 5) Courtesy of CHRYSLER LLC

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Fig. 364: UNDERBODY (3 OF 5) Courtesy of CHRYSLER LLC

Fig. 365: UNDERBODY (4 OF 5) Courtesy of CHRYSLER LLC

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Fig. 366: UNDERBODY (5 OF 5) Courtesy of CHRYSLER LLC

Fig. 367: UNDERBODY REAR (1 OF 4) Courtesy of CHRYSLER LLC

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Fig. 368: UNDERBODY REAR (2 OF 4) Courtesy of CHRYSLER LLC

Fig. 369: UNDERBODY REAR (3 OF 4) Courtesy of CHRYSLER LLC

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Fig. 370: UNDERBODY REAR (4 OF 4) Courtesy of CHRYSLER LLC

Fig. 371: MISCELLANEOUS BODY Courtesy of CHRYSLER LLC

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Fig. 372: SIDEMEMBER (1 OF 16) Courtesy of CHRYSLER LLC

Fig. 373: SIDEMEMBER (2 OF 16) Courtesy of CHRYSLER LLC

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Fig. 374: SIDEMEMBER (3 OF 16) Courtesy of CHRYSLER LLC

Fig. 375: SIDEMEMBER (4 OF 16) Courtesy of CHRYSLER LLC

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Fig. 376: SIDEMEMBER (5 OF 16) Courtesy of CHRYSLER LLC

Fig. 377: SIDEMEMBER (6 OF 16) Courtesy of CHRYSLER LLC

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Fig. 378: SIDEMEMBER (7 OF 16) Courtesy of CHRYSLER LLC

Fig. 379: SIDEMEMBER (8 OF 16) Courtesy of CHRYSLER LLC

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Fig. 380: SIDEMEMBER (9 OF 16) Courtesy of CHRYSLER LLC

Fig. 381: SIDEMEMBER (10 OF 16) Courtesy of CHRYSLER LLC

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Fig. 382: SIDEMEMBER (11 OF 16) Courtesy of CHRYSLER LLC

Fig. 383: SIDEMEMBER (12 OF 16) Courtesy of CHRYSLER LLC

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Fig. 384: SIDEMEMBER (13 OF 16) Courtesy of CHRYSLER LLC

Fig. 385: SIDEMEMBER (14 OF 16) Courtesy of CHRYSLER LLC

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Fig. 386: SIDEMEMBER (15 OF 16) Courtesy of CHRYSLER LLC

Fig. 387: SIDEMEMBER (16 OF 16) Courtesy of CHRYSLER LLC

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Fig. 388: MISCELLANEOUS COWL/FLOOR (1 OF 3) Courtesy of CHRYSLER LLC

Fig. 389: MISCELLANEOUS COWL/FLOOR (2 OF 3) Courtesy of CHRYSLER LLC

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Fig. 390: MISCELLANEOUS COWL/FLOOR (3 OF 3) Courtesy of CHRYSLER LLC

Fig. 391: UNDERBODY COMPLETE (1 OF 21) Courtesy of CHRYSLER LLC

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Fig. 392: UNDERBODY COMPLETE (2 OF 21) Courtesy of CHRYSLER LLC

Fig. 393: UNDERBODY COMPLETE (3 OF 21) Courtesy of CHRYSLER LLC

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Fig. 394: UNDERBODY COMPLETE (4 OF 21) Courtesy of CHRYSLER LLC

Fig. 395: UNDERBODY COMPLETE (5 OF 21) Courtesy of CHRYSLER LLC

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Fig. 396: UNDERBODY COMPLETE (6 OF 21) Courtesy of CHRYSLER LLC

Fig. 397: UNDERBODY COMPLETE (7 OF 21) Courtesy of CHRYSLER LLC

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Fig. 398: UNDERBODY COMPLETE (8 OF 21) Courtesy of CHRYSLER LLC

Fig. 399: UNDERBODY COMPLETE (9 OF 21) Courtesy of CHRYSLER LLC

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Fig. 400: UNDERBODY COMPLETE (10 OF 21) Courtesy of CHRYSLER LLC

Fig. 401: UNDERBODY COMPLETE (11 OF 21) Courtesy of CHRYSLER LLC

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Fig. 402: UNDERBODY COMPLETE (12 OF 21) Courtesy of CHRYSLER LLC

Fig. 403: UNDERBODY COMPLETE (13 OF 21) Courtesy of CHRYSLER LLC

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Fig. 404: UNDERBODY COMPLETE (14 OF 21) Courtesy of CHRYSLER LLC

Fig. 405: UNDERBODY COMPLETE (15 OF 21) Courtesy of CHRYSLER LLC

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Fig. 406: UNDERBODY COMPLETE (16 OF 21) Courtesy of CHRYSLER LLC

Fig. 407: UNDERBODY COMPLETE (17 OF 21) Courtesy of CHRYSLER LLC

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Fig. 408: UNDERBODY COMPLETE (18 OF 21) Courtesy of CHRYSLER LLC

Fig. 409: UNDERBODY COMPLETE (19 OF 21) Courtesy of CHRYSLER LLC

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Fig. 410: UNDERBODY COMPLETE (20 OF 21) Courtesy of CHRYSLER LLC

Fig. 411: UNDERBODY COMPLETE (21 OF 21) Courtesy of CHRYSLER LLC

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Fig. 412: BODY SIDE APERTURE (1 OF 14) Courtesy of CHRYSLER LLC

Fig. 413: BODY SIDE APERTURE (2 OF 14) Courtesy of CHRYSLER LLC

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Fig. 414: BODY SIDE APERTURE (3 OF 14) Courtesy of CHRYSLER LLC

Fig. 415: BODY SIDE APERTURE (4 OF 14) Courtesy of CHRYSLER LLC

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Fig. 416: BODY SIDE APERTURE (5 OF 14) Courtesy of CHRYSLER LLC

Fig. 417: BODY SIDE APERTURE (6 OF 14) Courtesy of CHRYSLER LLC

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Fig. 418: BODY SIDE APERTURE (7 OF 14) Courtesy of CHRYSLER LLC

Fig. 419: BODY SIDE APERTURE (8 OF 14) Courtesy of CHRYSLER LLC

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Fig. 420: BODY SIDE APERTURE (9 OF 14) Courtesy of CHRYSLER LLC

Fig. 421: BODY SIDE APERTURE (10 OF 14) Courtesy of CHRYSLER LLC

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Fig. 422: BODY SIDE APERTURE (11 OF 14) Courtesy of CHRYSLER LLC

Fig. 423: BODY SIDE APERTURE (12 OF 14) Courtesy of CHRYSLER LLC

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Fig. 424: BODY SIDE APERTURE (13 OF 14) Courtesy of CHRYSLER LLC

Fig. 425: BODY SIDE APERTURE (14 OF 14) Courtesy of CHRYSLER LLC

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Fig. 426: BODY SIDE APERTURE COMPLETE (1 OF 18) Courtesy of CHRYSLER LLC

Fig. 427: BODY SIDE APERTURE COMPLETE (2 OF 18) Courtesy of CHRYSLER LLC

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Fig. 428: BODY SIDE APERTURE COMPLETE (3 OF 18) Courtesy of CHRYSLER LLC

Fig. 429: BODY SIDE APERTURE COMPLETE (4 OF 18) Courtesy of CHRYSLER LLC

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Fig. 430: BODY SIDE APERTURE COMPLETE (5 OF 18) Courtesy of CHRYSLER LLC

Fig. 431: BODY SIDE APERTURE COMPLETE (6 OF 18) Courtesy of CHRYSLER LLC

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Fig. 432: BODY SIDE APERTURE COMPLETE (7 OF 18) Courtesy of CHRYSLER LLC

Fig. 433: BODY SIDE APERTURE COMPLETE (8 OF 18) Courtesy of CHRYSLER LLC

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Fig. 434: BODY SIDE APERTURE COMPLETE (9 OF 18) Courtesy of CHRYSLER LLC

Fig. 435: BODY SIDE APERTURE COMPLETE (10 OF 18) Courtesy of CHRYSLER LLC

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Fig. 436: BODY SIDE APERTURE COMPLETE (11 OF 18) Courtesy of CHRYSLER LLC

Fig. 437: BODY SIDE APERTURE COMPLETE (12 OF 18) Courtesy of CHRYSLER LLC

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Fig. 438: BODY SIDE APERTURE COMPLETE (13 OF 18) Courtesy of CHRYSLER LLC

Fig. 439: BODY SIDE APERTURE COMPLETE (14 OF 18) Courtesy of CHRYSLER LLC

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Fig. 440: BODY SIDE APERTURE COMPLETE (15 OF 18) Courtesy of CHRYSLER LLC

Fig. 441: BODY SIDE APERTURE COMPLETE (16 OF 18) Courtesy of CHRYSLER LLC

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Fig. 442: BODY SIDE APERTURE COMPLETE (17 OF 18) Courtesy of CHRYSLER LLC

Fig. 443: BODY SIDE APERTURE COMPLETE (18 OF 18) Courtesy of CHRYSLER LLC

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Fig. 444: BODY IN WHITE (1 OF 6) Courtesy of CHRYSLER LLC

Fig. 445: BODY IN WHITE (2 OF 6) Courtesy of CHRYSLER LLC

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Fig. 446: BODY IN WHITE (3 OF 6) Courtesy of CHRYSLER LLC

Fig. 447: BODY IN WHITE (4 OF 6) Courtesy of CHRYSLER LLC

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Fig. 448: BODY IN WHITE (5 OF 6) Courtesy of CHRYSLER LLC

Fig. 449: BODY IN WHITE (6 OF 6) Courtesy of CHRYSLER LLC

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Fig. 450: BODY IN WHITE COMPLETE (1 OF 6) Courtesy of CHRYSLER LLC

Fig. 451: BODY IN WHITE COMPLETE (2 OF 6) Courtesy of CHRYSLER LLC

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Fig. 452: BODY IN WHITE COMPLETE (3 OF 6) Courtesy of CHRYSLER LLC

Fig. 453: BODY IN WHITE COMPLETE (4 OF 6) Courtesy of CHRYSLER LLC

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Fig. 454: BODY IN WHITE COMPLETE (5 OF 6) Courtesy of CHRYSLER LLC

Fig. 455: BODY IN WHITE COMPLETE (6 OF 6) Courtesy of CHRYSLER LLC

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Fig. 456: BODY IN WHITE COMPLETE W/ROOF (1 OF 10) Courtesy of CHRYSLER LLC

Fig. 457: BODY IN WHITE COMPLETE W/ROOF (2 OF 10) Courtesy of CHRYSLER LLC

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Fig. 458: BODY IN WHITE COMPLETE W/ROOF (3 OF 10) Courtesy of CHRYSLER LLC

Fig. 459: BODY IN WHITE COMPLETE W/ROOF (4 OF 10) Courtesy of CHRYSLER LLC

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Fig. 460: BODY IN WHITE COMPLETE W/ROOF (5 OF 10) Courtesy of CHRYSLER LLC

Fig. 461: BODY IN WHITE COMPLETE W/ROOF (6 OF 10) Courtesy of CHRYSLER LLC

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Fig. 462: BODY IN WHITE COMPLETE W/ROOF (7 OF 10) Courtesy of CHRYSLER LLC

Fig. 463: BODY IN WHITE COMPLETE W/ROOF (8 OF 10) Courtesy of CHRYSLER LLC

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Fig. 464: BODY IN WHITE COMPLETE W/ROOF (9 OF 10) Courtesy of CHRYSLER LLC

Fig. 465: BODY IN WHITE COMPLETE W/ROOF (10 OF 10) Courtesy of CHRYSLER LLC

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2009 ACCESSORIES AND EQUIPMENT Electronic Control Modules - Service Information - Journey

STANDARD PROCEDURE MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE MODULE REPLACEMENT GUIDE MODULE Condition Condition Condition Condition Condition Condition Condition 1 2 3 4 5 6 7 Existing Existing New Part Existing New Part New Part New Part PCM Part Part Part Existing Existing Existing WCM/WIN New Part New Part New Part New Part Part Part Part "Ignition Keys / Existing Existing Existing New Part New Part New Part New Part FOBIKS" Part Part Part PROGRAMMING SCANTOOL MISC. FUNCTION ORDER Attempt to Program avoid this Ignition WIN Check WIN PCM PCM 1 Keys or Replaced PCM VIN Replaced Replaced Replaced situation. If possible, Key FOBs try to Program Program Program execute WIN Ignition Ignition Ignition condition 4 2 ------Keys or Replaced Keys or Keys or or 5 Key FOBs Key FOBs Key FOBs Otherwise, keys must Program be replaced Ignition also 3 ---------------Keys or (condition Key FOBs 3) MODULE PROGRAMMING The Wireless Ignition Node (WIN) controls the Vehicle Theft Security System (VTSS), Remote Keyless Entry (RKE). When a Powertrain Control Module (PCM) is in need of replacement, perform the following steps in order: NOTE:

The PCM and the WIN should never be replaced at the same time. They should be replaced independently of each other.

1. If applicable, first replace the PCM with the original WIN still connected to the vehicle. user Monday, June 04, 2012 9:30:53 9:30:48 AM

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2. Using a scan tool program the new PCM. (This will ensure the transfer of the Secret Key data from the original WIN into the new PCM). 3. Replace the WIN, using the scan tool program the new WIN module. This will transfer the Secret Key data from the PCM into the new WIN. 4. With the scan tool reprogram the key FOBIK to the new WIN. 5. Ensure all the customer's keys have been programmed to the new module. NOTE:

If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary.

NOTE:

Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary. CAUTION: Read all notes and cautions for programming procedures.

NOTE:

Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN.

NOTE:

If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN. CAUTION: Read all notes and cautions for programming procedures.

NOTE:

If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary.

NOTE:

A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle.

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CAUTION: Read all notes and cautions for programming procedures. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. PROGRAMMING THE SECRET KEY TO THE WIN

The secret key is an ID code that is unique to each WIN. This code is programmed and stored in the WIN, the PCM, and each ignition key transponder chip. When the PCM or WIN is replaced, it is necessary to program the Secret Key Code into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED , WIN REPLACED , or TIPM REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE menu item as appropriate. NOTE:

Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary.

PCM/WIN PROGRAMMING

When an PCM and the WIN are replaced at the same time, perform the following steps in order: 1. Program the new WIN. 2. Replace all ignition keys and program them to the new WIN. PROGRAMMING THE WIN

CAUTION: Read all notes and cautions for programming procedures.

1. Connect a battery charger to the vehicle. 2. Connect the scan tool. NOTE:

Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN.

3. Select "ECU View." 4. Select "WIN". user Monday, June 04, 2012 9:30:49 AM

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5. 6. 7. 8.

Select "Miscellaneous Functions." Select "WIN Replaced". Enter the PIN when prompted. Cycle ignition key after the successful routine completion. NOTE:

If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN.

PROGRAMMING IGNITION KEYS TO THE WIN

Each FOBIK has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the WIN, the module learns the transponder ID code and the transponder acquires the unique Secret Key ID code from the WIN. CAUTION: Read all notes and cautions for programming procedures.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Connect a battery charger to the vehicle. Connect the scan tool. Have a unique vehicle PIN readily available before running the routine. Ignition key should be in RUN position. Select "ECU View". Select "WIN Wireless Control". Select "Miscellaneous Functions." Select "Program Ignition Keys or Key FOBs", Start Enter the PIN when prompted. Verify the correct information. Cycle ignition key after the successful routine completion. NOTE:

If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary.

NOTE:

A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle.

PROGRAMMING THE PCM

CAUTION: Read all notes and cautions for programming procedures. user Monday, June 04, 2012 9:30:49 AM

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1. 2. 3. 4.

Connect a battery charger to the vehicle. Connect the scan tool. Have a unique vehicle PIN readily available before running the routine. Ignition key should be in RUN position. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN.

5. 6. 7. 8. 9. 10. 11.

Select "ECU View". Select "WIN Wireless Control". Select "Miscellaneous Functions." Select "PCM Replaced". Enter the PIN when prompted. Verify the correct information. Cycle ignition key after the successful routine completion.

COMMUNICATION DESCRIPTION DESCRIPTION

The primary on-board communication network between microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. A data bus network minimizes redundant wiring connections; and, at the same time, reduces wire harness complexity, sensor current loads and controller hardware by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN bus is a two-wire multiplex system. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between most vehicle nodes. However, in addition to the CAN bus network, certain nodes may also be equipped with a Local Interface Network (LIN) data bus. The LIN data bus is a single wire low-speed (9.6 Kbps) serial link bus used to provide direct communication between a LIN master module and certain switch or sensor inputs. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-Interior (also known as CAN Interior High Speed/IHS), the CAN-C and the Diagnostic CAN-C. The CAN-Interior and CAN-C systems provide on-board communication between all nodes in the vehicle. The CAN-C is the faster of the two systems providing near real-time communication (500 Kbps). The CAN-C is used typically for communications between more critical nodes, while the slower (125 Kbps) CAN-Interior system is used for communications between less critical nodes. The added speed of the CAN data bus is many times faster than previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new user Monday, June 04, 2012 9:30:49 AM

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electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) and a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located beneath the instrument panel on the driver side of the vehicle. The TIPM is located in the engine compartment near the battery. The central CAN gateway or hub module integral to the TIPM is connected to all three CAN buses. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. OPERATION OPERATION

The Controller Area Network (CAN) data bus allows all electronic modules or nodes connected to the bus to share information with each other. Regardless of whether a message originates from a module on the lower speed CAN-Interior (also known as CAN Interior High Speed/IHS) bus or on the higher speed CAN-C or CAND bus, the message structure and layout is similar, which allows the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) to process and transfer messages between the CAN buses. The TIPM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Each digital bit of a CAN bus message is carried over the bus as a voltage differential between the two bus circuits which, when strung together, form a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to be broadcast at the same time. The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is the Local Interface Network (LIN) master module in this vehicle and it gathers information from the compass module, the instrument panel switch bank, the Steering Control Module (SCM), and the Heated Seat Module (HSM) through the LIN data bus. There is also LIN bus communication between the individual Tire Pressure Monitor (TPM) transponders and the Wireless Ignition Node (WIN). Both the EMIC and the WIN either act directly upon the information received through the LIN data bus, relay the information to other nodes in the vehicle using electronic messages placed on the CAN bus, or both. The voltage network used to transmit messages requires biasing and termination. Each module on the CAN bus network provides its own biasing and termination. There are two types of nodes used in the CAN bus network. On the CAN-C or the IHS bus, a dominant node has a 120 ohm termination resistance while a non-dominant (or recessive) node has about a 2500 to 3000 ohm (2.5 to 3.0 kilohm) termination resistance. The dominant nodes on the CAN-C bus are the WIN and the Powertrain Control Module (PCM). The dominant nodes on the IHS bus are the EMIC and the TIPM. The termination resistance of two dominant nodes is combined in parallel to provide a total of about 60 ohms. This resistance value may vary somewhat by application, depending upon the number of non-dominant nodes user Monday, June 04, 2012 9:30:49 AM

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on the bus. On the CAN-D bus (or Diagnostic CAN-C) all of the 60 ohm termination resistance is present in the Central GateWay (TIPMCGW). NOTE:

All measurement of termination resistance is done with the vehicle battery disconnected.

The communication protocol being used for the CAN data bus is a non-proprietary, open standard adopted from the Bosch CAN Specification 2.0b. The CAN-C is the faster of the two primary buses in the CAN bus system, providing near real-time communication (500 Kbps). The CAN bus nodes are connected in parallel to the two-wire bus using a twisted pair, where the wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter (yard). While the CAN bus is operating (active), one of the bus wires will carry a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire will carry a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN BUS VOLTAGES chart.

CAN-C Bus Circuits

Sleep

CAN-L (-)

0V

CAN Bus Voltages (Normal Operation) Dominant CAN-L CAN-H CAN-L Recessive (Bus Short to Short to Short to (Bus Idle) Active) Ground Ground Battery 2.4 - 2.5 V 1.3 - 2.3 V

2.4 - 2.5 V 2.6 - 3.5 V

0V

CAN-H (+)

0V

0.02 V

CANInterior Bus Circuits

Key-Off (Bus Asleep)

Key-On (Bus Active)

CAN-L Short to Ground

CAN-L (-)

0.0 V

1.3 - 2.3 V

0V

CAN-H (+)

0.0 V

2.6 - 3.5 V

0.02 V

Battery 0.3 - 0.5V Voltage

CAN-H CAN-H Short to Short to Battery CAN-L Battery Voltage Less 0.75 2.45 V V

Battery Voltage Battery 0V 2.45 V Less 0.75 Voltage V CAN-H CAN-L CAN-H CAN-H Short to Short to Short to Short to Ground Battery Battery CAN-L Battery Voltage Battery 0.3 - 0.5 V 2.45 V Voltage Less 0.75 V Battery Voltage Battery 0V 2.45 V Less 0.75 Voltage V

Notes All measurements taken between node ground and CAN terminal with a standard DVOM. DVOM will display average network voltage. Total resistance of CAN-C network can also be measured (60 ohms). Total resistance of CAN-Interior user Monday, June 04, 2012 9:30:49 AM

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network varies, depending upon the number of optional non-dominant nodes on the bus. CAN-Interior total resistance should range between about 60 ohms with the minimal number of nodes, to about 42 ohms with the maximum number of nodes. In order to minimize the potential effects of Ignition-OFF Draw (IOD), the CAN-Interior network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network is awake only when the ignition switch is in the ON or START positions; however, the TIPM, which is on the CAN-C bus, may still be awake with the ignition switch in the ACCESSORY or UNLOCK positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-Interior bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep, and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-Interior bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The TIPM will keep either the CAN-Interior or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the Diagnostic CAN-C bus. In the CAN system, available options are configured into the TIPM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The TIPM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-Interior and CAN-C buses. The TIPM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC) may only be able to communicate with the TIPM. To aid in CAN network diagnosis, the TIPM will provide CAN-Interior and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus will identify a bus off hardware failure , while the transceiver in each node on the CAN-Interior bus will identify a general bus hardware failure . The transceivers for some CAN-Interior nodes will also identify certain failures for both CAN-Interior bus signal wires.

CONNECTOR, DATA LINK DESCRIPTION DESCRIPTION

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Fig. 1: Data Link Connector Courtesy of CHRYSLER LLC The Data Link Connector (DLC) (2) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement, just forward of the instrument panel steering column opening cover (1). OPERATION OPERATION

The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle.

MODULE, ANTI-LOCK BRAKE SYSTEM DESCRIPTION DESCRIPTION

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Fig. 2: Antilock Brake Module Courtesy of CHRYSLER LLC 1 - ANTILOCK BRAKE MODULE (ABM) 2 - HYDRAULIC CONTROL UNIT (HCU) 3 - PUMP/MOTOR The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. NOTE:

The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA.

The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. For information on the ICU. Refer to Brakes/Hydraulic/Mechanical/INTEGRATED CONTROL UNIT (ICU) - Description ). OPERATION OPERATION

The primary functions of the Antilock Brake Module (ABM) are to: z z

z

Monitor the antilock brake system for proper operation. Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. Control fluid modulation to the wheel brakes while the system is in an ABS mode.

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z z z z

z

Store diagnostic information. Provide communication to the scan tool while in diagnostic mode. Illuminate the amber ABS warning indicator lamp. Illuminate the ESP function lamp in the message center on the instrument panel when a traction control event occurs. Illuminate the ESP function lamp when the amber ABS warning indicator lamp illuminates.

The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE:

If the vehicle is equipped with traction control, the ESP function lamp will illuminate anytime the amber ABS warning indicator lamp illuminates.

The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS z z z z z z z

Wheel speed sensors (four) Brake lamp switch Ignition switch System and pump voltage Ground ESP/BAS warning indicator lamp Diagnostic communication

ABM OUTPUTS z z

Amber ABS warning indicator lamp actuation (via BUS) Red BRAKE warning indicator lamp actuation (via BUS)

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z z z

Instrument cluster (MIC) communication ESP/BAS warning indicator lamp Diagnostic communication

REMOVAL LEFT-HAND DRIVE

NOTE:

The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA.

1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the engine appearance cover.

Fig. 3: Cowl Top Screen Courtesy of CHRYSLER LLC 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

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Fig. 4: Cowl Screen Courtesy of CHRYSLER LLC 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3).

Fig. 5: Wheelhouse Brace Courtesy of CHRYSLER LLC 6. 7. 8. 9.

Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. Remove the wheelhouse brace (2). Remove two screws, then remove the fresh air plenum. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 6: Locating Integrated Control Unit (ICU) Courtesy of CHRYSLER LLC 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) upward to near the top of the slots in the bracket, then snug one or both of the mounting screws (2) to hold the ICU in this position. 12. Lower the vehicle. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 13. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar® Brake Parts Cleaner or equivalent.

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Fig. 7: ABM Connector Release Tabs Courtesy of CHRYSLER LLC NOTE:

Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs.

Fig. 8: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR 14. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: user Monday, June 04, 2012 9:30:49 AM

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a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1).

Fig. 9: ABM Mounting Courtesy of CHRYSLER LLC 15. Remove the four screws (1) attaching the ABM (2) to the HCU. A Torx T20 bit approximately 2 inches long works well.

Fig. 10: Identifying ABM, HCU, & Solenoid Valve Stem Courtesy of CHRYSLER LLC 1 - ABM user Monday, June 04, 2012 9:30:49 AM

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2 - HCU 3 - SOLENOID VALVE STEM CAUTION: When removing the ABM from the HCU, be sure to completely separate the two components (approximately 38 mm (1.5 inches)) before removing the ABM. Otherwise, damage to the pressure sensor or pump motor connection may result, requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 16. Separate the ABM (1) from the HCU (2). RIGHT-HAND DRIVE

NOTE:

The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA.

1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove air inlet hose (1) between air cleaner housing and engine. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 3. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar® Brake Parts Cleaner or equivalent.

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Fig. 11: ABM Connector Release Tabs Courtesy of CHRYSLER LLC NOTE:

Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs.

Fig. 12: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR 4. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1).

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Fig. 13: ABM Mounting Screws Courtesy of CHRYSLER LLC 1 - MOUNTING SCREWS 2 - ABM 5. Remove the four screws (1) attaching the ABM (2) to the HCU.

Fig. 14: ABM Assembly To HCU Courtesy of CHRYSLER LLC 1 - ABM user Monday, June 04, 2012 9:30:49 AM

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2 - HCU 3 - SOLENOID VALVE STEM CAUTION: When removing the ABM from the HCU, be sure to completely separate the two components (approximately 38 mm (1.5 inches)) before removing the ABM. Otherwise, damage to the pressure sensor or pump motor connection may result, requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 6. Separate the ABM (1) from the HCU (2). INSTALLATION LEFT-HAND DRIVE

1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant.

Fig. 15: Solenoid Valve Seal Courtesy of CHRYSLER LLC 1 - SEAL 2 - SOLENOID VALVE STEM user Monday, June 04, 2012 9:30:49 AM

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2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris;do not reuse solenoid valve stem seals.

Fig. 16: Internal Pump Connector O-Ring Courtesy of CHRYSLER LLC 1 - O-RING 2 - O-RING MOUNTING GROOVE 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2).

Fig. 17: Identifying ABM, HCU, & Solenoid Valve Stem user Monday, June 04, 2012 9:30:49 AM

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Courtesy of CHRYSLER LLC 1 - ABM 2 - HCU 3 - SOLENOID VALVE STEM 4. Align components and install the ABM (1) on the HCU (2).

Fig. 18: ABM Mounting Courtesy of CHRYSLER LLC 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.).

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Fig. 19: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 6. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 7. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 20: Locating Integrated Control Unit (ICU) Courtesy of CHRYSLER LLC 8. Loosen the two mounting screws (2) as necessary and allow the ICU (1) mounting bracket to slide down over the mounting screws and hang the assembly in place. Tighten the two mounting screws (2) to 23 N.m (17 ft. lbs.). 9. Lower the vehicle. 10. Position the fresh air plenum and install the two mounting screws.

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Fig. 21: Wheelhouse Brace Courtesy of CHRYSLER LLC 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Fig. 22: Cowl Screen Courtesy of CHRYSLER LLC 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper user Monday, June 04, 2012 9:30:49 AM

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Installation

Fig. 23: Cowl Top Screen Courtesy of CHRYSLER LLC 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Install the engine appearance cover. 16. Connect the negative cable on the battery negative post. 17. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Perform the ABS Verification Test and road test the vehicle. Refer to DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure RIGHT-HAND DRIVE

1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant.

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Fig. 24: Solenoid Valve Seal Courtesy of CHRYSLER LLC 1 - SEAL 2 - SOLENOID VALVE STEM 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris;do not reuse solenoid valve stem seals.

Fig. 25: Internal Pump Connector O-Ring Courtesy of CHRYSLER LLC 1 - O-RING user Monday, June 04, 2012 9:30:49 AM

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2 - O-RING MOUNTING GROOVE 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2).

Fig. 26: ABM Assembly To HCU Courtesy of CHRYSLER LLC 1 - ABM 2 - HCU 3 - SOLENOID VALVE STEM 4. Align components and install the ABM (1) on the HCU (2).

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Fig. 27: ABM Mounting Screws Courtesy of CHRYSLER LLC 1 - MOUNTING SCREWS 2 - ABM 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.).

Fig. 28: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) user Monday, June 04, 2012 9:30:49 AM

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2 - WIRING HARNESS CONNECTOR CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 6. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 7. Install the air inlet hose (1) between the air cleaner housing and engine. 8. Connect the negative cable on the battery negative post. 9. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Perform the ABS Verification Test and road test the vehicle. Refer to DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

MODULE, DOOR REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel as necessary to gain access to the door control module. Refer to Body/Door Front/PANEL, Door Trim - Removal . 3. Disconnect the electrical connectors. 4. Remove the door control module mounting fasteners and remove the module from the vehicle. INSTALLATION INSTALLATION

1. 2. 3. 4.

Place the door control module into position and install the mounting fasteners. Connect the electrical connectors. Install the door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Installation . Install the battery negative cable.

MODULE, ENGINE CONTROL DESCRIPTION DESCRIPTION

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Fig. 29: Removing/Installing ECM - 2.0L Diesel Courtesy of CHRYSLER LLC The ECM (3) is located in the left side of engine compartment attached to the left inner fender below the air filter housing. OPERATION OPERATION

The ECM has been programmed to monitor different circuits of the diesel fuel injection system. This monitoring is called on-board diagnostics. Certain criteria must be met for a diagnostic trouble code to be entered into the ECM memory. The criteria may be a range of: engine rpm, engine temperature, time or other input signals to the ECM. If all of the criteria for monitoring a system or circuit are met, and a problem is sensed, then a DTC will be stored in the ECM memory. It is possible that a DTC for a monitored circuit may not be entered into the ECM memory, even though a malfunction has occurred. This may happen when the monitoring criteria have not been met. The ECM compares input signal voltages from each input device with specifications (the established high and low limits of the input range) that are programmed into it for that device. If the input voltage is not within the specifications and other trouble code criteria are met, a DTC will be stored in the ECM memory. ECM OPERATING MODES

As input signals to the ECM change, the ECM adjusts its response to the output devices. For example, the ECM must calculate a different fuel quantity and fuel timing for engine idle condition than it would for a wide open throttle condition. There are several different modes of operation that determine how the ECM responds to the various input signals. Ignition Switch On (Engine Off)

When the ignition is turned on, the ECM activates the glow plug relay for a time period that is determined by user Monday, June 04, 2012 9:30:49 AM

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engine coolant temperature, atmospheric temperature and battery voltage. Engine Start-Up Mode

The ECM uses the engine temperature sensor and the crankshaft position sensor (engine speed) inputs to determine fuel injection quantity. Normal Driving Modes

Engine idle, warm-up, acceleration, deceleration and wide open throttle modes are controlled based on all of the sensor inputs to the ECM. The ECM uses these sensor inputs to adjust fuel quantity and fuel injector timing. Limp-In Mode

If there is a fault detected with the accelerator pedal position sensor, the ECM will set the engine speed at 1100 RPM. Overspeed Detection Mode

If the ECM detects engine RPM that exceeds 5200 RPM, the ECM will set a DTC in memory and illuminate the MIL until the DTC is cleared. After-Run Mode

The ECM transfers RAM information to ROM and performs an Input/Output state check. MONITORED CIRCUITS

The ECM is able to monitor and identify most driveability related trouble conditions. Some circuits are directly monitored through ECM feedback circuitry. In addition, the ECM monitors the voltage state of some circuits and compares those states with expected values. Other systems are monitored indirectly when the ECM conducts a rationality test to identify problems. Although most subsystems of the engine control module are either directly or indirectly monitored, there may be occasions when diagnostic trouble codes are not immediately identified. For a trouble code to set, a specific set of conditions must occur and unless these conditions occur, a DTC will not set. DIAGNOSTIC TROUBLE CODES

Each diagnostic trouble code (DTC) is diagnosed by following a specific procedure. The diagnostic test procedure contains step-by-step instruction for determining the cause of the DTC as well as no trouble code problems. Refer to the appropriate Diesel Powertrain Diagnostic service information for more information. HARD CODE

A DTC that comes back within one cycle of the ignition key is a hard code. This means that the problem is current every time the ECM/SKIM checks that circuit or function. Procedures in this service information verify if the DTC is a hard code at the beginning of each test. When the fault is not a hard code, an intermittent test must be performed. NOTE: If the scantool displays faults for multiple components (i.e. ECT, VSS, IAT user Monday, June 04, 2012 9:30:49 AM

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sensors) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5volt supply circuits). Refer to the appropriate schematic diagram to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic service information for more information. INTERMITTENT CODE

A DTC that is not current every time the ECM/SKIM checks the circuit or function is an intermittent code. Most intermittent DTCs are caused by wiring or connector problems. Problems that come and go like this are the most difficult to diagnose; they must be looked for under specific conditions that cause them. NOTE: Electromagnetic (radio) interference can cause an intermittent system malfunction. This interference can interrupt communication between the ignition key transponder and the SKIM. The following checks may assist you in identifying a possible intermittent problem: z

z z

Visually inspect the related wire harness connectors. Look for broken, bent, pushed out or corroded terminals. Visually inspect the related wire harness. Look for chafed, pierced or partially broken wire. Refer to hotlines or technical service bulletins that may apply.

Refer to the appropriate Diesel Powertrain Diagnostic service information for more information. ECM DIAGNOSTIC TROUBLE CODES

NOTE:

Before replacing the ECM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal failures to components (i.e. relays and solenoids) and shorted circuits (i.e. sensor pull-ups, drivers and ground circuits). These faults are difficult to detect when a double fault has occurred and only one DTC has set. If the scan tool displays faults for multiple components (i.e.VSS, ECT, Batt Temp, etc.) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to SYSTEM WIRING DIAGRAMS to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic service information for more information.

STANDARD PROCEDURE PCM/ECM REPROGRAMMING

Follow the instructions in order, refer to RECEIVER, Wireless Ignition Node . REMOVAL REMOVAL

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Fig. 30: Air Inlet Duct Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove air inlet duct (3). Disconnect negative battery cable. Disconnect vacuum hose (1). Remove air filter housing assembly (2). Refer to Engine/Air Intake System/BODY, Air Cleaner Removal .

Fig. 31: Removing/Installing ECM - 2.0L Diesel Courtesy of CHRYSLER LLC 5. Disconnect both ECM (1) electrical connectors. user Monday, June 04, 2012 9:30:50 AM

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6. Remove ECM bracket retaining bolts (2) and remove ECM (3). INSTALLATION INSTALLATION

Fig. 32: Removing/Installing ECM - 2.0L Diesel Courtesy of CHRYSLER LLC 1. Install ECM (3) on mounting bracket. Torque fastener to 10.7N.m (95 lbs. in.). 2. Connect both ECM electrical connectors (1).

Fig. 33: Air Inlet Duct user Monday, June 04, 2012 9:30:50 AM

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Courtesy of CHRYSLER LLC 3. Install air filter housing assembly (2). Refer to Engine/Air Intake System/BODY, Air Cleaner Installation . 4. Connect vacuum hose (1). 5. Connect negative battery cable. 6. Install air inlet tube (3). 7. Reprogram ECM. See Standard Procedure .

MODULE, FINAL DRIVE CONTROL DESCRIPTION DESCRIPTION

The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. OPERATION OPERATION

Fig. 34: AWD Outline Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:30:50 AM

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1 - ECC 2 - AWD ECU

5 - ENGINE 6 - NGC 7 - ABS CONTROLLER -

3 - PTU 4 - TRANSMISSION

The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the allwheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction user Monday, June 04, 2012 9:30:50 AM

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control. It only works on situations where front-torear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. REMOVAL REMOVAL

1. 2. 3. 4.

Remove the left front trim panel. Remove the electrical connector. Remove the mounting nuts. Remove the ECC module.

INSTALLATION INSTALLATION

1. 2. 3. 4.

Install ECC module into mounting studs. Install mounting nuts and tighten to 8N.m (71 in. lbs.) torque. Install the electrical connector. Install the left front trim panel.

MODULE, HEATED SEAT DESCRIPTION DESCRIPTION

Fig. 35: Locating Heated Seat Module user Monday, June 04, 2012 9:30:50 AM

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Courtesy of CHRYSLER LLC The heated seat module (2) is located under the driver front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan (4). The module can be accessed from under the Driver seat with the seat in the full back and up position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. OPERATION OPERATION

The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate Diagnostic Trouble Code (DTC). DIAGNOSIS AND TESTING HEATED SEAT MODULE

In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to SYSTEM WIRING DIAGRAMS for complete circuit schematic or connector pin-out information. NOTE:

Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle

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voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. REMOVAL REMOVAL

Fig. 36: Locating Heated Seat Module Courtesy of CHRYSLER LLC CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. 2. 3. 4. 5.

Position the driver front seat to the full rearward position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector (4) from the heated seat module (3). Unsnap the heated seat module retaining tab (2) from the seat pan (1). Remove the heated seat module (3) from the vehicle.

INSTALLATION INSTALLATION

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Fig. 37: Locating Heated Seat Module Courtesy of CHRYSLER LLC CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation.

MODULE, POWERTRAIN CONTROL DESCRIPTION POWERTRAIN CONTROL MODULE (PCM)

The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: z

PCM Inputs:

Air Conditioning Pressure Transducer

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z z z z z z z z z z z z z z z z z z z z z z z z

ASD/Main Relay Battery Voltage Brake Switch Camshaft Position Sensor Crankshaft Position Sensor Distance Sensor (from transmission control module) EGR Position Feedback (if equipped) Engine Coolant Temperature Sensor Heated Oxygen Sensors Ignition sense Inlet Air Temperature Sensor Knock Sensor Manifold Absolute Pressure (MAP) Sensor Park/Neutral (from trans range sensor) Power Steering Pressure Switch Proportional Purge Sense CAN C Bus Speed Control Transmission Control Relay (Switched B+) Transmission Pressure Switches Transmission Temperature Sensor Transmission Input Shaft Speed Sensor Transmission Output Shaft Speed Sensor Vehicle Speed

NOTE: z z z z z z z z z z z

PCM Outputs:

Air Conditioning Clutch Relay Data Link Connector (CAN C Bus) Double Start Override EGR Solenoid (if equipped) Fuel Injectors Generator Field High Speed Fan Relay Ignition Coils Natural Vacuum Leak Detection Low Speed Fan Relay MTV Actuator

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z z z z z z z z z

Proportional Purge Solenoid SRV Valve Speed Control Relay Speed Control Vent Relay Speed Control Vacuum Relay Torque Reduction Request Transmission Control Relay Transmission Solenoids 5 Volt Output

Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation and EGR if equipped. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. z z z z z z z

Manifold Absolute Pressure Engine Speed (crankshaft position sensor) Battery Voltage Inlet Air Temperature Sensor Engine Coolant Temperature Exhaust Gas Oxygen Content (heated oxygen sensors) Throttle Position

The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. z z z z z z z

Brake Switch Engine Coolant Temperature Engine Speed (crankshaft position sensor) Park/Neutral Transaxle Gear Engagement Throttle Position Vehicle Speed (from Transmission Control Module)

The PCM adjusts ignition timing based on the following inputs. z z z z

Inlet Air Temperature Engine Coolant Temperature Engine Speed (crankshaft position sensor) Knock Sensor

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z z z z

Manifold Absolute Pressure Park/Neutral (from trans range sensor) Transaxle Gear Engagement Throttle Position

The camshaft and crankshaft signals are sent to the Powertrain Control Module (PCM). If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the fuel pump. When deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 5.0 volts. The 5.0 volts power the camshaft position sensor, and crankshaft position sensor. The PCM also provides a regulated 5.0 volts supply for the, manifold absolute pressure sensor, throttle position sensor and EGR (if equipped). The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Service Information and the scan tool. If equipped with SKREEM, must use SKREEM function to program VIN number in new PCM. TRANSMISSION CONTROL CVI CALCULATION

An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur .

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Fig. 38: Example of CVI Calculation Courtesy of CHRYSLER LLC 1 - OUTPUT SPEED SENSOR 2 - OUTPUT SHAFT 3 - CLUTCH PACK 4 - SEPARATOR PLATE 5 - FRICTION DISCS 6 - INPUT SHAFT 7 - INPUT SPEED SENSOR 8 - PISTON AND SEAL Gear ratios can be determined by using the scan tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: user Monday, June 04, 2012 9:30:50 AM

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Clutch L/R 2/4 OD UD

CLUTCH VOLUMES When Updated Shift Sequence Oil Temperature 2-1 or 3-1 coast >21° C (70° F) downshift 1-2 shift 2-3 shift > 43° C (110° F) 4-3 or 4-2 shift

Throttle Angle

Proper Clutch Volume

< 5°

35 to 83

5 - 54° > 5°

20 to 77 48 to 150 24 to 70

SHIFT SCHEDULES

The PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: z z z z z

Shift lever position Throttle position Engine load Fluid temperature Software level

As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Schedule Extreme Cold

Cold

Expected Operation Oil temperature at Park, Reverse, start-up below -27° Neutral and 2nd C (16° F) gear only (prevents shifting which may fail a clutch with frequent shifts) Oil temperature at - Delayed 2-3 start-up above -24° upshift C (-12° F) and (approximately 35- below 2° C (36° F) 50 kmh (22-31 mph) - Delayed 3-4 upshift 72.5-85 kmh (45-53 mph) - Early 4-3 coastdown shift (approximately 30 mph) - Early 3-2 Condition

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Warm

Hot

Oil temperature at start-up above 2° C (36° F) and below 27° C (80° F) Oil temperature at start-up above 27° C (80° F)

Overheat

Oil temperature above 115° C (240° F) or engine coolant temperature above 118° C (244° F)

Super Overheat

Oil temperature above 127° C (260° F)

coastdown shift (approximately 27 kmh (17 mph)) - High speed 4-2, 32, 2-1 kickdown shifts are prevented - No EMCC - Normal operation (upshift, kickdowns, and coastdowns) - No EMCC - Normal operation (upshift, kickdowns, and coastdowns) - Full EMCC, no PEMCC except to engage FEMCC (except at closed throttle at speeds above 112.5-133.5 kmh (70-83 mph)) - Delayed 2-3 upshift 40-51.5 kmh (25-32 mph) - Delayed 3-4 upshift 66-77 kmh (41-48 mph) - 3rd gear FEMCC from 48-77 kmh (30-48 mph) - 3rd gear PEMCC from 43.5-50 kmh (27-31 mph) - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 35 kmh (22 mph) - Above 35 kmh (22 mph) the torque converter will not unlock unless the throttle is closed or if a wide open throttle 2nd

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PEMCC to 1 kickdown is made SENSOR RETURN - PCM INPUT

The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM REPLACEMENT DESCRIPTION

Use the scan tool to reprogram the new pcm with the vehicle's original identification number (vin) and the vehicle's original mileage. If this step is not done a Diagnostic Trouble Code (DTC) may be set. PCM GROUND

Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded via the mounting screws AND bracket to the chassis, separately from the ground pins. OPERATION OPERATION

The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: z z z z z z z

Camshaft Position Sensor (5V secondary) Crankshaft Position Sensor (5V primary) EGR Position feedback sensor (5V secondary) (if equipped) Engine coolant temperature sensor (connected to 5V internal via a pullup resistor) Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) Knock sensor (connected to 5V internal via a pullup resistor) Manifold absolute pressure sensor (5V secondary)

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z z z z z z

Oil Pressure Switch (connected to 5V internal via pullup resistor) Pedal Value Sensor #1 (5V Primary) Pedal Value Sensor #2 (5V Secondary) SRV Position Feedback Sensor (5V Secondary) Throttle Position Sensors (5V Primary) Variable Line Pressure Sensor (5V Secondary)

STANDARD PROCEDURE PCM/ECM REPROGRAMMING - GAS

Follow the instructions in order. See Standard Procedure. OBTAINING DIAGNOSTIC TROUBLE CODES BULB CHECK

Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 5 to 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC'S USING SCAN TOOL

1. Connect the scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column. 2. Turn the ignition switch on and access the "Read Fault" screen. 3. Record all the DTC's and "freeze frame" information shown on the scan tool. 4. To erase DTC's, use the "Erase Trouble Code" data screen on the scan tool.Do not erase any DTC's until problems have been investigated and repairs have been performed. PINION FACTOR SETTING

NOTE:

This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer.

The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. user Monday, June 04, 2012 9:30:50 AM

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4. Select Pinion Factor. Then follow the instructions on the scan tool screen. QUICK LEARN PROCEDURE

The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE:

z z z z z

The quick learn procedure should be performed if any of the following procedures are performed:

Transaxle Assembly Replacement Powertrain Control Module Replacement Solenoid/Pressure Switch Assembly Replacement Clutch Plate and/or Seal Replacement Valve Body Replacement or Recondition

To perform the Quick Learn Procedure, the following conditions must be met: z z z z z

z

1. 2. 3. 4.

The brakes must be applied The engine speed must be above 500 rpm The throttle angle (TPS) must be less than 3 degrees The shift lever position must stay until prompted to shift to overdrive The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. Go to the Transmission screen. Go to the Miscellaneous screen. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure.

REMOVAL REMOVAL - NGC CONTROLLER

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Fig. 39: Remove/Install PCM Courtesy of CHRYSLER LLC NOTE:

USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 4 electrical connectors at the PCM.

Fig. 40: Mounting Screws/Electrical Connectors user Monday, June 04, 2012 9:30:50 AM

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Courtesy of CHRYSLER LLC 3. Remove the 3 fasteners (1) holding the PCM to the bracket. REMOVAL - GPEC CONTROLLER (2.4L)

Fig. 41: GPEC Controller Courtesy of CHRYSLER LLC 1 - Connectors 2 - PCM NOTE:

USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 2 electrical connectors (1) at the PCM (2).

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Fig. 42: GPEC Controller Mounting Courtesy of CHRYSLER LLC 1 - Bracket 2 - PCM 3 - Bolts 3. Remove the 4 bolts (3) holding the PCM (2) to the bracket (1) and remove the PCM (2) from the vehicle. INSTALLATION INSTALLATION - NGC CONTROLLER

Fig. 43: Mounting Screws/Electrical Connectors Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:30:50 AM

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NOTE:

USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

1. Install PCM to bracket with 3 fasteners (1).

Fig. 44: Remove/Install PCM Courtesy of CHRYSLER LLC 2. Install and lock the 4 electrical connectors to the PCM. 3. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. INSTALLATION - GPEC CONTROLLER (2.4L)

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Fig. 45: GPEC Controller Mounting Courtesy of CHRYSLER LLC 1 - Bracket 2 - PCM 3 - Bolts NOTE:

USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

1. Install PCM (2) to bracket (1) with 4 bolts (3).

Fig. 46: GPEC Controller user Monday, June 04, 2012 9:30:50 AM

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Courtesy of CHRYSLER LLC 1 - Connectors 2 - PCM 2. Install and lock the 2 electrical connectors (1) to the PCM (2). 3. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage.

MODULE, STEERING COLUMN DESCRIPTION DESCRIPTION

Fig. 47: Steering Control Module Courtesy of CHRYSLER LLC This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure user Monday, June 04, 2012 9:30:50 AM

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the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Multifunction Removal . The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. OPERATION OPERATION

The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Multifunction - Removal . DIAGNOSIS AND TESTING STEERING CONTROL MODULE

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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. user Monday, June 04, 2012 9:30:50 AM

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This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information.

RECEIVER, WIRELESS IGNITION NODE DESCRIPTION DESCRIPTION

This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if user Monday, June 04, 2012 9:30:50 AM

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equipped). OPERATION OPERATION

Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH

The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a springloaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY," "RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS)

Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. Refer to Electrical - Vehicle Theft Security/Vehicle Theft Security - Operation . REMOTE KEYLESS ENTRY (RKE)

The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. Refer to Electrical - Power Systems/Power Locks - Operation TIRE PRESSURE MONITORING (TPM)

The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. Refer to Tires and Wheels/Tire Pressure Monitoring - Operation . REMOTE START WITH/EXTENDED RANGE ANTENNA

Further information concerning the Remote Start System can be located in , Starting System. Refer to Electrical - Engine Systems/Starting - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI)

The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. user Monday, June 04, 2012 9:30:50 AM

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PARK SHIFT INTERLOCK

The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. DIAGNOSIS AND TESTING FOBIK TRAPPED IN WIN

For more information. Refer to Electrical/Power Locks/TRANSMITTER, Integrated Key FOB - Diagnosis and Testing . REMOVAL REMOVAL

Fig. 48: Lower Instrument Panel Knee Blocker Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. Refer to Body/Instrument Panel/KNEEBLOCKER Removal . 3. Remove upper steering column shroud. Refer to Steering/Column/SHROUD, Steering Column Removal . 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). Refer to Electrical - Instrument Cluster/Instrument Cluster - Removal .

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Fig. 49: WIN Electrical Connector And Antenna Connector Courtesy of CHRYSLER LLC 5. 6. 7. 8.

Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. Remove the lower WIN attaching screw (5). Remove the lower WIN bracket attaching screw (4).

Fig. 50: Bracket-Wireless Ignition Node Courtesy of CHRYSLER LLC 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. INSTALLATION user Monday, June 04, 2012 9:30:50 AM

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INSTALLATION

NOTE:

The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. Refer to Electrical - Vehicle Theft Security/Vehicle Theft Security - Standard Procedure .

Fig. 51: Bracket-Wireless Ignition Node Courtesy of CHRYSLER LLC 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening.

Fig. 52: WIN Electrical Connector And Antenna Connector Courtesy of CHRYSLER LLC 2. Install the lower WIN bracket attaching screw (4). user Monday, June 04, 2012 9:30:50 AM

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3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2).

Fig. 53: Lower Instrument Panel Knee Blocker Courtesy of CHRYSLER LLC 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. Refer to Electrical - Instrument Cluster/Instrument Cluster - Installation . 7. Install upper steering column shroud. Refer to Steering/Column/SHROUD, Steering Column Installation . 8. Install knee blocker. Refer to Body/Instrument Panel/KNEEBLOCKER - Installation . 9. Connect negative battery cable. 10. If necessary, program the WIN. See Standard Procedure .

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2009 ACCESSORIES AND EQUIPMENT Audio and Video - Service Information - Journey

DESCRIPTION DESCRIPTION Several combinations of radio receivers and speaker systems are offered. The audio system uses an ignition switched source of battery current so that the system will only operate when the ignition switch is in the RUN or ACCESSORY positions. The audio system includes the following components: z z z z z z z

Antenna (Radio and Satellite) Power amplifier (with premium speaker system only) Radio noise suppression components Radio receiver Remote radio switches (if equipped) Satellite Receiver (integrated within the radio) Speakers

OPERATION OPERATION The audio system components are designed to provide audio entertainment and information through the reception, tuning and amplification of locally broadcast radio signals in both the Amplitude Modulating (AM) and Frequency Modulating (FM) commercial frequency ranges. The audio system components operate on battery current received through a fuse in the Power Distribution Center (PDC) (Diesel Only) or the Totally Integrated Control Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the system will only operate when the ignition switch is in the Run or Accessory positions.

DIAGNOSIS AND TESTING VIDEO VIDEO SYSTEM DIAGNOSIS CONDITION POSSIBLE CORRECTION CAUSES NO VIDEO (DVD 1. Fuse inoperative. 1. Check fuses. Replace fuses if required. PLAYER WILL NOT 2. Loose or damaged 2. Check for loose or corroded DVD player connector user Monday, June 04, 2012 9:47:38 9:47:32 AM

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LOAD OR EJECT)

DVD player connector 3. Loose or damaged wiring/DVD player inoperative

(16 pin). Repair or replace as required.

3. Check pin 1 (b+) and pin 9 (ground) of the 16 pin connector, then check pin 1 (b+) and pin 7 (ground) of the 12 pin connector. If the 16 pin connector does not show voltage, the 12 pin connector will not show voltage (the 12 pin is fed from the 16 pin). If voltage is ok on the 16 pin, but not present on the 12 pin, unplug the 12 pin harness from the player and check the connector pins on the back of the player. If voltage is present on the 12 pin connector, the screen or the 12 pin harness should be replaced. If there is still no voltage on the 12 pin connector, the DVD player should be replaced. 4. Ground connection 4. Check for continuity between DVD player and a damaged known good ground. There should be continuity. Repair ground if required. 5. DVD player 5. Exchange or replace DVD player if required. damaged 6. DVD damaged. 6. Insert known good DVD and test operation.

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NOTE: Avoid using CD's or DVD's that have adhesive type labels, as they may cause the disc to become jammed.

NO DISPLAY. AUDIO HEARD THROUGH SPEAKERS -

WHITE DISPLAY -

1. Loose or damaged 1. Check for loose or corroded DVD player connector connectors (12 pin). Check for loose or corroded video screen connector. Repair if required. Check for loose or damaged in-line connector. 2. Wiring damaged 2. With harness connected, check for video signal voltage at DVD player and at video screen harness. Place known good DVD into DVD player. Place positive lead of voltmeter on pin 5 (video signal) of the 12 pin connector. Place negative lead on pin 6 (video ground). Readings should be between 0.1v to 2v dc. 3. Video screen 3. Exchange or replace video screen if required. damaged 1. Low voltage 1. Check for battery voltage (9v-16v) at DVD player 12 pin connector (pin 1-battery, pin 7-ground). Display will be white if voltage drops below 6v. 2. Video screen 2. Exchange or replace video screen if required. damaged

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DARK OR BRIGHT SPOTS ON SCREEN

1. Brightness setting 1. Adjust brightness setting of video screen by requires adjustment. pressing buttons on side of video screen until desired level is reached. Start with a black screen, then press button up 16-20 times. There are 64 total steps of brightness. BRIGHT OR DARK 1. Video screen 1. The acceptable level of dots on the screen is DISPLAY display pixel defect. (green-1, red-2) or a total (green+red+blue+white+black) = 8. Replace or exchange video screen if necessary. VIDEO SELECTIONS DO 1. Aspect ratio is set 1. Using mode button, adjust until video appears NOT APPEAR FULL incorrectly. correctly. SCREEN WIDTH 2. Some DVD's are 2. Ensure that DVD is inserted correctly. two sided. One side is wide screen format and the other is full screen or there may be a wide screen or standard screen format on the disc. BUTTONS ON VIDEO 1. Video screen 1. Place known good DVD into DVD player. Once SCREEN INOPERATIVE damaged. image appears on video screen, press top button on side of video screen to adjust width of display. Press bottom buttons to adjust brightness. Once DVD menu appears on video screen, press middle button on video screen. Highlighted selection will begin to play. If any of the buttons do not function, replace or exchange video screen. AUDIO Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. AUDIO SYSTEM DIAGNOSIS user Monday, June 04, 2012 9:47:32 AM

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CONDITION NO AUDIO AT ALL SPEAKERS - RADIO DISPLAY AND CONTROLS ARE OPERATIONAL -

POSSIBLE CAUSES CORRECTION 1. Amplifier fuse faulty, if 1. Check and replace fuses, if required. equipped.

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4. Amplifier faulty, if equipped. 1. Radio faulty.

NO AUDIO AT SOME SPEAKERS - RADIO DISPLAY AND CONTROLS ARE OPERATIONAL POOR AUDIO AT ALL SPEAKERS - RADIO DISPLAY AND CONTROLS ARE OPERATIONAL POOR AUDIO AT SOME SPEAKERS - RADIO DISPLAY AND CONTROLS ARE OPERATIONAL -

2. Radio faulty. 3. Wiring to amplifier faulty, if equipped.

2. Exchange or replace radio, if required. 3. Verify radio on/off input to amplifier and verify battery and ground connections. Repair wiring as necessary. 4. Replace amplifier. 1. Exchange or replace radio, if required.

2. Speaker(s) faulty. 3. Wiring faulty between radio and speaker. 4. Wiring faulty between radio and amplifier. 5. Wiring faulty between amplifier and speaker. 6. Amplifier faulty. 1. Radio faulty.

2. Refer to speaker diagnostics. 3. Check wiring for open or short, repair wiring as necessary. 4. Refer to speaker diagnostics. Repair wiring as necessary. 5. Repair wiring as necessary.

2. Power/ground wiring open or shorted. 3. Amplifier faulty. 4. Power/ground wiring to amplifier open or shorted. 1. Radio faulty.

2. Repair wiring as necessary.

2. Speakers faulty. 3. Wiring faulty between radio and speaker. 4. Wiring faulty between radio and amplifier. 5. Wiring faulty between amplifier and speaker. 6. Amplifier faulty.

2. Refer to speaker diagnostics. 3. Check wiring for open or short, repair wiring as necessary. 4. Refer to speaker diagnostics. Repair wiring as necessary. 5. Wiring faulty between amplifier and speaker. 6. Replace amplifier.

6. Replace amplifier. 1. Exchange or replace radio, if required.

3. Replace amplifier. 4. Repair wiring as necessary. 1. Exchange or replace radio, if required.

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SOUND DISTORTION 1. Door trim panel loose (VIBRATION FROM or missing fasteners. SPEAKER AREA, BUZZING HUMMING) 2. Water shield loose or misaligned. 3. Items placed in door trim panel map pockets vibrating or moving from side to side. NO RADIO DISPLAY 1. Radio faulty. AUDIO AND CONTROLS ARE OPERATIONAL NO RADIO DISPLAY 1. Fuse faulty. AUDIO AND CONTROLS ARE NOT OPERATIONAL 2. Radio connector faulty.

1. Inspect door trim panel and correct as necessary. Replace any missing fasteners. 2. Inspect water shield and adjust as required. 3. Remove items from door trim panel. Ensure that vibration is no longer present. 1. Exchange or replace radio, if required.

1. Check radio fuse and Ignition-Off Draw (IOD) fuse in Junction Block (JB). Replace fuses, if required. 2. Check for loose or corroded radio connector. Repair, if required. CLOCK WILL NOT KEEP SET 1. Radio connector faulty. 1. Check for loose or corroded radio TIME connector. Repair, if required. 2. WIN connector faulty. 2. Check for loose or corroded WIN connector. Repair, if required. 3. Replace WIN, if required. Refer to Electrical - Electronic Control 3. WIN module faulty. Modules/Electronic Control Modules/RECEIVER, Wireless Ignition Node - Removal . 4. Radio faulty. 4. Exchange or replace radio, if required. POOR RADIO RECEPTION 1. Antenna faulty. 1. BODY AND CABLE, Antenna . WITH KEY IN ACCESSORY OR IGNITION ON POSITION 2. Radio ground faulty. 2. Check for continuity between radio chassis and a known good ground. There should be continuity. Repair ground, if required. 3. Radio noise suppression 3. Repair or replace ground strap as faulty. necessary. 4. Radio faulty. 4. Exchange or replace radio, if required. 5. Verify that the rear defogger grid is functioning properly, repair as necessary. 5. Faulty rear window Refer to Electrical - Heated/Cooled defogger. Systems/Heated Glass - Diagnosis and Testing NO COMPACT DISC 1. Faulty CD. 1. Insert known good CD and test operation. OPERATION user Monday, June 04, 2012 9:47:32 AM

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2. Foreign material on CD. 2. Clean CD and test operation. 3. Condensation on CD or 3. Allow temperature of vehicle interior to optics. stabilize and test operation. 4. Faulty CD player. 4. Exchange or replace radio, if required.

AMPLIFIER DESCRIPTION DESCRIPTION

The optional premium speaker system includes a separate audio power amplifier. The amplifier is an eight channel unit. The amplifier is located behind the right cowl trim panel. OPERATION 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 information of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through eight separate channels with dedicated feed and return circuits to the individual speakers. REMOVAL REMOVAL

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Fig. 1: Amplifier Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Disconnect and isolate the battery negative cable. Lower the glove box as necessary to gain access to the amplifier. Disconnect the electrical connectors. Loosen the mounting fasteners and remove the amplifier and bracket. Remove the amplifier from the bracket.

INSTALLATION INSTALLATION

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Fig. 2: Amplifier Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Install the amplifier to the mounting bracket. Install amplifier. Tighten the forward screw to 3 N.m (26.5 in. lbs.) and the rear nut to 2 N.m (18 in. lbs.). Connect the electrical connectors. Raise the glove box. Connect the battery negative cable.

ANTENNA, SATELLITE, AUDIO DESCRIPTION DESCRIPTION

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Fig. 3: Satellite Audio Courtesy of CHRYSLER LLC If the vehicle is equipped with satellite audio, a combined antenna for AM/FM and satellite is used. For removal. See Removal and for installation, see Installation . REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Lower the appropriate portion of the headliner as necessary to access the underside of the antenna. Refer to Body/Interior/HEADLINER - Removal . 3. Disconnect the antenna electrical connectors. 4. Remove the fastener and retainer. 5. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. INSTALLATION INSTALLATION

1. 2. 3. 4. 5.

Insert the antenna electrical connector through the hole in the roof panel. Press the antenna into position until both retainers snap into place. Tighten to 9 N.m (80 in. lbs.). Connect the antenna electrical connector to the antenna. Install headliner. Refer to Body/Interior/HEADLINER - Installation . Connect negative battery cable.

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ANTENNA, SATELLITE, VIDEO DESCRIPTION DESCRIPTION

The satellite video antenna cable connects the roof mounted antenna to the satellite receiver. It has two connectors at each end and is routed above the headliner, then down the right side A-pillar to the cowl area. OPERATION OPERATION

The satellite video antenna receives signals from orbiting satellites and sends these signals to the satellite receiver module. The satellite video antenna must have open space in which to operate. Items carried on the roof, parking inside etc. can have an effect on the antenna's ability to receive signals. REMOVAL REMOVAL

1. 2. 3. 4. 5.

Disconnect and isolate the battery negative cable. Lower the appropriate portion of the headliner as necessary, to access the underside of the antenna. Disconnect the electrical connectors from the antenna. Remove the fastener and retainer. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna.

INSTALLATION INSTALLATION

1. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. 2. Connect the electrical connector to the antenna. 3. Install the headliner. Refer to Body/Interior/HEADLINER - Installation . 4. Connect battery negative cable.

BODY AND CABLE, ANTENNA REMOVAL REMOVAL user Monday, June 04, 2012 9:47:32 AM

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NOTE:

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

SATELLITE AUDIO ONLY

1. Disconnect and isolate the battery negative cable 2. Lower the rear portion of the headliner as necessary to gain access to the audio antenna. Refer to Body/Interior/HEADLINER - Removal . 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. 8. Remove the passenger side quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim Removal . 9. Remove the passenger side C-pillar. Refer to Body/Interior/PANEL, C-Pillar Trim - Removal . 10. Remove the passenger side scuff plates. Refer to Body/Interior/PLATE, Scuff - Removal . 11. Remove the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Removal . 12. Remove the glove box. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel - Removal . 13. Remove the radio. See Removal . CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 14. Disconnect the antenna. SATELLITE AUDIO AND VIDEO AUDIO CABLE TO MODULE

NOTE:

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

1. Disconnect and isolate the battery negative cable. 2. Lower the rear portion of the headliner as necessary to gain access to the audio antenna. Refer to Body/Interior/HEADLINER - Removal . 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. user Monday, June 04, 2012 9:47:33 AM

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8. Remove the passenger side quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim Removal . 9. Remove the passenger side C-pillar. Refer to Body/Interior/PANEL, C-Pillar Trim - Removal 10. Remove the passenger side scuff plates. Refer to Body/Interior/PLATE, Scuff - Removal . 11. Position the passenger seat forward. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 12. Disconnect the audio antenna from the module. VIDEO CABLE TO MODULE

NOTE:

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

1. Disconnect and isolate the battery negative cable. 2. Lower the front portion of the headliner as necessary to gain access to the video antenna. Refer to Body/Interior/HEADLINER - Removal . 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. 8. Remove the passenger side front scuff plate. Refer to Body/Interior/PLATE, Scuff - Removal . 9. Remove the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Removal . 10. Position the passenger seat forward. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 11. Disconnect the video antenna from the module. SIGNAL (RADIO FEED) ANTENNA CABLE FROM MODULE TO COWL

NOTE:

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

1. Disconnect and isolate the battery negative cable. 2. Remove the passenger side front scuff plate. Refer to Body/Interior/PLATE, Scuff - Removal . 3. Remove the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Removal . user Monday, June 04, 2012 9:47:33 AM

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4. Position the passenger seat forward. 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 signal (radio feed) antenna from the module. 6. Disconnect the antenna cable from the instrument panel antenna cable in the cowl area. SIGNAL (RADIO FEED) ANTENNA FROM COWL TO RADIO

NOTE: 1. 2. 3. 4.

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

Disconnect and isolate the battery negative cable. Remove the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Removal . Remove the glove box. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel - Removal . Remove the radio. See Removal . 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 from the radio. INSTALLATION INSTALLATION SATELLITE AUDIO ONLY

NOTE: 1. 2. 3. 4. 5. 6. 7. 8.

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

Route the cable behind the glove box, up to the radio and secure. Connect the antenna to the radio. Install the radio. See Installation . Install the glove box. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel Installation . Route the antenna cable along the path of the old antenna wiring harness, securing where necessary. Install the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Installation . Install the passenger side quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim Installation . Install the passenger side scuff plates. Refer to Body/Interior/PLATE, Scuff - Installation .

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9. 10. 11. 12. 13. 14.

Install the passenger side C-pillar. Refer to Body/Interior/PANEL, C-Pillar Trim - Installation . Install the antenna base to the roof of the vehicle. Install the antenna bracket and mounting fastener. Install the antenna cable(s). Install the headliner. Refer to Body/Interior/HEADLINER - Installation . Connect the battery negative cable.

SATELLITE AUDIO AND VIDEO AUDIO CABLE TO MODULE

NOTE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

Connect the antenna cable to the module located under the front passenger seat. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. Install the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Installation . Install the passenger side quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim Installation . Install the passenger side scuff plates. Refer to Body/Interior/PLATE, Scuff - Installation . Install the passenger side C-pillar. Refer to Body/Interior/PANEL, C-Pillar Trim - Installation . Install the antenna base to the roof of the vehicle. Install the antenna bracket and mounting fastener. Install the antenna cable(s). Install the headliner. Refer to Body/Interior/HEADLINER - Installation . Position the passenger seat to its original position. Connect the battery negative cable.

VIDEO CABLE TO MODULE

NOTE: 1. 2. 3. 4. 5. 6. 7.

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

Connect the antenna cable to the module located under the passenger seat. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. Install the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Installation . Install the front passenger side scuff plate. Refer to Body/Interior/PLATE, Scuff - Installation . Install the antenna base to the roof of the vehicle. Install the antenna bracket and mounting fastener. Install the antenna cable(s).

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8. Install the headliner. Refer to Body/Interior/HEADLINER - Installation . 9. Position the passenger seat to its original position. 10. Connect the battery negative cable. SIGNAL (RADIO FEED) ANTENNA CABLE FROM MODULE TO COWL

NOTE: 1. 2. 3. 4. 5. 6. 7.

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

Connect the antenna cable to the instrument panel antenna cable in the cowl area. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. Connect the antenna cable to the module. Install the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Installation . Install the front passenger side scuff plate. Refer to Body/Interior/PLATE, Scuff - Installation . Position the passenger seat to its original position. Connect the battery negative cable.

SIGNAL (RADIO FEED) ANTENNA FROM COWL TO RADIO

NOTE:

The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness.

1. 2. 3. 4.

Connect the antenna to the radio. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. Install the radio. See Installation . Install the glove box. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel Installation . 5. Install the passenger side cowl panel. Refer to Body/Interior/PANEL, Cowl Trim - Installation . 6. Connect the battery negative cable.

CAMERA DESCRIPTION DESCRIPTION

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Fig. 4: Rear View Camera Courtesy of CHRYSLER LLC The Rear View Camera (RVC) (4) (also known as ParkView™), is a camera on chip device utilizing Complementary Metal Oxide Semiconductor (CMOS) technology. CMOS technology is used for a wide variety of digital or analog circuits. In this application, it supports the analog image sensor of the RVC. The RVC function is to provide a wide angle video image of the area behind the vehicle, including areas that might not be normally visible from the seated position of the vehicle operator, only while the transaxle gear selector is in the Reverse position. This video image then displays to the vehicle operator within the display screen of the audio system receiver unit near the center of the instrument panel. The RVC is intended to be an auxiliary viewing aid and is not promoted as an obstacle detection or safety device. It does not remove vehicle operator responsibility to recognize and obey official traffic laws or regulations or to take sensible precautions and care to avoid pedestrians, other vehicle traffic or both fixed and moving obstacles through the habitual use of safe and defensive driving techniques. The RVC is located on the underside of the light bar (1) mounted above the license plate tub on the vehicle liftgate. The camera lens is visible just to the left of the vehicle center line, while the body of the camera and the camera connections are concealed within the light bar above a camera mounting bracket (3), to which the camera is secured with three screws. The camera mounting bracket secures to the light bar assembly to the left of the left license plate lamp (2) with two additional screws. A light bar wire harness routes through a rubber grommet into the interior of the liftgate where it connects the RVC and both license plate lamps to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness.

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Fig. 5: Camera Image Sensor & Electronics Courtesy of CHRYSLER LLC The camera image sensor and electronics are sealed and protected within a two-piece die cast zinc housing (1), held together by four screws (2). The camera lens (5) extends from the lower surface of the housing and an integral connector receptacle (3) containing five terminal pins that extends from the right side of the housing. Additionally, there are three mounting bosses (4) integral to the camera housing, two on the left side and one on the right. The mounting bosses receive the three self-tapping screws securing the unit to the camera bracket. Hardwired circuitry connects the RVC to the electrical system of the vehicle. These hardwired circuits are integral to several wire harnesses, which routes throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds. The RVC cannot be adjusted or repaired. If the RVC is damaged or ineffective, it must be replaced. OPERATION user Monday, June 04, 2012 9:47:33 AM

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OPERATION

The Rear View Camera (RVC) is powered by a battery feed received through the backup lamp switch output circuit from the Totally Integrated Power Module (TIPM) so that is only active when the transaxle is shifted into the REVERSE position. In addition, the radio receiver monitors messages on the Controller Area Network (CAN) data bus to determine the selected transaxle gear and overrides any other display to show the RVC video output, whenever it detects that the transaxle is in REVERSE. A momentary blank video display screen immediately following the gearshift transition into the REVERSE position is considered normal operation. The camera electronics receive a path to ground at all times through a takeout and eyelet terminal of the liftgate wire harness that is secured by a ground screw to the right side of the liftgate inner panel. The output of the camera is a video signal compatible to the National Television System Committee (NTSC) standard composite video M format, or NTSC-M. The video signal is delivered to the radio video display unit through the entire length of the vehicle by camera signal and the camera return circuits that are arranged as a twisted pair, with an additional grounded foil jacket to protect the video signal from corruption due to stray radiated signals within the vehicle environment. The ground shield is terminated only at the video display (radio) end, not at the camera. Portions of these video signal wires are contained within the liftgate lightbar wire harness, the liftgate wire harness, the body wire harness and a jumper harness located between the radio and the body harness connector below the instrument panel at the right cowl side inner panel. DIAGNOSIS AND TESTING Rear Camera

The hardwired circuits of the Rear View Camera (RVC) and those between the RVC and the radio receiver may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RVC or the radio receiver. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to radio receiver operation, as well as the retrieval or erasure of a DTC requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE:

Be certain to confirm both of the following prior to attempting any further diagnosis or testing of the RVC. Use a diagnostic scan tool to confirm the rear view camera is setup in the vehicle configuration. From the initial start up

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screen of the diagnostic scan tool, navigate to ECU VIEW , select TIPMCGW CENTRAL GATEWAY , MORE OPTIONS , ECU DETAILS and then CONFIG INFO . Verify that REAR CAMERA PRESET - - - - SET is present. If not, the Sales Code XAC (Park View Rear Back-Up Camera) will have to be added to the vehicle configuration to enable the RVC, in vehicles equipped with a MyGIG multimedia entertainment system (Sales Codes RE1, REN, REP, RER, REU, REW, REX or REZ), be certain that the RVC is set to ENABLED using the CAMERA SETUP option in the MyGIG system settings. CONDITION

NO VIDEO DISPLAY IN RADIO DOES NOT DISPLAY CHECK ENTIRE SURROUNDINGS MESSAGE BRIEFLY AFTER SHIFTING INTO REVERSE

NO CAMERA IMAGE IN RADIO VIDEO DISPLAY AND NO BACKUP LAMPS IN REVERSE

NO CAMERA IMAGE IN RADIO

POSSIBLE CAUSES

CORRECTION 1. Check to be certain that the radio 1. Incorrect radio has the latest software update software. installed. Install the radio software update if required. 2. Test and replace the radio fuses if 2. Ineffective radio fuse. required. 3. Check for loose or damaged wiring connections at the radio. 3. Ineffective radio Test and repair the open radio ground circuit. ground circuit if required. 4. Check for loose or damaged 4. Ineffective radio feed wiring connections at the radio. circuit. Test and repair the open radio feed circuit if required. 5. Ineffective radio inputs 5. Use a diagnostic scan tool to test or outputs. the radio inputs and outputs including those received over the CAN data bus. Refer to the appropriate diagnostic information. 6. Use a diagnostic scan tool to test the radio. Refer to the appropriate 6. Ineffective radio. diagnostic information. 1. Test and repair the open backup 1. Left backup lamp lamp switch output circuit between inoperative, right backup the right and left tail lamps if lamp okay. required. 2. Test and repair the open backup lamp switch output circuit between 2. Both backup lamps the Totally Integrated Power inoperative. Module (TIPM) and the tail lamps if required. 3. Use a diagnostic scan tool to test 3. Ineffective TIPM the TIPM inputs and outputs. Refer inputs or outputs. to the appropriate diagnostic information. 1. Ineffective camera 1. Check for loose or damaged

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VIDEO DISPLAY - DOES DISPLAY CHECK ENTIRE SURROUNDINGS MESSAGE BRIEFLY AFTER SHIFTING INTO REVERSE AND BACKUP LAMPS DO OPERATE

ground circuit.

wiring connections at the camera, liftgate light bar and liftgate. Test and repair the open camera ground circuit if required. 2. Ineffective camera 2. Check for loose or damaged feed (backup lamp switch wiring connections at the camera, output) circuit. liftgate light bar and upper liftgate opening header. Test and repair the open camera feed (backup lamp switch output) circuit if required. 3. Check for loose or damaged wiring connections at the camera, liftgate light bar, upper liftgate 3. Ineffective camera opening header, right cowl side shield circuit. inner panel and radio. Test and repair the open or shorted camera shield circuit if required. 4. Check for loose or damaged wiring connections at the camera, liftgate light bar, upper liftgate 4. Ineffective camera opening header, right cowl side return circuit. inner panel and radio. Test and repair the open or shorted camera feed circuit if required. 5. Check for loose or damaged wiring connections at the camera, liftgate light bar, upper liftgate 5. Ineffective camera opening header, right cowl side signal circuit. inner panel and radio. Test and repair the open or shorted camera signal circuit if required. 6. Replace the ineffective camera if 6. Ineffective camera. required.

REMOVAL REMOVAL

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Fig. 6: Backup Camera & Liftgate & Lights Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Disconnect the negative battery cable. Remove the four retainers (1) holding the lightbar (5) to the liftgate (6). Using a trim stick or equivalent, release the lightbar (5) from the clips. Disconnect the electrical connectors from the backup camera (2) and the lights (3). Disconnect the liftgate release cable (4) from the lightbar (5). Remove the retainer from the back of the camera. Unclip the camera cover from the lightbar. Remove the camera mounting retainers. Remove the camera from the lightbar.

INSTALLATION INSTALLATION

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Fig. 7: Backup Camera & Liftgate & Lights Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Install the camera to the lightbar. Install the camera mounting retainers. Clip the camera cover to the lightbar. Install the retainer to the back of the camera. Connect the liftgate release cable (4) to the lightbar (5). Connect the electrical connectors to the backup camera (2) and the lights (3). Install the lightbar to the tailgate. Install the four retainers (1) holding the lightbar (5) to the liftgate (6). Connect the negative battery cable.

MODULE, SATELLITE VIDEO REMOVAL REMOVAL

1. Disconnect and isolate the negative battery cable. 2. Move the front passenger seat to the most forward position.

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Fig. 8: Antenna & Electrical Connectors Courtesy of CHRYSLER LLC 3. Disconnect the three antenna connectors (1) and the electrical connector (2).

Fig. 9: Retainers & Video Module Housing Courtesy of CHRYSLER LLC 4. Remove the three retainers (1) securing the video module housing (2) to the floor, remove video housing and module from vehicle.

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Fig. 10: Video Module Retainers & Video Module Housing Courtesy of CHRYSLER LLC 5. Remove the video module retainers (1) to the video module housing (2). INSTALLATION INSTALLATION

Fig. 11: Video Module Retainers & Video Module Housing Courtesy of CHRYSLER LLC 1. Install the video module to the housing.

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Fig. 12: Retainers & Video Module Housing Courtesy of CHRYSLER LLC 2. Install the video module into the vehicle and Install the three retainers (1) securing the video module housing (2) to the floor. Tighten to 6 N.m (53 in. lbs.).

Fig. 13: Antenna & Electrical Connectors Courtesy of CHRYSLER LLC 3. Connect the three antenna connectors (1) and the electrical connector (2). 4. Move the front passenger seat back to the original position. 5. Connect the battery negative cable. user Monday, June 04, 2012 9:47:33 AM

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MONITOR, MEDIA SYSTEM REMOVAL REMOVAL

Fig. 14: Removing / Installing Mounting Fasteners Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Open the video screen to access the mounting fasteners. 3. Remove the mounting fasteners.

Fig. 15: Removing/Installing Video Monitor Connectors Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:47:33 AM

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4. If equipped, disconnect the rear heat control connector (1). 5. Disconnect the video monitor connectors (2) and remove the assembly from the vehicle.

Fig. 16: Fasteners Courtesy of CHRYSLER LLC 6. Remove the fasteners (1) and remove the rear A/C and heater control. INSTALLATION INSTALLATION

Fig. 17: Fasteners Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:47:33 AM

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1. Install the rear A/C and heater control and the fasteners (1).

Fig. 18: Removing/Installing Video Monitor Connectors Courtesy of CHRYSLER LLC 2. If equipped, connect the rear A/C and heater control connector (1). 3. Connect the video monitor connectors (2).

Fig. 19: Removing / Installing Mounting Fasteners Courtesy of CHRYSLER LLC 4. Install the mounting fasteners. 5. Connect the battery negative cable.

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STANDARD PROCEDURE RADIO BACKUP

The radio hard disk drive (HDD) can be backed up to save customer data in the event that a radio replacement is required. This procedure can only be done with all radios with a hard disk drive. All other radios do not have a HDD. 1. Turn the ignition to RUN, engine OFF. 2. Power on the external HDD. 3. Connect the external HDD to the radio using the USB (Universal Serial Bus) cable. The radio display will change to the "Manage My Files" screen. 4. Connect the scan tool and preform the following steps to place the radio into "Dealership Mode": z ECU View z Radio z Misc. Functions z Service Mode z Start z Next 5. Follow the on screen instructions on the radio to back up the radio HDD. REMOVAL REMOVAL

REMOVAL RADIO/RADIO HEAD REMOTE RADIO DISPLAY NOTE:

Refer to the RADIO/RADIO HEAD for removal procedures. Refer to the REMOTE RADIO DISPLAY for removal procedures.

REQ radios only must be put into "Transportation Mode" before removal. With Ignition in RUN or ACCESSORY, press SET and DISC simultaneously until the radio displays "TRANSPORTATION" on the display or for 5 seconds.

RADIO/RADIO HEAD

1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Remove the radio mounting fasteners. 4. Carefully pull the radio out as necessary and disconnect the electrical connectors and antenna cables. 5. Remove the radio from the vehicle. REMOTE RADIO DISPLAY

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1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Remove the radio display mounting fasteners. 4. Carefully pull the radio display out as necessary and disconnect the electrical connectors and antenna cables. 5. Remove the radio display from the vehicle. INSTALLATION INSTALLATION

INSTALLATION RADIO/RADIO HEAD REMOTE RADIO DISPLAY

Refer to the RADIO/RADIO HEAD installation procedures. Refer to the REMOTE RADIO DISPLAY installation procedures.

RADIO/RADIO HEAD

1. Connect the electrical connectors and antenna cables. 2. Firmly seat the radio into position and install the mounting fasteners. 3. Install the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel Installation . 4. Connect the battery negative cable. REMOTE RADIO DISPLAY

1. Connect the electrical connectors. 2. Seat the display into position and install the mounting fasteners. 3. Install the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel Installation . 4. Connect the battery negative cable. NOTE:

REQ RADIO , After installation of the radio, remove the radio from "Transportation Mode" by pulling the IOD fuse or using the scan tool and perform a battery reset.

SPEAKER OPERATION OPERATION

Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output user Monday, June 04, 2012 9:47:33 AM

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signal electrical current to flow through the voice coil. For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. DIAGNOSIS AND TESTING SPEAKER

Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. If all speakers are inoperative, check the radio fuses in the Totally Integrated Power Module (TIPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the TIPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier. disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuit(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (user Monday, June 04, 2012 9:47:33 AM

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) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. REMOVAL REMOVAL

REMOVAL DOOR SPEAKER INSTRUMENT PANEL SPEAKER SUBWOOFER

Refer to the DOOR SPEAKER removal procedure. Refer to the INSTRUMENT PANEL SPEAKER removal procedure. Refer to the SUBWOOFER removal procedure.

DOOR SPEAKER

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Removal . Remove the mounting fasteners. Disconnect the electrical connector and remove the speaker from the vehicle.

INSTRUMENT PANEL SPEAKER

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Removal . Remove the mounting fasteners. Disconnect the electrical connector and remove the speaker from the vehicle.

SUBWOOFER

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the left rear quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim - Removal . Remove the subwoofer mounting fasteners. Disconnect the electrical connectors and remove the subwoofer from the vehicle.

INSTALLATION INSTALLATION

INSTALLATION DOOR SPEAKER INSTRUMENT PANEL SPEAKER SUBWOOFER

Refer to the DOOR SPEAKER installation procedure. Refer to the INSTRUMENT PANEL SPEAKER installation procedure. Refer to the SUBWOOFER installation procedure.

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DOOR SPEAKER

1. 2. 3. 4.

Install the speaker and connect the electrical connector. Install the mounting fasteners. Install the door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Installation . Connect the battery negative cable.

INSTRUMENT PANEL SPEAKER

1. 2. 3. 4.

Install the speaker and connect the electrical connector. Install the mounting fasteners. Install the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Installation . Connect the battery negative cable.

SUBWOOFER

1. 2. 3. 4.

Install the subwoofer and connect the electrical connector. Install the mounting fasteners. Install the left rear quarter trim panel. Refer to Body/Interior/PANEL, Quarter Trim - Installation . Connect the battery negative cable.

SWITCH, REMOTE RADIO DESCRIPTION DESCRIPTION

Remote radio control switches are rocker-type switch units are mounted in the upper spoke covers of the rear (instrument panel side) steering wheel trim cover. The switch unit on the left side is the seek switch and has seek up, seek down, and preset station advance switch functions. The switch unit on the right side is the volume control switch and has volume up, volume down, and mode advance switch functions. The two remote radio switch units are each retained in a mounting hole located on opposite sides of the rear steering wheel trim cover by four integral snap features. A plastic bracket on the back of each switch unit provides additional support for the unit by extending towards the center of the steering wheel where it is clamped between the steering wheel armature and the steering wheel rear trim cover mounting boss by the trim cover mounting screw. The two remote radio switch units share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. DIAGNOSIS AND TESTING REMOTE SWITCHES user Monday, June 04, 2012 9:47:33 AM

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Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in REMOTE RADIO SWITCH TEST. If the remote radio switch resistances check OK , go to 3. If not OK, replace the faulty switch. REMOTE RADIO SWITCH TEST Switch Switch Minimum Nominal Maximum Position Resistance Resistance Resistance Right Volume 6.732 6.868 6.8 ohms (White) Up ohms ohms Right Volume 14.850 15.151 15 ohms (White) Down ohms ohms Right Mode 0 ohms 0 ohms 0 ohms (White) Advance Left 1.188 1.212 Seek Up 1.2 ohms (Black) ohms ohms Left Seek 3.267 3.333 3.3 ohms (Black) Down ohms ohms Pre-Set Left Station 465 ohms 47 ohms 474 ohms (Black) Advance 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, refer to BODY . If not OK, repair the circuit as required. REMOVAL REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering user Monday, June 04, 2012 9:47:33 AM

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column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

Fig. 20: Removing / Installing Driver Side Airbag Module Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. Refer to Restraints/AIR BAG, Driver Removal .

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Fig. 21: Retainers, Horn Connector And Button Assembly Courtesy of CHRYSLER LLC 3. Disconnect the horn connector (3). 4. Remove retainers (1) and remove the horn button assembly (2).

Fig. 22: Speed Control Switch Courtesy of CHRYSLER LLC 5. Remove the speed control switch (3). Refer to Electrical/8P - Speed Control/Speed Control/SWITCH, Speed Control - Removal .

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Fig. 23: Radio Switches Courtesy of CHRYSLER LLC 6. Disconnect the radio switches (1). 7. From the inside of the steering wheel rear trim cover, press firmly and evenly outward on the back of the switch to disengage the four snap features that secure the switch to the inside of the mounting hole. 8. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION INSTALLATION

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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.

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Fig. 24: Radio Switches Courtesy of CHRYSLER LLC 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch snap features is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch (1).

Fig. 25: Speed Control Switch Courtesy of CHRYSLER LLC 4. Install the speed control switch (3). Refer to Electrical/8P - Speed Control/Speed Control/SWITCH, user Monday, June 04, 2012 9:47:33 AM

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Speed Control - Installation .

Fig. 26: Retainers, Horn Connector And Button Assembly Courtesy of CHRYSLER LLC 5. Install the horn button assembly (2) and install the three retainers (1). 6. Connect the horn connector (3).

Fig. 27: Removing / Installing Driver Side Airbag Module Courtesy of CHRYSLER LLC 7. Install the driver side airbag module to the steering wheel. Refer to Restraints/AIR BAG, Driver Installation . 8. Connect the battery negative cable. user Monday, June 04, 2012 9:47:33 AM

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2009 ACCESSORIES AND EQUIPMENT Lamps/Lighting - Exterior - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Exterior Lighting System Courtesy of CHRYSLER LLC The exterior lighting system for this vehicle includes the following exterior lamp units: z

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Center High Mounted Stop Lamp (3) - A standard equipment Center High Mounted Stop Lamp (CHMSL) is centered on the upper liftgate header above the liftgate glass opening at the rear of the vehicle. Front Fog Lamps (7) - Vehicles equipped with this option have a separate front fog lamp unit mounted near each outboard end of the front fascia, below each front lamp unit. Front Lamp Units (1) - A standard equipment front lamp unit with two, single-filament headlamp bulbs is located at each outboard side of the grille opening in the Front End Module (FEM). Front Position Lamps - A front position lamp is integral to each front lamp unit on vehicles manufactured for export markets where they are required. License Plate Lamps (4) - Two standard equipment rear license plate lamp units are integral to the liftgate handle assembly, just above the license plate tub formation on the outer liftgate panel.

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z

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Rear Fog Lamps (5) - A rear fog lamp unit is mounted near each outboard end of the rear fascia, below each rear lamp unit on vehicles manufactured for export markets where they are required. Rear Lamp Units (2) - A standard equipment two-piece rear lamp unit is mounted on each side at the rear of the vehicle. One piece of the rear lamp is secured to the end of each quarter panel on either side of the liftgate opening and the second piece is secured to each side of the liftgate outer panel, adjacent to the first piece of the rear lamp when the liftgate is closed. Repeater Lamps (6) - A repeater lamp is mounted to each front fender just behind the front wheel opening on vehicles manufactured for export markets where they are required.

These exterior lighting lamp units and their controls are combined to provide the following exterior lighting features: z

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Automatic Headlamps - Vehicles with the automatic headlamps option are equipped with a unique left (lighting) multi-function switch that includes an AUTO (Automatic) position and have an automatic headlamp sensor to sense ambient light levels. The automatic headlamp sensor is integral to the sun load sensor located on the top of the instrument panel. When the AUTO position of the headlamp switch is selected, the headlamps are turned ON and OFF automatically as ambient light levels dictate. Backup Lamps - The backup (or reverse) lamps include a clear bulb, reflector and clear lens that are integral to the liftgate portions of each rear lamp unit. Brake Lamps - The brake (or stop) lamps include a clear bulb, reflector and red lens that are integral to the quarter panel portions of each rear lamp unit, and the red lens and multiple Light-Emitting Diode (LED) units of the CHMSL. Daytime Running Lamps - Daytime Running Lamps (DRL) are standard equipment on vehicles manufactured for sale in Canada and optional on vehicles manufactured for the United States. Vehicles with the DRL feature enabled illuminate the high beam headlamp bulb in each front lamp unit at a reduced intensity to serve as the DRL. Exterior Lamp Fail-Safe Operation - The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and the Totally Integrated Power Module (TIPM) provide a failsafe feature which will automatically turn ON the low beam headlamps and all park lamps when the ignition switch is in the ON position and there is no detected communication from the Steering Control Module (SCM), or when the Local Interface Network (LIN) data bus or Controller Area Network (CAN) data bus are inoperative. Exterior Lamp Load Shedding - The TIPM provides a battery saver feature which will automatically turn OFF all exterior lamps (except the park/tail lamps in certain export markets) that remain ON with the ignition switch in the LOCK position after a timed interval of about eight minutes. Front Fog Lamps - The optional front fog lamps include the clear bulb, reflector and clear lens of each adjustable front fog lamp unit. Hazard Warning Lamps - The hazard warning lamps include the bulbs, reflectors and lenses of each lamp in the right and left, front and rear turn signal circuits. Headlamps - The headlamps include dual, single filament halogen bulbs, an adjustable reflector and a clear lens integral to each front lamp unit. Headlamp Leveling - Headlamp leveling is available only in certain markets where it is required equipment. A headlamp leveling actuator motor on each headlamp unit and a headlamp leveling switch integral to the switch pod in the instrument panel center stack allows the headlamp beam pattern to be

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z

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adjusted by the vehicle operator from the interior of the vehicle to compensate for passenger or cargo loads. Headlamp Time Delay - On vehicles equipped with the automatic headlamps option, when this feature is enabled the low or high beam headlamps remain illuminated for a programmable delay interval of 0 (disabled), 30, 60 or 90 seconds after the ignition switch has been turned to the OFF position. If the vehicle is equipped with the optional Electronic Vehicle Information Center (EVIC), this feature is customer programmable through the EVIC. Headlamps With Wipers - Vehicles with the automatic headlamps option have an automatic headlampswith-wipers feature. When this feature is enabled and the AUTO position of the headlamp switch is selected, the headlamps are turned ON automatically whenever the windshield wipers are turned ON; and, if the headlamps were turned ON automatically when the wipers were turned ON, they will also turn OFF automatically when the wipers are turned OFF if the appropriate ambient light conditions exist. If the vehicle is equipped with the optional EVIC, this feature is customer programmable through the EVIC. Optical Horn - Also known as flash-to-pass, the beam selection function of the left (lighting) multifunction switch control stalk has a momentary intermediate position that allows the headlamp high beams to be flashed momentarily, without changing the headlamp beam selection. Park/Tail Lamps - The front park lamps include the amber bulbs, reflectors and clear lenses integral to each front lamp unit and, if the vehicle is so equipped, the clear position lamp bulb integral to each front lamp unit. The rear tail lamps include the clear bulbs, reflectors and red lenses integral to both the quarter panel and liftgate portions of each rear lamp unit as well as the bulbs and lenses of the license plate lamp units. Rear Fog Lamps - Rear fog lamps are available only in certain export markets where they are required equipment. The rear fog lamps include a clear bulb, a red lens and a reflector that are integral to each rear fog lamp unit. Turn Signal Lamps - The front turn signal lamps include an amber bulb, a reflector and a clear lens that are integral to each front lamp unit. In certain export markets where they are required, the clear bulbs and lenses of the repeater lamps on each front fender will also be included in the front turn signal circuits. The rear turn signal lamps include an amber bulb, a reflector and a clear lens that are integral to the quarter panel portion of each rear lamp unit.

Other components of the exterior lighting system for this vehicle include: z

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Backup Lamp Switch - A plunger-type backup lamp switch is installed through the transmission housing of vehicles equipped with a manual transmission and is actuated by the shifter mechanism within the transmission when REVERSE gear is selected. On vehicles with an optional automatic transmission, a stand alone Transmission Range Sensor (TRS) performs the backup lamp switch function. Brake Lamp Switch - A plunger-type brake lamp switch is located on the brake pedal support bracket under the instrument panel and is actuated by the brake pedal arm when the brake pedal is depressed. Clockspring - The clockspring includes an integral turn signal cancel cam, which provides automatic turn signal cancellation as the steering wheel is rotated back to its centered position following a vehicle turning maneuver. The clockspring is located near the top of the steering column, directly beneath the steering wheel. Refer to Restraints/CLOCKSPRING - Description . Hazard Switch - A latching push button-actuated hazard switch is integral to the switch pod located just above the heater and air conditioner controls in the center stack area of the instrument panel. Headlamp Leveling Switch - A four mode push button-actuated headlamp leveling switch is integral to

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z

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the switch pod located just above the heater and air conditioner controls in the center stack area of the instrument panel of vehicles manufactured for certain export markets where the headlamp leveling feature is required. Instrument Cluster - The ElectroMechanical Instrument Cluster (EMIC) is also known as the Cab Compartment Node (CCN) in this vehicle. The EMIC/CCN is located in the instrument panel above the steering column opening, directly in front of the driver. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Instrument Panel Switch Pod - The instrument panel switch pod contains the hazard switch and, on vehicles so equipped, the headlamp leveling switch. The switch pod is located just above the heater and air conditioner controls in the center stack area of the instrument panel. Refer to Electrical - Instrument Cluster/Instrument Cluster/POD, Switch - Description . Left Multi-Function Switch - The left (lighting) multi-function switch is located on the steering column, just below the steering wheel. A control stalk that extends from the left side of the switch is used to select the turn signal lamps (right or left) and to select the headlamp beam (low, high or optical horn). A control knob on the control stalk is used to select the park lamps, headlamps or fog lamps. Park Brake Switch - A park brake switch is located on the park brake mechanism. On vehicles with a manual transmission, a park brake hand lever mechanism is located on the side of the floor panel transmission tunnel between the two front seats. On vehicles with an automatic transmission, a park brake foot lever mechanism is located on the driver side cowl side inner panel below the instrument panel. Steering Control Module - The Steering Control Module (SCM) is located within the left multi-function switch housing on the top of the steering column, just below the steering wheel. Refer to Electrical Electronic Control Modules/Electronic Control Modules/MODULE, Steering Column Description . Stop Lamp Inhibit Relay - A stop lamp inhibit relay (also known as a brake lamp relay, brake lamp activation relay or trailer tow damping relay) is located in a connector on the left rear quarter inner panel just forward of the shock tower within the passenger compartment. Totally Integrated Power Module - The Totally Integrated Power Module (TIPM) is located in the engine compartment, near the battery. Refer to Electrical - Wiring/Power Distribution/MODULE, Totally Integrated Power (TIPM) - Description . Trailer Tow Wiring - Vehicles equipped with an optional Trailer Tow Prep package include a wire harness, four relays, a conventional 4-way light duty trailer tow connector and an installation instruction sheet shipped loose in the glove box from the factory for installation by the vehicle owner or the dealer.

Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the exterior lighting components through the use of a combination of soldered splices, splice block connectors and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds.

OPERATION OPERATION user Monday, June 04, 2012 5:42:44 PM

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Following are paragraphs that briefly describe the operation of each of the major exterior lighting systems. The lamps and the hard wired circuits between components related to the exterior lighting system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the exterior lighting system or the electronic controls or communication between modules and other devices that provide some features of the exterior lighting system. The most reliable, efficient and accurate means to diagnose the exterior lighting system or the electronic controls and communication related to exterior lighting system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. AUTOMATIC HEADLAMPS

The optional automatic headlamp system includes the left (lighting) multi-function switch, the Steering Control Module (SCM), the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Totally Integrated Power Module (TIPM), the heater and air conditioner control unit and the sun load sensor on the top of the instrument panel. The sun load sensor provides an ambient light level input to the A/C - heater control whenever the ignition switch is in the ON position. The A/C - heater control responds to this input by sending the appropriate electronic light level messages to the TIPM over the Controller Area Network (CAN) data bus. When the AUTO (Automatic) position is selected with the left multi-function switch, the SCM responds to this input by sending the appropriate electronic lighting switch status messages to the EMIC over the Local Interface Network (LIN) data bus. The EMIC responds to this input by sending the appropriate electronic lighting request messages to the TIPM over the CAN data bus. With the engine running, the TIPM responds to these messages by automatically controlling a pulse width modulated voltage output to the selected headlamp bulb filaments through the right and left low or high beam driver circuits to illuminate the headlamps. The TIPM also remembers which beams (low or high) were selected when the headlamps were last turned OFF, and energizes those beams and lamps again the next time it turns the headlamps ON. BACKUP LAMPS

The backup (or reverse) lamps have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is secured to the body sheet metal within the passenger compartment. On vehicles with a manual transmission, the backup lamp switch provides an input to the TIPM through a backup lamp switch signal circuit, and the TIPM provides battery voltage to the backup lamps on the backup lamp control output circuit whenever the ignition switch is in the ON position and the REVERSE position is selected with the transmission shift linkage. On vehicles with an automatic transmission, the Powertrain Control Module (PCM) continually monitors a hard wired multiplex input from the Transmission Range Sensor (TRS), then sends the appropriate electronic transmission gear selector status messages to other electronic modules over the Controller Area Network (CAN) data bus. Whenever the ignition switch is in the ON position and the TIPM receives an electronic message indicating the status of the transmission gear selector is REVERSE, it provides a battery voltage output user Monday, June 04, 2012 5:42:44 PM

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to the backup lamps on the backup lamp control output circuit. BRAKE LAMPS

The brake (or stop) lamps and the Center High Mounted Stop Lamp (CHMSL) each have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is secured by a ground screw to the body sheet metal within the passenger compartment. The TIPM and the CHMSL receive battery voltage on the brake lamp switch output circuit when the brake lamp switch is closed by the brake pedal arm. The brake lamps are then controlled by the TIPM through High Side Drivers (HSD) on the left and right stop lamp control circuits. A stop lamp inhibit relay (also known as a brake lamp relay, brake lamp activation relay or trailer tow damping relay) is used by the Controller Antilock Brake (CAB) to mitigate undesirable brake lamp operation when the CAB activates various brake hydraulic circuits as part of its Traction Control System (TCS) and Trailer Sway Control (TSC) functions. The brake lamp function of the trailer tow wiring is also controlled by an output from the TIPM based upon a hard wired input from the brake lamp switch. DAYTIME RUNNING LAMPS

Vehicles equipped with this option or manufactured for sale in Canada illuminate the high beam filament of both headlamps at a reduced intensity when the engine is running, the parking brake is released and the exterior lamps are turned OFF. The TIPM must be programmed appropriately for this feature to be enabled. Once enabled, anytime the TIPM receives electronic messages over the CAN data bus from the PCM indicating the engine is running and from the EMIC indicating the status of the left multi-function switch exterior lighting switch input is OFF and that the parking brake is released, the TIPM provides a pulse width modulated voltage output to the proper headlamp bulb filaments through the right and left high beam feed circuits to produce illumination at a reduced intensity. FRONT FOG LAMPS

Vehicles equipped with optional front fog lamps include a front fog lamp switch integral to the left (lighting) multi-function switch on the steering column. The front fog lamps have a path to ground at all times through their connection to the headlamp and dash wire harness and a takeout with an eyelet terminal that is secured to the body sheet metal. The SCM monitors a hard wired multiplex input from the left multi-function switch to determine whether the fog lamps are selected, then sends the appropriate electronic front fog lamp switch status messages to the EMIC over the LIN data bus. The EMIC then relays the appropriate electronic front fog lamp switch request messages to the TIPM over the CAN data bus. When the TIPM receives a front fog lamp switch request message, it controls front fog lamp operation by providing a battery voltage output to the fog lamps through the right and left front fog lamp control circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to illuminate or extinguish the front fog lamp indicator. The TIPM will automatically de-energize the front fog lamps any time the headlamp high beams are selected, except on vehicles manufactured for certain export markets. The TIPM also provides a battery saver (load shedding) feature for the front fog lamps, which will turn these lamps OFF if they are left ON for more than about eight minutes with the ignition switch in the LOCK position, if there is a charging system failure, or if the electrical system voltage falls below about 11.75 volts for more than about 30 seconds. Each front fog lamp includes an integral adjustment screw to be used for static aiming of the fog lamp beams. user Monday, June 04, 2012 5:42:44 PM

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HAZARD WARNING LAMPS

The hazard warning system includes the EMIC, the TIPM and the hazard switch in the switch pod located in the center stack area of the instrument panel, above the heater and air conditioner control unit. The hazard switch provides a hard wired input to the TIPM. When the TIPM receives an input from the hazard switch it controls hazard warning system operation and flash rate by controlling battery voltage outputs through high side drivers on the front and rear, right and left turn signal control circuits. On vehicles manufactured for certain export markets where they are required, the TIPM provides battery voltage to the repeater lamps through right and left repeater lamp control output circuits based upon the hazard switch input. The TIPM also sends the appropriate electronic messages back to the EMIC over the CAN data bus to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. HEADLAMPS

The headlamp system includes the SCM, the EMIC, the TIPM, the headlamp switch on the instrument panel and the left (lighting) multi-function switch on the steering column. The headlamp bulbs have a path to ground at all times through their connection to the headlamp and dash wire harness. The headlamp and dash wire harness has takeouts with eyelet terminals that are secured to the body sheet metal. The TIPM will store a Diagnostic Trouble Code (DTC) for any shorts or opens in the headlamp circuits. The SCM monitors hard wired multiplex inputs to determine the status of the exterior lighting switches in the left multi-function switch and whether the headlamp high or low beams are selected. The SCM then sends the appropriate electronic lighting switch status and headlamp beam select switch status messages to the EMIC over the LIN data bus. The EMIC then sends the appropriate electronic headlamp request and headlamp beam request messages to the TIPM over the CAN data bus. The TIPM responds to these messages by providing a Pulse Width Modulated (PWM) voltage output to the headlamps through high side drivers on the right and left low and high beam feed circuits to illuminate the selected headlamp filaments. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination of the high beam indicator. When the optical horn feature is selected, the low beams will shut OFF about 200 milliseconds after the high beams are activated. The TIPM also remembers which beams (LOW or HIGH) were selected when the headlamps were last turned OFF, and energizes those beams again the next time the headlamps are turned ON. The TIPM provides a battery saver (load shedding) feature for the headlamps, which will turn these lamps OFF if they are left ON for more than about eight minutes with the ignition switch in the LOCK position. The SCM and the EMIC each provide a fail-safe feature for the headlamps, which will cause the TIPM to turn the low beam headlamps ON automatically if there is no input available from the SCM or the left multi-function switch. The TIPM also provides a fail-safe feature for the headlamps that will turn the headlamps ON automatically whenever a loss of CAN bus communication is detected with the ignition switch in the ON position. Each headlamp includes integral reflector adjustment screws to be used for static aiming of the headlamps. HEADLAMP DELAY

The headlamp delay feature includes the left (lighting) multi-function switch, the SCM, the EMIC and the user Monday, June 04, 2012 5:42:44 PM

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TIPM. On vehicles equipped with an optional Electronic Vehicle Information Center (EVIC), this feature has customer programmable delay intervals of 0 seconds (disabled), 30 seconds, 60 seconds and 90 seconds. If the exterior lighting switch is in the AUTO (Automatic) position when the ignition switch is moved from the ON position to any position except ON, then the headlamps will remain illuminated until after the selected delay interval has elapsed. The park lamps will not stay ON during the headlamp delay interval. The default delay interval is 90 seconds, but can be reprogrammed by the customer using the customer programmable features function of the EVIC, if the vehicle is so equipped. HEADLAMP LEVELING

In certain export markets where required, a headlamp leveling system is provided on the vehicle. The headlamp leveling system includes unique front lamp units each equipped with a headlamp leveling actuator motor, and a rocker-actuated headlamp leveling switch integral to the switch pod in the instrument panel center stack. The headlamp leveling system allows the headlamp beams to be adjusted to one of four vertical positions to compensate for changes in inclination caused by the loading of the vehicle suspension. The leveling motors are mechanically connected through an integral pushrod to the adjustable headlamp reflector. Each time the headlamp leveling switch is depressed the circuitry of the switch pod provides the appropriate electronic select status up or select status down messages to the EMIC over the LIN data bus. The EMIC then sends the appropriate electronic select request up or select request down messages to the TIPM over the CAN data bus. The TIPM responds to these messages by providing a voltage output to the headlamp leveling motors through a high side driver on the headlamp level sensor signal circuit to move the headlamp reflectors to the selected position based upon the voltage input received from the TIPM. The TIPM also sends the appropriate electronic messages back to the EMIC and the EMIC relays the messages back to the switch to control the illumination of the 1 , 2 , or 3 Light Emitting Diode (LED) selected position indicator in the headlamp leveling switch button. The EMIC and TIPM logic will only allow the headlamp leveling system to operate while the ignition switch is in the ON position and the exterior lighting is turned ON. PARK LAMPS

The park lamps system includes the left multi-function switch on the steering column, the SCM, the EMIC and the TIPM. The front park lamp, side marker lamp and, on vehicles manufactured for certain export markets, position lamp bulbs each have a path to ground at all times through their connection to the headlamp and dash wire harness. The headlamp and dash wire harness has takeouts with eyelet terminals that are secured to the body sheet metal. The rear park/tail lamp, side marker lamp and license plate lamp bulbs each have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is secured by a ground screw to the body sheet metal. The SCM monitors a hard wired multiplex input from the exterior lighting switch of the left multi-function switch, then sends the appropriate electronic lighting switch status messages to the EMIC over the LIN data bus. The EMIC then relays the appropriate electronic lighting request messages to the TIPM over the CAN data bus. The TIPM responds to these messages by providing a battery voltage output to the appropriate lamp bulbs through high side drivers on the front and rear, right and left lamp driver and control circuits. The TIPM provides a battery saver (load shedding) feature for the park lamps, which will turn these lamps OFF if they are left ON for more than about eight minutes with the ignition switch in the LOCK position. The SCM user Monday, June 04, 2012 5:42:44 PM

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and the EMIC each provide a fail-safe feature for the park lamps, which will cause the TIPM to turn the park lamps and low beam headlamps ON automatically if there is no input available from the SCM or the left multifunction switch. The TIPM also provides a fail-safe feature for the park lamps that will turn the park lamps and low beam headlamps ON automatically whenever a loss of CAN bus communication is detected with the ignition switch in the ON position. REAR FOG LAMPS

Rear fog lamps are installed on vehicles manufactured for certain export markets where they are required. The rear fog lamp system includes the left (lighting) multi-function switch, the SCM, the EMIC and the TIPM. The rear fog lamp bulbs have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is secured to the body sheet metal. The SCM monitors a hard wired multiplex input from the left multi-function switch to determine whether the rear fog lamps are selected, then sends the appropriate electronic rear fog lamp switch status messages to the EMIC over the LIN data bus. Then the EMIC relays the appropriate electronic rear fog lamp request messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output to the rear fog lamp bulbs through a high side driver on the rear fog lamp signal control circuit. The TIPM also sends the appropriate electronic messages back to the EMIC to control the rear fog lamp indicator. The TIPM will automatically energize and de-energize the front fog lamps in concert with the rear fog lamps. The TIPM also provides a battery saver (load shedding) feature for the rear fog lamps, which will turn these lamps OFF if they are left ON for more than about eight minutes with the ignition switch in the LOCK position. TRAILER TOW WIRING

Vehicles equipped with an optional trailer tow preparation package are shipped from the factory with a trailer tow wiring harness and 4-pin trailer connector that is packaged with an instruction card and placed in the glove box of the vehicle. The trailer tow harness includes four relays designed to isolate the trailer turn signal and stop lamp lighting from the rear vehicle lighting and prevent overloading of the turn signal and stop lamp lighting drivers in the TIPM. These vehicles also include a dedicated park lamp control output circuit protected by a 15 ampere fuse located in the TIPM. If the trailer lighting is connected directly to the vehicle wiring without using the necessary relays, the vehicle electrical system will become overloaded and the rear lighting of the vehicle will cease to function. The TIPM will store a Diagnostic Trouble Code (DTC) for this condition. TURN SIGNAL LAMPS

The turn signal lamps system includes the left (lighting) multi-function switch on the steering column, the SCM, the EMIC and the TIPM. The front turn signal lamp bulbs each have a path to ground at all times through their connection to the headlamp and dash wire harness. The headlamp and dash wire harness has takeouts with eyelet terminals that are secured to the body sheet metal. The rear turn signal lamp bulbs have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is secured by a ground screw to the body sheet metal. The SCM monitors a hard wired multiplex input from the left multi-function switch to determine the status of the turn signal switch, then sends the appropriate electronic turn signal switch status messages to the EMIC user Monday, June 04, 2012 5:42:44 PM

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over the LIN data bus. Then the EMIC relays the appropriate electronic turn signal request messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps through high side drivers on the appropriate front and rear, right or left turn signal control circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right or left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The EMIC also provides a turn signal ON warning that will generate repetitive chimes to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per-hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers (2.49 miles) for this feature. The chime will continue until the turn signal input becomes inactive or until the vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first.

WARNING WARNINGS WARNING: To avoid serious or fatal injury, eye protection should be used when servicing any glass components. CAUTION: Do not contaminate the glass of halogen bulbs with fingerprints or allow contact with other possibly oily surfaces. Reduced bulb life will result. CAUTION: Do not use bulbs with higher candle power than indicated in the Bulb Application table. See Electrical/Lamps/Lighting - Exterior - Specifications. In addition, do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owner's Manual. Damage to lamps, lenses, wiring and other related electrical components can result.

DIAGNOSIS AND TESTING LAMPS/LIGHTING - EXTERIOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. user Monday, June 04, 2012 5:42:44 PM

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NOTE:

When diagnosing the exterior lighting circuits, remember that high generator output can burn out bulbs rapidly and repeatedly; and, that dim or flickering bulbs can be caused by low generator output or poor battery condition. If one of these symptoms is a problem on the vehicle, be certain to diagnose the battery and charging system, then repair as necessary.

NOTE:

A good ground is necessary for proper lighting operation. If a lighting problem is being diagnosed that involves multiple symptoms, systems, or components, the problem can often be traced to a loose, corroded, or open ground.

The lamps and the hard wired circuits between components related to the exterior lighting system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices that provide some features of the exterior lighting system. The most reliable, efficient, and accurate means to diagnose the exterior lighting system or the electronic controls and communication related to exterior lighting system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. BACKUP LAMPS

CONDITION POSSIBLE CAUSES CORRECTION BACKUP LAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace backup lamp bulb if ILLUMINATE required. 2. Ineffective ground circuit. 2. Test and repair open backup lamp ground circuit if required. 3. Ineffective feed circuit. 3. Test and repair open backup lamp feed circuit if required. 4. Ineffective switch. 4. Test and replace backup lamp switch (manual transmission) or transmission range sensor (automatic transmission) if required. 5. Ineffective TIPM inputs or 5. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. BACKUP LAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted backup lamp EXTINGUISH feed circuit if required. 2. Ineffective switch. 2. Test and replace backup lamp switch (manual transmission) or transmission range sensor (automatic transmission) if required. 3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the user Monday, June 04, 2012 5:42:44 PM

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outputs.

TIPM inputs and outputs. Refer to the appropriate diagnostic information.

BRAKE LAMPS

NOTE:

The Center High Mounted Stop Lamp (CHMSL) is illuminated by several LightEmitting Diode (LED) units that are soldered to the electronic circuit board within the lamp housing. The CHMSL is hard wired to the output of the brake lamp switch, while the brake lamps are powered by high side drivers within the TIPM based upon an input from the brake lamp switch. If the brake lamps and all of the LED units within the CHMSL fail to operate, diagnose and repair the brake lamps before attempting to repair the CHMSL. If the brake lamps operate but none of the CHMSL LED units illuminate, test and repair the CHMSL ground or feed circuit if required. If some of the CHMSL LED units operate and others do not, the CHMSL assembly must be replaced with a new unit.

CONDITION POSSIBLE CAUSES CORRECTION BRAKE LAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace brake lamp bulb if ILLUMINATE required. 2. Ineffective ground circuit. 2. Test and repair open brake lamp ground circuit if required. 3. Ineffective fuse. 3. Test and replace the fuse in the TIPM if required. 4. Test and repair open brake lamp switch output circuit or stop lamp output circuit 4. Ineffective feed circuit. if required. 5. Test and replace brake lamp switch if 5. Ineffective switch. required. 6. Ineffective TIPM inputs or 6. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. BRAKE LAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted brake lamp EXTINGUISH switch output circuit or stop lamp output circuit if required. 2. Improperly adjusted switch. 2. Adjust the brake lamp switch if required. 3. Test and replace brake lamp switch if 3. Ineffective switch. required. 4. Ineffective TIPM inputs or 4. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. DAYTIME RUNNING LAMPS

NOTE:

Before performing the following tests, determine whether the headlamp low and

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high beams operate. If the headlamp low and high beams are also ineffective, diagnose and repair that problem before attempting to repair the Daytime Running Lamps. CONDITION DAYTIME RUNNING LAMPS WILL NOT ILLUMINATE

POSSIBLE CAUSES 1. Incorrect TIPM programming. 2. Automatic transmission in PARK position. 3. Parking brake applied. 4. Engine not running. 5. Ineffective TIPM inputs or outputs.

CORRECTION 1. Use a diagnostic scan tool to check and configure TIPM if required. 2. Place the transmission gear selector lever in any position except PARK. 3. Release the parking brake. 4. Start the engine. 5. Use a diagnostic scan tool to test the TIPM inputs and outputs. Refer to the appropriate diagnostic information.

FRONT FOG LAMPS

NOTE:

The front fog lamp switch is integral to the left multi-function switch/Steering Control Module (SCM), which communicates with the ElectroMechanical Instrument Cluster (EMIC)/Cab Compartment Node (CCN) over the Local Interface Network (LIN) data bus. Before performing any of the following tests, determine whether the other functions of the left multi-function switch/SCM are operational. If the other left multi-function switch/SCM functions are ineffective, diagnose and repair that problem before attempting to repair the Front Fog Lamps.

CONDITION POSSIBLE CAUSES CORRECTION FRONT FOG LAMP DOES 1. Ineffective or missing bulb. 1. Test and replace front fog lamp bulb if NOT ILLUMINATE required. 2. Ineffective ground circuit. 2. Test and repair open front fog lamp ground circuit if required. 3. Ineffective feed circuit. 3. Test and repair open front fog lamp feed circuit if required. 4. Use a diagnostic scan tool to test the 4. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 5. Ineffective TIPM inputs or 5. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. FRONT FOG LAMP DOES 1. Ineffective feed circuit. 1. Test and repair shorted front fog lamp NOT EXTINGUISH feed circuit if required. 2. Use a diagnostic scan tool to test the 2. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the user Monday, June 04, 2012 5:42:44 PM

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outputs.

TIPM inputs and outputs. Refer to the appropriate diagnostic information.

HAZARD WARNING LAMPS

NOTE:

The hazard switch is integral to the upper instrument panel switch pod, which provides a hard wired output to the TIPM. Before performing any of the following tests, confirm whether the left and right turn signals operate satisfactorily. Then determine whether the other functions of the upper instrument panel switch pod are operational. If the turn signals are ineffective or operate improperly, or if the other instrument panel switch pod functions are ineffective, diagnose and repair those problems before attempting to repair the hazard warning lamps system.

CONDITION HAZARD WARNING LAMPS DO NOT FLASH

HAZARD WARNING LAMPS DO NOT STOP FLASHING

POSSIBLE CAUSES CORRECTION 1. Ineffective upper instrument 1. Test and replace upper instrument panel switch pod. panel switch pod if required. 2. Use a diagnostic scan tool to test the 2. Ineffective TIPM inputs or TIPM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 1. Ineffective upper instrument 1. Test and replace upper instrument panel switch pod. panel switch pod if required. 2. Use a diagnostic scan tool to test the 2. Ineffective TIPM inputs or TIPM inputs and outputs. Refer to the outputs. appropriate diagnostic information.

HEADLAMPS

NOTE:

As part of the exterior lighting fail-safe feature, upon ignition ON, all exterior park lamps and the headlamp low beams will illuminate regardless of the left multi-function switch control knob position if the SCM cannot detect an input from the left multi-function switch, or if there is a loss of communication between the left multi-function switch/SCM and the EMIC or between the EMIC and the TIPM. Diagnose and repair those problems before attempting to repair the Headlamps. In addition, the TIPM will store a Diagnostic Trouble Code (DTC) for an open or shorted headlamp circuit.

CONDITION HEADLAMP DOES NOT ILLUMINATE

POSSIBLE CAUSES CORRECTION 1. Ineffective or missing bulb. 1. Test and replace headlamp bulb if required. 2. Ineffective ground circuit. 2. Test and repair open headlamp ground circuit if required. 3. Ineffective feed circuit. 3. Test and repair open headlamp low beam or high beam feed circuit if required.

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4. Use a diagnostic scan tool to test the EMIC (CCN) inputs and outputs. Refer to the appropriate diagnostic information. 5. Ineffective TIPM inputs or 5. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. HEADLAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted headlamp low EXTINGUISH beam or high beam feed circuit if required. 2. Ineffective EMIC (CCN) 2. Use a diagnostic scan tool to test the inputs or outputs. EMIC (CCN) inputs and outputs. Refer to the appropriate diagnostic information. 3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. HEADLAMPS ILLUMINATE 1. Loss of LIN or CAN data 1. Test and repair the LIN or CAN data WITH IGNITION ON AND bus communication. bus if required. Refer to the appropriate HEADLAMP SWITCH OFF diagnostic information. (FAIL-SAFE OPERATION) HEADLAMPS WILL NOT 1. Ineffective EMIC (CCN) 1. Use a diagnostic scan tool to test the SWITCH FROM HIGH TO inputs or outputs. EMIC (CCN) inputs and outputs. Refer to LOW BEAMS, OR FROM the appropriate diagnostic information. LOW TO HIGH BEAMS 2. Ineffective TIPM inputs or 2. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. 4. Ineffective EMIC (CCN) inputs or outputs.

HEADLAMP LEVELING

NOTE:

The headlamp leveling switch is integral to the instrument panel switch pod, which communicates with the EMIC/CCN over the LIN data bus. Before performing any of the following tests, confirm whether the park lamps operate satisfactorily. Then determine whether the other functions of the instrument panel switch pod are operational. If the park lamps are ineffective or operate improperly, or if the other instrument panel switch pod functions are ineffective, diagnose and repair those problems before attempting to repair the Headlamp Leveling function.

CONDITION POSSIBLE CAUSES ONE LEVELING MOTOR IS 1. Ineffective ground circuit. INEFFECTIVE 2. Ineffective feed circuit. 3. Ineffective signal circuit. 4. Ineffective motor.

CORRECTION 1. Test and repair open leveling motor ground circuit if required. 2. Test and repair open leveling motor feed circuit if required. 3. Test and repair open headlamp leveling motor signal circuit if required. 4. Test and replace headlamp leveling

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motor if required. 1. Use a diagnostic scan tool to test the EMIC (CCN) inputs and outputs. Refer to the appropriate diagnostic information. 2. Ineffective motor ground 2. Test and repair open leveling motor circuit. ground circuit if required. 3. Ineffective motor feed 3. Test and repair open leveling motor circuit. feed circuit if required. 4. Ineffective signal circuit. 4. Test and repair open or shorted headlamp leveling motor signal circuit if required. 5. Ineffective TIPM inputs or 5. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. 6. Ineffective motors. 6. Test and replace leveling motors if required.

BOTH LEVELING MOTORS 1. Ineffective EMIC (CCN) ARE INEFFECTIVE inputs or outputs.

PARK LAMPS

NOTE:

As part of the exterior lighting fail-safe feature, upon ignition ON, all exterior park lamps and the headlamp low beams will illuminate regardless of the left multi-function switch control knob position if the SCM cannot detect an input from the left multi-function switch, or if there is a loss of communication between the left multi-function switch/SCM and the EMIC or between the EMIC and the TIPM. Diagnose and repair those problems before attempting to repair the Park Lamps.

CONDITION PARK LAMP DOES NOT ILLUMINATE

PARK LAMP DOES NOT EXTINGUISH

POSSIBLE CAUSES CORRECTION 1. Ineffective or missing bulb. 1. Test and replace park lamp bulb if required. 2. Ineffective ground circuit. 2. Test and repair open park lamp ground circuit if required. 3. Ineffective feed circuit. 3. Test and repair open park lamp feed circuit if required. 4. Use a diagnostic scan tool to test the 4. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 5. Ineffective TIPM inputs or 5. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. 1. Ineffective feed circuit. 1. Test and repair shorted park lamp feed circuit if required. 2. Use a diagnostic scan tool to test the 2. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information.

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3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. REAR FOG LAMPS

NOTE:

The rear fog lamp switch is integral to the left multi-function switch/SCM, which communicates with the EMIC/CCN over the LIN data bus. Before performing any of the following tests, determine whether the other functions of the left multifunction switch/SCM are operational. If the other left multi-function switch/SCM functions are ineffective, diagnose and repair that problem before attempting to repair the Rear Fog Lamps.

CONDITION REAR FOG LAMP DOES NOT ILLUMINATE

REAR FOG LAMP DOES NOT EXTINGUISH

POSSIBLE CAUSES CORRECTION 1. Ineffective or missing bulb. 1. Test and replace rear fog lamp bulb if required. 2. Ineffective ground circuit. 2. Test and repair open rear fog lamp ground circuit if required. 3. Ineffective feed circuit. 3. Test and repair open fog lamp relay control rear circuit if required. 4. Use a diagnostic scan tool to test the 4. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 5. Use a diagnostic scan tool to check and 5. Incorrect TIPM correct the TIPM configuration settings if configuration. required. Refer to the appropriate diagnostic information. 6. Ineffective TIPM inputs or 6. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. 1. Ineffective feed circuit. 1. Test and repair shorted fog lamp relay control rear circuit if required. 2. Use a diagnostic scan tool to test the 2. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information.

TURN SIGNAL LAMPS

NOTE:

The turn signal switch is integral to the left multi-function switch/SCM, which communicates with the EMIC/CCN over the LIN data bus. Before performing any of the following tests, determine whether the other functions of the left multifunction switch/SCM are operational. If the other left multi-function switch/SCM

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functions are ineffective, diagnose and repair that problem before attempting to repair the Turn Signal Lamps. CONDITION POSSIBLE CAUSES CORRECTION ONE TURN SIGNAL LAMP 1. Ineffective or missing bulb. 1. Test and replace turn signal bulb if DOES NOT ILLUMINATE required. 2. Ineffective ground circuit. 2. Test and repair open ground circuit if required. 3. Test and repair open right or left turn 3. Ineffective feed circuit. signal feed circuit if required. 4. Ineffective TIPM inputs or 4. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. ALL RIGHT SIDE OR ALL 1. Ineffective feed circuit. 1. Test and repair open right or left turn LEFT SIDE TURN SIGNAL signal feed circuit if required. LAMPS (OR BOTH SIDES) 2. Use a diagnostic scan tool to test the 2. Ineffective EMIC (CCN) DO NOT FLASH EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 3. Ineffective TIPM inputs or 3. Use a diagnostic scan tool to test the outputs. TIPM inputs and outputs. Refer to the appropriate diagnostic information. ALL RIGHT SIDE OR ALL 1. Ineffective or missing bulb. 1. Test and replace turn signal bulb if LEFT SIDE TURN SIGNALS required. FLASH TOO RAPIDLY 2. Ineffective ground circuit. 2. Test and repair open bulb ground (MORE THAN 100 FLASHES circuit if required. PER MINUTE) 3. Ineffective feed circuit. 3. Test and repair open right or left turn signal feed circuit if required. TURN SIGNALS DO NOT 1. Inspect and replace the turn signal 1. Ineffective cancel cam. AUTOMATICALLY cancel cam (clockspring) if required. CANCEL 2. Inspect and replace the turn signal 2. Ineffective cancel actuator. cancel actuator (left multi-function switch) if required.

STANDARD PROCEDURE FRONT LAMP AIMING VEHICLE PREPARATION FOR LAMP ALIGNMENT

1. Check for and correct any burnt out bulbs. 2. If the vehicle is equipped with headlamp leveling, be certain that the headlamp leveling switch is in the 0 (zero) position. 3. Repair or replace any ineffective, worn or damaged body or suspension components that could hinder user Monday, June 04, 2012 5:42:44 PM

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4. 5. 6. 7. 8.

proper lamp alignment. Verify proper tire inflation pressures. Remove any accumulations of mud, snow or ice from the vehicle underbody and clean the front lamp lenses. Verify that there is no load in the vehicle (cargo or passengers), except for the driver. The fuel tank should be FULL. Add 2.94 kilograms (6.5 pounds) of weight over the fuel tank for each estimated gallon of missing fuel. Verify correct vehicle suspension height.

LAMP ALIGNMENT SCREEN PREPARATION

Fig. 2: Lamp Alignment Screen Preparation Courtesy of CHRYSLER LLC The procedure that follows will prepare a suitable front lamp alignment screen. 1. Tape a line on a level floor 7.62 meters (25 feet) away from and parallel to the flat wall that will be used as the lamp alignment screen. The level floor will be used as the horizontal zero reference. 2. An adjacent wall or floor member that is perpendicular to the alignment screen can be used as the vertical zero reference. If there is no adjacent wall or floor member that is perpendicular to the screen, tape a user Monday, June 04, 2012 5:42:44 PM

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3.

4. 5. 6.

7.

8.

second line on the floor perpendicular to both the alignment screen and the first line, and outboard of either side of where the vehicle will be positioned. This will be used as the vertical zero reference. Position the vehicle so that the side of the vehicle is parallel to the vertical zero reference, and so that the front of the lamp lenses are in the vertical plane of the parallel line taped on the floor 7.62 meters (25 feet) away from the screen. Rock the vehicle side-to-side three times to allow the suspension to stabilize. Jounce the front suspension three times by pushing downward on the front bumper and releasing. Measure the distance between the optical center of one of the lamps being aimed (head or fog) and the floor (horizontal zero reference). Transfer this measurement to the alignment screen with a piece of tape placed horizontally to the floor. This line will be used as the lamp horizontal reference. Measure the distance between the vertical zero reference and the optical center of the nearest lamp being aimed (head or fog). Transfer this measurement to the alignment screen with a piece of tape placed vertically across the appropriate lamp (head or fog) horizontal reference. This is the centerline reference for the first lamp. Measure the distance on center between the first and the second lamp being aimed. Transfer this measurement to the alignment screen with a second piece of tape placed vertically across the appropriate lamp (head or fog) horizontal reference. This is the centerline reference for the second lamp.

HEADLAMP ALIGNMENT

NOTE:

Due to the linear nature of the headlamp cutoff, a properly aimed low beam headlamp will project the top edge of the high intensity pattern on the alignment screen just below the horizontal line to 50 millimeters (2 inches) below the horizontal line for domestic market vehicles, or to 130 millimeters (5.12 inches) below the horizontal line for export market vehicles. No horizontal (right/left) adjustment is required for this headlamp beam pattern in domestic market vehicles. Export market vehicles have a second horizontal (right/left) adjustment screw provided on the outboard side of the headlamp unit rear housing. The high beam pattern will be correct when the low beams are properly aimed.

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Fig. 3: Headlamp Alignment Courtesy of CHRYSLER LLC 1. Turn the headlamps ON and select the LOW beams. 2. Rotate the vertical adjustment screw (3) on each front lamp unit (1) to adjust the beam height as required. 3. For export markets only, rotate the horizontal adjustment screw (2) on each lamp to adjust the beam right or left as required. FOG LAMP ALIGNMENT

NOTE:

A properly aimed front fog lamp will project a pattern on the alignment screen 100 millimeters (4 inches) below the fog lamp centerline and straight ahead of the lamp for domestic market vehicles. On export market vehicles, a properly aimed fog lamp will project a pattern on the alignment screen 200 millimeters (8 inches) below the fog lamp centerline and straight ahead of the lamp.

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Fig. 4: Fog Lamp Alignment Courtesy of CHRYSLER LLC 1. Turn the fog lamps ON. 2. Raise the lower portion of the inner wheel house shield to gain access to the rear of the fog lamp unit. 3. Rotate the vertical adjustment screw (1) on each lamp to adjust the beam height as required.

SPECIFICATIONS SPECIFICATIONS BULB APPLICATION TABLE LAMP BACKUP BRAKE CENTER HIGH MOUNTED STOP FRONT FOG FRONT PARK FRONT SIDE MARKER FRONT TURN SIGNAL HEADLAMP (LOW BEAM) HEADLAMP (HIGH BEAM) LICENSE POSITION (EXPORT ONLY) REAR FOG (EXPORT ONLY) REAR PARK (TAIL) REAR TURN SIGNAL

BULB 3157 (P27W/7W) 3157 (P27W/7W) LIGHT-EMITTING DIODES SERVICED IN ASSEMBLY 9145 (H10) 3757AK (PY27W/7W) 168 3757AK (PY27W/7W) 9006 - DOMESTIC H11 - EXPORT 9005 168 W5W PS19W 3157 (P27W/7W) 3757AK (PY27W/7W)

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REPEATER (EXPORT ONLY)

W5W

CAM, TURN SIGNAL CANCEL DESCRIPTION DESCRIPTION

The turn signal cancel cam is concealed within the clockspring case on the steering column. The turn signal cancel cam consists of integral eccentrics on the outer circumference of the molded plastic clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, Electronic Vehicle Information Center (EVIC) switches and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring is secured to the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If ineffective or damaged, the entire clockspring unit must be replaced. Refer to Restraints/CLOCKSPRING - Removal . OPERATION OPERATION

When the left multi-function switch control stalk is moved to a latched turn signal ON position, a turn signal cancel actuator is extended from the inside surface of the switch housing through a small rectangular opening on the left side of the clockspring case toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the cam eccentrics will contact the actuator, automatically cancelling the turn signal event and releasing the latched left multi-function switch control stalk to the neutral or OFF position.

LAMP, CENTER HIGH MOUNTED STOP REMOVAL REMOVAL

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Fig. 5: Center High Mounted Stop Lamp Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws (4) that secure the Center High Mounted Stop Lamp (CHMSL) (3) to the liftgate header panel (1). 3. Pull the CHMSL away from the liftgate far enough to access and disconnect the connector (2) of the liftgate wire harness (1) from the connector receptacle on the back of the lamp. 4. Remove the CHMSL from the liftgate. INSTALLATION INSTALLATION

Fig. 6: Center High Mounted Stop Lamp user Monday, June 04, 2012 5:42:44 PM

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Courtesy of CHRYSLER LLC 1. Check to be certain that the two U-nuts in the Center High Mounted Stop Lamp (CHMSL) opening of the liftgate header panel are properly installed and in good condition. 2. Position the CHMSL (3) near the opening in the liftgate header panel. 3. Reconnect the connector (2) of the liftgate wire harness (1) to the connector receptacle on the back of the lamp. 4. Position the CHMSL into the liftgate header opening. 5. Install and tighten the two screws (4) that secure the CHMSL to the liftgate header panel. Tighten the screws to 1.5 N.m (15 in. lbs.). 6. Reconnect the battery negative cable.

LAMP, FOG, FRONT REMOVAL BULB

CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

Fig. 7: Front Fog Lamp Bulb Connector Receptacle Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the lower inner front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash Installation . 3. Disconnect the headlamp and dash wire harness connector from the front fog lamp bulb (2) connector receptacle (1). user Monday, June 04, 2012 5:42:44 PM

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4. Firmly grasp the bulb on the back of the front fog lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. LAMP

Fig. 8: Front Fog Lamp Bulb Connector Receptacle Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the lower inner front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash Removal . 3. Disconnect the headlamp and dash wire harness connector from the front fog lamp bulb (2) connector receptacle (1). 4. Remove the three screws (3) that secure the front fog lamp mounting bracket to the fog lamp bezel on the back of the lower front fascia. 5. Remove the front fog lamp from the vehicle. INSTALLATION BULB

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. user Monday, June 04, 2012 5:42:44 PM

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Fig. 9: Front Fog Lamp Bulb Connector Receptacle Courtesy of CHRYSLER LLC 1. Align the front fog lamp bulb (2) with the keyed opening on the back of the front fog lamp housing. 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. The bulb connector receptacle should be pointed outboard and horizontal in orientation. 4. Reconnect the headlamp and dash wire harness connector to the front fog lamp bulb connector receptacle (1). 5. Reinstall the lower inner front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash Installation . 6. Reconnect the battery negative cable. LAMP

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Fig. 10: Front Fog Lamp Bulb Connector Receptacle Screw Courtesy of CHRYSLER LLC 1. Position the front fog lamp mounting bracket to the fog lamp bezel on the back of the lower front fascia. 2. Install and tighten the three screws (3) that secure the mounting bracket to the bezel. Tighten the screws securely. 3. Reconnect the headlamp and dash wire harness connector to the front fog lamp bulb (2) connector receptacle (1). 4. Reinstall the lower inner front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash Installation . 5. Reconnect the battery negative cable. 6. Confirm proper fog lamp alignment. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior Standard Procedure.

LAMP, FOG, REAR EXPORT REMOVAL BULB

Fig. 11: Rear Fascia Wire Harness Connector Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fog lamp from the rear fascia. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Fog - Removal. 3. Disconnect the rear fascia wire harness connector (1) from the rear fog lamp bulb connector receptacle. 4. Firmly grasp the bulb (2) by the two latch features and squeeze them together to unlock the bulb from the user Monday, June 04, 2012 5:42:44 PM

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back of the rear fog lamp housing. 5. Pull the bulb straight out from the keyed opening in the housing. LAMP

NOTE:

The following procedure applies only to vehicles manufactured for certain export markets where rear fog lamps are optional or required equipment. Rear fog lamps are not available for vehicles manufactured for North American markets.

Fig. 12: Rear Bumper Reinforcement Courtesy of CHRYSLER LLC NOTE:

The rear fog lamps can be removed without removing the rear fascia. The graphic shows the fascia removed only to clearly identify the involved components.

1. Disconnect and isolate the battery negative cable. 2. From behind the rear fascia (2), reach between the body sheet metal and above the rear bumper reinforcement (1) to access the back of the rear fog lamp (3).

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Fig. 13: Integral Latch Feature Of Rear Fog Lamp Courtesy of CHRYSLER LLC 3. Locate the integral latch feature (5) of the rear fog lamp (3) protruding through the outboard side of the rear fog lamp seat (1) integral to the rear fascia. 4. Press the latch feature toward the center of the lamp and out through the face of the rear fog lamp seat of the rear fascia. 5. From the face of the rear fascia, pull the lamp outboard far enough to disengage the integral interlocking tab mounting feature (2) from behind the inboard side of the rear fog lamp seat of the fascia. 6. Pull the rear fog lamp out from the rear fascia far enough to access and disconnect the rear fascia wire harness connector from the rear fog lamp bulb connector receptacle (4) on the back of the lamp. 7. Remove the rear fog lamp from the vehicle. INSTALLATION BULB

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring.

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Fig. 14: Rear Fascia Wire Harness Connector Courtesy of CHRYSLER LLC 1. Align the index tabs of the rear fog lamp bulb (2) with the slots in the collar of the bulb opening on the back of the rear fog lamp housing. 2. Insert the bulb into the housing until the index tabs are engaged in the slots of the collar. 3. Firmly and evenly push the bulb straight into the lamp housing until both bulb latch features snap into place and are fully engaged. 4. Reconnect the rear fascia wire harness connector (1) to the rear fog lamp bulb connector receptacle. 5. Reinstall the rear fog lamp into the rear fascia. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Fog - Installation. 6. Reconnect the battery negative cable. LAMP

NOTE:

The following procedure applies only to vehicles manufactured for certain export markets where rear fog lamps are optional or required equipment. Rear fog lamps are not available for vehicles manufactured for North American markets.

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Fig. 15: Integral Latch Feature Of Rear Fog Lamp Courtesy of CHRYSLER LLC 1. From the face of the rear fascia, position the rear fog lamp (3) close enough to the rear fog lamp seat (1) to access and reconnect the rear fascia wire harness connector to the rear fog lamp bulb connector receptacle (4). 2. Engage the integral interlocking tab mounting feature (2) behind the inboard side of the rear fog lamp seat of the fascia. 3. Align the integral latch feature (5) on the outboard side of the rear fog lamp housing with the clearance hole in the rear fog lamp seat of the fascia. 4. Using hand pressure, push the outboard side of the rear fog lamp firmly and evenly into the seat until the latch engages the back of the rear fascia and the lamp is fully seated. 5. Reconnect the battery negative cable.

LAMP, LICENSE PLATE REMOVAL BULB

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Fig. 16: License Plate Lamp Bulb Socket Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the license plate lamp from the underside of the liftgate handle and light bar assembly. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/LAMP, License Plate - Removal. 3. Pull the base of the bulb straight out of the license plate lamp bulb socket (1). LAMP

Fig. 17: License Plate Lamps Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Locate the two license plate lamps (2) on the underside of the liftgate handle and light bar assembly (3) user Monday, June 04, 2012 5:42:44 PM

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3.

4. 5. 6. 7. 8.

above the license plate tub on the liftgate outer panel. Insert the end of a trim stick or a small screwdriver into the open end of the hood formation (4) on one end of the lamp lens to depress the latch tab (1) and pull that end of the lamp down from the handle and light bar assembly. Pull the lamp towards the center of the vehicle far enough to disengage the lamp interlocking tab mounting feature from the outboard edge of the mounting hole. Pull the lamp out of the mounting hole far enough to access the lamp wiring and bulb socket on the top of the lamp housing. Firmly grasp the socket and rotate it counterclockwise about 30 degrees to unlock it. Pull the socket and bulb straight out from the keyed opening in the lamp housing. Remove the lamp from the vehicle.

INSTALLATION BULB

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring.

Fig. 18: License Plate Lamp Bulb Socket Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Align the base of the license plate lamp bulb with the socket (1). Push the bulb straight into the socket until the base is firmly seated. Align the socket and bulb with the keyed opening on the top of the license plate lamp housing. Insert the bulb and socket into the housing until the socket is firmly seated. Rotate the socket clockwise about 30 degrees to lock it into place.

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6. Reinstall the lamp into the mounting hole on the underside of the liftgate handle and light bar assembly. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/LAMP, License Plate - Installation. LAMP

Fig. 19: License Plate Lamps Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Position the license plate lamp (2) to the underside of the liftgate handle and light bar assembly (3). Align the socket and bulb with the keyed opening on the top of the lamp housing. Insert the bulb and socket into the housing until the socket is firmly seated. Rotate the socket clockwise about 30 degrees to lock it into place. Engage the lamp interlocking tab mounting feature at the end of the lamp housing opposite from the hooded (4) latch (1) with the outboard edge of the mounting hole in the handle and light bar assembly. 6. Push the lamp toward the outboard side of the vehicle while pushing the inboard end of the lamp firmly and evenly into the mounting hole until the lamp latch feature snaps into place. 7. Reconnect the battery negative cable.

LAMP, SIDE REPEATER, EXPORT REMOVAL BULB

NOTE:

Side repeater lamps are used only on vehicles manufactured for certain export markets where they are required.

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Fig. 20: Remove/Install Repeater Lamp Bulb Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the side repeater lamp from the fender mounting hole, but do not disconnect the wire harness connector. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/LAMP, Side Repeater Removal. 3. Firmly grasp the bulb socket (1) on the back of the lamp lens/housing (4) and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the lamp housing. 5. Pull the base of the bulb (3) straight out of the socket. LAMP

NOTE:

Side repeater lamps are used only on vehicles manufactured for certain export markets where they are required.

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Fig. 21: Remove/Install Repeater Lamp Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. NOTE:

The same repeater lamp is used on both sides of the vehicle. Regardless of which side of the vehicle the lamp is mounted on, when properly oriented the fixed hook interlock tab feature integral to the back of the lamp housing is on the right-hand side of the lamp and the latch feature is on the left-hand side.

2. Using hand pressure, press the right edge of the repeater lamp lens/housing (1) toward the left against the spring pressure of the latch feature, then pull the right edge of the lamp outward far enough to disengage the fixed hook interlock tab feature from the right side of the fender mounting hole (3). 3. Pull the lamp out from the fender far enough to access and disconnect the wire harness connector (2) from the connector receptacle of the bulb socket on the back of the lamp lens/housing. 4. Remove the repeater lamp from the fender. INSTALLATION BULB

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE:

Side repeater lamps are used only on vehicles manufactured for certain export markets where they are required.

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Fig. 22: Remove/Install Repeater Lamp Bulb Courtesy of CHRYSLER LLC 1. Align the base of the bulb (3) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber O-ring seal (2) is properly installed and in good condition around the base of the bulb socket. 4. Align the socket and bulb with the keyed opening on the back of the side repeater lamp lens/housing (4). 5. Insert the socket and bulb into the housing until the socket is firmly seated. 6. Rotate the socket clockwise about 30 degrees to lock it into place. 7. Reinstall the side repeater lamp into the fender mounting hole. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/LAMP, Side Repeater - Installation. 8. Reconnect the battery negative cable. LAMP

NOTE:

Side repeater lamps are used only on vehicles manufactured for certain export markets where they are required.

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Fig. 23: Remove/Install Repeater Lamp Courtesy of CHRYSLER LLC 1. Position the repeater lamp lens/housing (1) close enough to the fender mounting hole (3) to access and reconnect the wire harness connector (2) to the bulb socket on the back of the lamp lens/housing. NOTE:

The same repeater lamp is used on both sides of the vehicle. Regardless of which side of the vehicle the lamp is mounted on, when properly oriented the fixed hook interlock tab features integral to the back of the lamp housing is on the right-hand side of the lamp and the latch feature is on the left-hand side.

2. With the lamp lens/housing properly oriented, engage the fixed hook interlock tab feature on the back of the right side of the lamp with the right edge of the fender mounting hole. 3. Using hand pressure, press the left side of the lamp lens/housing into the mounting hole against the spring pressure of the latch feature until the latch snaps into place. 4. Reconnect the battery negative cable.

LAMP, TAIL STOP TURN REMOVAL BULB

Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. user Monday, June 04, 2012 5:42:44 PM

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OUTER LAMP

Fig. 24: Tail/Stop/Rear Side Marker And Turn Signal Courtesy of CHRYSLER LLC NOTE:

The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ.

1. Disconnect and isolate battery negative cable. 2. Remove the outer rear lamp unit. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Tail Stop Turn - Removal. 3. Firmly grasp the appropriate bulb socket (1 or 2 ) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. INNER LAMP

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Fig. 25: Bulb Socket On Back Of Lamp Housing Courtesy of CHRYSLER LLC NOTE:

The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ.

1. Disconnect and isolate the battery negative cable. 2. Remove the inner rear lamp unit. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Tail Stop Turn - Removal. 3. Firmly grasp the appropriate bulb socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. LAMP

Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. These lamp units are serviced individually as follows. OUTER

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Fig. 26: Outer Rear Lamp Unit Courtesy of CHRYSLER LLC 1. Disconnect and isolate battery negative cable. 2. Open the liftgate to access and remove the two push pin fasteners (2) that secure the inboard side of the outer rear lamp unit (1) to the side jamb of the liftgate opening. 3. Pull the outboard side of the outer rear lamp unit rearward far enough to disengage the two locating pins on the back of the lamp housing from the plastic grommets in the lamp opening of the body sheet metal (3).

Fig. 27: Body Wire Harness Connectors Courtesy of CHRYSLER LLC 4. Pull the lamp (1) away from the vehicle far enough to access and disconnect the two body wire harness connectors (2 and 3) from the bulb socket connector receptacles on the back of the lamp housing. user Monday, June 04, 2012 5:42:44 PM

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5. Remove the lamp from the vehicle. INNER

Fig. 28: Inner Rear Lamp Unit Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate (1) to access and remove the two screws (3) that secure the outboard side of the inner rear lamp unit (2) to the liftgate lamp opening. 3. Pull the inboard side of the inner rear lamp unit rearward far enough to disengage the two locating pins on the back of the lamp housing from the plastic grommets in the liftgate lamp opening.

Fig. 29: Liftgate Wire Harness Connectors Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:42:44 PM

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4. Pull the lamp (1) away from the vehicle far enough to access and disconnect the two liftgate wire harness connectors (2) from the bulb socket connector receptacles on the back of the lamp housing. 5. Remove the lamp from the vehicle. INSTALLATION BULB

Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring.

Fig. 30: Tail/Stop/Rear Side Marker And Turn Signal Courtesy of CHRYSLER LLC NOTE:

1. 2. 3. 4.

The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ.

Align the base of the bulb with the appropriate bulb socket (1 or 2). Push the bulb straight into the socket until the base is firmly seated. Align the socket and bulb with the keyed opening on the back of the outer rear lamp unit housing. Insert the socket and bulb into the housing until the socket is firmly seated.

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5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the outer rear lamp unit. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Tail Stop Turn - Installation. 7. Reconnect the battery negative cable. INNER LAMP

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring.

Fig. 31: Bulb Socket On Back Of Lamp Housing Courtesy of CHRYSLER LLC NOTE:

The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ.

1. 2. 3. 4. 5. 6.

Align the base of the bulb with the appropriate bulb socket (3). Push the bulb straight into the socket until the base is firmly seated. Align the socket and bulb with the keyed opening on the back of the inner rear lamp unit housing. Insert the socket and bulb into the housing until the socket is firmly seated. Rotate the socket clockwise about 30 degrees to lock it into place. Reinstall the inner rear lamp unit. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/LAMP, Tail Stop Turn - Installation. 7. Reconnect the battery negative cable.

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Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. These lamp units are serviced individually as follows. OUTER

Fig. 32: Plastic Grommets Courtesy of CHRYSLER LLC 1. Check to be certain that the two plastic grommets (2 and 3) are in good condition and properly installed in the outboard side of the lamp opening of the body sheet metal (1).

Fig. 33: Body Wire Harness Connectors Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:42:45 PM

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2. Position the outer rear lamp unit (1) to the lamp opening of the body sheet metal. 3. Reconnect the two body wire harness connectors (2 and 3) to the bulb socket connector receptacles on the back of the lamp housing.

Fig. 34: Outer Rear Lamp Unit Courtesy of CHRYSLER LLC 4. Align the two locating pins on the back of the lamp housing (1) with the plastic grommets in the lamp opening of the body sheet metal (3). 5. Using hand pressure, push firmly and evenly on the outboard top and bottom of the lamp until both alignment pins snap into the grommets. 6. Reinstall the two push pin fasteners (2) that secure the inboard side of the outer rear lamp unit to the side jamb of the liftgate opening. 7. Reconnect the battery negative cable. INNER

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Fig. 35: Liftgate Wire Harness Connectors Courtesy of CHRYSLER LLC 1. Check to be certain that the two plastic grommets are in good condition and properly installed on the inboard side of the liftgate lamp opening. If a grommet is removed, it must be replaced with a new unit. 2. Check to be certain that the two U-nuts are in good condition and properly installed on the outboard side of the inner rear lamp unit (1). 3. Position the lamp to the liftgate lamp opening. 4. Reconnect the two liftgate wire harness connectors (2) to the bulb socket connector receptacles on the back of the lamp housing.

Fig. 36: Inner Rear Lamp Unit Courtesy of CHRYSLER LLC 5. Align the two locating pins on the back of the lamp housing (2) with the plastic grommets in the liftgate user Monday, June 04, 2012 5:42:45 PM

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(1) lamp opening. 6. Using hand pressure, push firmly and evenly on the inboard top and bottom of the lamp until both alignment pins snap into the grommets. 7. Install and tighten the two screws (3) that secure the outboard side of the inner rear lamp unit to the liftgate lamp opening. Tighten the screws to 1.5 N.m (15 in. lbs.). 8. Reconnect the battery negative cable.

MOTOR, HEADLAMP LEVELING, EXPORT DESCRIPTION DESCRIPTION

Fig. 37: Headlamp Leveling Motor Courtesy of CHRYSLER LLC The headlamp leveling motor (1) is located on the rear surface of each front lamp unit on vehicles equipped with the headlamp leveling system, which is available only in certain export markets where it is required equipment. The motor is encased within a molded plastic housing and is secured by an integral wedge-type mounting flange (2) to a keyed flange on the back of the front lamp unit housing. A rubber seal around the circumference of the mounting boss seals the motor to the lamp housing. The outside of the motor housing features an integral molded connector (4) on its upper rearward surface and a plastic pushrod with a ball formation (3) on its free end extends from the motor mounting flange. Within the motor housing is a 12-volt Direct Current (DC) servo motor, an electronic controller board that includes the motor logic circuits, and an integral screw-drive transmission. The headlamp leveling motor is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The headlamp leveling motor cannot be repaired and, if ineffective or damaged, the entire motor unit must be replaced. user Monday, June 04, 2012 5:42:45 PM

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OPERATION OPERATION

The controller board and logic circuitry of the headlamp leveling motor controls motor operation based upon a voltage signal input received from the Totally Integrated Power Module (TIPM). The TIPM uses electronic messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to determine the correct voltage signal to provide the leveling motor, while the EMIC uses electronic messages received over the Local Interface Network (LIN) data bus from the instrument panel switch pod to monitor the headlamp leveling switch selection. The headlamp leveling motors have a path to ground at all times. The motors operate on battery voltage received through the headlamp low beam feed circuits so that the system will only operate when the headlamp low beams are turned ON. When the motor is energized it will extend or retract the motor pushrod through an integral screw-drive transmission. The ball on the end of the pushrod is snapped into a saddle bracket on the back of the reflector within the front lamp unit housing, which will cause the reflector to move as the pushrod is extended or retracted, changing the angle at which the light is projected from the headlamp bulb filaments. The hard wired circuits for the headlamp leveling motors may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the active electronic elements within the headlamp leveling motors or the electronic controls and communication between other modules and devices that provide some features of the headlamp leveling system. The most reliable, efficient, and accurate means to diagnose the headlamp leveling motor or the electronic controls and communication related to headlamp leveling system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL REMOVAL

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Fig. 38: Headlamp Leveling Motor On Back Of Lamp Housing Courtesy of CHRYSLER LLC NOTE:

The graphic shows the right side front lamp unit as viewed from the back of the lamp with the housing removed. However, the housing cannot be removed from the lamp for service. This view was necessary in order to clearly illustrate the internal engagement of the headlamp leveling motor pushrod with the saddle bracket on the lamp reflector.

1. Disconnect and isolate the battery negative cable. 2. Remove front lamp unit from the vehicle. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/UNIT, Front Lamp - Removal. 3. Rotate the headlamp leveling motor (4) on the back of the lamp housing counterclockwise about 30 degrees to unlock it from the housing. 4. Grasp the motor firmly with one hand and twist it toward the inboard side of the lamp far enough to disengage the ball on the end of the motor pushrod (3) from the saddle bracket (1) secured to the reflector (2) within the lamp housing. 5. Pull the motor and pushrod straight back and out of the front lamp unit housing. INSTALLATION INSTALLATION

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Fig. 39: Headlamp Leveling Motor On Back Of Lamp Housing Courtesy of CHRYSLER LLC NOTE:

The graphic shows the right side front lamp unit as viewed from the back of the lamp with the housing removed. However, the housing cannot be removed from the lamp for service. This view was necessary in order to clearly illustrate the internal engagement of the headlamp leveling motor pushrod with the saddle bracket on the lamp reflector.

1. Align and insert the headlamp leveling motor (4) and pushrod into the front lamp unit housing. 2. Grasp the motor firmly with one hand and twist it toward the inboard side of the lamp far enough to align the ball on the end of the motor pushrod (3) with the saddle bracket (1) secured to the reflector (2) within the lamp housing. NOTE:

It may be helpful to also remove a headlamp bulb from the lamp reflector and insert a finger through the bulb opening to move the reflector far enough to align the saddle bracket with the motor pushrod ball.

3. With the motor pushrod ball and reflector saddle bracket aligned, twist the motor back toward the outboard side of the lamp far enough to engage the pushrod ball into the reflector saddle bracket. 4. Insert the mounting flange of the headlamp leveling motor into the mounting boss on the back of the front lamp unit housing until the motor is firmly seated. 5. Rotate the motor clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit into the vehicle. See Electrical - Lamps and Lighting/Lamps/Lighting Exterior/UNIT, Front Lamp - Installation. 7. Reconnect the battery negative cable. user Monday, June 04, 2012 5:42:45 PM

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RELAY, TRAILER TOW DESCRIPTION DESCRIPTION

Fig. 40: Identifying Relay & Terminals Courtesy of CHRYSLER LLC Vehicles equipped with an optional trailer tow preparation package have four trailer tow relays, one each for the trailer tow stop/turn right and left and one each for the trailer stop lamp right and left. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are included with the trailer tow preparation wire harness that is shipped loose in the glove box for customer or dealer installation at the rear of the vehicle. A trailer tow stop/turn relay is located behind the rear fascia below each outer tail lamp, while a trailer stop lamp relay is located behind the rear fascia below each outboard end of the rear bumper reinforcement. Each relay and connector is wrapped within an isolator envelope for sound deadening and anti-rattle protection. Refer to SYSTEM WIRING DIAGRAMS for specific relay cavity assignment information. Any of the trailer tow relays cannot be adjusted or repaired and, if ineffective or damaged, the affected unit must be replaced. OPERATION OPERATION

The trailer tow relays are electromechanical switches that use a low current input from the Totally Integrated Power Module (TIPM) to the tail lamps to control a high current output to the trailer brake and turn signal user Monday, June 04, 2012 5:42:45 PM

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lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: z

z

z

z

z

Common Supply Terminal (30) - The common feed terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right trailer tow stop/turn signal pins of the 4-way trailer tow connector at all times. The common feed terminals of both the left and right trailer tow stop relays is connected to the normally closed (87A) terminal of their respective left or right trailer tow stop/turn relay at all times. Coil Ground Terminal (85) - The coil ground terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. The coil ground terminals of both the left and right trailer tow stop relays are connected to the stop lamp control circuit from the TIPM at all times. Coil Battery Terminal (86) - The coil battery terminal of both the left and right trailer tow stop/turn relays is connected to a path to ground at all times. The coil battery terminal of both the left and right trailer tow stop relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. Normally Open Terminal (87) - The normally open terminal of both the left and right trailer tow stop/turn relays is connected to the stop lamp control circuit from the TIPM whenever that relay is energized. The normally open terminal of both the left and right trailer tow stop relays is connected to a path to ground whenever that relay is energized. Normally Closed Terminal (87A) - The normally closed terminal of both the left and right trailer tow stop/turn relays is connected are connected to the common supply (30) terminal of their respective left or right trailer tow stop relay whenever the relay is de-energized. The normally closed terminal of both the left and right trailer tow stop relays is not connected to any circuit in this application.

The trailer tow relays and the hard wired circuits for the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that provide some features of the trailer tow turn and stop lamp lighting system. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to trailer tow turn and stop lamp lighting operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL REMOVAL

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Fig. 41: Isolator Envelope Courtesy of CHRYSLER LLC TRAILER TOW STOP/TURN RELAYS

1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. Refer to Frame and Bumpers/Bumpers/FASCIA, Rear Removal 3. Disengage the left or right trailer tow stop/turn relay and connector from the isolator envelope (3) secured to the trailer tow wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Pull the relay straight out from the wire harness connector. TRAILER TOW STOP LAMP RELAYS

1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. Refer to Frame and Bumpers/Bumpers/FASCIA, Rear Removal 3. Disengage the left or right trailer tow stop lamp relay and connector from the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Pull the relay straight out from the wire harness connector. INSTALLATION INSTALLATION

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Fig. 42: Isolator Envelope Courtesy of CHRYSLER LLC TRAILER TOW STOP/TURN RELAYS

1. Align the terminals of the left or right trailer tow stop/turn relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (3) secured to the wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Reinstall the rear fascia onto the vehicle. Refer to Frame and Bumpers/Bumpers/FASCIA, Rear Installation . 5. Reconnect the battery negative cable. TRAILER TOW STOP LAMP RELAYS

1. Align the terminals of the left or right trailer tow stop lamp relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Reinstall the rear fascia onto the vehicle. Refer to Frame and Bumpers/Bumpers/FASCIA, Rear Installation . 5. Reconnect the battery negative cable.

SWITCH, BACKUP LAMP user Monday, June 04, 2012 5:42:45 PM

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DESCRIPTION DESCRIPTION

Fig. 43: Backup Lamp Switch Courtesy of CHRYSLER LLC Vehicles equipped with a manual transmission (2) have a normally open, spring-loaded plunger type backup lamp switch (1). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the left facing surface of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Refer to the service and diagnostic information for the manual transmission type installed in the vehicle. OPERATION OPERATION

The backup lamp switch controls a path to ground for the Totally Integrated Power Module (TIPM) on the reverse switch signal circuit. The TIPM reads this input through an internal pull-up, then controls an output through a high side driver that regulates the flow of battery voltage to the backup lamp bulbs as appropriate on user Monday, June 04, 2012 5:42:45 PM

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the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives ground at all times through a take out and eyelet terminal of the wire harness that is secured to the body sheet metal. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the backup lamp switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to backup lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. DIAGNOSIS AND TESTING BACKUP LAMP SWITCH

1. Disconnect and isolate the battery negative cable. 2. Locate and disconnect the engine wire harness connector from the backup lamp switch connector receptacle. 3. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 4. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch.

SWITCH, HAZARD WARNING DESCRIPTION DESCRIPTION

Fig. 44: Instrument Panel Switch Pod Courtesy of CHRYSLER LLC The hazard switch (3) is integral to the instrument panel switch pod (1), which is secured to the instrument panel center bezel just above the heater and air conditioner controls. A red, stencil-like International Control and Display Symbol icon for Hazard Warning identifies the hazard switch button. The remainder of the hazard user Monday, June 04, 2012 5:42:45 PM

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switch circuitry is concealed within the instrument panel switch pod. The hazard switch button has panel lamps dimmer controlled illumination for night visibility. The switch button latches to a slightly lowered position when the hazard warning system is activated and the icon on the switch button will illuminate at an increased intensity while the turn signals and turn signal indicators are flashing. The switch button unlatches to a position flush with the other push buttons in the switch pod when the hazard warning is deactivated. All of the circuitry and components of the hazard switch are contained within a molded black plastic instrument panel switch pod housing. A single connector receptacle is integral to the back of the switch pod housing. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The hazard switch cannot be adjusted or repaired and, if ineffective or damaged, the entire instrument panel switch pod unit must be replaced. Refer to Electrical - Instrument Cluster/Instrument Cluster/POD, Switch - Removal . OPERATION OPERATION

The status of the hazard switch is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and a path to ground at all times through the instrument panel wire harness. The only other inputs to the switch pod consists of electronic communication with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire Local Interface Network (LIN) data bus. Whenever the hazard switch is in its unlatched and raised position, the hazard warning system is selected and the switch pod circuitry provides a hard wired output to the Totally Integrated Power Module (TIPM). When the TIPM receives a hazard switch input it then controls hazard warning system operation and flash rate by controlling battery voltage outputs through high side drivers on the right and left, front and rear turn signal feed circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the hazard warning switch or the electronic controls and communication between other modules and devices that provide some features of the hazard warning system. The most reliable, efficient, and accurate means to diagnose the hazard switch or the electronic controls and communication related to hazard warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.

SWITCH, HEADLAMP LEVELING, EXPORT DESCRIPTION user Monday, June 04, 2012 5:42:45 PM

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DESCRIPTION

Fig. 45: Identifying Park Assist Switch Courtesy of CHRYSLER LLC The headlamp leveling switch (3) is used only on vehicles manufactured for certain export markets where the headlamp leveling system is required. The headlamp leveling switch is integral to the switch pod (1), which is secured to the instrument panel center bezel just above the heater and air conditioner controls. A stencil-like International Control and Display Symbol icon for Headlamp Levelling Control identifies the headlamp leveling switch button. The switch push button is also marked with the numbers 0 , 1 , 2 , and 3 , which indicates each of the four headlamp leveling positions. Each higher number represents a lower aiming position of the headlamp beam relative to the road surface. The headlamp leveling switch button has panel lamps dimmer controlled illumination for night visibility. The switch button also features a jewel like Light Emitting Diode (LED) indicator adjacent to the numbers 1 , 2 , and 3 . The appropriate LED is illuminated when that headlamp position is currently selected. The momentary switch push button is operated by depressing, then releasing the top or bottom of the button in a rocker-like manner to enable the selection of a sequentially higher or lower position with each button press. All of the circuitry and components of the headlamp leveling switch are contained within the molded black plastic instrument panel switch pod housing. A single connector receptacle is integral to the back of the switch pod housing. The switch pod is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The headlamp leveling switch cannot be adjusted or repaired and, if ineffective or damaged, the entire instrument panel switch pod unit must be replaced. Refer to Electrical - Instrument Cluster/Instrument Cluster/POD, Switch - Removal . OPERATION OPERATION

The status of the headlamp leveling switch is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and a path to ground at all times through the instrument panel wire harness. The only other inputs to and outputs from the switch pod consist of electronic communication with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire Local Interface Network (LIN) data bus. user Monday, June 04, 2012 5:42:45 PM

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Whenever the headlamp leveling switch push button is depressed the switch pod circuitry sends an electronic select status up or select status down message input to the EMIC over the LIN data bus. The EMIC then sends the appropriate electronic select request up or select request down message to the TIPM over the Controller Area Network (CAN) data bus. The TIPM responds to these messages by providing a voltage output to the headlamp leveling motors through high side drivers on the headlamp leveling motor right and left signal circuits to move the headlamp reflectors to the selected position based upon the voltage input received from the TIPM. The TIPM also sends the appropriate electronic messages back to the EMIC and the EMIC relays the messages back to the switch pod to control the illumination of the 1 , 2 or 3 Light Emitting Diode (LED) selected position indicator in the leveling switch button. The EMIC and TIPM logic will only allow the headlamp leveling system to operate while the ignition switch is in the ON position and the exterior lighting is turned ON. The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the headlamp leveling switch or the electronic controls and communication between other modules and devices that provide some features of the headlamp leveling system. The most reliable, efficient, and accurate means to diagnose the headlamp leveling switch or the electronic controls and communication related to headlamp leveling system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.

SWITCH, MULTIFUNCTION, LEFT DESCRIPTION DESCRIPTION

Fig. 46: Left Multifunction Switch Courtesy of CHRYSLER LLC The left (lighting) multi-function switch is located on the left side of the steering column, just below the user Monday, June 04, 2012 5:42:45 PM

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steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds.

Fig. 47: Steering Control Module Courtesy of CHRYSLER LLC The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: z

z

z

Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. Headlamps - The left multi-function switch control knob provides detent switching for the headlamps.

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z

z

z z

z

Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-topass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps.

The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: z

z

z

z

Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on.

The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. OPERATION OPERATION

The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available user Monday, June 04, 2012 5:42:45 PM

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(SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a fail-safe mode of operation for the exterior lighting system. The fail-safe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING

Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: z

z

z

z

z

Automatic Headlamps - The optional automatic headlamps feature is requested when the left multifunction switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multifunction switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle.

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z

z

z

Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multifunction switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle.

INTERIOR LIGHTING

Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: z

z

Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message

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z

z

over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle.

REMOVAL REMOVAL

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment.

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Fig. 48: Identifying Left Multi-Function Switch, Screw & Clockspring Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. Refer to Steering/Column/SHROUD, Steering Column - Removal . 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column.

Fig. 49: Left Stalk Electrical Connector Courtesy of CHRYSLER LLC 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. INSTALLATION INSTALLATION

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper user Monday, June 04, 2012 5:42:45 PM

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precautions could result in accidental airbag deployment.

Fig. 50: Left Stalk Electrical Connector Courtesy of CHRYSLER LLC 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated.

Fig. 51: Identifying Left Multi-Function Switch, Screw & Clockspring Courtesy of CHRYSLER LLC 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 N.m (10 in. lbs.). user Monday, June 04, 2012 5:42:45 PM

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4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. Refer to Steering/Column/SHROUD, Steering Column - Installation . 6. Reconnect the battery negative cable.

SWITCH, PARKING BRAKE DESCRIPTION DESCRIPTION

There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a footoperated or hand-operated park brake lever mechanism. FOOT-OPERATED

Fig. 52: Foot-Operated Park Brake Switch Courtesy of CHRYSLER LLC The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. user Monday, June 04, 2012 5:42:45 PM

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The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED

Fig. 53: Hand-Operated Park Brake Switch Courtesy of CHRYSLER LLC The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. OPERATION OPERATION

Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and user Monday, June 04, 2012 5:42:45 PM

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may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. DIAGNOSIS AND TESTING PARK BRAKE SWITCH

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE:

If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. Refer to Brakes - Diagnosis and Testing . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch.

INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED

1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY

1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity user Monday, June 04, 2012 5:42:45 PM

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with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. REMOVAL REMOVAL

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED

Fig. 54: Park Brake Lever Mechanism Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from user Monday, June 04, 2012 5:42:45 PM

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the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED

Fig. 55: Parking Brake Lever Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel. Refer to Body/Interior/CONSOLE, Center - Removal 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. INSTALLATION INSTALLATION

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate user Monday, June 04, 2012 5:42:45 PM

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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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED

Fig. 56: Park Brake Lever Mechanism Courtesy of CHRYSLER LLC 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 N.m (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED

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Fig. 57: Parking Brake Lever Courtesy of CHRYSLER LLC 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 N.m (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel. Refer to Body/Interior/CONSOLE, Center - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes.

SWITCH, STOP LAMP DESCRIPTION DESCRIPTION

Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and both are illustrated and described in the paragraphs that follow. EARLY PRODUCTION

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Fig. 58: Brake Lamp Switch Courtesy of CHRYSLER LLC This brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket on the dash panel under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. This brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. LATE PRODUCTION

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Fig. 59: Brake Lamp Switch Courtesy of CHRYSLER LLC This brake lamp switch (1) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (4) containing six terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (2) on one end of the switch housing. The plunger has a telescoping self-adjustment feature that is activated after the switch is installed by pulling the brake pedal upward to its normal at-rest position. The telescoping plunger can be pulled outward from the switch housing to repeat the self-adjustment procedure if necessary. This brake lamp switch cannot be repaired. If the switch is damaged or ineffective it must be replaced with a new unit. OPERATION OPERATION

Both the early and late production brake lamp switches control three independent circuits. These circuits are described as follows: z

z

Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the Center High Mounted Stop Lamp (CHMSL) and the Totally Integrated Power Module (TIPM) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake signal 1 circuit only when the brake pedal is released (brake lamp switch plunger is depressed).

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z

Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Totally Integrated Power Module (TIPM) on an ignition run/start control output circuit, and supplies this battery voltage to the PCM on a brake signal 2 circuit only when the brake pedal is released (brake lamp switch plunger is depressed).

The PCM sends electronic brake lamp switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus for use as an additional logic input for controlling many other vehicle functions and features. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication that provide some features related to brake lamp switch operation. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to brake lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. DIAGNOSIS AND TESTING BRAKE LAMP SWITCH

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment.

Fig. 60: Brake Lamp Switch - Early Production Courtesy of CHRYSLER LLC

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Fig. 61: Brake Lamp Switch - Late Production Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the Eary Production-type brake lamp switch from the mounting bracket. The self-adjusting plunger of this switch is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table below. BRAKE LAMP SWITCH TESTS PLUNGER CONTINUITY POSITION BETWEEN (2) Released Pins 1 and 2 (Extended) Compressed Pins 3 and 4, 5 (Depressed) and 6 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. REMOVAL REMOVAL user Monday, June 04, 2012 5:42:45 PM

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Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Description. EARLY PRODUCTION

Fig. 62: Stop Lamp Switch Wiring Routing Clip, Brake Pedal Bracket, Stop Lamp Switch & Wiring Connector Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Removal . 3. Locate the brake lamp switch (3) on the brake pedal support bracket (2) under the instrument panel. 4. Disconnect the wire harness connector (4) from the switch.

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Fig. 63: STOP LAMP SWITCH REMOVAL Courtesy of CHRYSLER LLC 1. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket (1). 2. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 3. Discard the removed brake lamp switch. The brake lamp switch self-adjusting plunger is a one time only feature. If the switch is removed from the bracket, it MUST be replaced with a new switch. LATE PRODUCTION

Fig. 64: Brake Lamp Switch On Brake Pedal Support Bracket Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:42:45 PM

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1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Removal . 3. Locate the brake lamp switch (2) on the brake pedal support bracket (4) under the instrument panel. 4. Depress and hold the brake pedal in the depressed position. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket. 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Release the brake pedal. 8. Disconnect the wire harness connector (1) from the switch. INSTALLATION INSTALLATION

Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. EARLY PRODUCTION

CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch.

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Fig. 65: Switch Adjustment Lever Courtesy of CHRYSLER LLC 1. Obtain a new brake lamp switch. The adjustment lever on the new switch should be at about a 45 degree angle to the switch connector receptacle. If the adjustment lever is parallel with the connector receptacle, the switch adjustment has already been set and the switch must be scrapped.DO NOT ATTEMPT TO RESET OR READJUST THE BRAKE LAMP SWITCH.

Fig. 66: Identifying Stop Lamp Switch & Pedal Clip Courtesy of CHRYSLER LLC 2. Depress and hold the brake pedal in the depressed position. 3. Align the tabs on the brake lamp switch (2) locking collar with the keyed hole in the brake pedal support bracket (1) below the instrument panel. 4. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the brake pedal support bracket until the switch housing is firmly seated against the bracket. user Monday, June 04, 2012 5:42:45 PM

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5. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. 6. Release the brake pedal, but do not pull it upward. 7. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch MUST be installed.

Fig. 67: Stop Lamp Switch Wiring Routing Clip, Brake Pedal Bracket, Stop Lamp Switch & Wiring Connector Courtesy of CHRYSLER LLC 8. Reconnect the wire harness connector (4) to the brake lamp switch (3). 9. If equipped, reinstall the silencer pad below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Installation . 10. Reconnect the battery negative cable. LATE PRODUCTION

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Fig. 68: Brake Lamp Switch On Brake Pedal Support Bracket Courtesy of CHRYSLER LLC 1. Be certain that the brake lamp switch (2) plunger is pulled all the way out of the switch housing to its fully extended position. 2. Reconnect the wire harness connector (1) to the connector receptacle on the switch. 3. Depress and hold the brake pedal in the depressed position. 4. Align the tabs on the brake lamp switch locking collar with the keyed hole in the brake pedal support bracket (2). 5. Insert the tab on the brake lamp switch locking collar through the keyed hole in the support bracket until the switch housing is firmly seated against the bracket. 6. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the support bracket. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 7. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 8. If equipped, reinstall the silencer pad below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Installation . 9. Reconnect the battery negative cable. ADJUSTMENTS ADJUSTMENT - LATE PRODUCTION TYPE ONLY user Monday, June 04, 2012 5:42:45 PM

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Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and, only the late production type switch can be readjusted following initial installation using this adjustment procedure. If the early production type switch requires readjustment for any reason, it must be replaced with a new switch. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Removal . 3. Depress and hold the brake pedal in the depressed position. 4. Pull the brake lamp switch plunger all the way out of the switch housing to its fully extended position. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 5. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 6. If equipped, reinstall the silencer pad below the steering column. Refer to Body/Instrument Panel/PANEL, Silencer - Installation . 7. Reconnect the battery negative cable.

UNIT, FRONT LAMP STANDARD PROCEDURE FRONT LAMP UNIT MOISTURE CLEARING

Some occasional moisture accumulation inside a vented front lamp unit is normal and appears as a fogging on the inside of the lamp lens, similar to the fog that sometimes appears on the inside of a windshield. This condition is caused by rapidly changing temperature and humidity levels between the air internal and external to the lamp, and will usually dissipate once the temperature and humidity conditions have been allowed to stabilize. Accelerated removal of such moisture may be accomplished by activating the headlamps on HIGH beam for about 15 minutes. user Monday, June 04, 2012 5:42:45 PM

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However, water droplets larger than 1 millimeter (0.039 inch) in size accumulated on the inside of the lamp lens, water droplets visible on most internal lamp surfaces or large quantities of water within the lamp indicates a problem with the lamp sealing that has allowed excessive amounts of water to enter the lamp. Once such excessive moisture has entered the lamp, it will always be present and will never disappear. A lamp with permanent internal moisture should be replaced. REMOVAL BULBS HEADLAMP HIGH BEAM

CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

Fig. 69: Headlamp Bulb Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the connector receptacle integral to the headlamp bulb (5) on the back of the front lamp unit housing. 3. Firmly grasp the bulb base and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the bulb and base straight out from the keyed opening in the reflector. HEADLAMP LOW BEAM

CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. user Monday, June 04, 2012 5:42:45 PM

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1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the connector receptacle integral to the headlamp bulb (2) on the back of the front lamp unit housing. 3. Firmly grasp the bulb base and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the bulb and base straight out from the keyed opening in the reflector. POSITION LAMP

NOTE:

The following procedure applies only to vehicles manufactured for certain export markets. Vehicles manufactured for domestic markets do not have a position lamp bulb, socket or wiring provided in the front lamp unit.

1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the connector receptacle integral to the position lamp bulb socket (3) on the back of the front lamp unit housing. 3. Firmly grasp the position lamp bulb socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. TURN SIGNAL/SIDE MARKER LAMP

1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the connector receptacle integral to the turn signal/side marker lamp bulb socket (1) on the back of the front lamp unit housing. 3. Firmly grasp the turn signal/side marker lamp bulb socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. LAMP

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Fig. 70: Fascia & Grille Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Loosen the front fascia on the same side of the vehicle as the front lamp unit being removed. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Removal . 3. Remove the four plastic push-pin fasteners that secure the upper grille to the Front End Module (FEM). 4. Flex the fascia and grille (1) outward far enough to access and remove the three screws (2) that secure the front lamp unit to the FEM. 5. Pull the front lamp unit away from the FEM far enough to access and disconnect the headlamp and dash wire harness connectors from the back of the lamp housing. 6. Remove the front lamp unit from the vehicle. INSTALLATION BULBS HEADLAMP HIGH BEAM

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

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Fig. 71: Headlamp Bulb Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Align the headlamp bulb and base (5) with the keyed opening on the back of the front lamp unit reflector. Insert the bulb into the reflector until the base is firmly seated. Rotate the bulb base clockwise about 30 degrees to lock it into place. Reconnect the wire harness connector to the connector receptacle integral to the headlamp bulb base. Reconnect the battery negative cable.

HEADLAMP LOW BEAM

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. 2. 3. 4. 5.

Align the headlamp bulb and base (2) with the keyed opening on the back of the front lamp unit reflector. Insert the bulb into the reflector until the base is firmly seated. Rotate the bulb base clockwise about 30 degrees to lock it into place. Reconnect the wire harness connector to the connector receptacle integral to the headlamp bulb base. Reconnect the battery negative cable.

POSITION LAMP

CAUTION: Always use the correct bulb size and type for replacement. An incorrect user Monday, June 04, 2012 5:42:45 PM

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bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE:

The following procedure applies only to vehicles manufactured for certain export markets. Vehicles manufactured for domestic markets do not have a position lamp bulb, socket or wiring provided in the front lamp unit.

1. 2. 3. 4. 5. 6.

Align the base of the bulb with the position lamp bulb socket (3). Push the bulb straight into the socket until the base is firmly seated. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing. Insert the socket and bulb straight into the housing until the socket is firmly seated. Rotate the socket clockwise about 30 degrees to lock it into place. Reconnect the wire harness connector to the connector receptacle integral to the position lamp bulb socket. 7. Reconnect the battery negative cable. TURN SIGNAL/SIDE MARKER LAMP

CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. 2. 3. 4. 5. 6.

Align the base of the bulb with the park/turn signal lamp bulb socket (1). Push the bulb straight into the socket until the base is firmly seated. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing. Insert the socket and bulb straight into the housing until the socket is firmly seated. Rotate the socket clockwise about 30 degrees to lock it into place. Reconnect the wire harness connector to the connector receptacle integral to the park/turn signal lamp bulb socket. 7. Reconnect the battery negative cable. LAMP

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Fig. 72: Fascia & Grille Courtesy of CHRYSLER LLC NOTE: 1. 2. 3. 4. 5. 6. 7. 8.

If the front lamp is being replaced with a new unit, the bulbs and sockets must be transferred from the unit being replaced.

Position the front lamp unit to the front of the vehicle. Reconnect the headlamp and dash wire harness connectors to the back of the lamp housing. Position the front lamp unit into the Front End Module (FEM). Flex the fascia and grille (1) outward far enough to install and tighten the three screws (2) that secure the front lamp unit to the FEM. Tighten the screws securely. Reinstall the four plastic push-pin fasteners that secure the upper grille to the FEM. Reinstall the front fascia on the same side of the vehicle as the front lamp unit being installed. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Installation Reconnect the battery negative cable. Confirm proper headlamp alignment. See Electrical - Lamps and Lighting/Lamps/Lighting - Exterior - Standard Procedure.

WIRING, TRAILER TOW DESCRIPTION DESCRIPTION

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Fig. 73: Instruction Sheet Are Placed In Glove Box Courtesy of CHRYSLER LLC Vehicles equipped with an optional Trailer Tow Preparation package have a trailer tow wiring harness and an instruction sheet (1) that are placed in the glove box (2) of the vehicle when it is shipped from the factory. This package also includes four relays to isolate the trailer lighting from the vehicle lighting and a four-way trailer tow wiring connector that are all concealed behind the rear bumper fascia after installation is complete. OPERATION OPERATION

The trailer tow preparation wiring harness is connected to the body wire harness at the right and left outer rear lamp unit connections. After installation is complete, a trailer tow stop/turn relay is secured to the harness behind the rear bumper fascia just below each outer rear lamp unit, while a trailer tow stop lamp relay is located on the underside of each outboard end of the rear bumper reinforcement behind the rear fascia. The four-way trailer tow connector is located near the center of the rear fascia. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds. Also refer to the Instruction Sheet packaged with the harness for additional details.

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2009 ACCESSORIES AND EQUIPMENT Frame and Bumpers - Journey

BUMPERS SPECIFICATIONS FASTENER TORQUE

FASTENER TORQUE DESCRIPTION Rear bumper reinforcement attaching nut Front Crossmember to cradle bolts (3) Front suspension crossmember frame rail torque boxes attaching bolts Front suspension crossmember attaching front and rear Fore/Aft crossmember anti roll through bolt Radiator support crossmember attaching bolts Shear bracket fasteners

N.m 28 50

Ft. Lbs. 21 41

In. Lbs. -

135

100

-

55

41

-

50

37

-

115

85

-

55

41

-

FASCIA, FRONT Removal REMOVAL

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Fig. 1: Pushpins Courtesy of CHRYSLER LLC 1. Release hood latch and open hood. 2. Remove the pushpins for the fascia (2) at the radiator support.

Fig. 2: Pop Rivets Courtesy of CHRYSLER LLC 3. Hoist and support vehicle on safety stands. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure for proper hoisting and jacking procedures. 4. Remove the pop rivets (2) at the wheel well opening.

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Fig. 3: Fascia Tabs & Bracket Courtesy of CHRYSLER LLC 5. Remove the Torx® screw (3) at the wheel well housing. 6. Separate the fascia tabs (2) at the bracket (1).

Fig. 4: Lower Pushpins Courtesy of CHRYSLER LLC 7. Remove the pushpins (1) for the fascia (2) at the lower closeout panel.

Fig. 5: Fascia & Mounting Tab Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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8. 9. 10. 11.

Slide the fascia (2) out from the mounting tab (1) under the headlamp. Disengage fog lamp wire connector and side marker connector from body harness, if equipped. Disengage the ambient temp sensor wire connector, if equipped. Remove fascia from vehicle.

Installation INSTALLATION

Fig. 6: Fascia & Mounting Tab Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Install the fascia to the vehicle. Reconnect the ambient temp sensor wire connector, if equipped. Reconnect the fog lamp wire connector and side marker connector from body harness, if equipped. Slide the fascia (2) into the mounting tab (1) under the headlamp.

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Fig. 7: Lower Pushpins Courtesy of CHRYSLER LLC 5. Install the pushpins (1) for the fascia (2) at the lower closeout panel.

Fig. 8: Fascia Tabs & Bracket Courtesy of CHRYSLER LLC 6. Insert and snap into place the fascia tabs (2) at the bracket (1). 7. Install the Torx® screw (3) at the wheel well housing.

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Fig. 9: Pop Rivets Courtesy of CHRYSLER LLC 8. Install the pop rivets (2) at the wheel well opening. 9. Lower the vehicle.

Fig. 10: Pushpins Courtesy of CHRYSLER LLC 10. Install the pushpins for the fascia (2) at the radiator support. 11. close the hood and check for proper fit. FASCIA, FRONT LOWER, CLOSEOUT user Monday, June 04, 2012 10:02:47 AM

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Removal REMOVAL

Fig. 11: Lower Fascia Courtesy of CHRYSLER LLC 1. Remove fasteners (5) to lower closeout.

Fig. 12: Push Pins - Front Lower Fascia Courtesy of CHRYSLER LLC 2. Remove push pins (1) to lower closeout. user Monday, June 04, 2012 10:02:47 AM

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3. Remove the front lower fascia. Installation INSTALLATION

Fig. 13: Push Pins - Front Lower Fascia Courtesy of CHRYSLER LLC 1. Install the front lower fascia. 2. Install the push pins (1) to lower closeout.

Fig. 14: Lower Fascia user Monday, June 04, 2012 10:02:47 AM

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Courtesy of CHRYSLER LLC 3. Install the fasteners (5) to lower closeout. FASCIA, REAR Removal REMOVAL

Fig. 15: Push Pins Courtesy of CHRYSLER LLC 1. Open the hatch. 2. Remove the 6 pushpins (1) securing the fascia (2).

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Fig. 16: Rivets Courtesy of CHRYSLER LLC 3. Remove the rivets (2) and the Torx® screw (3) around the wheel well for the fascia (1).

Fig. 17: Tabs, Fascia & Bracket Courtesy of CHRYSLER LLC 4. Separate the tabs (2) securing the fascia (3) to the bracket (1).

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Fig. 18: Tail Light Push Pin Courtesy of CHRYSLER LLC 5. Remove the push pin (2) under the taillight (1) to the fascia (3). 6. Remove fascia (3) from vehicle. Installation INSTALLATION

Fig. 19: Tail Light Push Pin Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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1. Install the fascia (3) to the vehicle and install the pushpin (2) at the tailight (1) to the body.

Fig. 20: Tabs, Fascia & Bracket Courtesy of CHRYSLER LLC 2. Clip the fascia (3) into the tabs (2) to the bracket (1).

Fig. 21: Rivets Courtesy of CHRYSLER LLC 3. Install the Torx® screw (3) for the fascia top the wheel opening and then install the pop rivets (2).

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Fig. 22: Push Pins Courtesy of CHRYSLER LLC 4. Install the 6 push pins (1) to secure the fascia (2) to the body. 5. Close the hatch and check for fit. REINFORCEMENT, BUMPER, FRONT Removal REMOVAL

Fig. 23: Front Bumper Reinforcement Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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1. 2. 3. 4. 5. 6.

Remove the front fascia. See Removal . Support bumper reinforcement (3) on a suitable lifting device. Mark the position of the bolts (1) on frame rail to aid in installation. Remove the smaller bolts (2) attaching bumper reinforcement (3) to frame rail. Remove the larger bolts (1) attaching bumper reinforcement (3) to frame rail. Remove bumper reinforcement (3) from vehicle.

Installation INSTALLATION

Fig. 24: Front Bumper Reinforcement Courtesy of CHRYSLER LLC 1. Position the bumper reinforcement (3) on vehicle. NOTE:

Use marks made previously to properly position bumper reinforcement

2. Install the larger bolts (1) attaching bumper reinforcement (3) to frame rail. Tighten bolts (1) to 28 N.m (250 in. lbs.). 3. Install the smaller bolts (2) attaching bumper reinforcement (3) to frame rail. 4. Install front fascia. See Installation . REINFORCEMENT, BUMPER, REAR Removal REMOVAL

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Fig. 25: Rear Bumper Reinforcement Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove rear fascia. See Removal . Support bumper reinforcement (1) on a suitable lifting device. Mark position of bolts (2) on frame rail to aid in installation. Remove bolts (2) attaching rear bumper reinforcement (1) to frame rail. Remove bumper reinforcement (1) from vehicle.

Installation INSTALLATION

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Fig. 26: Rear Bumper Reinforcement Courtesy of CHRYSLER LLC 1. Position rear bumper reinforcement (1) on vehicle. 2. Install bolts (2) attaching bumper reinforcement to frame rail. Use marks made previously to properly position bumper reinforcement. 3. Tighten bolts (2) to 28 N.m (250 in. lbs.). 4. Install rear fascia. See Installation .

FRAME SPECIFICATIONS FRAME DIMENSIONS

Frame dimensions are listed in metric scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location. VEHICLE PREPARATION

Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Vertical dimensions can be taken from the work surface to the locations indicated were applicable. VEHICLE PREPARATION INDEX DESCRIPTION FRAME DIMENSIONS - SIDE VIEW FRAME DIMENSIONS - BOTTOM VIEW

FIGURE Fig. 27 Fig. 28

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Fig. 27: Frame Dimensions - Side View Courtesy of CHRYSLER LLC

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Fig. 28: Frame Dimensions - Bottom View Courtesy of CHRYSLER LLC FASTENER TORQUE

FASTENER TORQUE DESCRIPTION Front Engine Mount Crossmember Mounting Bolts Front Fore/Aft Crossmember Forward Mounting Bolts Front Fore/Aft Crossmember Rearward Mounting Bolts Front Suspension Crossmember Mounting Bolts Front Suspension Crossmember Reinforcement Bracket Mounting Screws Rear Suspension Crossmember Mounting Bolts Rear Suspension Crossmember Reinforcement Bracket Mounting Nuts Rear Suspension Crossmember Reinforcement Bracket Mounting Screws

N.m 50 55 55 135

Ft. Lbs. 37 41 41 100

In. Lbs. -

55

41

-

95

70

-

50

37

-

55

41

-

CROSSMEMBER, FRONT FORE AND AFT Removal user Monday, June 04, 2012 10:02:47 AM

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REMOVAL

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 2. If equipped, remove the engine belly pan.

Fig. 29: Removing/Installing Fore/Aft Crossmember Courtesy of CHRYSLER LLC 3. Remove the front engine mount thru-bolt (2).

Fig. 30: Fore-Aft Crossmember Forward Mounting Bolts Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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4. 5. 6. 7.

Remove the fore-aft crossmember forward mounting bolts at the radiator support. Remove the fore-aft crossmember rearward mounting bolts at the crossmember. Remove the fore-aft crossmember. Remove the front engine mount mounting bolts (2) and damper (1). Remove the mount (3) from the crossmember.

Installation INSTALLATION

Fig. 31: Fore-Aft Crossmember Forward Mounting Bolts Courtesy of CHRYSLER LLC 1. Install the front engine mount (3) on the crossmember. Install the mounting bolts (2) and damper (1). Tighten the bolts to 50 N.m (37 ft. lbs.). 2. Position the fore-aft crossmember in the engine compartment and install the mounting bolts. Tighten the forward mounting bolts at the radiator support to 55 N.m (41 ft. lbs.). Tighten the rearward mounting bolts at the suspension crossmember to 55 N.m (41 ft. lbs.).

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Fig. 32: Removing/Installing Fore/Aft Crossmember Courtesy of CHRYSLER LLC 3. Install the front engine mount thru-bolt (4). Tighten the bolt to 60 N.m (44 ft. lbs.). 4. If equipped, install the engine belly pan. 5. Lower the vehicle. CROSSMEMBER, FRONT SUSPENSION Removal REMOVAL

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .

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Fig. 33: Tire And Wheel Mounting Courtesy of CHRYSLER LLC 2. On each side of the vehicle, remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).

Fig. 34: Lower Ball Joint To Control Arm Courtesy of CHRYSLER LLC 3. On each side of the vehicle, remove the nut (1) attaching the lower ball joint to the lower control arm (2).

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Fig. 35: Using 9360 On Lower Ball Joint Courtesy of CHRYSLER LLC 4. On each side of the vehicle, release the lower ball joint (3) from the lower control arm (1) using Remover (2), Special Tool 9360. Do not lift the knuckle out of the lower control arm at this time. 5. If equipped, remove the engine belly pan. 6. Remove the fore/aft crossmember. See Removal. 7. Remove the rear engine mount. Refer to Engine/Engine Mounting/INSULATOR, Engine Mount Removal .

Fig. 36: Hoses At Rear Of Crossmember Courtesy of CHRYSLER LLC 8. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the user Monday, June 04, 2012 10:02:47 AM

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crossmember.

Fig. 37: Heat Shield Over Gear Courtesy of CHRYSLER LLC 9. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2).

Fig. 38: Steering Gear Mounting Courtesy of CHRYSLER LLC 10. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 11. Support the steering gear using a bungee cord or other to keep the steering gear from lowering when the crossmember is lowered. user Monday, June 04, 2012 10:02:47 AM

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Fig. 39: Stabilizer Bar Mounting Courtesy of CHRYSLER LLC 12. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. NOTE:

Before lowering the front suspension crossmember, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost.

Fig. 40: Marking Location Of Crossmember user Monday, June 04, 2012 10:02:47 AM

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Courtesy of CHRYSLER LLC 13. Using a crayon or marker (2) that will not break the paint surface, mark the location of the front crossmember (1) on the body near each mounting bolt. Do not use any type of sharp instrument that will damage the underbody of the vehicle.

Fig. 41: Front Crossmember Mounting Courtesy of CHRYSLER LLC 14. Support the crossmember (9) with a transmission jack. Secure the crossmember to the jack. 15. Remove the four mounting bolts (6) securing the front crossmember (9) to the body. 16. Remove the mounting screws (8) securing the front crossmember reinforcement brackets (7) (one each side of vehicle) to the body (1). Remove the brackets. 17. Slowly lower the crossmember and control arms to a comfortable working height using the jack.

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Fig. 42: Lower Control Arm Mounting Courtesy of CHRYSLER LLC 18. To remove each lower control arm: a. Remove the front bolt (1) attaching the lower control arm (3) to the front suspension crossmember. b. Remove the nut on the rear bolt (2) attaching the lower control arm (3) to the front suspension crossmember. Remove the bolt. c. Remove the lower control arm (3) from the crossmember. Installation INSTALLATION

1. Support the crossmember with a transmission jack. Secure the crossmember to the jack.

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Fig. 43: Lower Control Arm Mounting Courtesy of CHRYSLER LLC 2. To install each lower control arm on the crossmember: a. Place the lower control arm (3) into the front suspension crossmember. b. Insert the rear bolt (2) up through the crossmember and lower control arm (3). Install the nut on the top-end of the bolt, but do not tighten it at this time. c. Install, but do not fully tighten, the front bolt (1) attaching the lower control arm (3) to the crossmember. d. With no weight or obstruction on the lower control arm, tighten the lower control arm front mounting bolt (2) to 145 N.m (107 ft. lbs.). e. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut to 145 N.m (107 ft. lbs.).

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Fig. 44: Front Crossmember Mounting Courtesy of CHRYSLER LLC 3. Slowly raise the crossmember (9) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. As the crossmember is raised, guide the lower ball joints into the mounting holes in the lower control arms. Also, make sure the stabilizer bar is properly positioned on the crossmember. 4. Position the front crossmember reinforcement brackets (7) (one each side of vehicle) over the crossmember rear mounting bushings and install the mounting screws (8), but do not tighten at this time.

Fig. 45: Front Crossmember Mounting Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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5. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 135 N.m (100 ft. lbs.). 6. Tighten the crossmember reinforcement bracket mounting screws (8) to 55 N.m (41 ft. lbs.). 7. Remove the transmission jack.

Fig. 46: Stabilizer Bar Mounting Courtesy of CHRYSLER LLC 8. Position both stabilizer bar bushing retainers and install the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar cushion retainer screws to 60 N.m (44 ft. lbs.).

Fig. 47: Steering Gear Mounting user Monday, June 04, 2012 10:02:47 AM

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Courtesy of CHRYSLER LLC 9. Remove the bungee cord or other supporting the steering gear (2). 10. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 100 N.m (74 ft. lbs.).

Fig. 48: Heat Shield Over Gear Courtesy of CHRYSLER LLC 11. Position the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins. Tighten the screws to 6 N.m (53 in. lbs.).

Fig. 49: Hoses At Rear Of Crossmember Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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12. Position the power steering hose routing clamps (2) on the crossmember. Install and tighten the screws to 8 N.m (71 in. lbs.). 13. Install the rear engine mount. Refer to appropriate Engine SERVICE INFORMATION article. 14. Install the fore/aft crossmember. See Installation. 15. If equipped, install the engine belly pan. NOTE:

If a new or cleaned lower control arm is being installed, it is important to have a film of general purpose grease around the ball joint mounting hole on the lower control arm to avoid any future corrosion issues. Make sure the grease does not get inside the ball joint mounting hole or on the ball joint stud during installation.

Fig. 50: Lower Ball Joint To Control Arm Courtesy of CHRYSLER LLC 16. On each side of the vehicle, install a NEW ball joint stud nut (1). Tighten the nut to 95 N.m (70 ft. lbs.).

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Fig. 51: Tire And Wheel Mounting Courtesy of CHRYSLER LLC 17. On each side of the vehicle, install the tire and wheel assembly (1). Refer to Tires and Wheels Installation . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 18. Lower the vehicle. 19. Perform wheel alignment as necessary. Refer to Front Suspension/Wheel Alignment - Standard Procedure . CROSSMEMBER, REAR SUSPENSION Removal REMOVAL

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .

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Fig. 52: Tire And Wheel Mounting Courtesy of CHRYSLER LLC 2. On each side of the vehicle, remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).

Fig. 53: Hub Nut And Washer Courtesy of CHRYSLER LLC 3. If equipped with all-wheel-drive, remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. user Monday, June 04, 2012 10:02:47 AM

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Fig. 54: Wheel Speed Sensor Routing Clamp Courtesy of CHRYSLER LLC 4. On each side of the vehicle, remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3). 5. Remove the exhaust system from the vehicle. Refer to Exhaust System/PIPE, Exhaust - Removal .

Fig. 55: Right Cable At Crossmember Courtesy of CHRYSLER LLC 6. Remove the screws securing the four right rear parking brake cable routing clamps to the rear crossmember.

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Fig. 56: Supporting Rear Shock Courtesy of CHRYSLER LLC 7. On each side of the vehicle, if equipped with load-leveling shocks, support the lower shock (1) with a jack (2) using just enough force to allow easy removal of the lower shock mounting bolt in the following step. Lower the jack following bolt removal.

Fig. 57: Rear Lower Shock Mounting Courtesy of CHRYSLER LLC 8. On each side of the vehicle, remove the lower shock mounting nut (1) and bolt (4). 9. If equipped with all-wheel-drive, remove the rear driveline module, but instead of using a drive-on hoist, place jacks under the outboard ends of the lower control arms and adjust the rear suspension height at the hub and bearings to simulate curb riding height. Refer to Differential and Driveline/Rear Driveline user Monday, June 04, 2012 10:02:47 AM

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Module - Removal . Once the rear driveline module is removed, remove the jacks. 10. If equipped with all-wheel-drive, slide the half shaft out of the hub and bearing on each side of the vehicle and remove it.

Fig. 58: Rear Stabilizer Bar Retainer Courtesy of CHRYSLER LLC 11. On each side of the vehicle, while holding the stabilizer bar link upper stud stationary, remove the nut (2) securing the link (4) to the stabilizer bar (3). 12. On each side of the vehicle, remove the screws (1) securing the stabilizer bar retainer (5) to the crossmember. 13. Remove the stabilizer bar (3) from the vehicle.

Fig. 59: Rear Lower Control Arm Mounting user Monday, June 04, 2012 10:02:47 AM

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Courtesy of CHRYSLER LLC 14. On each side of the vehicle: a. Loosen (do not remove) the nut (2) and bolt (7) securing the lower control arm (3) to the knuckle (1). b. Remove the nut (4) and bolt (6) securing the lower control arm (3) to the rear crossmember (5). c. Swing the lower control arm down away from the rear crossmember.

Fig. 60: Rear Toe Adjustment Cam Bolt Courtesy of CHRYSLER LLC 15. On each side of the vehicle: a. Mark the position of the cam bolt (4) cams on the crossmember using a paint marker or crayon. Do not use any type marker that will scratch or damage the surface of the crossmember. b. While holding the cam bolt (4) head stationary, loosen and remove the toe link mounting cam bolt nut (3) and washer (1). Remove the cam bolt.

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Fig. 61: Toe Link Courtesy of CHRYSLER LLC 16. On each side of the vehicle, loosen (do not remove) the mounting bolt (2) and nut securing the toe link (3) to the knuckle.

Fig. 62: Upper Control Arm Mounting Courtesy of CHRYSLER LLC 17. On each side of the vehicle: a. Loosen (do not remove) the nut (3) and bolt (4) securing the upper control arm (5) to the knuckle. b. Remove the nut (2) and bolt (1) securing the upper control arm (5) to the crossmember. 18. On each side of the vehicle, using wire or a bungee cord, support the knuckle to keep it from sagging. user Monday, June 04, 2012 10:02:47 AM

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NOTE:

Before lowering the rear suspension crossmember, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the crossmember is not reinstalled in exactly the same location as before removal, the rear wheel alignment settings may be lost.

19. Using a crayon or marker that will not break the paint surface, mark the location of the rear suspension crossmember on the body near each mounting bolt. Do not use any type of sharp instrument that will damage the underbody of the vehicle. 20. Support the crossmember with a transmission jack. Secure the crossmember to the jack. 21. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body. 22. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts. Remove the brackets. 23. Remove the four mounting bolts securing the crossmember to the body. 24. Slowly lower the crossmember using the jack. Installation INSTALLATION

1. Support the rear suspension crossmember with a transmission jack. Secure the crossmember to the jack. 2. Slowly raise the crossmember into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. As the crossmember is raised, guide the rear suspension components into place. 3. Install the four mounting bolts (rear bolts have stud heads) securing the crossmember to the body. Tighten the crossmember mounting bolts to 95 N.m (70 ft. lbs.). 4. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 5. Install the mounting screws securing the crossmember reinforcement brackets to the body. Tighten the screws to 55 N.m (41 ft. lbs.). 6. Tighten the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 7. Remove the transmission jack.

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Fig. 63: Upper Control Arm Mounting Courtesy of CHRYSLER LLC 8. On each side of the vehicle, position the upper control arm (5) and install the bolt (1) and nut (2) securing the arm to the crossmember. Do not tighten either upper control arm mounting bolts at this time.

Fig. 64: Rear Toe Adjustment Cam Bolt Courtesy of CHRYSLER LLC CAUTION: When installing the cam bolt (4) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult. 9. On each side of the vehicle: user Monday, June 04, 2012 10:02:47 AM

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a. Position the toe link (2) and install the cam bolt (4) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position if not available. b. Install the cam washer (1) and nut (3) securing the toe link (2) to the crossmember. Do not tighten at this time.

Fig. 65: Rear Lower Control Arm Mounting Courtesy of CHRYSLER LLC 10. On each side of the vehicle, position the lower control arm (3) and install the bolt (6) and nut (4) securing the lower control arm to the crossmember (5). Do not tighten nut and bolt at crossmember or knuckle at this time.

Fig. 66: Rear Stabilizer Bar Retainer user Monday, June 04, 2012 10:02:47 AM

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Courtesy of CHRYSLER LLC NOTE:

When installing the stabilizer bar on a vehicle with all-wheel-drive, position the bar so that the bar loops over the axle half shafts once installed, not under the axle half shafts.

11. Position the stabilizer bar (3) on the rear crossmember. CAUTION: Before installing the screws in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent. 12. Install the two retainers (5 - right side shown in illustration) over the cushions at the mounting holes and install the retainer screws (1). Do not tighten the screws at this time. CAUTION: Before installing the nut in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent. 13. On each side of the vehicle, install the stabilizer link (4) upper stud in the end of the stabilizer bar (3). Install the nut (2) on the upper stud and while holding the stabilizer link stud stationary, tighten the nut to 48 N.m (35 ft. lbs.). 14. On each side of the vehicle, tighten the stabilizer bar retainer screws (1) to 25 N.m (18 ft. lbs.).

Fig. 67: Hub Nut And Washer Courtesy of CHRYSLER LLC NOTE:

Always install a new hub nut. The original hub nut is one-time use only

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and should be discarded when removed. 15. If equipped with all-wheel-drive, slide the half shaft into the hub and bearing on each side of the vehicle and hand-start the washer and hub nut (3) Support the shafts to keep them from overextending the joints. 16. If equipped with all-wheel-drive, install the rear driveline module. In place of using a drive-on hoist, place jacks under the outboard ends of the lower control arms and adjust the rear suspension height at the hub and bearings to simulate curb riding height. Refer to Differential and Driveline/Rear Driveline Module - Removal . Once the rear driveline module is installed, remove the jacks.

Fig. 68: Supporting Rear Shock Courtesy of CHRYSLER LLC 17. On each side of the vehicle, if equipped with load-leveling shocks, place a jack (2) against the lower shock eye and support the lower end of the shock assembly (1). Lift the shock assembly using the jack until the hole in the lower shock eye lines up with that in the lower control arm.

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Fig. 69: Rear Lower Shock Mounting Courtesy of CHRYSLER LLC 18. On each side of the vehicle, install the mounting bolt (4) and nut (1) fastening the shock assembly (2) to the lower control arm (3). Do not tighten at this time.

Fig. 70: Right Cable At Crossmember Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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19. Position the four parking brake cable routing clamps along the front of the rear crossmember and install the screws. Tighten the screws to 6 N.m (55 in. lbs.). 20. Install the exhaust system. Refer to Exhaust System/PIPE, Exhaust - Installation .

Fig. 71: Wheel Speed Sensor Routing Clamp Courtesy of CHRYSLER LLC 21. On each side of the vehicle, attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 N.m (15 ft. lbs.).

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Fig. 72: Hub Nut And Washer Courtesy of CHRYSLER LLC 22. While a helper applies the brakes to keep the hub (1) from rotating, on each side of the vehicle: a. Tighten the hub nut (3) to 245 N.m (181 ft. lbs.). b. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. c. Wrap the cotter pin (2) ends tightly around the lock nut.

Fig. 73: Tire And Wheel Mounting Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:02:47 AM

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23. On each side of the vehicle, install tire and wheel assembly (1). Refer to Tires and Wheels Installation . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 24. Lower the vehicle. 25. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 26. Tighten the lower control arm mounting bolt nut at the crossmember to 105 N.m (77 ft. lbs.). 27. Tighten the lower control arm mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.). 28. Tighten the shock assembly lower mounting bolt nut to 99 N.m (73 ft. lbs.). 29. Tighten the upper control arm mounting bolt nut at the crossmember to 105 N.m (77 ft. lbs.). 30. Tighten the upper control arm mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.). 31. Tighten the toe link mounting bolt nut at the knuckle to 105 N.m (77 ft. lbs.). 32. Perform wheel alignment as necessary. Refer to Front Suspension/Wheel Alignment - Standard Procedure .

Fig. 74: Rear Toe Adjustment Cam Bolt Courtesy of CHRYSLER LLC 33. Once rear toe is set, while holding the cam bolt (4) head stationary, tighten the toe link mounting cam bolt nut (3) to 100 N.m (74 ft. lbs.).

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Heated Glass - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Heated Glass - Service Information - Journey

DESCRIPTION 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 recommended.

Fig. 1: EBL System Courtesy of CHRYSLER LLC The rear window defogger system, also known as electric backlight (EBL), consists of two vertical bus bars (1) and a series of grid lines (2) fired onto the inside surface of the rear window (3). The EBL system is turned on or off by a push-button switch located in the A/C-heater control. Refer to Heating and Air Conditioning/Controls/CONTROL, A/C and Heater - Description .

OPERATION OPERATION

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Fig. 2: EBL Switch (MTC) Courtesy of CHRYSLER LLC NOTE:

Manual tri-zone temperature A/C-heater control shown in illustration. Other A/Cheater controls similar.

The electric backlight (EBL) system is controlled by a momentary push-button switch (1) located on the A/Cheater control (2) in center of the instrument panel. When the rear window defogger switch is pressed to ON with the ignition switch in RUN, the switch sends a request signal on the CAN-B Bus to the totally integrated power module (TIPM) to energize the internal EBL high side driver. When energized, the EBL high side driver provides battery current to the rear window defogger grid lines and the heated side view mirrors (when equipped). The grid lines heat the glass to help clear the rear window and side mirror surfaces of fog or frost. An amber indicator (3) will illuminate to indicate when the EBL system is turned on. NOTE:

The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes.

The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. Repair of the rear window defogger grid lines, bus bars, terminals or pigtail wires can be accomplished using the Mopar® Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent. See Standard Procedure . The EBL control system is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC - Diagnosis and Testing . user Monday, June 04, 2012 9:45:12 AM

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DIAGNOSIS AND TESTING ELECTRIC BACKLIGHT (EBL) SYSTEM NOTE:

Illumination of the defogger switch indicator lamp does not necessarily mean that electrical current is reaching the rear window glass and/or the outside rear view mirror heating grids (when equipped).

NOTE:

See appropriate wiring information for circuit descriptions and diagrams of the rear window defogger (EBL) and heated mirror systems.

Operation of the electrical backlight (EBL) system can be confirmed by the following:

Fig. 3: Rear Window Glass Grid Test Courtesy of CHRYSLER LLC NOTE:

Typical heated rear window glass shown in illustration.

1. Use a scan tool and check for diagnostic trouble codes (DTCs) related to the rear window defogger switch and the totally integrated power module (TIPM). If no DTCs are found, go to step 2. If any DTCs are found, repair as required, then proceed to step 2. 2. Turn the ignition switch to RUN. Set the rear window defogger switch to ON. Rear window defogger operation can be checked by feeling the rear window glass (1), or the heated outside rear view mirror glass when equipped with heated mirrors. A distinct difference in temperature between the grid lines (2) and the adjacent clear glass or the heated mirror glass should be detected within 3 to 4 minutes of operation. 3. If a temperature difference is not detected, use a 12-volt DC voltmeter (6) and contact the rear glass heating grid terminal A (5) with the positive lead, and terminal B (7) with the negative lead. The user Monday, June 04, 2012 9:45:12 AM

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voltmeter should read battery voltage. If the voltmeter does not read battery voltage, check the following: z Confirm the ignition switch is in RUN. z Confirm the rear window defogger switch is ON. z Confirm the EBL feed wire is connected to the heating grid positive terminal and that there is continuity between the TIPM and the heating grid. z Confirm the EBL ground wire is connected to the heating grid negative terminal and that there is continuity to ground. z When diagnosing a heated mirror concern, check the heated mirror circuit fuse located in the TIPM. The fuse must be in the receptacle and all electrical connections must be secure. 4. If broken defogger grid lines or bus bars (3) are suspected, use a 12-volt DC voltmeter and contact terminal B with the negative lead and each rear glass heating grid line at its mid-point C (4) with the positive lead. The voltmeter should read approximately 6 volts at each grid line mid-point. If the voltmeter does not read approximately 6 volts, repair the open grid line(s) or bus bar(s). See Standard Procedure . 5. If EBL system operation has been verified but the rear window defogger indicator does not illuminate, replace the A/C-heater control. Refer to Heating and Air Conditioning/Controls/CONTROL, A/C and Heater - Removal .

GRID, DEFOGGER, REAR STANDARD PROCEDURE GRID LINE AND TERMINAL REPAIR

WARNING: Materials contained in the Repair Kit (Part Number 04549275) may cause skin or eye irritation. The kit contains epoxy resin and amine type hardener, which are harmful if swallowed. Avoid contact with the skin and eyes. For skin contact, wash the affected areas with soap and water. For contact with the eyes, flush with plenty of water. Do not take internally. If taken internally, induce vomiting and call a physician immediately. Use with adequate ventilation. Do not use near fire or flame. Contains flammable solvents. Keep out of the reach of children. Failure to follow these instructions may result in serious or fatal injury. Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished using the Mopar® Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent.

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Fig. 4: Grid Line Repair - Typical Courtesy of CHRYSLER LLC 1. Mask the repair area with masking tape (3) so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line (2) or the bus bar on each side of the break (1). 2. Follow the instructions in the repair kit for preparing the damaged area. 3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy. 4. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch). 5. For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fastened and onto the adjacent grid line. 6. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or clamped. 7. Carefully remove the masking tape or template. CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture. 8. Allow the epoxy to cure 24 hours at room temperature or carefully use a heat gun for 15 minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F). 9. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or pigtail wire. 10. Connect the wire harness leads to the grid terminals or pigtail wires and verify EBL operation.

SWITCH, DEFOGGER, REAR DESCRIPTION user Monday, June 04, 2012 9:45:12 AM

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DESCRIPTION

Fig. 5: EBL Switch (MTC) Courtesy of CHRYSLER LLC NOTE:

Manual tri-zone temperature A/C-heater control shown in illustration. Other A/Cheater controls similar.

The momentary push-button switch (1) for the rear window defogger (EBL) system is located in the A/C-heater control (2) in the center of the instrument panel. An amber indicator (3) will illuminate to indicate when the EBL system is turned on. OPERATION OPERATION

An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE:

The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes.

The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. user Monday, June 04, 2012 9:45:12 AM

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The rear window defogger switch is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC Diagnosis and Testing . The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is inoperative or damaged. Refer to Heating and Air Conditioning/Controls/CONTROL, A/C and Heater - Removal .

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2009 ACCESSORIES AND EQUIPMENT Heated Mirrors - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Rear Window Defogger (EBL) System Courtesy of CHRYSLER LLC NOTE:

Manual tri-zone temperature A/C-heater control shown. Other A/C-heater controls similar.

When equipped, the heated mirror system operates in concert with the rear window defogger (EBL) system and is controlled by the rear window defogger switch (1) located in the A/C-heater control (2) in the center of the instrument panel. An amber indicator lamp (3) in the rear window defogger switch will illuminate to indicate when the heated mirror system is turned on. The heated mirror system will be automatically turned off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the heated mirror system will automatically turn off after about 5 minutes. The heated mirror system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. Circuit protection for the heated mirror system is provided by a fuse located in the totally integrated power module (TIPM).

OPERATION user Monday, June 04, 2012 9:42:40 9:42:37 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Heated Mirrors - Service Information - Journey

OPERATION When equipped, the heated mirror system is activated when the rear window defogger (EBL) system is turned on. Refer to Electrical - Heated/Cooled Systems/Heated Glass - Operation . When the heated mirror system is activated, an electric heater grid located behind the glass of each outside rear view mirror becomes energized and produces heat to help clear the mirror of ice, snow, or fog. If the outside mirror heating grids are both inoperative. Refer to Electrical - Heated/Cooled Systems/Heated Glass - Diagnosis and Testing . The heating grid behind each outside mirror glass cannot be repaired and the mirror assembly must be replaced if the heating grid is found inoperative or damaged. Refer to Body/Exterior/MIRROR, Outside Rearview Removal .

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Heated Seats - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Heated Seats - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Accessory Switch Bank Module Courtesy of CHRYSLER LLC Vehicles with the heated seat option can be visually identified by the two heated seat switches (1) located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM is located just below the vents and just above the heater and air conditioner controls in the center stack area of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system includes the following major components: z

z

z

z

Heated Seat Elements - Four heated seat elements are used per vehicle. Two heated seat elements are integral to each seat, one in the seat back and the other in the seat cushion. Heated Seat Module - One heated seat module is used per vehicle. The Heated Seat Module is mounted under the Driver front seat. This module contains the control logic and software for the front heated seat system. The module communicates on the Local Interface Network (LIN) data bus. Heated Seat Switches - Two heated seat switches are used per vehicle, one for each heated seat. Both switches are integral to the ASBM mounted in the instrument panel center stack. Instrument Cluster (CCN) - The instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) utilizes integrated software and information carried on the LIN data bus. The CCN serves as the link between the heated seat switches and the heated seat module.

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OPERATION OPERATION

Fig. 2: Locating Heated Seat Module Courtesy of CHRYSLER LLC The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (Run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the ON position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except ON. A Heated Seat Module (2) is used to control the heated seat system. The module is located under the driver front seat mounted to the seat pan (4). The heated seat module responds to heated seat switch messages and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays.

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Fig. 3: Accessory Switch Bank Module Courtesy of CHRYSLER LLC When either of the heated seat switches (1) are depressed a switch status message is sent to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The heated seat module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after 26 minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting also turns off automatically after 30 minutes. The module will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit.

DIAGNOSIS AND TESTING HEATED SEAT SYSTEM In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. user Monday, June 04, 2012 9:33:34 AM

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Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE:

Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative.

Before any testing of the heated seat system is attempted, the battery should be fully-charged.

MODULE, HEATED SEAT DESCRIPTION DESCRIPTION

Fig. 4: Locating Heated Seat Module Courtesy of CHRYSLER LLC The heated seat module (2) is located under the driver front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan (4). The module can be accessed from under the Driver seat with the seat in the full back and up position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. OPERATION user Monday, June 04, 2012 9:33:34 AM

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OPERATION

The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate Diagnostic Trouble Code (DTC). DIAGNOSIS AND TESTING HEATED SEAT MODULE

In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE:

Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative.

Before any testing of the heated seat system is attempted, the battery should be fully-charged. REMOVAL REMOVAL

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Fig. 5: Locating Heated Seat Module Courtesy of CHRYSLER LLC CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. 2. 3. 4. 5.

Position the driver front seat to the full rearward position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector (4) from the heated seat module (3). Unsnap the heated seat module retaining tab (2) from the seat pan (1). Remove the heated seat module (3) from the vehicle.

INSTALLATION INSTALLATION

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Fig. 6: Locating Heated Seat Module Courtesy of CHRYSLER LLC CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation.

PAD, HEATER DESCRIPTION DESCRIPTION

Vehicles equipped with the optional heated seat system have two carbon fiber heated seat elements located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat elements consist of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element user Monday, June 04, 2012 9:33:34 AM

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assembly must be installed. OPERATION OPERATION

One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat module. The heated seat module will energize the heated seat element when the heated seat switch is depressed in the LOW or HIGH position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. DIAGNOSIS AND TESTING HEATED SEAT ELEMENT

Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors for the heating elements are located under the seat. NOTE:

When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test.

1. Locate and disconnect the seat element electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.0 - 5.5 ohms for a seat cushion element and 4.0 - 6.0 ohms for a seat back element. If OK, see Diagnosis and Testing . If not OK, replace the inoperative heated seat element. REMOVAL REMOVAL

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Fig. 7: Removing/Installing Heated Seat Element Courtesy of CHRYSLER LLC NOTE:

The factory installed heating element can be removed from foam cushion by carefully peeling the element off along the adhesive lines.

NOTE:

Heated seat cushion shown in illustration. Heated seat back similar.

1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat cushion trim cover or seat back trim cover. Refer to Body/Seats/COVER, Seat Cushion - Removal . Refer to Body/Seats/COVER, Seat Back - Removal . 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Peel the heater element off the foam pad, being careful not to remove excessive foam in the process. INSTALLATION INSTALLATION

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Fig. 8: Identifying Replacement Heating Element And Factory Installed Heating Element Courtesy of CHRYSLER LLC CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. NOTE:

Heated seat cushion shown in illustration. Heated seat back similar.

1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick on foam pad directly where the original element was placed (there will be adhesive marks on the foam outlining factory installed element) (1).

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Fig. 9: Connecting New Heating Element Electrical Connectors Courtesy of CHRYSLER LLC 2. 3. 4. 5.

Connect the new heating element electrical connectors (3 AND 4). Connect the battery negative cable. Verify heated seat system operation. Install the appropriate seat cushion trim cover or seat back trim cover. Refer to Body/Seats/COVER, Seat Cushion - Installation . Refer to Body/Seats/COVER, Seat Back - Installation . NOTE:

Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. The factory installed heater element should be completely removed from the system and discarded.

SWITCH, HEATED SEAT DESCRIPTION DESCRIPTION

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Fig. 10: Locating Accessory Switch Bank Module Courtesy of CHRYSLER LLC Two heated seat switches are located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM (3) is located just below the radio (1) and just above the heater and air conditioner controls (2) in the center stack area of the instrument panel. If either of the switches is damaged or inoperative the complete ASBM assembly must be replaced.

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Fig. 11: Identifying Assembly Switch Bank Module Callouts Courtesy of CHRYSLER LLC Each heated seat switch (4) provides a resistor-multiplexed signal to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). Amber Light Emitting Diodes (LEDs) on the outside edge of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete ASBM assembly must be replaced. See Removal . OPERATION OPERATION

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Fig. 12: Identifying Assembly Switch Bank Module Callouts Courtesy of CHRYSLER LLC The heated seat switches (4) are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. DIAGNOSIS AND TESTING HEATED SEAT SWITCH

In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE:

Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical

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system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. REMOVAL REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. NOTE:

The heated seat switches are integral to the Accessory Switch Bank Module (ASBM) and cannot be serviced separately. The complete ASBM assembly must be replaced.

Fig. 13: Removing/Installing Assembly Switch Bank Module (ASBM) Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Remove the four screws (1) that secure the ASBM (2) to the back of the instrument panel center bezel (3) and remove the ASBM. INSTALLATION INSTALLATION

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Fig. 14: Removing/Installing Assembly Switch Bank Module (ASBM) Courtesy of CHRYSLER LLC NOTE:

There are different Accessory Switch Bank Module (ASBM) configurations available based on the option content of the vehicle. Ensure the ASBM being installed matches the vehicle options.

1. Position the ASBM (2) onto the back of the instrument panel center bezel (3). 2. Install the four screws (1) that secure the ASBM to the center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Install the center bezel onto the instrument panel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Installation . 4. Connect the battery negative cable. 5. Verify heated seat system operation.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Horn System - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Horn System - Service Information - Journey

DESCRIPTION DESCRIPTION The dual-note horn system features two electromagnetic horn units. The horn system includes the following major components: z z

Horn - The two horns are located at the front center of the vehicle, behind the grille. Horn Switch - The horn switch is mounted under the driver airbag. It consists of four pads that make contact when the horn is pressed.

Vehicles with an optional Electronic Vehicle Information Center (EVIC) and steering wheel mounted switches (except LX) have a unique horn switch electrical architecture. For more information on the EVIC. Refer to Electrical - Message Systems/Message Center/CENTER, Electronic Vehicle Information - Description .

OPERATION OPERATION The horn system operates on battery current received through a fuse located in the Totally Integrated Power Module (TIPM). The horn system circuit is designed so that the system will remain operational, regardless of the ignition switch position. On vehicles equipped with an optional Electronic Vehicle Information Center (EVIC), the right EVIC switch is also a Local Interface Network (LIN) bus slave, sharing a LIN input circuit with the Steering Control Module (SCM) within the left multifunction switch, to the CCN (LIN master). Both the right and left EVIC switches also share an IOD feed and a ground feed in common with the SCM. On vehicles with an EVIC, the right EVIC switch microprocessor is connected to and monitors the outputs of the left EVIC switch. The right EVIC switch also is connected to the horn switch and the remote radio switches through a common sensor signal circuit. The right EVIC switch monitors the horn switch state through a dedicated return circuit and monitors the resistor multiplexed remote radio switches through a second dedicated return circuit. Finally, the right EVIC microprocessor communicates the status of each and every one of these switches to the CCN over the LIN data bus.

DIAGNOSIS AND TESTING HORN SYSTEM The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. user Monday, June 04, 2012 9:44:23 9:44:20 AM

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Refer to the appropriate wiring information. In most cases, any problem involving continually sounding horns can be quickly alleviated by removing the horn fuse from the Totally Integrated Power Module (TIPM). 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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. HORN SYSTEM TEST TABLE CONDITION HORN SOUNDS CONTINUOUSLY.

POSSIBLE CAUSE 1. Horn control circuit shorted to ground.

NOTE: IMMEDIATELY UNPLUG HORN 2. Pinched horn switch wire under driver airbag module. 3. Inoperative horn switch HORN SOUND INTERMITTENTLY AS 1. Pinched horn switch THE STEERING WHEEL IS TURNED. wire under driver airbag. 2. Inoperative horn switch. HORN DOES NOT SOUND 1. Blown fuses in the TIPM. 2. No voltage at horn and fuse is OK. 3. Open circuit from TIPM to horn switch. 4. Inoperative or damaged horn. 5. Inoperative horn switch 6 Inoperative Right EVIC switch. FUSE BLOWS WHEN THE HORN 1. Short circuit in horn SWITCH IS PRESSED or horn wiring FUSE BLOWS WITHOUT PRESSING

1. Short circuit within

CORRECTION 1. Find the short and repair as necessary. 2. Replace the horn switch. 3. Replace the horn switch. 1. Replace the horn switch. 2. Replace the horn switch. 1. Replace fuses 22 and 23 in the TIPM. 2. Repair TIPM or circuit x2 as necessary. 3. Repair circuit x3 as necessary. 4. Replace horn. 5. Replace the horn switch. 6. Replace the Right EVIC switch. 1. Check for shorted horn or horn wiring. Disconnect horn wire harness to isolate short and repair as necessary. 1. Check for short and repair as

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THE HORN SWITCH NOTE: FOR WIRING REPAIRS REFER TO THE APPROPRIATE WIRE DIAGRAMS.

the TIPM

necessary.

-

-

HORN REMOVAL REMOVAL

Fig. 1: Removing / Installing Horns Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Disconnect and isolate the negative battery cable. Remove the push pin type retainers along the top of the grille assembly and position the grille aside. Disconnect the wire harness connectors (3) from the horns (2). Remove mounting bolt (1) securing the horn bracket and remove horns.

INSTALLATION INSTALLATION

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Fig. 2: Removing / Installing Horns Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Install the horn assemblies (2). Install the horn mounting bolt (1). Connect the wire harness connector (3). Position the grille and install the retainers. Connect the negative battery cable.

SWITCH, HORN REMOVAL REMOVAL

WARNING: On vehicles equipped with an airbag, refer to Restraint SERVICE INFORMATION article for warnings and cautions before servicing the horn switch.

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Fig. 3: Removing Horn Switch Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Disconnect and isolate the battery negative cable. Remove the driver airbag. Refer to Restraints/AIR BAG, Driver - Removal . Disconnect the connector from the clockspring. Remove the three mounting fasteners. Remove the horn switch.

INSTALLATION INSTALLATION

Fig. 4: Installing Horn Switch Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:44:20 AM

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1. 2. 3. 4. 5.

Install the horn switch. Install the three mounting fasteners. Connect the electrical connector to the clockspring. Install the driver airbag. Refer to Restraints/AIR BAG, Driver - Installation Connect the battery negative cable.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Instrument Cluster - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Instrument Cluster - Service Information - Journey

DESCRIPTION DESCRIPTION The instrument cluster contains the necessary hardware and software to serve as the vehicle electronic body control module and is commonly referred to as the Cab Compartment Node (CCN). The CCN utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus and the Local Interface Network (LIN) data bus, along with several hardwired analog and multiplexed inputs to monitor sensors and switches throughout the vehicle. The CCN also contains various indicators, analog gauges, and a standard bluegreen digital Vacuum Fluorescent Display (VFD) unit. The standard VFD is a fixed segment unit that displays odometer information, automatic transmission gear selector position (PRNDL), and several other indicators, some of which are model dependant. There are several versions of the CCN offered for this vehicle. These versions accommodate all of the variations of optional equipment for the various markets in which the vehicle is offered. The CCN may also contain a separate reconfigurable blue-green digital VFD unit that has either a Compass Mini-Trip Computer (CMTC) option or an Electronic Vehicle Information Center (EVIC) option. Both of these options provide the outside ambient temperature, compass headings, average fuel economy, and elapsed time. The EVIC option also offers a user interface for customer programmable features, audio system setting displays, numerous textual warnings, reminder indicators, and certain diagnostic information. A dedicated Light Emitting Diode (LED) soldered onto the circuit board illuminates each indicator in the CCN, except those within a VFD unit. Several dimmable LED units illuminate each gauge dial face for visibility when the exterior lighting is turned on. These LED units are not available for service replacement and, if damaged or ineffective, the entire CCN must be replaced. The CCN is serviced only as a complete unit and cannot be adjusted or repaired. If a gauge, LED unit, VFD unit, electronic circuit board, circuit board hardware, cluster overlay, or cluster housing is damaged or ineffective, the entire CCN must be replaced. The cluster lens is available for separate service replacement.

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Fig. 1: Mechanical Instrument Cluster Courtesy of CHRYSLER LLC The mechanical instrument cluster is an electromechanical module that receives most of its information directly from the various control modules, with the data bus. The cluster includes: z z z z

A speedometer (10) A tachometer (14) A fuel gauge (2) A coolant Temperature gauge (1)

The warning and information indicators include the following: z z z z z z z z z z z

Coolant temperature warning (4) Front fog lamp indicator, front (5), and rear (7) (export only) Low fuel (6) Turn signal indicator (8) High beam (9) Vehicle theft security system alarm LED indicator (if equipped) (11) All-Wheel Drive (AWD) failure indicator (12) Front position lamps (13) (export only) Transaxle range indicator (15) Seat belt reminder (16) Odometer/Trip odometer (17)

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z z z z z

z z z z z z z z z z

Electronic Throttle Control (ETC) warning lamp (18) Low oil pressure (19) Charging system (20) Cruise (if equipped) (21) Trip odometer reset button (cycle to change display; Trip A, Trip B, Outside Temperature for base vehicle) (22) Tire Pressure Monitoring (TPM) (23) Wait to Start Indicator (Export Diesel) (24) Anti-lock brake system (If equipped) (25) Electronic Stability Program (ESP) and Traction Control System (TSC) (26) Check engine (27) Electronic Stability Program (ESP) and / Brake Assist System (BAS) Malfunction Lamp (28) Brake/park brake warning (29) (Export will display an ICON) Airbag (30) Compass/Temp display and calibrate button (CMTC Only) (31) Vacuum Fluorescent Display (VFD) (32) (if equipped) - For CMTC option, use 31 Compass/Temp display and calibrate button to interface with display. For EVIC option, use front mounted steering wheel switches to interface with display.

Vehicle Warning Messages

When the appropriate conditions exist, messages such as "HOOD" (hood ajar), "DOOR" (door ajar), "GATE" (liftgate ajar), "LoCOOL" (low engine coolant), "LoWASH" (low washer fluid), "GASCAP" (fuel cap fault), "ESPOFF" (ESP in partial off mode), "NoBUS" (data bus communication fault), "NoFUSE" (IOD fuse out), "HotOIL" (2.4L engine oil temp too hot), or "CHANGE OIL" displays in the odometer. Change Oil Message (Base and mid line clusters only)

Your vehicle is equipped with an engine oil change indicator system. The "CHANGE OIL" message flashes in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message continues to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the TRIP ODOMETER button on the instrument cluster. To reset the oil change indicator system, (after performing the scheduled maintenance) perform the following procedure: 1. Turn the ignition switch to the ON position. (Do not start the engine). 2. Fully press the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the LOCK position.

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NOTE:

If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure

OPERATION OPERATION The instrument cluster contains the necessary hardware and software to serve as the vehicle's electronic body control module and is commonly referred to as the Cab Compartment Node (CCN). The following information deals primarily with the instrument cluster functions of this unit. Additional details of the electronic body control functions may be found within the service information for the system or component that the CCN controls. For example, additional details of the audible warning functions of the CCN are found within the CHIME/BUZZER - SERVICE INFORMATION . The CCN is designed to allow the vehicle operator to monitor the conditions of many of the vehicle components and operating systems. The gauges and indicators in the CCN provide valuable information about the various standard and optional powertrains, fuel and emissions systems, cooling systems, lighting systems, safety systems and many other convenience items. The CCN is installed in the instrument panel so that the operator of the vehicle can view all of these monitors easily, yet still allow relative ease of access for service. The microprocessor-based CCN hardware and software uses various inputs to control the gauges and indicators visible on the face of the cluster. Some of these inputs are hard wired, but most are in the form of electronic messages that are transmitted by other electronic modules over the Controller Area Network (CAN) data bus and the Local Interconnect Network (LIN) data bus. The CCN is the master of the LIN bus. These four modules talk to the CCN: The Heated Seat Module (HSM); the Remote Compass Module (RCM); the Steering Control Module (SCM); and the Accessory Switch Bank Module (ASBM). Refer to Electrical - Electronic Control Modules/Electronic Control Modules/COMMUNICATION - Operation . The CCN microprocessor smooths the input data using algorithms to provide gauge readings that are accurate, stable, and responsive to operating conditions. These algorithms are designed to provide gauge readings during normal operation that are consistent with customer expectations. However, when abnormal conditions exist such as high coolant temperature, the algorithm can drive the gauge pointer to an extreme position and the microprocessor can sound a chime through the on-board audible tone transducer to provide distinct visual and audible indications of a problem to the vehicle operator. The CCN may also produce audible warnings for other electronic modules in the vehicle based upon electronic tone request messages received over the CAN/LIN data bus. Each audible warning is intended to provide the vehicle operator with an audible alert to supplement a visual indication. The CCN circuitry operates on battery current received through a fused B(+) fuse on a non-switched fused B(+) circuit, and on battery current received through a fused ignition switch output (run-start) fuse on a fused ignition switch output (run-start) circuit. This arrangement allows the/CCN to provide some features regardless of the ignition switch position, while other features will operate only with the ignition switch in the On or Start positions. The CCN circuitry is grounded through a ground circuit of the instrument panel wire harness. The CCN also has a self-diagnostic actuator test capability that tests each of the CAN bus message-controlled functions of the cluster. This test illuminates the appropriate indicators, positions the gauge needles at several predetermined calibration points across the gauge faces, and illuminates all segments of the odometer/trip user Monday, June 04, 2012 9:46:10 AM

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odometer/gear selector indicator Vacuum-Fluorescent Display (VFD) unit and Electronic Vehicle Information Center (EVIC). The EVIC will display the hardware/software version, and the CAN and LIN Vehicle Maintenance Monitor (VMM) used in the CCN. See Diagnosis and Testing . The CCN collects data and provides control signals for the following electrical equipment via the CAN data bus: z z z z z z z z z z z z z z z z z z z

Gauges Interior lighting controls Variable-intensity cluster lighting and illumination of instrument panel mounted equipment Vehicle Theft Alarm and Sentry Key Theft Deterrent System Power door lock system controls (automatic locking, and Remote Keyless Entry locking and unlocking) Headlamp switch actuation signal Steering wheel radio actuation signals Accessory power delay relay control Wiper control Turn signal flasher audible click Heated seat actuation signal (if equipped) UConnect® Hands-Free, Voice-Actuated Communication system actuation signal (if equipped) Display of the outputs for the HomeLink® universal home security system and compass (if equipped) Illuminated entry system Key-in-ignition warning chime Seat belt warning chime and lamp (Including BeltAlert®) Door ajar warning indicator Liftgate/trunk ajar warning indicator LIN master module

The CCN also provides the following enhancements to the above features: z z

z z z

z

Time-out for interior lamps left on inadvertently Driver programmability of the power locks to unlock only the driver's door or all doors with the first actuation of the RKE unlock button Ability to program vehicle response to lock and unlock commands from the RKE transmitter The improved BeltAlert® seatbelt warning indication Filtering of input signals to the fuel gauge, temperature gauge, and speedometer to avoid sudden, unexpected pointer movements Headlamp control for turning the headlamps on if the windshield wipers are operated in daylight as required by law in some states

GAUGES user Monday, June 04, 2012 9:46:10 AM

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All gauges receive battery current through the CCN circuitry only when the ignition switch is in the On or Start positions. With the ignition switch in the Off position, battery current is not supplied to any gauges, and the CCN circuitry is programmed to move all of the gauge needles back to the low end of their respective scales. Therefore, the gauges do not accurately indicate any vehicle condition unless the ignition switch is in the On or Start positions. All of the CCN gauges are stepper motors. The gauges are diagnosed using the CCN self-diagnostic actuator test. See Diagnosis and Testing . Proper testing of the CAN data bus and the electronic data bus message inputs to the CCN that control each gauge require the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. Specific operation details for each gauge may be found elsewhere in this service information. VACUUM-FLUORESCENT DISPLAYS

The Vacuum-Fluorescent Display (VFD) units are soldered to the CCN electronic circuit board. With the ignition switch in the Off or Accessory positions, the standard left and optional right VFD displays are activated when the driver door is opened and is deactivated when the driver door is closed. Otherwise, the display units are active when the ignition switch is in the On or Start positions, and inactive when the ignition switch is in the Off or Accessory positions. The illumination intensity of the VFD units are controlled by the CCN circuitry based upon an input from the headlamp switch and a dimming level input received from the panel dimmer switch. The CCN synchronizes the illumination intensity of other VFD units with that of the unit in the CCN by sending electronic dimming level messages to other electronic modules in the vehicle over the CAN/LIN data bus. The CCN VFD units have several display capabilities. The standard VFD unit displays odometer, trip odometer, engine hours, gear selector indication (PRNDL) for models with an automatic transmission, several warning or reminder indications, and various diagnostics information when certain fault conditions exist. An odometer/trip odometer switch on the CCN circuit board is used to control some of the display modes of the standard VFD. This switch is actuated manually by depressing the odometer/trip odometer switch button, which extends through the cluster lens below the speedometer at the bottom right hand side. Actuating this switch momentarily with the ignition switch in the On position will toggle the VFD between odometer, trip odometer modes, and outside ambient temperature (for base vehicle only). Depressing the switch button for about two seconds while the VFD is in the trip odometer mode will reset the trip odometer value to zero. The optional VFD unit on the left hand side displays the Compass Mini-Trip Computer (CMTC) or the Electronic Vehicle Information Center (EVIC). The left switch button, which extends through the cluster lens below the speedometer at the bottom left hand side, is used as a STEP button for the CMTC display and for customer programmable features. Refer to Electrical - Message Systems/Message Center/CENTER, Electronic Vehicle Information - Operation . The front mounted steering wheel switches are used to interface with the EVIC display. NOTE:

If the vehicles OnBoard Diagnostic (OBD) system determines that the fuel filler cap is loose, improperly installed, or damaged; a "GASCAP" message will be displayed in the Odometer/Trip Odometer. In this instance, tighten the fuel filler cap and press the odometer/trip odometer reset button once to turn the message OFF. The key must be in the Run/Start position during the reset, or you may just cycle the key. If left loose for three trips, or key cycles, a DTC will set and the MIL lamp will illuminate.

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Holding the right switch depressed while turning the ignition switch from the Off position to the On position will initiate the CCN self-diagnostic actuator test. Refer toDiagnosis and Testing service information for additional details on this cluster function. The CCN microprocessor remembers which display mode is active when the ignition switch is turned to the Off position, and returns the VFD display to that mode when the ignition switch is turned On again. The VFD unit is diagnosed using the CCN self-diagnostic actuator test. See Diagnosis and Testing . Proper testing of the CAN data bus and the electronic data bus message inputs to the CCN that control some of the VFD functions requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. Specific operation details for the odometer, the trip odometer, the gear selector indicator, and the various warning and reminder indicator functions of the VFD unit may be found elsewhere in this service information. Refer to the vehicle owner's manual for further information on various readout messages. ODOMETER/TRIP ODOMETER DISPLAY

The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. The engine hours give an indication of the cumulative engine-ON time. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) or Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The odometer/trip odometer will display some warning messages such as "DOOR" and "GATE" ajar. If equipped with the optional Electronic Vehicle Information Center (EVIC), the EVIC will display all messages except GASCAP. The odometer, trip odometer, and engine hours information is displayed by the instrument cluster Vacuum Fluorescent Display (VFD). The VFD will display the odometer information whenever the driver side front door is opened with the ignition switch in the OFF or ACCESSORY positions, and will display the last previously selected odometer or trip odometer information when the ignition switch is turned to the ON or START positions. If your vehicle is equipped with an engine oil change indicator system, the "Change Oil" message will flash in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The instrument cluster circuitry controls the VFD and provides the following features: z

z

z

Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the ON or START positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for 10 seconds with the ignition switch in the ON position and the engine not running and the engine speed message from the PCM is zero, the trip odometer information will be momentarily displayed, then the engine hours information will be displayed. The VFD must be displaying the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours will remain displayed for about 30 seconds, until the engine speed message is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the ON or START position, the trip odometer will reset to

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z

z

z

z

0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to reset. GASCAP Message Display - For vehicles manufactured with a United States country code, each time the cluster receives an electronic message from the PCM indicating a monitored leak in the evaporative emissions system the cluster replaces the displayed odometer/trip odometer value with the textual message, GASCAP . This message serves as a reminder to the vehicle operator to check that the gas cap is properly installed and tightened, but could also indicate another source of air leakage in the on-board evaporative and vapor recovery emissions systems. Unless the leak is corrected, this message will latch and remain displayed during the current and each subsequent ignition cycle until the trip odometer reset button is pressed and released momentarily, which will revert the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. Once the source of a leak has been corrected, the GASCAP message display will stay illuminated until the evaporative emission system runs the next leak check and passes. Change Oil Indicator A change oil indicator is standard equipment on all instrument clusters built for the US market. The change oil indication appears within the fixed segment odometer Vacuum Fluorescent Display (VFD) unit on vehicles not equipped with an optional Electronic Vehicle Information Center (EVIC). On vehicles equipped with the optional EVIC, the change oil indication in the odometer VFD is electronically suppressed so as not to duplicate indications that are provided by the EVIC. The odometer VFD change oil indicator consists of cycling textual CHANGE then OIL messages, which appear in place of the odometer/trip odometer information. The EVIC change oil indicator consists of a textual Oil Change Required message that appears within the EVIC VFD Communication Error - If the cluster fails to receive an electronic distance message during normal operation, it will hold and display the last data received until the ignition switch is turned to the OFF position. If the cluster does not receive a distance message within one second after the ignition switch is turned to the ON position, it will display the last distance value stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD will display Error . Actuator Test - Each time the cluster is put through the actuator test, the odometer VFD will display all of its segments simultaneously, and then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry.

The PCM continually monitors the vehicle speed pulse information received from the Vehicle Speed Sensor (VSS) or the Controller Anti-lock Brake (CAB) and engine speed pulse information received from the crankshaft position sensor, and then sends the proper messages to the CCN. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions. See Diagnosis and Testing . For proper diagnosis of the VSS, the crankshaft position sensor, the CAB, the PCM, the CAN data bus, or the electronic communication related to odometer/trip odometer operation a diagnostic scan tool is required. Refer to the appropriate diagnostic service information. COMPASS MINI-TRIP COMPUTER (CMTC) DISPLAY

The CMTC system conveniently allows the driver to select a variety of useful information by pressing the Compass/Temp Display and Calibrate button, which extends through the cluster lens below the speedometer at the bottom left hand side. The CMTC displays the following information: user Monday, June 04, 2012 9:46:10 AM

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z z z z

Compass display Outside temperature display Trip computer functions Elapsed time

For additional information. Refer to Electrical - Message Systems/Message Center/CENTER, Electronic Vehicle Information - Operation . ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) DISPLAY

The EVIC system conveniently allows the driver to select a variety of useful information by pressing the MENU button and STEP/SELECT button, which are located on the front of the steering wheel. The EVIC displays information related to the following: z z z z z z z z z

Audio mode display Compass display Navigation system screens (if equipped) Outside temperature display Personal Settings (customer programmable features) System Status Trip computer functions UConnect™ hands-free communication system displays (if equipped) Vehicle information warning message displays

For additional information. Refer to Electrical - Message Systems/Message Center/CENTER, Electronic Vehicle Information - Operation . INDICATORS

Indicators are located in various positions within the CCN and are all connected to the CCN electronic circuit board. All indicators, except the inverter indicator (if equipped), are controlled by CAN data bus messages. The brake indicator is controlled by CAN data bus messages from the Controller Antilock Brake (CAB) as well as by hard-wired park brake switch inputs to the CCN. The seatbelt indicator is controlled by the CCN and is turned on and off depending upon the CAN message received. The Malfunction Indicator Lamp (MIL) is normally controlled by CAN data bus messages from the Powertrain Control Module (PCM); however, if the CCN loses CAN data bus communication, the CCN circuitry will automatically turn the MIL on and display NoBUS in the right VFD until CAN data bus communication is restored. The CCN uses CAN data bus messages from the Totally Integrated Power Module (TIPM), the ORC, the CAB, and the Sentry Key Remote Entry Module (SKREEM) to control all of the remaining indicators. The various CCN indicators are controlled by different strategies. Some receive fused ignition switch output from the CCN circuitry and have a switched ground. Others are grounded through the CCN circuitry and have a switched battery feed. However, all indicators are completely controlled by the CCN microprocessor based upon various hard wired and electronic message inputs. The cruise indicator located within the VFD unit is user Monday, June 04, 2012 9:46:10 AM

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dimmable. All other indicators are illuminated at a fixed intensity, which is not affected by the selected illumination intensity of the CCN general illumination LED's. The illumination intensity of the dimmable indicators is synchronized with that of the CCN general illumination LED's. In addition, certain indicators in this instrument cluster are automatically configured or self-configured. This feature allows the configurable indicators to be enabled by the CCN circuitry for compatibility with certain optional equipment. The CCN defaults for the ABS indicator and airbag indicator are enabled, and these configuration settings must be programmatically disabled in the CCN using a diagnostic scan tool for vehicles that do not have this equipment. The automatically configured or self-configured indicators remain latent in each CCN at all times and will be active only when the CCN receives the appropriate CAN message inputs for that optional system or equipment. The hard-wired indicator inputs may be diagnosed using conventional diagnostic methods. However, the CCN circuitry and CAN/LIN bus message controlled indicators are diagnosed using the CCN self-diagnostic actuator test. Some indicators are requested to be turned on via the LIN bus. See Diagnosis and Testing . Proper testing of the CAN/LIN data bus and the electronic message inputs to the CCN that control an indicator requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. Specific details of the operation for each indicator may be found elsewhere in this service information. CLUSTER ILLUMINATION

The CCN has several illumination lamps that are illuminated whenever the exterior lighting is turned On. The illumination intensity of these lamps is adjusted when the left multifunction dimming control ring is rotated (down to dim, up to brighten) to one of five available minor detent positions. The CCN monitors a resistormultiplexed input from the headlamp switch on a dimmer input circuit. In response to that input, the CCN electronic circuitry converts a fused 12-volt input it receives on a hard-wired panel lamps dimmer switch signal circuit into a 12-volt Pulse Width Modulated (PWM) output. The CCN uses this PWM output to control the illumination intensity of the cluster, the instrument panel center stack illumination, and the VFD unit on the CCN circuit board. The CCN also transmits electronic dimming level messages over the LIN data bus to other electronic modules (such as the ASBM, HVAC control head, the radio, and the clock) in the vehicle to control and synchronize their illumination intensity. In addition, the dimming control ring on the headlamp switch has a Parade Mode position to provide a parade or funeral mode. The CCN monitors the request for this mode from the headlamp switch, then transmits an electronic dimming level message to illuminate all VFD units in the vehicle at full (daytime) intensity for easier visibility when driving in daylight with the exterior lighting turned on. The hard-wired headlamp switch and panel lamps dimmer inputs to and outputs from the CCN may be diagnosed using conventional diagnostic methods. However, proper testing of the PWM processing of the CCN and the electronic dimming level messages sent by the CCN over the CAN data bus requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information.

DIAGNOSIS AND TESTING INSTRUMENT CLUSTER user Monday, June 04, 2012 9:46:10 AM

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As a quick diagnosis, the cluster will perform a functional check of the odometer display, transmission range display and warning indicators after the ignition is switched to RUN/START. If the cluster is not receiving any bus messages, the cluster will appear non-functional and "no bus" will appear in the odometer display. A self-test of the cluster can also be initiated by pressing and holding the odometer reset button and switching the ignition from lock to unlock. The cluster will then step through several displays for functional verification. By pressing the trip odometer reset button while going through the self-test, you can temporarily freeze the test. Pressing the bottom again will continue sequence. The cluster will store bus communication faults with other modules. It will also store faults for the AIRBAG and ABS lamps. During the self-diagnostics, the AIRBAG and ABS lamps are tested. If the cluster is not functioning properly, refer to BODY article. If the cluster is not receiving bus messages, refer to BODY article. In order to diagnose the instrument cluster functions, a scan tool and the proper Body Diagnostic article are required. If the diagnostic procedure determines that a replacement of an instrument cluster component is required, refer to Removal and Installation .

REMOVAL REMOVAL

Fig. 2: Instrument Cluster Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. NOTE:

The left hand side of the instrument cluster trim bezel is under the AC vent

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on the inboard side. When removing the instrument cluster trim bezel, it may be necessary to flex the AC vent slightly to relieve the bezel from under the AC vent. 2. Remove the instrument cluster trim bezel using a trim stick or equivalent and gently prying at point (1).

Fig. 3: Instrument Cluster Courtesy of CHRYSLER LLC 3. Remove the four attaching screws (1) from the cluster.

Fig. 4: Instrument Cluster & Electrical Connectors Courtesy of CHRYSLER LLC 4. Pull the cluster forward and disconnect the two electrical connectors (1). user Monday, June 04, 2012 9:46:10 AM

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5. Remove the cluster from the instrument panel.

INSTALLATION INSTALLATION

Fig. 5: Instrument Cluster & Electrical Connectors Courtesy of CHRYSLER LLC 1. Carefully slide the cluster into its location and connect the two electrical connectors (1) to the cluster.

Fig. 6: Instrument Cluster Courtesy of CHRYSLER LLC 2. Position the cluster in the instrument panel and Install the four cluster attaching screws (1). user Monday, June 04, 2012 9:46:10 AM

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Fig. 7: Instrument Cluster Courtesy of CHRYSLER LLC NOTE:

When installing the cluster trim bezel, be sure to place the left hand side of the bezel underneath the AC vent. It may be necessary to flex the trim on the AC vent slightly to allow the cluster trim bezel locking clips secure entry into the instrument panel.

3. Install the cluster trim bezel. 4. Connect the battery negative cable.

LENS, INSTRUMENT CLUSTER REMOVAL REMOVAL

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Fig. 8: Instrument Cluster Lens Locking Tabs Courtesy of CHRYSLER LLC 1. Remove instrument cluster from vehicle. See Removal . 2. Separate the lens from the cluster by gently prying on the locking clips (1) around the perimeter of the lens. 3. Separate lens from instrument cluster and remove. INSTALLATION INSTALLATION

Fig. 9: Instrument Cluster Lens Locking Tabs Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:46:10 AM

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1. Align lens locking tabs (1) with instrument cluster mask assembly and snap securely into place. 2. Install the instrument cluster into vehicle. See Installation . 3. Connect battery negative cable.

POD, SWITCH DESCRIPTION DESCRIPTION

Fig. 10: Accessory Switch Bank Module Courtesy of CHRYSLER LLC The Accessory Switch Bank Module (ASBM) is located in the center stack area of the instrument panel just below the heater and air conditioner duct and above the radio. This switch is available in multiple configurations, which vary from a single momentary push button switch to as many as six momentary push button switches, depending upon the optional equipment in the vehicle. The pod may include the following switches: z z z z z

Heated Seats (if equipped) (1) Electronic Stability Program Off (2) Hazard Warning (3) Headlamp Leveling (export only) (4) Electrical Inverter On/Off (domestic only) (5)

The switch housing and the push buttons are constructed of molded plastic. Each push button has a smooth finish and is clearly identified with the appropriate text and International Control and Display Symbol icons. Several of the push buttons feature Light Emitting Diode (LED) units to give the vehicle operator an indication when the function of that switch is currently active. user Monday, June 04, 2012 9:46:10 AM

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Four screws secure the switch to the back of the instrument panel center bezel through integral mounting tabs that are molded into each corner of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch provide back lighting for visibility at night, but these lamps are not serviceable. The individual switches in the ASBM cannot be repaired and are not serviced individually. If any component within the switch pod is ineffective or damaged, the entire switch pod must be replaced. The Domestic version of the ASBM is as follows: z

z z

z

Heated Seat Switches (if equipped) -. Refer to Electrical - Heated/Cooled Systems/Heated Seats/SWITCH, Heated Seat - Description . ESP Off -. Refer to Brakes - Description . Hazard Switch (all models) -. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/SWITCH, Hazard Warning - Description . Electrical Inverter (domestic models).

The Export version of the ASBM will vary from the domestic: z

z

z

Heated Seat Switches (if equipped) -. Refer to Electrical - Heated/Cooled Systems/Heated Seats/SWITCH, Heated Seat - Description . Hazard Switch (all models) -. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/SWITCH, Hazard Warning - Description . Headlamp Leveling Switch (if equipped) -. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Headlamp Leveling - Description .

Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. See Removal . To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic service information. OPERATION OPERATION

For information covering details of operation for the individual switches or indicator contained within the instrument panel switch pod, refer to the specific service information covering the system to which that switch or indicator belongs. z

z z

Heated Seat Switches (if equipped) -. Refer to Electrical - Heated/Cooled Systems/Heated Seats/SWITCH, Heated Seat - Description . ESP On/Off (domestic models) -. Refer to Brakes - Description . Hazard Switch (all models) -. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/SWITCH, Hazard Warning - Description .

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z z

Electrical Inverter (domestic models) Headlamp Leveling Switch (if equipped) -. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Headlamp Leveling - Description .

REMOVAL REMOVAL

Fig. 11: Instrument Panel Center Bezel Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Disconnect the electrical connector from the switch by depressing the lock tab and pulling connector from the ASBM. 4. Remove the four screws (1) to the Accessory Switch Bank Module (ASBM). 5. Remove the ASBM from the instrument panel center bezel. INSTALLATION INSTALLATION

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Fig. 12: Instrument Panel Center Bezel Courtesy of CHRYSLER LLC 1. Position the accessory switch bank module (ASBM) in the center bezel and install the four screws (1). 2. Connect the electrical connector to the ASBM. Be sure the lock tab engages securely into the ASBM. 3. Install the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel Installation . 4. Connect the battery negative cable.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

SPECIAL TOOLS SPECIAL TOOLS

Fig. 1: De Gauser - 6029 Courtesy of CHRYSLER LLC

Fig. 2: RF Detector - 9001 Courtesy of CHRYSLER LLC

CENTER, ELECTRONIC VEHICLE INFORMATION DESCRIPTION DESCRIPTION

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

Fig. 3: Electronic Vehicle Information Center Courtesy of CHRYSLER LLC The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel (2) and engine temperature (1) gauges. The display in the lower right part of the instrument cluster (15) below the tachometer (13) shows the vehicle odometer related functions. These functions include Trip Odometer (ODO), Trip A and Trip B readouts. The instrument cluster push-button (21) can be used to scroll through the different odometer functions. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description for additional information on the instrument cluster and related functions. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display. It is located in the instrument cluster below the fuel and temperature gauges. Vehicles equipped with steering wheel-mounted buttons (described in this information) are also equipped with the EVIC. The EVIC consists of the following: z z z z z z z

System Status Vehicle information warning message displays Tire Pressure Monitor System (TPM) - If Equipped Personal Settings (customer programmable features) Compass display Outside temperature display Trip computer functions

The EVIC system is comprised of several different components. Those components are: z z z

Instrument Cluster (sometimes referred to as Cab Compartment Node [CCN]) ASBM EVIC Function Buttons Ambient Temperature Sensor

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

z z z

Remote Compass Module (RCM) Controller Area Network (CAN) Data Bus Local Interface Network (LIN) Data Bus

The EVIC display is part of the Instrument Cluster assembly and is not serviced as a separate component. If the display is inoperative the complete Instrument Cluster assembly must be replaced. Refer to Electrical Instrument Cluster/Instrument Cluster - Removal . OPERATION OPERATION

The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the "ON" position. When the ignition switch is turned to the "ON" position, the EVIC display will return to the last function being displayed before the ignition was turned to the "OFF" position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC function buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button allows the driver to select the Compass/Temperature, Trip Computer, Personal Settings or System Status functions. The STEP button is used to toggle through options or features of the Trip Computer, Personal Settings or System Status functions. Pressing and releasing the RESET button allows the selection of setting or resetting of the function currently displayed at that time. Pressing and releasing the C/T (compass/temperature) button will cause the EVIC to return to the compass/temperature display mode from any other mode. EVIC DISPLAY MODES SYSTEM STATUS MODE

System display mode displays warnings and user interaction messages on the EVIC display. The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: z

z z z z z

Turn Signal On (with a continuous warning chime if the vehicle is driven more than 1 mile [1.6 km] with either turn signal on) Left Front Turn Signal Lamp Out (with a single chime) Left Rear Turn Signal Lamp Out (with a single chime) Right Front Turn Signal Lamp Out (with a single chime) Right Rear Turn Signal Lamp Out (with a single chime) RKE (Remote Keyless Entry ) Battery Low (with a single chime)

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z z z z z z z z z z z z z z z z z z

Channel # Transmit. Channel # Training. Channel # Trained. Clearing Channels. Channels Cleared. Did Not Train. Left Front Low Pressure (with a single chime). Left Rear Low Pressure (with a single chime). Right Front Low Pressure (with a single chime). Right Rear Low Pressure (with a single chime). Check TPM System (with a single chime). Low Fuel Cal Oil Change Required (with a single chime) Low Washer Fluid Coolant Low Key in Ignition Lights On

PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES)

Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. Pressing and releasing the STEP button will scroll through the following personal settings choices: z

Language When in this display you may select one of three languages for all display nomenclature, including the trip functions and the navigation system (if equipped). Press the RESET button while in this display to select English, Espanola, or French. Then, as you continue, the information will display in the selected language. NOTE:

z

z

z

The EVIC will not change the UConnect™ language selection.

Unlock Doors Automatically on Exit When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Remote Key Unlock When DRIVER DOOR 1ST PRESS is selected, only the driver's door will unlock on the first press of the remote keyless entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. When ALL DOORS 1ST PRESS is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "Driver Door 1st Press" or "All Doors 1st Press" appears. Sound Horn with Remote Key Lock When ON is selected, a short horn sound will occur when the

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

z

z

z

z

z

z

remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Flash Lights with Remote Key Lock When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Delay Turning Headlights Off When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears. Headlights On with Wipers (Available with Auto Headlights Only) When this feature is selected and the headlight switch is in the AUTO position, the headlights will activate approximately 10 seconds after the wipers are turned on. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Delay Power Off to Accessories Until Exit When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped), power sunroof (if equipped), and power outlets will remain active for up to 10 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," or "10 min." appears. Confirmation of Voice Commands - If Equipped When ON is selected, all voice commands from the UConnect™ system are confirmed. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Display Units of Measure in The EVIC, odometer, and navigation system (if equipped) can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears.

COMPASS/TEMPERATURE

Compass heading and outside temperature are displayed on the EVIC display screen. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and one of 15 compass variance settings can be programmed. Outside temperature is displayed in °C (degrees Celsius) or °F (degrees Fahrenheit). For additional information regarding the compass, refer to Personal Settings (Customer Programmable Features) in this information. TRIP COMPUTER

Press and release the MENU button until one of the following Trip Functions displays in the EVIC: z z z z

Average Fuel Economy Distance To Empty Elapsed Time Display Units of Measure in

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

Press the STEP button to cycle through all the Trip Computer functions. The Trip Functions mode displays the following information: z

z

z

z

Average Fuel Economy Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. DTE cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. Elapsed Time Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. Display Units of Measure in: To make your selection, press and release the RESET button until "US" or "METRIC" appears.

To Reset The Display Reset will only occur while a resettable function is being displayed. Press and release the RESET button once to clear the resettable function being displayed. To reset all resettable functions, press and release the RESET button a second time within 3 seconds of resetting the currently displayed function (>Reset ALL will display during this 3 second window). DIAGNOSIS AND TESTING ELECTRONIC VEHICLE INFORMATION CENTER

CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not receive. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN and LIN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). Should the RCM become disconnected, the instrument cluster display will go blank. The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the Instrument Cluster, the RCM, the CAN Data Bus and the LIN Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. user Monday, June 04, 2012 9:41:50 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

STANDARD PROCEDURE MANUAL COMPASS CALIBRATION

CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. NOTE:

Calibration is required anytime a new RCM is installed. Upon installation of the new RCM the "CAL" message will appear in the Electronic Vehicle Information Center (EVIC) display. The RCM will automatically calibrate if the vehicle is driven in two or more circles, slowly, and away from large metal objects. The RCM can also be calibrated by performing the following procedure.

NOTE:

Confirmation that the proper variance zone is programmed, is recommended whenever manual compass calibration is performed. See Standard Procedure for the appropriate procedure.

The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows:

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Fig. 4: EVIC Function Buttons Courtesy of CHRYSLER LLC NOTE:

Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines.

1. Start the engine but leave the vehicle in "PARK". 2. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (4) several times until "Calibrate Compass (Yes)" is displayed. 4. Momentarily depress and release the RESET push button (3) to initiate the calibration procedure. The "CAL" symbol will come on solid in the EVIC display. 5. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" symbol will disappear from the display to indicate successful compass calibration. NOTE:

A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary.

NOTE:

If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis.

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NOTE:

If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location.

COMPASS DEMAGNETIZING

Fig. 5: Degaussing Tool #6029 Courtesy of CHRYSLER LLC A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel of the vehicle. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

Fig. 6: View Of Roof Panel Grid Courtesy of CHRYSLER LLC 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the vehicle. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass and adjust the compass variance. See Standard Procedure. . COMPASS VARIANCE ADJUSTMENT user Monday, June 04, 2012 9:41:50 AM

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Fig. 7: Magnetic And Geographic North Map Courtesy of CHRYSLER LLC Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE:

If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance will need to be updated to the new zone number to function properly.

NOTE:

The default for the compass variance from the factory is 8.

To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number.

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Fig. 8: EVIC Function Buttons Courtesy of CHRYSLER LLC 2. Turn the ignition switch to the ON/RUN position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. 4. Press and release the RESET push button (3) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. NOTE:

The default for the compass variance from the factory is 8. During programming, the Zone value will wrap around from Zone 15 to Zone 1.

5. Press and release the Compass Temperature (C/T) push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass.

MODULE DESCRIPTION DESCRIPTION

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Fig. 9: Remote Compass Module Courtesy of CHRYSLER LLC The Remote Compass Module (RCM) (2) is a separate stand alone module mounted to the top of the instrument panel (1). The RCM can be accessed by removing the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Removal . If the compass position sensor (Remote Compass Module) is inoperative and requires replacement. See Removal for the appropriate procedure. DIAGNOSIS AND TESTING REMOTE COMPASS MODULE

The Remote Compass Module (RCM) data is transferred on the Controller Area Network (CAN) Data Bus circuit. The RCM and Electronic Vehicle Information Center (EVIC) will not function properly if the bus messages are not properly received. If no EVIC data is displayed, check the CAN Data Bus circuit communications, the RCM, the Instrument Cluster functions and the Totally Integrated Power Module (TIPM). Any diagnosis of the RCM and EVIC display should begin with the use of a scan tool and the appropriate diagnostic service information. For complete circuit diagrams, refer to the appropriate 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 connectors, splices and grounds. REMOVAL REMOVAL

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Fig. 10: Remote Compass Module Courtesy of CHRYSLER LLC 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Removal 3. Remove the retaining screw (3) securing the Remote Compass Module (RCM) (2) to the instrument panel (1). 4. Disconnect the RCM electrical connector (4). 5. Remove the RCM from the vehicle. INSTALLATION INSTALLATION

Fig. 11: Remote Compass Module user Monday, June 04, 2012 9:41:50 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8.

Position the Remote Compass Module (RCM) (2) onto the top of the Instrument Panel (IP) (1). Connect the electrical connector (4). Install the RCM retaining screws (3). Install the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Installation Connect the battery negative cable. Perform the Compass Variance Adjustment. See Standard Procedure . Perform the Manual Compass Calibration. See Standard Procedure . Verify proper compass operation.

SENSOR, AMBIENT TEMPERATURE DESCRIPTION DESCRIPTION

Fig. 12: Locating Ambient Temperature Sensor Courtesy of CHRYSLER LLC The ambient temperature sensor (1) is a variable resistor located under the bottom right side of the front bumper reinforcement (2). The sensor is attached to the power steering line bracket with a pushpin style retainer and can be accessed through the right opening in the front fascia assembly.

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Fig. 13: Ambient Temperature Sensor Courtesy of CHRYSLER LLC The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, must be replaced. OPERATION OPERATION

The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The applicable instrument cluster display then displays the proper ambient temperature. DIAGNOSIS AND TESTING AMBIENT TEMPERATURE SENSOR

The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus, the Local Area Network (LIN) data bus and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (130° F), or if the sensor circuit is shorted, 60° C (130° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the instrument cluster may be necessary. Refer to Electrical/Instrument Cluster - Diagnosis and Testing for the appropriate procedure. SENSOR TEST

1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is user Monday, June 04, 2012 9:41:50 AM

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336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, further testing of the instrument cluster may be necessary. Refer to Electrical/Instrument Cluster - Diagnosis and Testing for the appropriate procedure. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST

For complete circuit diagrams, refer to the appropriate 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 connectors, splices and grounds. NOTE:

Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the "ON" position for readings to meet test specifications.

1. Turn the ignition switch to the "OFF" position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the "ON" position. The display should now read - 40° C (- 40° F). If OK, go to step 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the "OFF" position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the "ON" position. The display should now read 60° C (130 F). If OK, go to step 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE:

If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update.

5. Turn the ignition switch to the "OFF" position. Remove the jumper wire. Turn the ignition switch to the "ON" position and wait until the display again reads - 40° C (- 40° F). Turn the ignition switch to the "OFF" position. Reconnect the ambient temperature sensor. Turn the ignition switch to the "ON" position. The display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to step 6. 6. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the LIN data bus circuit, the TIPM and the ambient temperature sensor (refer to SENSOR TEST). REMOVAL REMOVAL

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Fig. 14: Locating Ambient Temperature Sensor Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Working through the opening in the right side of the front fascia, disconnect the wire harness connector from the ambient temperature sensor (1). 3. Remove the fastener that secures the ambient temperature sensor to the power steering line bracket. 4. Remove the ambient temperature sensor from the vehicle. INSTALLATION INSTALLATION

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

Fig. 15: Locating Ambient Temperature Sensor Courtesy of CHRYSLER LLC 1. Working through the opening in the right side of the front fascia, position the ambient temperature sensor (1) in the vehicle. 2. Install the fastener that secures the ambient temperature sensor (1) to the power steering line bracket. 3. Connect the wire harness connector to the ambient temperature sensor. 4. Connect the battery negative cable.

SWITCH, EVIC CONTROL REMOVAL REMOVAL

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Message Center - Service Information - Journey

Fig. 16: Removing/Installing EVIC Switch And Bezel Assembly Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. Refer to Restraints/AIR BAG, Driver - Removal . 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry the switch and bezel assembly (3) away from the steering wheel at the inner retaining tab (1) and the outer bezel edge (2). 4. With the switch and bezel assembly free from the steering wheel, lift the assembly up and disconnect the switch electrical connector.

Fig. 17: EVIC Switch Separated From Bezel Courtesy of CHRYSLER LLC 5. Using trim stick (special tool # C-4755) or equivalent, gently pry the switch bezel retainers (2) away from the switch tabs (1), while applying pressure to the back side of the switch. Remove the switch from the user Monday, June 04, 2012 9:41:50 AM

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bezel. INSTALLATION INSTALLATION

Fig. 18: EVIC Switch Separated From Bezel Courtesy of CHRYSLER LLC 1. Position the steering wheel switch onto the switch bezel aligning the switch tabs (1) with the bezel retainers (2). 2. Press the switch into the bezel, until the switch is held in place by all four retainers.

Fig. 19: Removing/Installing EVIC Switch And Bezel Assembly Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:41:50 AM

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3. Position the switch and bezel assembly (3) over the steering wheel and connect the switch electrical connector. 4. Align the switch bezel tab (1) with the slot in the steering wheel and press the switch and bezel assembly (3) into the steering wheel until it is secured in place. 5. Install the driver airbag. Refer to Restraints/AIR BAG, Driver - Installation . 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. Refer to DTCBased Diagnostics/CONTROLLER, Occupant Restraint (ORC) - Standard Procedure . 7. Connect the battery negative cable.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Navigation/Telecommunication - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Navigation/Telecommunication - Service Information - Journey

DESCRIPTION DESCRIPTION TELECOMMUNICATIONS

The hands-free cellular system on this vehicle uses Bluetooth™ technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the handsfree system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the call will be transferred to the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. The hands free module is contained within the radio for premium systems. With the low line radio, the hands free module is located on the left side of the instrument panel to the left of the steering column. NAVIGATION

The navigation system offers several new customer features for expanded usability and convenience with hands-free voice-activated operation in addition to the touch screen buttons. The navigation system uses the Bluetooth microphone in the rear view mirror. Navigation routes can be based on a variety of formats including some of the following: z

z z z

z

z

z

Destination entry by street intersection, city, zip code, street name, street address and number, state/province/country and phone number Stop/change route Save current position Personal menu, including Guide Me Home (Go Home), Trip Itinerary, List of Saved Locations, Favorite Points of Interest (from a data base), Manage Personal User and Choose User Personal Interests including recent routes, address book, Where Am I Now, Emergency (police stations, Dodge dealerships, fire stations, hospitals and emergency care centers), Trail and geo- coordinates Route options include shortest, quickest, maximize freeways, minimize freeways, avoid toll roads and avoid ferries Navigation can be put into DEMO mode to enhance trip planning

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Navigation/Telecommunication - Service Information - Journey

This navigation system will support Traffic Messaging. Traffic Messaging displays voice and pop up warning messages for medium and high priority situations on the route such as road closures due to accidents/hazardous situations and it can even generate a traffic detour for a traffic event located on the route.

OPERATION OPERATION TELECOMMUNICATION

Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: z

z

z z z

z

Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. Four memory locations - Home, Work, Mobile, and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. Voice tag dialing - Dials the number associated with a voice tag and memory location. Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. Receiving calls - A voice prompt notifies the user of an incoming call. Pressing the UConnect button accepts or rejects the call. Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired.

NAVIGATION

The navigation system collects data from GPS satellites in orbit around the Earth. This information is sent to the radio to be processed and provides the user with present location and is used to provide the route planing and guidance as the vehicle is driven.

ANTENNA, NAVIGATION REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Remove the radio. Refer to Electrical - Audio and Video/Audio and Video/RADIO - Removal . 4. Remove the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Removal . 5. Remove the GPS antenna mounting fasteners and remove the antenna. user Monday, June 04, 2012 9:35:58 AM

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Navigation/Telecommunication - Service Information - Journey

INSTALLATION INSTALLATION

1. 2. 3. 4.

Install the GPS antenna and mounting fasteners. Install the defroster grille. Refer to Body/Instrument Panel/GRILLE, Defroster - Installation . Install the radio. Refer to Electrical - Audio and Video/Audio and Video/RADIO - Installation . Install the instrument panel center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel Installation . 5. Connect the battery negative cable.

MODULE, HANDS FREE (HFM) REMOVAL REMOVAL

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the knee bolster. Refer to Body/Instrument Panel/KNEEBLOCKER - Removal . Remove the hands free module mounting fasteners. Disconnect the electrical connectors and remove the module.

INSTALLATION INSTALLATION

1. 2. 3. 4.

Connect the electrical connectors and install the hands free module. Install the hands free module mounting fasteners. Install the knee bolster. Refer to Body/Instrument Panel/KNEEBLOCKER - Installation . Connect the battery negative cable.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Identifying Overhead Console Components Courtesy of CHRYSLER LLC There are two different style's of overhead console (1) available on this vehicle, High line and Mid or Low line. All overhead consoles are equipped with a sunglasses storage bin (2) and two reading and courtesy lamps (4). On High line models, the reading lamps are a Light Emitting Diode (LED) multi directional design, and on the Mid or Low line design the lamps are fixed with a replaceable incandescent bulb. The sunglasses storage bin also has a conversation mirror that is visible when the bin is locked in the partial open position. On vehicles equipped with a power sunroof, the sunroof switch (5) is located behind the sunglasses bin. On vehicles equipped with automatic climate control an infrared temperature sensor (3) is located between the reading and courtesy lamps. Both overhead console designs are mounted with six snap clips into a molded plastic retainer bracket located above the headliner to provide secure overhead console attachment.

REMOVAL SUNGLASSES BIN

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

Fig. 2: Identifying Overhead Console Components Courtesy of CHRYSLER LLC 1. Remove the overhead console (5). See Removal . 2. Remove the four fasteners (3) that secure the sunglasses bin (6) to the console. 3. Remove the bin from the console. CONSOLE ASSEMBLY

Fig. 3: Console Assembly Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Using your fingertips, grasp the sides of the overhead console (1) and pull straight down evenly to disengage the snap clips from the mounting bracket. user Monday, June 04, 2012 9:40:19 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

Fig. 4: Identifying Overhead Console Components Courtesy of CHRYSLER LLC 3. Lower the overhead console (5) far enough to access the wire harness connectors. 4. If equipped, disconnect the courtesy lamps (1), infrared temperature sensor (2) and power sunroof switch (4) electrical connectors. 5. Remove the overhead console assembly from the vehicle.

INSTALLATION SUNGLASSES BIN

Fig. 5: Identifying Overhead Console Components Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:40:19 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

1. Install the sunglasses bin (6) into the overhead console (5). 2. Install the four fasteners (3) that secure the bin to the console. 3. Install the overhead console. See Installation . CONSOLE ASSEMBLY

Fig. 6: Identifying Overhead Console Components Courtesy of CHRYSLER LLC 1. Position the overhead console (5) in the vehicle near the headliner assembly. 2. If equipped, connect the courtesy lamps (1), infrared temperature sensor (2) and power sunroof switch (4) electrical connectors. 3. Position the overhead console so that the six retaining clips are lined up properly with the bracket.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Overhead Console - Service Information - Journey

Fig. 7: Console Assembly Courtesy of CHRYSLER LLC 4. Applying pressure to the overhead console (1), push straight up evenly to engage the snap clips into the mounting bracket. 5. Connect the battery negative cable.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

OPERATION OPERATION The power distribution system for this vehicle is designed to provide safe, reliable, centralized and convenient access to distribution of the electrical current required to operate all of the many standard and optional factoryinstalled electrical and electronic powertrain, chassis, safety, comfort and convenience systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items. These power distribution systems also incorporate various types of circuit control and protection features, including: z z z z z

Automatic resetting circuit breakers Cartridge fuses Fusible links Mini and standard fuses Relays

The power distribution system for this vehicle may consist of the following components: z z z z

Accessory power outlet Junction Block (JB) Power Distribution Center (PDC) Totally Integrated Power Module (TIPM)

SPECIAL TOOLS SPECIAL TOOLS

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

Fig. 1: 9857 Power Outlet Remover Courtesy of CHRYSLER LLC 1. RETAINING TABS 2. ELECTRICAL CONNECTOR

3. POWER OUTLET 4. POWER OUTLET REMOVER

FUSE, IOD DESCRIPTION DESCRIPTION

All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. OPERATION OPERATION

The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to user Monday, June 04, 2012 5:00:56 PM

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restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. REMOVAL REMOVAL

NOTE:

When removing or installing the Ignition Off Draw (IOD) fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition.

1. Turn the ignition switch to the OFF position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Pull on IOD fuse (J13) holder until it reaches the first detent. INSTALLATION INSTALLATION

1. Push on IOD fuse until completely seated. 2. Install the cover to the Totally Integrated Power Module (TIPM).

JUNCTION BLOCK DESCRIPTION DESCRIPTION

An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. user Monday, June 04, 2012 5:00:56 PM

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MODULE, POWER INVERTER DIAGNOSIS AND TESTING INVERTER MODULE

For complete circuit diagrams, refer to the appropriate wiring information. 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 isolate the negative battery (ground) cable. 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS CONDITION POSSIBLE CAUSES NO POWER AT THE 110 VOLT 1. Fuse inoperative. POWER OUTLET

CORRECTION 1. Check Totally Integrated Power Module (TIPM) fuse number 37. Replace fuse, if required. 2. Power outlet connector 2. Check for loose or corroded power damaged. outlet connector. Repair, if required. 3. Inverter module connector 3. Check for loose or corroded inverter damaged. module connector. Repair, if required. 4. Wiring damaged. 4. Check for shorted or open wires. Repair wiring, if required. 5. Inverter module ground 5. Check for continuity between the damaged. inverter module and a known good ground. There should be continuity. Repair ground, if required. 6. Power outlet inoperative. 6. Replace the power outlet. 7. Inverter module 7. Replace the inverter module. inoperative.

REMOVAL REMOVAL

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

Fig. 2: Removing / Installing Power Inverter And Mounting Retainers Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Disconnect and isolate the battery negative cable. Position the front drivers seat to the full rearward position. Remove the power inverter (2) mounting retainers (1) located under the carpet. Disconnect the electrical connectors. Remove the power inverter module from the vehicle.

INSTALLATION INSTALLATION

Fig. 3: Removing / Installing Power Inverter And Mounting Retainers Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:00:56 PM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

1. 2. 3. 4.

Position the inverter into the vehicle and install mounting fasteners. Connect the electrical connectors. Connect the battery negative cable. Position the front drivers seat back to the original position.

MODULE, TOTALLY INTEGRATED POWER (TIPM) DESCRIPTION DESCRIPTION

All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. OPERATION OPERATION

All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to appropriate wiring information for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. STANDARD PROCEDURE PROGRAMMING

1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE:

Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge.

3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. user Monday, June 04, 2012 5:00:56 PM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

6. 7. 8. 9. 10. 11. 12. 13.

Select "ECU View". Select "TIPMCGW" or "FCMCGW". Select "MISC". Select "Restore Vehicle Configuration". Follow prompts on StarSCAN to complete the reconfigure procedure. Once complete, Wait one minute and turn the ignition key to the "OFF" position. Remove the StarSCAN unit, cable and charger from the vehicle. Verify proper operation.

REMOVAL REMOVAL

1. 2. 3. 4. 5. 6. 7.

Open hood. Disconnect and isolate the battery negative cable. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. Remove the TIPM positive cable retaining nut and remove the cable from the stud. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. Disconnect each of the seven TIPM wire harness connectors. Remove the TIPM from the vehicle.

INSTALLATION INSTALLATION

CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT 1. 2. 3. 4.

Position the TIPM into the engine compartment. Connect each of the seven TIPM wire harness connectors. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 N.m (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. user Monday, June 04, 2012 5:00:56 PM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Distribution - Journey

8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation.

OUTLET, POWER, 12 V REMOVAL REMOVAL

Fig. 4: Removing Cigar Lighter/Power Outlet Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Using Power Outlet Remover 9857 (4). Insert the tool with tips against bosses (1). Pull out the base (3) through mounting ring by gently rocking power outlet remover. Disconnect the base wires (2).

INSTALLATION INSTALLATION

1. Connect wire harness connectors. 2. Install power outlet to instrument panel. 3. Connect battery negative cable.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

DESCRIPTION DESCRIPTION POWER DOOR LOCKS

The power lock system allows all doors to be locked or unlocked electrically by operating the switch on either front door trim panel. The power lock system operates on non-switched battery current supplied through a fuse in the junction block so that the system remains functional, regardless of the ignition switch position. AUTOMATIC DOOR LOCKS

The system includes an automatic door locking feature actuated by the Cab Compartment Node (CCN). The vehicle is built with the system enabled. The system can be enabled/disabled by the customer. Refer to the owner's manual for information. The CCN will automatically lock all doors when all of the conditions below are met: z z z

All doors are closed The vehicle speed exceeds 15 ± 1 M.P.H. (24km/h) The throttle position sensor tip-in is greater than 10 ± 2 degrees

When the system is disabled the door locks will work by use of the door lock switches only. When this system is enabled the automatic door locks will work automatically. CHILD PROTECTION LOCK

The child protection locks are on the rear doors only. When enabled, they render the inside remote door release handles inoperative. DOOR LOCK INHIBIT

The door lock inhibit feature is designed to prevent the locking of keys in a vehicle. The doors cannot be locked with either front door open unless the keys are removed from the ignition switch. REMOTE KEYLESS ENTRY

The system allows locking and unlocking of vehicle door(s), deck lid release, and panic by remote control using a hand held radio frequency transmitter. The vehicle must be in PARK before the trunk lid can be unlatched with the transmitter. The receiver may receive signals from up to four transmitters. Each transmitter has its own code, and the code is programmed and stored into receiver memory. If a transmitter is replaced or additional transmitters are added, user Monday, June 04, 2012 9:48:38 9:48:34 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

the codes for all units have to be reprogrammed into the receiver memory. If a receiver module is replaced, the transmitter codes must be stored in the new receiver memory. HORN CHIRP TOGGLE

Once the transmitters have been programmed, the horn chirp can be enabled/disabled by sending the horn chirp toggle operation code to the CCN.

OPERATION OPERATION POWER DOOR LOCKS

All doors can be locked or unlocked electrically by operating the switch on either front door panel. The rear doors can be locked or unlocked by actuation of the front door switch, or can be locked or unlocked mechanically and independently with their respective locking knobs. The front doors can be locked or unlocked mechanically with the locking knob regardless of electrical locking and unlocking actuation with the front door knobs. The left front door on all vehicles can be locked or unlocked mechanically from the outside with the key or electrically as described above. The left and right front doors can also be unlocked by actuation of the inside remote door handle. AUTOMATIC DOOR LOCKS

The CCN controls the power locks when the door lock switch is activated. If the door lock switch is pressed for longer than eight consecutive seconds, the CCN will de-energize the door lock relay. The automatic door lock system can be enabled/disabled either by the customer or with the scan tool. Refer to the scan tool or the vehicle owners manual for enabling/disabling procedures. The CCN will automatically re-lock all doors if the above conditions are met and if any of the doors become ajar and then closes again. The power latches are also equipped with a thermal protection system which prevents the latches from burning out. CHILD PROTECTION LOCK

The lock when engaged, will disable the inside door handle from opening the door. The lock is part of the latch/lock assembly. The lock is engaged by moving a lever that is located on the rearward inside edge of the door. DOOR LOCK INHIBIT user Monday, June 04, 2012 9:48:34 AM

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With the key in the ignition switch in the ON or OFF position and the driver's door open the CCN will ignore the command to lock the power door locks. Once the key is removed, or the driver's door is closed, the CCN will allow the power door locks to lock. REMOTE KEYLESS ENTRY

The transmitter has four buttons for operation. They are LOCK, UNLOCK, DECK LID RELEASE, and PANIC. z

The UNLOCK button will unlock the driver's door and enable illuminated entry. Pushing and releasing the button once will unlock the driver's door. Pushing and releasing the button two times, within a five second interval, will unlock all doors. The unlock sequence can be toggled between driver door first and all door unlock functions.

z

z

z

Upon pressing the LOCK button, the horn will sound a short CHIRP (if enabled) and flash the park lamps to notify that the all door lock signal was received and set. Illuminated entry is cancelled and the interior lamps are faded to off. DECK LID RELEASE - The Deck Lid release button changes from a default "press twice" actuation to a "press and hold" (for approximately one third of a second) default. Note that this is customer programmable to "no delay" if so desired. Pushing and holding the PANIC button will cause the panic alarm to sound for three minutes, until the panic button is pressed and held a second time, or the vehicle reaches a speed of 15 mph.

The receiver is capable of retaining a Vehicle Access Code (VAC) even when power is removed. Each Remote Keyless Entry (RKE) module must have at least one and no more than four transmitters. HORN CHIRP TOGGLE

This can be done using a scan tool or by the customer. The horn chirp will enter the opposite state of its current programmed state by receiving this operation code. The CCN is responsible for keeping track of the horn chirp status.

DIAGNOSIS AND TESTING REMOTE KEYLESS ENTRY When trouble shooting problems with the Remote Keyless Entry System, always verify that the power door lock/unlock switches are functional. If the doors do not lock/unlock with the power switches, the following components should be analyzed: z z z z

Door Lock Switches Door lock/unlock motors Fuses Lock and unlock relays

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

z z

Radio/clock Remote keyless entry system

MOTOR, DOOR LOCK DIAGNOSIS AND TESTING DOOR LOCK MOTOR

Make certain battery is in normal condition before circuits are tested. To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem maybe caused by a shorted motor, a bad switch, or a bad relay. Disconnecting a defective motor will allow the others to work. To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. The door lock motor is integral to the door latch. If faulty, the entire door latch must be replaced.

SOLENOID, RELEASE, LIFTGATE REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch assembly. Refer to Body/Decklid/Hatch/Liftgate/Tailgate/LATCH Removal . 3. Remove the liftgate release solenoid. INSTALLATION INSTALLATION

1. Install the liftgate latch. Refer to Body/Decklid/Hatch/Liftgate/Tailgate/LATCH - Installation . 2. Install the liftgate trim panel. Refer to Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim Installation . 3. Connect the battery negative cable.

SWITCH, DOOR LOCK CYLINDER user Monday, June 04, 2012 9:48:34 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

REMOVAL REMOVAL

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Removal . Disconnect the wiring clip and pigtail wire connector. Remove the Door Cylinder Lock Switch from door lock cylinder.

INSTALLATION INSTALLATION

1. 2. 3. 4.

Install the Door Cylinder Lock Switch onto the door lock cylinder. Connect the wiring clip and pigtail wire connector. Install door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Installation . Connect the battery negative cable.

SWITCH, LOCK DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING VOLTAGE

The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: z z z

Touch other test light lead to battery feed B+ terminal. If test light comes on, the wiring circuit between the battery and switch is functional. If test light does not come on, check for a blown fuse. Refer to SYSTEM WIRING DIAGRAMS for circuit information.

DOOR LOCK SWITCH

NOTE:

Vehicles equipped with the auto-express feature for power windows, the local interface network (LIN) controls the lock, mirror and window features.

Remove the non-express switch from its mounting location. Using an ohmmeter, refer to the DOOR LOCK user Monday, June 04, 2012 9:48:34 AM

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SWITCH CONTINUITY table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. DOOR LOCK SWITCH CONTINUITY SWITCH POSITION MASTER DOOR LOCK LOCK MASTER DOOR LOCK UNLOCK PASSENGER DOOR LOCK LOCK PASSENGER DOOR UNLOCK LOCK

CONTINUITY BETWEEN 3 AND 4 3 AND 4

RESISTANCE VALUE

4 AND 8

330 ohms ± 10%

4 AND 8

102 ohms ± 10%

330 ohms ± 10% 102 ohms ± 10%

REMOVAL REMOVAL

1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. INSTALLATION INSTALLATION

1. Connect switch wire connector. 2. Install the switch by snapping into place. 3. Connect the battery negative remote cable.

TRANSMITTER, INTEGRATED KEY FOB DIAGNOSIS AND TESTING REMOTE KEYLESS ENTRY TRANSMITTER

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

Fig. 1: Radio Frequency Detector 9001 Courtesy of CHRYSLER LLC Using special tool 9001, first test to ensure that the transmitter is functioning. Typical testing distance is 2.5 centimeters (1 inch) for Asian transmitters and 30.5 centimeters (12 inches) for all others. To test, position the transmitter as shown in illustration. Press any transmitter button, then test each button individually. The tool will beep if a radio signal strength that lights five or more LEDs is detected. Repeat this test three times. If transmitter fails any of the test refer to the proper Diagnostic Procedures information. FOBIK TRAPPED IN WIN

The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. CONDITION

POSSIBLE CAUSES CORRECTION 1. Damaged, binding or 1. Inspect and replace or adjust gearshift cable, if improperly adjusted required. gearshift cable.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

2. Damaged or binding 2. Inspect and replace or adjust gearshift lever gearshift lever mechanism. mechanism. 3. Use a diagnostic scan tool with software release version 8.05 or greater to read and 3. No gated park switch confirm no gated park switch input to the WIN. CANNOT TURN FOBIK TO input to WIN. Refer to the appropriate CONDITION that LOCK POSITION follows. 4. Use a diagnostic scan tool with software 4. Key lock solenoid (WIN) unresponsive to release version 8.05 or greater to read and confirm gated park switch input to the WIN. gated park switch Refer to the appropriate CONDITION that input. follows. 1. Repair the open TRS park signal circuit 1. Open TRS park between the gated park switch (gearshift lever signal circuit. mechanism) and the WIN, if required NO GATED PARK SWITCH INPUT 2. Damaged or 2. Replace the damaged or ineffective gated park ineffective gated park switch (gearshift lever mechanism), if required. switch. KEY LOCK SOLENOID 1. Damaged or UNRESPONSIVE TO 1. Replace the damaged or ineffective key lock ineffective key lock GATED PARK SWITCH solenoid (WIN), if required. solenoid. INPUT STANDARD PROCEDURE FOBIK TRANSMITTER BATTERY REPLACEMENT FOBIK WITH BATTERY COVER

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

Fig. 2: FOBIK With Battery Cover Courtesy of CHRYSLER LLC NOTE:

Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol.

To replace the FOBIK transmitter battery: 1. Using a small flat bladed tool, carefully remove the battery cover on the back of the FOBIK.

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Fig. 3: FOBIK With Battery Cover Removed Courtesy of CHRYSLER LLC 2. 3. 4. 5. 6.

Remove the battery one at a time by slightly lifting up and sliding out from the FOBIK. Replace the battery with the same type of battery cell. Install the battery with the positive terminal up. Install battery cover and snap into place. Test FOBIK operation.

FOBIK WITHOUT BATTERY COVER

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Fig. 4: FOBIK Without Battery Cover Courtesy of CHRYSLER LLC NOTE:

Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol.

This design is a clam shell design whereby both halves are split apart. 1. Remove the valet/spare key from the FOBIK if present. 2. Using a trim stick C-4755 or equivalent, carefully separate the top half from the bottom half.

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Fig. 5: FOBIK Without Battery Cover Separated Courtesy of CHRYSLER LLC 3. 4. 5. 6. 7.

Lift up on the battery to remove. Replace battery with the same type of cell. Install new battery negative side up. Snap the top and bottom halves together. Test FOBIK operation.

FOBIK PROGRAMING

Make sure instructions are followed in order. Refer to MODULE PROGRAMMING . . SPECIFICATIONS SPECIFICATIONS BATTERY

The transmitter has two 3 volt batteries, which can be removed and replaced without special tools. Insert a dime in the side slot of the transmitter case and twist. The halves should separate and the batteries are stacked on top of each other. The batteries are available at local retail stores. Recommended batteries are Duracell DL 2016 or equivalent. Typical battery life is about two years. CAUTION: Do not handle the batteries any more than necessary. Hands must be clean and dry.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Locks - Service Information - Journey

RANGE

Normal Remote Keyless Entry (RKE) transmitter operation range for vehicles manufactured for domestic markets is up to 20 meters (66 feet) away from the vehicle. On vehicles manufactured for export markets, normal RKE transmitter range is up to 10 meters (33 feet) away from the vehicle. If a domestic market vehicle is equipped with the optional factory-installed Remote Start System, the normal transmitter range is increased to up to 91 meters (300 feet). Please note that the actual RKE transmitter range values may be better or worse than specified above, depending upon many possible variables in the environment at the specific time and location that any RKE transmission is attempted.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Mirrors - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Power Mirrors - Service Information - Journey

DESCRIPTION DESCRIPTION AUTOMATIC DAY/NIGHT MIRROR

The automatic day/night mirror system is able to automatically change the reflectance of the inside rear view mirror in order to reduce the glare of headlamps approaching the vehicle from the rear. The automatic day/night rear view mirror receives battery current through a fuse in the junction block only when the ignition switch is in the ON position. OUTSIDE REAR VIEW MIRROR

The power operated outside rear view mirrors allow the driver to adjust both outside mirrors electrically from the driver side front seat position by operating a switch on the door panel above the window switches. Vehicles equipped with the auto-express feature for power windows, the local interface network (LIN) controls the lock, mirror and window features.

OPERATION OPERATION AUTOMATIC DAY/NIGHT MIRROR

A switch located on the bottom of the automatic day/night mirror housing allows the vehicle operator to select whether the automatic dimming feature is operational. When the automatic day/night mirror is turned on, the mirror switch is lighted by an integral Light-Emitting Diode (LED). The mirror will automatically disable its self-dimming feature whenever the vehicle is being driven in reverse. OUTSIDE REAR VIEW MIRROR

The power mirrors receive a non-switched battery feed through a fuse in the junction block so that the system will remain operational, regardless of the ignition switch position.

DIAGNOSIS AND TESTING POWER MIRRORS For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the power mirror switch. See Removal . user Monday, June 04, 2012 9:43:18 9:43:15 AM

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3. Disconnect wire connector from the switch. 4. Using two jumper wires, one connected to a 12 volt battery source, and the other connected to a good body ground. Refer to MIRROR MOTOR TEST for appropriate mirror response, using the mirror switch wiring harness connector. 5. If test results are not obtained as shown in the MIRROR MOTOR TEST table, check for open or shorted circuit, or replace mirror assembly as necessary. If mirror motor tests OK, go to Mirror Switch Test. MIRROR MOTOR TEST 12 VOLT 6 2 7 7 1 8 7 7

MIRROR REACTION GROUND LEFT 7 7 UP 6 2 DOWN 7 7 RIGHT 1 8 LEFT

RIGHT UP DOWN RIGHT LEFT -

MIRROR, AUTOMATIC DAY AND NIGHT DESCRIPTION DESCRIPTION

The automatic day/night mirror uses a thin layer of electrochromatic material between two pieces of conductive glass to make up the face of the mirror. When the mirror switch is in the On position, two photocell sensors are used by the mirror circuitry to monitor external light levels and adjust the reflectance of the mirror. OPERATION OPERATION

The ambient photocell sensor is located on the forward-facing (windshield side) of the rear view mirror housing, and detects the ambient light levels outside of the vehicle. The headlamp photocell sensor is located inside the rear view mirror housing behind the mirror glass and faces rearward, to detect the level of the light being received at the rear window side of the mirror. When the circuitry of the automatic day/night mirror detects that the difference between the two light levels is too great (the light level received at the rear of the mirror is much higher than that at the front of the mirror), it begins to darken the mirror. The automatic day/night mirror circuitry also monitors the transmission using an input from the backup lamp circuit. The mirror circuitry is programmed to automatically disable its self-dimming feature whenever it senses user Monday, June 04, 2012 9:43:15 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Mirrors - Service Information - Journey

that the transmission backup lamp circuit is energized. The automatic day/night mirror is a completely self-contained unit and cannot be repaired. If faulty or damaged, the entire mirror assembly must be replaced. DIAGNOSIS AND TESTING AUTOMATIC DAY/NIGHT INSIDE MIRROR

For complete circuit diagrams, refer to the appropriate wiring information. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the automatic day/night mirror. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the automatic day/night mirror wire harness connector. If OK, go to step 2. If not OK, repair the open circuit as required. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the automatic day/night mirror wire harness connector and a good ground. There should be continuity. If OK, go to step 3. If not OK, repair the circuit to ground as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Set the parking brake. Place the transmission gear selector lever in the Reverse position. Check for battery voltage at the backup lamp switch output circuit cavity of the automatic day/night mirror wire harness connector. If OK, go to step 4. If not OK, repair the open circuit as required. 4. Turn the ignition switch to the Off position. Disconnect the battery negative cable. Plug in the automatic day/night mirror wire harness connector. Connect the battery negative cable. Turn the ignition switch to the On position. Place the transmission gear selector lever in the Neutral position. Place the mirror switch in the On (the LED in the mirror switch is lighted) position. Cover the forward facing ambient photocell sensor to keep out any ambient light. NOTE:

The ambient photocell sensor must be covered completely, so that no light reaches the sensor. Use a finger pressed tightly against the sensor, or cover the sensor completely with electrical tape.

5. Shine a light into the rearward facing headlamp photocell sensor. The mirror glass should darken. If OK, go to step 6. If not OK, replace the faulty automatic day/night mirror unit. 6. With the mirror glass darkened, place the transmission gear selector lever in the Reverse position. The mirror should return to its normal reflectance. If not OK, replace the faulty automatic day/night mirror unit.

MIRROR, OUTSIDE REARVIEW REMOVAL REMOVAL user Monday, June 04, 2012 9:43:15 AM

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For service procedures. Refer to Body/Exterior/MIRROR, Outside Rearview - Removal .

SWITCH, MIRROR REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. INSTALLATION INSTALLATION

1. Connect switch wire connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Seats - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Power Seats - Service Information - Journey

DESCRIPTION DESCRIPTION POWER SEAT SYSTEM

Fig. 1: Identifying Power Seat Switch, Seat Cushion & Seat Cushion Side Shield Courtesy of CHRYSLER LLC The driver six-way power seat is available on this vehicle. The power seat system allows the seat occupant to electrically adjust the seating position using the power seat switch assembly (2) located on the outboard seat cushion side shield (3). The six-way power seat includes a six-way adjustable seat cushion track (1). The power seat can be adjusted up, down, front up, front down, forward, rearward. The power seat system is also available with the heated seat option. Refer to Electrical - Heated/Cooled Systems/Heated Seats - Description for additional information on the heated seats.

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Fig. 2: Identifying Power Seat Adjuster Courtesy of CHRYSLER LLC The power seat adjuster (1) contains two reversible motors that are connected to worm-drive gearboxes that move the seat adjusters through screw-type drive units. These motors are the height adjust motor (3) and the front tilt motor (2). The third motor on the power seat adjuster is responsible for the fore and aft movement of the power seat. The fore/aft motor (4) is a reversible motor that is connected through two flex drive cables to a worm-drive gearbox that moves the seat adjuster through a screw-type drive unit. Each motor contains a selfresetting circuit breaker to protect it from overload. Consecutive or frequent resetting of the circuit breakers may damaged the motors. The power seat adjuster assembly (1) includes the following major components: The Front Tilt Motor (2) is located on the upper power seat adjuster assembly and controls the up and down movement of the seat front only. The front tilt motor is available as a service part and if found to be inoperative or damaged should be replaced. See Removal . The Height Adjust Motor (3) is located on the rear of the lower power seat adjuster assembly and controls the up and down movement of the entire seat. The height adjust motor is available as a service part and if found to be inoperative or damaged should be replaced. See Removal . The Fore/Aft Motor (4) is a reversible motor that is connected through two flex drive cables to a worm-drive gearbox that moves the seat adjuster through a screw-type drive unit. This motor is responsible for the fore and user Monday, June 04, 2012 9:35:01 AM

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aft movement of the power seat. The fore/aft motor is available as a service kit that includes the flex drive cables. If the motor is found to be inoperative or damaged it should be replaced. See Removal

Fig. 3: Power Seat Switch Courtesy of CHRYSLER LLC Power Seat Switch - Vehicles may be equipped with a driver side six-way power seat switch. The power seat switches are paddle-type levers mounted on the outboard seat side shields. Movement of the seat cushions mimics the action of the switch paddles.

OPERATION OPERATION The power seat system receives battery current through a fuse in the Totally Integrated Power Module (TIPM) so that the power seats remain operational, regardless of the ignition switch position. When a power seat switch is actuated, a battery feed and a ground path are applied through the power seat switch contacts to the appropriate motor or motors. The motor and drive unit operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat track is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor is reversed through the switch contacts. This causes the motor to run in the opposite direction.

DIAGNOSIS AND TESTING POWER SEAT SYSTEM Operate the power seat switch and move the seat in all directions. The seat should move in each of the selected directions. If the power seat adjuster fails to operate in more than one direction, proceed as follows: user Monday, June 04, 2012 9:35:01 AM

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1. Inspect the power seat adjuster motors to ensure the electrical connectors are fully seated to the motors. If OK, go to 2. If not OK, connect the electrical connector to the fully seated position. 2. Check the power seat fuse in the Totally Integrated Power Module (TIPM). If OK, go to 3. If not OK, replace the inoperative fuse. 3. Remove the power seat switch from the seat cushion side panel. Check for battery voltage at the fused B (+) circuit cavity of the power seat switch wire harness connector. If OK, go to 4. If not OK, repair the open circuit to the TIPM as required. 4. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to 5. If not OK, repair the open circuit to ground as required. 5. See Diagnosis and Testing . If the switch tests OK, check the wire harness between the power seat switch and the motor. If the circuits check OK, replace the faulty power seat motor, track or seat back frame assembly. If the circuits are not OK, repair the wire harness as required. POWER SEAT DIAGNOSIS CHART SYMPTOM POSSIBLE CAUSE Power seat inoperative in all directions

Blown Fuse or inoperative circuit breaker

-

Power seat switch

-

Wiring problems (system or vehicle)

Fore/aft seat movement completely inoperative

Power seat switch

-

Fore aft motor or flex drive cable.

-

Up/down seat movement completely inoperative -

CORRECTION Check for damaged wiring and possible circuit short, Refer to SYSTEM WIRING DIAGRAMS for complete circuit schematic or connector pin-out information. Repair as necessary Perform appropriate power seat switch test. See Diagnosis and Testing . Replace switch as necessary Check for loose wire connections or damaged wiring, Refer to SYSTEM WIRING DIAGRAMS for complete circuit schematic or connector pin-out information. Repair as necessary Perform appropriate power seat switch test. See Diagnosis and Testing . Replace switch as necessary Replace the fore aft motor assembly.

Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Perform appropriate power seat switch Power seat switch test. See Diagnosis and Testing . Replace switch as necessary Height adjust motor or drive Replace the height adjust motor and drive assembly assembly.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Seats - Service Information - Journey

Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Perform appropriate power seat switch Seat tilt movement completely Power seat switch test. See Diagnosis and Testing . Replace inoperative switch as necessary Front tilt motor or drive Replace the front tilt motor and drive assembly assembly. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Seat motion chattering or Foreign material under seat or Remove foreign material. Clean and vibrating during fore/aft in seat track lubricate seat tracks as necessary movement Poor seat track lubrication Lubricate the lower portion of the effected seat tracks Loose components Check and tighten loose components as necessary Binding or sticking of Loosen seat track to vehicle mounting components bolts. Using the power seat switch, move the effected seat reward to the track stops. Tighten track bolts to proper torque and recheck seat operation. If seat motion is still abnormal, replace the fore aft motor assembly. Fore aft motor or flex drive Replace the fore aft motor assembly. cable. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Seat motion chattering or Remove foreign material. Clean and Foreign material under seat or vibrating during up/down lubricate upper seat track pivots as in upper seat track pivots necessary movement Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots Poor height adjust motor Lubricate the height adjust motor drive drive assembly lubrication assembly Check and tighten loose components as Loose components necessary user Monday, June 04, 2012 9:35:01 AM

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-

Seat motion chattering or vibrating during seat tilt movement -

-

Slow seat motion during fore/aft movement

-

-

Inspect and lubricate the effected upper seat track pivots. Recheck seat operation. If seat motion is still abnormal, replace the power seat track assembly. height adjust motor or drive Replace the height adjust motor and drive assembly assembly. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Remove foreign material. Clean and Foreign material under seat or lubricate upper seat track pivots as in upper seat track pivots necessary Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots Poor front tilt motor drive Lubricate the front tilt motor drive assembly lubrication assembly Check and tighten loose components as Loose components necessary Inspect and lubricate the effected upper seat track pivots. Recheck seat operation. Binding or sticking of If seat motion is still abnormal, replace components the power seat track assembly. Front tilt motor or drive Replace the front tilt motor and drive assembly assembly. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Check vehicle charging system operation. Repair charging system and charge Battery voltage low battery as necessary Check for loose ground connections or damaged wiring, Refer to SYSTEM Poor power seat system WIRING DIAGRAMS for complete ground circuit schematic or connector pin-out information. Repair as necessary Foreign material under seat or Remove foreign material. Clean and in seat track lubricate seat tracks as necessary Lubricate the lower portion of the Poor seat track lubrication effected seat tracks Check and tighten loose components as Loose components necessary Binding or sticking of components

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-

Binding or sticking of components

Loosen seat track to vehicle mounting bolts. Using the power seat switch, move the effected seat reward to the track stops. Tighten track bolts to proper torque and recheck seat operation. If seat motion is still abnormal, replace the fore aft motor assembly.

-

Fore aft motor or flex drive cable.

Replace the fore aft motor assembly.

-

Slow seat motion during up/down movement

-

-

-

Slow seat motion during seat tilt movement

Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Check vehicle charging system operation. Battery voltage low Repair charging system and charge battery as necessary Check for loose ground connections or damaged wiring, Refer to SYSTEM Poor power seat system WIRING DIAGRAMS for complete ground circuit schematic or connector pin-out information. Repair as necessary Remove foreign material. Clean and Foreign material under seat or lubricate upper seat track pivots as in upper seat track pivots necessary Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots Poor height adjust motor Lubricate the height adjust motor drive drive assembly lubrication assembly Check and tighten loose components as Loose components necessary Inspect and lubricate the effected upper Binding or sticking of seat track pivots. Recheck seat operation. components If seat motion is still abnormal, replace the power seat track assembly. Height adjust motor or drive Replace the height adjust motor and drive assembly assembly. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Check vehicle charging system operation. Battery voltage low Repair charging system and charge battery as necessary

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-

-

Squeaks, noises and rattles during fore/aft movement -

-

Squeaks, noises and rattles during up/down movement -

Check for loose ground connections or damaged wiring, Refer to SYSTEM Poor power seat system WIRING DIAGRAMS for complete ground circuit schematic or connector pin-out information. Repair as necessary Remove foreign material. Clean and Foreign material under seat or lubricate upper seat track pivots as in upper seat track pivots necessary Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots Poor front tilt motor drive Lubricate the front tilt motor drive assembly lubrication assembly Check and tighten loose components as Loose components necessary Inspect and lubricate the effected upper seat track pivots. Recheck seat operation. Binding or sticking of If seat motion is still abnormal, replace components the power seat track assembly. Front tilt motor or drive Replace the front tilt motor and drive assembly assembly. Check for loose wire connections or damaged wiring, Refer to SYSTEM Wiring problems (system or WIRING DIAGRAMS for complete vehicle) circuit schematic or connector pin-out information. Repair as necessary Foreign material under seat or Remove foreign material. Clean and in seat track lubricate seat tracks as necessary Lubricate the lower portion of the Poor seat track lubrication effected seat tracks Check and tighten loose components as Loose components necessary Loosen seat track to vehicle mounting bolts. Using the power seat switch, move the effected seat reward to the track stops. Binding or sticking of Tighten track bolts to proper torque and components recheck seat operation. If seat motion is still abnormal, replace the fore aft motor assembly. Fore aft motor or flex drive Replace the fore aft motor assembly. cable. Foreign material under seat or Remove foreign material. Clean and lubricate upper seat track pivots as in upper seat track pivots necessary Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots

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-

Poor height adjust motor drive assembly lubrication

-

Loose components

-

Binding or sticking of components

-

height adjust motor or drive assembly

Squeaks, noises and rattles during seat tilt movement -

Lubricate the height adjust motor drive assembly Check and tighten loose components as necessary Inspect and lubricate the effected upper seat track pivots. Recheck seat operation. If seat motion is still abnormal, replace the power seat track assembly. Replace the power seat track assembly.

Remove foreign material. Clean and Foreign material under seat or lubricate upper seat track pivots as in upper seat track pivots necessary Poor upper seat track pivot Lubricate the effected upper seat track lubrication pivots Poor front tilt motor drive Lubricate the front tilt motor drive assembly lubrication assembly Check and tighten loose components as Loose components necessary Inspect and lubricate the effected upper Binding or sticking of seat track pivots. Recheck seat operation. components If seat motion is still abnormal, replace the power seat track assembly. Front tilt motor or drive Replace the power seat track assembly. assembly

SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION Fore/Aft Motor to Mounting Bracket Screws Front Tilt Motor and Gearbox Assembly to Mounting Bracket Screws Front Tilt Motor Gearbox Spindle to Front Seat Track Tube Screw Height Adjust Motor and Gearbox Assembly to Mounting Bracket Screws Height Adjust Motor

N.m

Ft. Lbs.

In. Lbs.

5

-

45

12

-

106

17

-

150

12

-

106

17

-

150

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Gearbox Spindle to Rear Seat Track Tube Screw Power Seat Track to Front Seat Cushion Bolts Seat Riser to Power Seat Track Nuts/Bolts Seat Riser to Vehicle Floor Nuts

28

21

-

48

35

-

88

65

-

MOTOR, SEAT, FORE AFT REMOVAL REMOVAL

Fig. 4: Identifying Power Seat Fore/Aft Motor Courtesy of CHRYSLER LLC WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the inoperative front seat assembly. Refer to Body/Seats/SEAT - Removal . 3. Remove the flex drive cable cover (2). user Monday, June 04, 2012 9:35:01 AM

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a. Using a small flat bladed tool, release the mounting strap (1) that secures the flex drive cable cover (2) to the fore/aft motor (5). b. Pivot the cover away from the cable and pull it away from the seat frame (4) to disengage the cover slot from the mounting tab (3).

Fig. 5: Flex Drive Cable Courtesy of CHRYSLER LLC 4. Remove the flex drive cable. a. Carefully bend the flex drive cable at the center and pull the motor end (3) away from the fore/aft motor (1) to disengage. b. Pull the cable out of the screw drive assembly (2) and remove from seat track.

Fig. 6: Seat Frame Assembly Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:35:01 AM

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5. 6. 7. 8.

Disconnect the fore aft motor electrical connector. Remove the fore/aft motor to mounting bracket retaining screws (1). Remove the fore/aft motor (3). Remove the short flex drive cable (2) from the seat frame assembly (4).

INSTALLATION INSTALLATION

WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. CAUTION: Seat track side to side timing may be off if the fore aft motor was completely inoperative prior to removal. In the event the track timing is in question, proceed to 1 for track timing procedure. If track timing is not in question proceed to 2. 1. Using the square drive end of the old flex drive cable and a variable speed drill motor, drive the seat track screw drive assemblies reward until they reach the rear stops. a. Clamp one end of the old cable into the drill motor chuck. b. Put the other cable end into the seat track screw drive cable slot and slowly drive the seat track assembly reward until it reaches the rear stops. Take care not to bind the cable when the drive reaches the stop. c. Repeat this procedure for the other seat track.

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Fig. 7: Seat Frame Assembly Courtesy of CHRYSLER LLC 2. Install the short flex drive cable (2) into the seat frame assembly (4). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the screw drive assembly. 3. Install the fore/aft motor (3) ensuring the square cable end is properly aligned and fully inserted into the square drive slot of the motor. 4. Install the motor retaining screws (1). Tighten the screws to 5 N.m (45 in. lbs.).

Fig. 8: Flex Drive Cable Courtesy of CHRYSLER LLC 5. Install the flex drive cable. a. Install the flex drive cable into the seat frame assembly (2). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the screw drive assembly. user Monday, June 04, 2012 9:35:01 AM

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b. Install the flex drive cable into the fore/aft motor (1). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the motor assembly (3).

Fig. 9: Identifying Power Seat Fore/Aft Motor Courtesy of CHRYSLER LLC 6. Position the flex drive cable cover (2) onto the seat track assembly (4). Ensure the cover slots are properly aligned and fully inserted onto the mounting tabs (3). 7. Pivot the cable cover towards the cable and onto the fore/aft motor (5). 8. Secure the cover to the motor with the retaining strap (1). 9. Connect the fore/aft motor electrical connector. 10. Install the power seat. Refer to Body/Seats/SEAT - Installation . 11. Verify proper power seat operation.

MOTOR, SEAT, HEIGHT ADJUST REMOVAL REMOVAL

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Fig. 10: Height Adjust Motor And Gearbox Assembly Courtesy of CHRYSLER LLC WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Use caution when removing the height adjust motor and gearbox assembly (2) if the motor is inoperative, and the power seat is not in the full up position. The seat adjuster assembly is under load from the height adjust assist spring and may cause the motor to rotate under pressure when the fasteners are removed. The seat adjuster assembly also may spring upward when the motor is removed. If the height adjust motor is operative, move the power seat to the full up position prior to disconnecting the battery. 1. 2. 3. 4. 5. 6.

Disconnect and isolate the battery negative cable. Remove the inoperative front seat assembly. Refer to Body/Seats/SEAT - Removal . Disconnect the height adjust motor electrical connector. Remove the height adjust motor gearbox spindle (1) retaining screw (4). Remove the motor retaining screws (3). Remove the height adjust motor and gearbox assembly (2) from the seat track.

INSTALLATION INSTALLATION user Monday, June 04, 2012 9:35:01 AM

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Fig. 11: Height Adjust Motor And Gearbox Assembly Courtesy of CHRYSLER LLC 1. Screw the height adjust motor gearbox spindle (1) in or out as necessary until the motor retaining screws (3) and spindle screw (4) holes are aligned and all fasteners can be installed. 2. Position the height adjust motor and gearbox assembly (2) onto the seat track. 3. Install the motor retaining screws (3). Tighten the screws to 12 N.m (106 in. lbs.). 4. Install the height adjust motor gearbox spindle (1) retaining screw (4). Tighten the screw to 17 N.m (150 in. lbs.). 5. Connect the motor electrical connector. 6. Install the power seat. Refer to Body/Seats/SEAT - Installation . 7. Verify proper power seat operation.

MOTOR, SEAT, TILT REMOVAL REMOVAL

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Fig. 12: Power Seat Tilt Motor And Drive Assembly Courtesy of CHRYSLER LLC WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. 1. 2. 3. 4. 5. 6.

Disconnect and isolate the battery negative cable. Remove the inoperative front seat assembly. Refer to Body/Seats/SEAT - Removal . Disconnect the front tilt motor electrical connector. Remove the front tilt motor gearbox spindle (3) retaining screw (2). Remove the motor retaining screws (4). Remove the front tilt motor and gearbox assembly (1) from the seat track.

INSTALLATION INSTALLATION

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Fig. 13: Power Seat Tilt Motor And Drive Assembly Courtesy of CHRYSLER LLC 1. Screw the front tilt motor gearbox spindle (3) in or out as necessary until the motor retaining screws (4) and spindle screw (2) holes are aligned and all fasteners can be installed. 2. Position the front tilt motor and gearbox assembly (1) onto the seat track. 3. Install the motor retaining screws (4). Tighten the screws to 12 N.m (106 in. lbs.). 4. Install the front tilt motor gearbox spindle (3) retaining screw (2). Tighten the screw to 17 N.m (150 in. lbs.). 5. Connect the motor electrical connector. 6. Install the power seat. Refer to Body/Seats/SEAT - Installation . 7. Verify proper power seat operation.

SWITCH, SEAT DESCRIPTION DESCRIPTION

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Fig. 14: Identifying Power Seat Switch, Seat Cushion & Seat Cushion Side Shield Courtesy of CHRYSLER LLC The driver power seat can be adjusted in six different ways using the power seat switch. The power seat switch (2) is located on the lower outboard side of the seat cushion (1) on the seat cushion side shield (3). The power seat system incorporates a seat switch with a seat cushion control paddle. The individual components in the power seat switch assembly cannot be repaired. If the switch is damaged or inoperative, the entire power seat switch must be replaced. OPERATION OPERATION

When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. DIAGNOSIS AND TESTING POWER SEAT SWITCH

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Fig. 15: Power Seat Switch Terminals Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. See Removal . 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to POWER SEAT SWITCH CONTINUITY table. If not OK, replace the faulty power seat switch. If switch tests OK. See Diagnosis and Testing . POWER SEAT SWITCH CONTINUITY SWITCH POSITION OFF HORIZONTAL FORWARD HORIZONTAL REARWARD FRONT TILT DOWN FRONT TILT UP REAR TILT DOWN REAR TILT UP

CONTINUITY BETWEEN 7-4, 7-5, 7-8, 7-9, 7-10, 7-11 6-8, 7-4, 7-5, 7-9, 7-10, 7-11 6-4, 7-5, 7-8, 7-9, 7-10, 7-11 6-5, 7-4, 7-8, 7-9, 7-10, 7-11 6-9, 7-4, 7-5, 7-8, 7-10, 7-11 6-10, 7-4, 7-5, 7-8, 7-9, 7-11 6-11, 7-4, 7-5, 7-8, 7-9, 7-10

REMOVAL REMOVAL

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Fig. 16: Power Seat Switch Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the outboard seat cushion side shield (3). Disconnect the power seat switch electrical harness connector (4). Using a small flat bladed tool, gently release the four mounting tabs (1) that secure the power seat switch (2) and separate switch from side shield (3).

INSTALLATION INSTALLATION

Fig. 17: Power Seat Switch Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:35:01 AM

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1. Position the power seat switch (2) onto the seat cushion side shield (3). Gently apply pressure to the switch until the four mounting tabs (1) are fully seated into place. 2. Connect the power seat switch electrical connector (4). 3. Install the seat cushion outboard side shield. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly.

TRACK, SEAT REMOVAL REMOVAL

WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (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 may result in accidental airbag deployment and possible serious or fatal injury. NOTE:

Driver seat shown in illustrations. Passenger seat similar.

Fig. 18: Front Seat Bottom Closeout Courtesy of CHRYSLER LLC 1. Position the seat so that the heads of the bolts which secure the rear of the seat riser to the track can be accessed. 2. Remove the seat from the vehicle and place it on a workbench. Refer to Body/Seats/SEAT - Removal . user Monday, June 04, 2012 9:35:01 AM

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3. Remove the inboard seat cushion side shield. Refer to Body/Seats/SIDE SHIELDS, Seat Cushion Removal . 4. Remove the push-pin retainers (1) that secure the two elastic straps (4) of the seat bottom closeout (3) to the bottom of the seat cushion frame (2) and remove the closeout.

Fig. 19: Seat Cushion Frame Courtesy of CHRYSLER LLC NOTE:

Heated seat shown in illustration. Non-heated seat similar.

5. If equipped, remove the heated seat module (4) from the bottom of the seat cushion frame (3). 6. Disconnect the wire harness connectors from the power seat motors (1) and the seat track position sensor (8) and remove the wire harness (7) from the bottom of the seat cushion frame and the seat riser (9). 7. If required, remove the seat track position sensor from the seat track. 8. Remove the bolt (2) that secures the four seat track mounting brackets (3) to the bottom of the seat cushion frame. 9. Disengage the seat track mounting brackets from the bottom of the seat cushion frame and remove the seat track assembly (6) from the frame.

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Fig. 20: Seat Riser Courtesy of CHRYSLER LLC 10. If required, remove the wire harness retaining bracket (4) from the bottom of the seat riser (2). 11. Remove the two nuts (1) and the two bolts (3) that secure the seat riser to the seat track and remove the riser. INSTALLATION INSTALLATION

NOTE:

Driver seat shown in illustrations. Passenger seat similar.

Fig. 21: Seat Riser Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:35:01 AM

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1. Position the seat riser (2) to the seat track and install the retaining two nuts (1) and bolts (3). Tighten the nuts and bolts to 48 N.m (35 ft. lbs.). 2. Install the wire harness retaining bracket (4) onto the seat riser.

Fig. 22: Seat Track Courtesy of CHRYSLER LLC NOTE:

Heated seat shown in illustration. Non-heated seat similar.

3. If removed, install the seat track position sensor (8). 4. Position the seat track assembly (6) to the bottom of the seat cushion frame (5). Make sure the seat track is properly located and that the plastic isolators are correctly installed. 5. Engage the four seat track mounting brackets (3) to the bottom of the seat cushion frame and install the retaining bolts (2). Tighten the bolts to 28 N.m (21 ft. lbs.). 6. Install the wire harness (7) to the bottom of the seat cushion frame and to the seat riser (9) and connect the wire harness connectors to the power seat motors (1) and the seat track position sensor. 7. If equipped, install the heated seat module (4) onto the bottom of the seat cushion frame.

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Fig. 23: Front Seat Bottom Closeout Courtesy of CHRYSLER LLC 8. Position the seat bottom closeout (3) to the rear of the seat and install the push-pin retainers (1) that secure the two elastic straps (4) to the bottom of the seat cushion frame (2). 9. Install the inboard seat cushion side shield. Refer to Body/Seats/SIDE SHIELDS, Seat Cushion Installation . 10. Install the seat into the vehicle. Refer to Body/Seats/SEAT - Installation .

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2009 ACCESSORIES AND EQUIPMENT Power Top, Sunroof - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Power Top/Sunroof Components Courtesy of CHRYSLER LLC 1 - DRAIN TROUGH 2 - GLASS ASSEMBLY 3 - SUN SHADE 4 - WIND DEFLECTOR user Monday, June 04, 2012 10:00:38 10:00:27 AM

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5 - MOTOR 6 - MOTOR SCREWS (3) 3 N.m (26 in. lbs.) 7 - GLASS ASSEMBLY SCREWS (4) 3.5 N.m (31 in. lbs.) 8 - FRAME ASSEMBLY 9 - BRACKETS 10 - END CAPS WARNING: Keep fingers and other body parts out of sunroof opening at all times.

The sunroof features a power sliding glass panel and a sunshade which can be manually positioned anywhere along its travel, rearward of glass panel front edge. The sunroof is electrically operated from two switches located on the windshield header, between the map lamp. To operate the sunroof the ignition switch must be in either the Accessory or On/Run position. One switch (vent) is a push button type and opens the sunroof to the vent position only. The other switch (open/close) is a rocker type for opening and closing the sunroof. Pressing and releasing the open button once the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and holding the close button will close the sunroof. If the close button is released the sunroof will stop in that position. Also, by pressing the close button the sunroof will close automatically. SUNROOF OPERATION INSTRUCTIONS

-

FULL VENT

VENT RANGE

FLUSH

SWITCH INPUTS OPEN CLOSE 1. Push and hold switch 1. Push and hold switch until glass stops in flush until glass stops in flush closed position glass will closed position. then express open 2. Press switch for less 2. Press switch for less than 0.65 seconds for than 0.65 seconds for express to full open. express to flush closed. 1. Push and hold switch 1. Push and hold switch until glass passes through until glass stops in flush flush closed position. closed position. Glass will then open 2. Press switch for less 2. Press switch for less than 0.65 seconds for than 0.65 seconds for express to full open. express to flush closed. 1. Press switch for less No action than 0.65 seconds for express to full open.

VENT No action

1. Push and hold switch until glass stops in full vent position. 2. Press switch for less than 0.65 seconds for express to full vent. 1. Press and hold switch. Glass will travel through flush closed to full vent. Glass will stop when switch is released or when fully vented.

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FULL OPEN

2. Press switch for more than 0.65 seconds and glass will stop when switch is released No action 1. Press and hold switch until glass stops in flush closed position or anywhere in between. -

2. Press switch for less than 0.65 seconds for express to flush closed.

2. Press switch for less than 0.65 seconds for express to full vent. 1. Press and hold switch. Glass will travel through flush closed to full vent. Glass will stop when switch is released. 2. Press switch for less than 0.65 seconds for express to full vent.

OPERATION OPERATION This vehicle has a vent, tilt and slide power sunroof system with express (one-touch) open/close feature. The sunroof system receives battery feed through the "sunroof" relay and a 25 amp mini fuse located in the Totally Integrated Power Module (TIPM). The sunroof system power is supplied when the ignition switch is in the RUN and ACCESSORY positions. The sunroof will operate normally with the key in any position while the Accessory Delay system is active. The sunroof is electrically operated from two switches located in the overhead console in between the two reading lamps. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position.

DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES Before beginning sunroof diagnostics, verify that all other power accessories are in proper operating condition. Refer to SUNROOF DIAGNOSIS CHART table for possible causes. If not, a common electrical problem may exist. Refer to appropriate wiring diagrams information for circuit, splice and component descriptions. Check the condition of the circuit protection (20 amp circuit breaker in the Totally Integrated Power Module (TIPM)). Inspect all wiring connector pins for proper engagement and continuity. Check for battery voltage at the power sunroof drive motor. Refer to SYSTEM WIRING DIAGRAMS for circuit information. If battery voltage of more than 9 volts is detected at the drive motor, proceed with the following tests (the drive motor will not operate at less than 9 volts). Before beginning diagnosis for wind noise or water leaks, verify that the problem was not caused by releasing the control switch before the sunroof was fully closed. The sunroof module has a water-management system. If user Monday, June 04, 2012 10:00:27 AM

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however, the sunroof glass is in a partial closed position, high pressure water may be forced beyond the water management system boundaries and onto the headlining. SUNROOF DIAGNOSIS CHART SYMPTOM Sunroof motor inoperative.

POSSIBLE CAUSE Faulty control switch. Faulty circuit ground between sunroof drive motor, control switch, and body harness. Faulty power circuit between sunroof drive motor, control switch, and body harness. Faulty drive motor. Faulty drive motor electrical connector. Audible whine when switch is depressed, Faulty drive motor. sunroof does not operate. Binding cable. Audible clicking or ratcheting when switch Broken or worn drive cable. is pressed, sunroof does not operate. Worn drive motor gear. Mechanisms not synchronized. Sunroof vents and opens, but does not close. Binding cable. Faulty circuit. Faulty control switch. Faulty drive motor. Broken trough guide Sunroof vents, but does not open. Binding cable or mechanism. Faulty circuit. Faulty switch. Faulty drive motor. Sunroof does not vent. Binding cable or mechanism. Faulty circuit. Faulty control switch. Faulty drive motor. Sunroof water leak. Drain tubes clogged or kinked or disconnected from the sunroof. Glass panel improperly adjusted. Faulty glass panel seal. Gurgling sound from sunroof. Low spot in drain hose routing, allowing water to stand. Wind noise from sunroof. Front of glass panel to high or rear to low. Wind deflector not deploying. Glass not centered in opening. Faulty glass panel seal. Rattles from open sunroof while driving. Loose or broken attaching hardware. Worn or broken mechanism. Sunroof does not stop in the fully closed Drive motor has lost position of glass, teach procedure position. required to reprogram drive motor. Refer to Standard user Monday, June 04, 2012 10:00:27 AM

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Procedure .

MOTOR, SUNROOF STANDARD PROCEDURE DRIVE MOTOR TEACH PROCEDURE REPLACEMENT DRIVE MOTOR

1. Upon first powering up the sunroof, continuously press the close button on the power sunroof switch. The sunroof will begin moving in the tilt up direction. 2. The glass panel will move to the hard stop (just past the full tilt position) and then reverse to the soft stop (the full tilt position). 3. Once the sunroof has reversed immediately (within 5 seconds of stopping travel), release the switch and continuously press the close button again. 4. The sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. ORIGINAL DRIVE MOTOR

1. Cycle the sunroof to full close position and release close button on the power sunroof switch. 2. Once the sunroof is in the fully closed position, press and continuously hold the close button again. 3. After a ten second delay the sunroof will begin to move past the normal vent position to the hard stop position. It will then reverse to the normal full vent position (also called the soft stop). 4. Once the sunroof has reversed to the vent soft stop, immediately (within 5 seconds of stopping travel) release the close button and continuously press it again. 5. After a three second delay the sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. REMOVAL REMOVAL

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Fig. 2: Identifying Drive Motor Components Courtesy of CHRYSLER LLC 1 - ELECTRICAL CONNECTOR 2 - MODULE ASSEMBLY 3 - DRIVE MOTOR 4 - MOUNTING SCREWS 1. Remove headliner. Refer to Body/Interior/HEADLINER - Removal . 2. Disconnect the electrical connector (1). 3. Remove three motor assembly attaching screws (4) from bottom side of motor assembly (3) and remove motor assembly from the motor bracket. INSTALLATION INSTALLATION

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Fig. 3: Identifying Lifter Arm, Trolley, & Alignment Pin Courtesy of CHRYSLER LLC 1 - LIFTER ARM 2 - TROLLEY 3 - ALIGNMENT PIN 1. If sunroof was open when drive motor was removed, carefully move glass panel into closed position and remove glass panel. Refer to Body/Sunroof/GLASS, Sunroof - Removal . 2. Set lifter arm timing by manually sliding the mechanisms (1) in the track until timing holes in the trollies are aligned with the timing holes in the lifter arm cams (2) and insert pins (3) into the mechanisms to hold mechanisms in closed position.

Fig. 4: Drive Motor Components Courtesy of CHRYSLER LLC 1 - ELECTRICAL CONNECTOR 2 - MODULE ASSEMBLY 3 - DRIVE MOTOR 4 - MOUNTING SCREWS 3. Place motor (3) into position and install screws (4) attaching motor to bracket (2). 4. Tighten the screws (4) to 3 N.m (26 in. lbs.). 5. If sunroof glass panel was removed previously, remove the timing pins and install the sunroof glass panel. Refer to Body/Sunroof/GLASS, Sunroof - Installation . 6. Partially install the headliner and connect the sunroof wiring electrical connectors. Refer to Body/Interior/HEADLINER - Installation . 7. Temporarily install sunroof switch and perform the sunroof motor teach procedure. See Standard Procedure . 8. Test sunroof operation, adjust glass as necessary. Refer to Body/Sunroof/GLASS, Sunroof user Monday, June 04, 2012 10:00:27 AM

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Adjustments . 9. Complete the headliner installation. Refer to Body/Interior/HEADLINER - Installation .

SWITCH, SUNROOF DESCRIPTION DESCRIPTION

Fig. 5: Power Sunroof Switch Courtesy of CHRYSLER LLC The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: z z z z z

Power sunroof open (back of switch pushed) Power sunroof express open (back of switch pushed and released) Power sunroof closed (front of switch pushed) Power sunroof express closed (front of switch pushed and released) Power sunroof vent (switch center button pushed)

The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced. See Removal . OPERATION OPERATION

The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp user Monday, June 04, 2012 10:00:27 AM

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assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. DIAGNOSIS AND TESTING SUNROOF SWITCH

For complete circuit diagrams, refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. 1. Remove the overhead console. Refer to Electrical - Message Systems/Overhead Console - Removal . 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to step 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to step 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Top, Sunroof - Service Information - Journey

Fig. 6: Power Sunroof Switch Wire Harness Connector Courtesy of CHRYSLER LLC 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the overhead console assembly. Refer to Electrical - Message Systems/Overhead Console - Removal . POWER SUNROOF SWITCH CONTINUITY TABLE SWITCH POSITION CONTINUITY BETWEEN PINS OFF NO CONTINUITY SUNROOF OPEN B AND D SUNROOF CLOSED B AND C SUNROOF VENT B AND A REMOVAL REMOVAL

1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Electrical - Message Systems/Overhead Console - Removal . 3. Using a suitable flat bladed tool, release the mounting tabs from the sides of the sunroof control switch and pull the switch out of the overhead console assembly. INSTALLATION INSTALLATION

1. Insert the sunroof control switch into the overhead console assembly. Push the switch until it is securely user Monday, June 04, 2012 10:00:27 AM

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held in place by the mounting tabs. 2. Install the overhead console. Refer to Electrical - Message Systems/Overhead Console - Installation . 3. Connect the battery negative cable.

user Monday, June 04, 2012 10:00:27 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Windows - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Power Windows - Service Information - Journey

DESCRIPTION DESCRIPTION The power window system allows each of the door windows to be raised and lowered electrically by actuating a switch on the trim panel of each respective door. A master switch on the driver side front door trim panel allows the driver to raise or lower each of the passenger door windows, and to lock out the individual switches on the passenger doors from operation. The power window system receives battery feed only when the ignition switch is in the RUN or ACCESSORY position. The power window system will also operate when in power accessory delay For service of mechanical components, such as the regulator, lift plate, window tracks, or glass, refer to BODY article.

OPERATION OPERATION Front and rear door window lift motors are of the permanent magnet type. A battery positive and negative connection to either of the two motor terminals will cause the motor to rotate in one direction. Reversing current through these same two connections will cause the motor to rotate in the opposite direction. Each individual motor is grounded through the master switch. EXPRESS DOWN WINDOW FEATURE

This feature allows you to remotely lower both front door windows at the same time. To use this feature, press and release the UNLOCK button on the RKE transmitter and then immediately press and hold the UNLOCK button until the windows lower to the desired level or until they lower completely.

STANDARD PROCEDURE CLEAR/RELEARN NOTE:

Make sure battery is fully charged before proceeding.

NOTE:

This needs to be completed every time the window glass is adjusted/removed, motor replaced, and or regulator replaced.

CLEAR/DENORMALIZE USING A SCAN TOOL user Monday, June 04, 2012 9:27:57 9:27:53 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Windows - Service Information - Journey

To clear/denormalize the door module memory, using a scan tool under the Miscellaneous menu look for Denormalization Window Command/ECU reset, and follow the directions. RELEARN/NORMALIZE USING A SCAN TOOL To relearn/normalize the door module memory, using a scan tool under the Miscellaneous menu look for Normalization Window command, and follow the directions. CLEAR/DENORMALIZE, RELEARN/NORMALIZE WITHOUT A SCAN TOOL Hold up/down the window switch for at least 30 seconds until the DTC is set for stuck switch. This will clear the memory of the calibration information (CLEAR/DENORMALIZE). Proceed to relearn/normalize. 1. Put a battery charger on vehicle. 2. If equipped with express-up/express-down, reset the express-up/down module for the door window glass. The window switch on the corresponding door must be used to control the window. Do not use the master switch for the passenger window. 3. To calibrate, start by moving the window to the middle position. 4. Drive the glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the glass is fully closed. Do not release the window switch. Continue to hold the window switch up for 2 seconds after the window glass is full closed. 5. Drive the glass to the full - down position by pushing down (depress) the window switch, (second detent if equipped with express-down) until the window glass is down for 2 seconds after the window glass is fully open. Do not release the window switch. Continue to hold the window switch down for 2 seconds after the window glass is fully open. 6. Check the operation of the express-up/ express-down feature. 7. If the express up/down doesn't work, repeat step # 3, waiting for 3 seconds. 8. Check that the window glass reverses when in the express-up mode by holding a pen in the path of the glass. 9. Once the proper operation of the express-up/express-down feature has been verified, clear all Diagnostic Trouble Codes (DTC's).

MOTOR, WINDOW REGULATOR DIAGNOSIS AND TESTING WINDOW MOTOR

1. 2. 3. 4.

Remove door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Removal . Connect positive (+) lead from a test battery to either of the two motor terminals. Connect negative (-) lead from test battery to remaining motor terminal. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed.

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5. 6. 7. 8.

b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in steps 1 and 2 and window should now move. If window does not move, replace motor. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. If window does not move, check to make sure that it is free. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. To determine if the glass is free, disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand.

REMOVAL REMOVAL

1. 2. 3. 4.

Disconnect and isolate the battery negative cable. Remove the door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Removal . Disconnect the electrical connector. Remove the mounting fasteners and remove the motor.

INSTALLATION INSTALLATION

1. 2. 3. 4.

Install the window motor and install the mounting fasteners. Connect the electrical connector. Install the door trim panel. Refer to Body/Door - Front/PANEL, Door Trim - Installation . Connect the battery negative cable.

SWITCH, POWER WINDOW DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING

For switch testing, remove the switch. See Removal . Using an ohmmeter, refer to MASTER WINDOW SWITCH TEST table to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. user Monday, June 04, 2012 9:27:54 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Power Windows - Service Information - Journey

MASTER WINDOW SWITCH TEST SWITCH POSITION OFF LEFT FRONT UP-NON EXPRESS LEFT FRONT DOWN-NON EXPRESS RIGHT FRONT UP-NON EXPRESS RIGHT FRONT DOWN-NON EXPRESS LEFT REAR UP LEFT REAR DOWN RIGHT REAR UP RIGHT REAR DOWN LOCKOUT SWITCH (SWITCH NOT DEPRESSED)

CONTINUITY BETWEEN 5/13 AND 2 5/13 AND 3 5/13 AND 6 5/13 AND 7 1 AND 10 1 AND 9 1 AND 12 1 AND 14 1 AND 2 1 AND 3 1 AND 6 1 AND 7 1 AND 4

PASSENGER WINDOW SWITCH TEST SWITCH CONTINUITY POSITION UP DOWN

BETWEEN

RESISTANCE VALUE 330 ohms ± 10% 3000 ohms ± 10%

4 AND 9 4 AND 9

REMOVAL REMOVAL

SWITCH - FRONT DOOR SWITCH - REAR DOOR

Refer to the SWITCH - FRONT DOOR removal procedure. Refer to the SWITCH - REAR DOOR removal procedure.

SWITCH - FRONT DOOR

1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. SWITCH - REAR DOOR

1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door user Monday, June 04, 2012 9:27:54 AM

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trim panel. 3. Disconnect the electrical connector. 4. Remove the switch from the handle. INSTALLATION INSTALLATION

SWITCH - FRONT DOOR SWITCH - REAR DOOR

Refer to the SWITCH - FRONT DOOR installation procedure. Refer to the SWITCH - REAR DOOR installation procedure.

SWITCH - FRONT DOOR

1. 2. 3. 4.

Install the switch by snapping into place. Connect switch wire connector. Install the switch to the door trim panel. Connect the battery negative cable.

SWITCH - REAR DOOR

1. Connect the electrical connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable.

user Monday, June 04, 2012 9:27:54 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Speed Control - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Speed Control - Service Information - Journey

SWITCH, SPEED CONTROL REMOVAL REMOVAL

Fig. 1: Removing/Installing Horn Switch Courtesy of CHRYSLER LLC WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury. Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag. Refer to Restraints/AIR BAG, Driver - Removal . 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. user Monday, June 04, 2012 9:50:31 9:50:28 AM

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Fig. 2: Identifying Speed Control Switch Screws & Electrical Connector Courtesy of CHRYSLER LLC 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. INSTALLATION INSTALLATION

Fig. 3: Identifying Speed Control Switch Screws & Electrical Connector Courtesy of CHRYSLER LLC 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. user Monday, June 04, 2012 9:50:28 AM

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2. Install speed control switch mounting screws (4) and tighten screws to 1.6 N.m (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3).

Fig. 4: Removing/Installing Horn Switch Courtesy of CHRYSLER LLC 4. 5. 6. 7. 8. 9.

Install horn switch (2) to steering wheel. Install horn switch mounting screws (3) and tighten screws to 8 N.m (71 ins. lbs.). Connect electrical connector to horn switch. Install driver's side airbag. Refer to Restraints/AIR BAG, Driver - Installation . Connect negative battery cable, tighten nut to 4.5 N.m (40 in. lbs.). Verify vehicle and system operation.

user Monday, June 04, 2012 9:50:28 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Vehicle Theft Security - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Vehicle Theft Security - Service Information - Journey

DESCRIPTION DESCRIPTION The Vehicle Theft Security System (VTSS) is an available factory-installed option on this vehicle. The VTSS is comprised of two primary subsystems: Vehicle Theft Alarm (VTA) and Sentry Key Immobilizer System (SKIS). The VTA is an active system that provides visual and audible responses as deterrents to and warnings of unauthorized vehicle tampering. The SKIS is a passive system that effectively immobilizes the vehicle against unauthorized operation. Following are paragraphs, which describe these subsystems of the VTSS. Certain functions and features of the VTSS rely upon resources shared with or controlled by other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. Other modules that may affect VTSS operation are: z

z

z

z

Totally Integrated Power Module (TIPM) - The TIPM is located in the engine compartment, near the battery. The TIPM provides the VTA system logic, driver and front passenger door ajar switch status, and power lock switch status. Refer to Electrical - Wiring/Power Distribution/MODULE, Totally Integrated Power (TIPM) - Description . ElectroMechanical Instrument Cluster - The ElectroMechanical Instrument Cluster (EMIC) is also known as the Cab Compartment Node (CCN) in this vehicle. The EMIC/CCN is located in the instrument panel above the steering column opening, directly in front of the driver. The EMIC provides the security indicator. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Powertrain Control Module - The Powertrain Control Module (PCM) provides the SKIS engine control logic. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Powertrain Control - Description . Wireless Ignition Node - The Wireless Ignition Node (WIN) provides ignition switch status. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/RECEIVER, Wireless Ignition Node - Description .

Except for the Sentry Key transponders integral to the FOB with Integrated Key (FOBIK), which rely upon Low Frequency (LF) communication, hard-wired circuitry connects the VTA and SKIS components to the electrical system of the vehicle. These hard-wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system, and to the SKIS components through a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices, and grounds. VEHICLE THEFT ALARM

The VTA is available in two different configurations for this vehicle: One configuration is designed for vehicles user Monday, June 04, 2012 9:49:33 9:49:30 AM

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manufactured for sale in North America; while, the other configuration is designed for vehicles manufactured for sale in markets outside of North America, also referred to as export markets within the context of this service information. All vehicles equipped with VTA are also equipped with the Remote Keyless Entry (RKE) system and the Sentry Key Immobilizer System (SKIS), regardless of their market destination. The North American and export base version of the VTA system provide perimeter vehicle protection by monitoring the vehicle doors, the ignition switch, the liftgate, and the hood for vehicles built for certain markets where it is required equipment. If unauthorized vehicle use or tampering is detected these systems respond by pulsing the vehicle horn as an audible deterrent and flashing certain exterior lamps as a visual deterrent. The VTA includes the following major components, which are described in further detail elsewhere in this service information: z

z

z

z

Door Ajar Switches - A door ajar switch is integral to the door latch mechanism of each front and rear door. Hood Ajar Switch - A hood ajar switch is located in a bracket on the right inner fender side shield of vehicles built for sale in certain export markets where it is required equipment. Liftgate Ajar Switch - A liftgate ajar switch is integral to the latch for the liftgate in the vehicle. Refer to Body/Decklid/Hatch/Liftgate/Tailgate/LATCH - Removal . Security Indicator - A security indicator is integral to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). Refer to Electrical - Instrument Cluster/Instrument Cluster - Description .

SENTRY KEY IMMOBILIZER SYSTEM

The Sentry Key Immobilizer System (SKIS) is standard on all vehicles equipped with a Wireless Ignition Node (WIN). Vehicles equipped with the Vehicle Theft Alarm (VTA) are also equipped with SKIS. The SKIS provides passive vehicle protection by preventing the engine from operating unless a valid electronically encoded key is detected in the ignition lock cylinder. The SKIS includes the following major components, which are described in further detail elsewhere in this service information: z

z

z

Security Indicator - A security indicator is integral to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Sentry Key Transponder - The Sentry Key transponder is integral to the FOB with Integrated Key (FOBIK), which also includes an integral Remote Keyless Entry (RKE) transmitter and an integral mechanical valet key. See Description. Wireless Ignition Node - The Wireless Ignition Node (WIN) is located behind the instrument panel, and is partially concealed by the ignition switch bezel. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. The WIN contains the integral ignition switch and performs all of the same SKIS functions performed by a Sentry Key Immobilizer Module (SKIM) used on prior vehicles. See Description .

OPERATION user Monday, June 04, 2012 9:49:30 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Vehicle Theft Security - Service Information - Journey

OPERATION The Vehicle Theft Security System (VTSS) is divided into two basic subsystems: Vehicle Theft Alarm (VTA) and Sentry Key Immobilizer System (SKIS). Following are paragraphs that briefly describe the operation of each of these two subsystems. VEHICLE THEFT ALARM

The Totally Integrated Power Module (TIPM) is used on this vehicle to control and integrate many of the functions and features included in the Vehicle Theft Alarm (VTA). In the VTA system, the TIPM receives inputs indicating the status of the door ajar switches, the ignition switch, the liftgate ajar switch, and the power lock switches. In vehicles built for certain export markets where it is required, the hood ajar switch provides a hard-wired input to the TIPM. The TIPM processes the information from all of these inputs and sends the appropriate electronic messages over the CAN data bus. The TIPM internally controls the output to the hazard warning lamps and sends a control output to energize or de-energize the horn relay as appropriate. The hard-wired circuits between components related to the VTA system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information, and location views for the various wire harness connectors, splices, and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the VTA system or the electronic controls or communication between modules and devices that provide some features of the VTA system. The most reliable, efficient, and accurate means to diagnose the VTA system or the electronic controls and communication related to VTA system operation requires the use of a diagnostic scan tool. See the Vehicle Theft Security System menu item on the scan tool. Refer to the appropriate diagnostic service information. Following are paragraphs that briefly describe the operation of each of the VTA features. See the owner's manual in the vehicle glove box for more information on the features, use, and operation of the VTA. ENABLING

The TIPM must have the VTA function electronically enabled in order for the VTA to perform as designed. The logic in the TIPM keeps its VTA function dormant until it is enabled using a diagnostic scan tool. The VTA function of the TIPM is enabled on vehicles equipped with the VTA option at the factory, but a service replacement TIPM must be VTA-enabled by the dealer using a diagnostic scan tool. Refer to the appropriate diagnostic service information. ARMING

Passive arming of the VTA occurs when the vehicle is exited with the FOB with Integrated Key (FOBIK) removed from the ignition switch, the headlamps are turned OFF, and the doors are locked while they are open using the power lock switch. Active arming occurs when the LOCK button on the Remote Keyless Entry (RKE) transmitter integral to the FOBIK is depressed to lock the vehicle. For active arming to occur, the doors, and the liftgate must be closed and the ignition switch must be in the OFF position when the FOBIK RKE transmitter LOCK button is depressed. The power lock switch will not function if the FOBIK is in the ignition switch or the headlamps are turned ON with the driver side front door open. user Monday, June 04, 2012 9:49:30 AM

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Pre-arming of the VTA is initiated when a door or the liftgate is open when the vehicle is locked using a power door lock switch or when the RKE transmitter LOCK button is depressed. Pre-arming will not occur if the FOBIK is in the ignition switch or the headlamps are turned ON with the driver side front door open. When the VTA is pre-armed, the arming sequence is delayed until all of the doors and the liftgate have been closed. The VTA will remain in pre-armed mode for up to 16 seconds after all doors and the liftgate have been closed. Once the VTA begins the passive or active arming sequence, the security indicator in the instrument cluster will flash rapidly for about 16 seconds. This indicates that VTA arming is in progress. If the ignition switch is turned to the ON position, if a door or the liftgate is unlocked and opened by any means, or the RKE PANIC button (if equipped) is depressed during the 16 second arming process, the security indicator will stop flashing and the arming process will abort. Once the arming sequence is successfully completed, the security indicator will flash at a slower rate, indicating that the VTA is armed. On vehicles equipped with the hood ajar switch, the VTA arming sequence will occur regardless of whether the hood is open or closed, but the underhood area will not be protected unless the hood is closed when the VTA arming sequence begins. Also, if the status of the hood ajar switch changes from open to closed during the 16 second arming process, the security indicator will stop flashing and the VTA arming sequence will abort. Once the arming process is successfully completed, the security indicator will flash at a slower rate, indicating that the VTA is armed. DISARMING

For vehicles built for the North American market, passive disarming of the VTA occurs by inserting a valid Sentry Key Immobilizer System (SKIS) FOBIK into the ignition switch. Active disarming of the VTA for all markets occurs when the vehicle is unlocked by depressing the UNLOCK button of the FOBIK RKE transmitter. Once the alarm has been activated, either disarming method will also deactivate the alarm. Depressing the PANIC button (if equipped) on the FOBIK RKE transmitter will not disarm the VTA. POWER-UP MODE

When the armed VTA senses that the battery has been disconnected and reconnected, it enters its power-up mode. In the power-up mode, the alarm system remains armed following a battery failure or disconnect. If the VTA was armed prior to a battery disconnect or failure, the technician, or vehicle operator will have to actively or passively disarm the alarm system after the battery is reconnected. The power-up mode will also apply if the battery goes dead while the system is armed, and battery jump-starting is attempted. The VTA will be armed until the technician or vehicle operator has actively or passively disarmed the alarm system. If the VTA is in the disarmed mode prior to a battery disconnect or failure, it will remain disarmed after the battery is reconnected or replaced, or if jump-starting is attempted. ALARM

The VTA alarm output varies by the version of the VTA with which the vehicle is equipped. In all cases, the alarm provides both visual and audible outputs; however, the time intervals of these outputs vary by the requirements of the market for which the vehicle is manufactured. In all cases, the visual output will be a flashing ON and OFF of the exterior lamps. For vehicles equipped with the North American or the export base version of the VTA, the audible output will be a pulsing of the horn. See the owner's manual in the vehicle glove box for details of the alarm output requirements of the specific market for which the vehicle was manufactured. The inputs that will trigger the alarm include the door ajar switches, the liftgate ajar switch, and user Monday, June 04, 2012 9:49:30 AM

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in vehicles built for certain markets where required, the hood ajar switch. TAMPER ALERT

The VTA tamper alert feature will pulse the horn three times upon VTA disarming if the alarm was triggered and has since timed out or if the battery has been disconnected and reconnected. This feature alerts the vehicle operator that the VTA alarm was activated while the vehicle was unattended. SENTRY KEY IMMOBILIZER SYSTEM

The Sentry Key Immobilizer System (SKIS) is designed to provide passive protection against unauthorized vehicle use by disabling the engine whenever any method other than a valid Sentry Key FOB with Integrated Key (FOBIK) is used to start the vehicle. The SKIS is considered a passive protection system, because it is always active when the ignition system is energized and it does not require any customer intervention. The SKIS uses Low Frequency (LF) communication to obtain confirmation that the FOBIK in the ignition switch is valid for operating the vehicle. The microprocessor-based SKIS hardware and software also uses electronic messages to communicate with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/COMMUNICATION - Operation . Pre-programmed Sentry Key FOBIK transponders are provided with the vehicle from the factory. Each Wireless Ignition Node (WIN) will recognize a maximum of eight Sentry Key FOBIK transponders. If the customer would like additional FOBIKs, other than those provided with the vehicle, they may be purchased from any authorized dealer. These additional FOBIKs must be programmed to the WIN in the vehicle in order for the system to recognize them as valid. This can be done by the dealer using a diagnostic scan tool, or if Customer Learn programming is an available SKIS feature in the market where the vehicle was purchased, the customer can program the additional FOBIKs, as long as at least two valid Sentry Key FOBIKs are already available. See Standard Procedure . The WIN performs a self-test of the SKIS each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) if a system malfunction is detected. The WIN will also send an electronic message to the instrument cluster if a fault is detected, and the instrument cluster illuminates the security indicator. The hard-wired circuits between components related to the SKIS may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKIS or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKIS or the electronic controls and communication related to SKIS operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information.

DIAGNOSIS AND TESTING user Monday, June 04, 2012 9:49:30 AM

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VEHICLE THEFT SECURITY SYSTEM The Vehicle Theft Security System (VTSS) is divided into two basic subsystems: Vehicle Theft Alarm (VTA) and Sentry Key Immobilizer System (SKIS). Following are the recommended procedures for diagnosis of each of these two subsystems. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. VEHICLE THEFT ALARM

The hard-wired circuits between components related to the VTA system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices, and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the VTA system or the electronic controls or communication between other modules and devices that provide some features of the VTA system. The most reliable, efficient, and accurate means to diagnose the VTA system or the electronic controls and communication related to VTA system operation requires the use of a diagnostic scan tool. See the Vehicle Theft Security System menu item on the scan tool. Refer to the appropriate diagnostic service information. SENTRY KEY IMMOBILIZER SYSTEM

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard-wired circuits between components related to the SKIS may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices, and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKIS or the electronic controls or communication between other modules and devices that provide some features of the user Monday, June 04, 2012 9:49:30 AM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Vehicle Theft Security - Service Information - Journey

SKIS. The most reliable, efficient, and accurate means to diagnose the SKIS or the electronic controls and communication related to SKIS operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information.

STANDARD PROCEDURE WIN INITIALIZATION - EXPORT WITH COLUMN LOCK MODULE CAUTION: On vehicles equipped with the optional export premium Vehicle Theft System, when either the Wireless Ignition Node (WIN) or the shaft lock module (also known as Elektrische LenksAulenverriegelung/ELV or electric steering column lock) is replaced with a new unit, the existing WIN or ELV MUST also be replaced with a new unit. In other words, any time either the WIN or the ELV is replaced with a new unit, BOTH the WIN and the ELV MUST be replaced with new units, WITHOUT EXCEPTION. Following replacement of BOTH the WIN and the column lock module/ELV, the two modules MUST be initialized using diagnostic scan tool routines in the EXACT SEQUENCE that follows. Failure to follow this sequence may result in BOTH the new WIN and the new ELV being rendered unusable, requiring BOTH units to be replaced a second time. 1. After both the WIN and the ELV have been replaced with new units, connect the diagnostic scan tool to the Data Link Connector (DLC) and turn the ignition key to the ON/RUN position. 2. Navigate to the WIN in the ECU View of the diagnostic scan tool. 3. Run the WIN Replaced routine found under the Miscellaneous Functions menu item of the scan tool. 4. Turn the ignition key to the OFF position, wait 30 seconds, then cycle the key back to the ON/RUN position. 5. Scan tool to program the ignition key(s) to the WIN. See Standard Procedure . 6. Run the ELV Replaced routine, also found under the Miscellaneous Functions menu item of the r WIN in the ECU View of the diagnostic scan tool. 7. Turn the ignition key to the OFF position, wait 30 seconds, then cycle the key back to the ON/RUN position. 8. Verify that the ELV Locks the steering column when the key is removed from the ignition lock cylinder, and Unlocks the steering column when the key is inserted into the ignition lock cylinder.

SPECIAL TOOLS VEHICLE THEFT SECURITY SYSTEMS

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Fig. 1: TPM - RKE Analyzer No. 9936 Courtesy of CHRYSLER LLC

KEY, TRANSPONDER DESCRIPTION DESCRIPTION

Fig. 2: Transponder Key Courtesy of CHRYSLER LLC The Sentry Key Immobilizer System (SKIS) has a transponder chip included on the circuit board beneath the user Monday, June 04, 2012 9:49:30 AM

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cover of each FOB with Integrated Key (FOBIK) (1) included with the vehicle. The FOBIK includes an integral mechanical valet key which is stored within the bottom of the FOBIK housing until it is released using the latch button (2). The valet key is cut to match the mechanical coding of the door and glove box lock cylinders. Each new replacement FOBIK must be programmed for operation of the Remote Keyless Entry (RKE) system and has a unique transponder identification code that is permanently programmed into it by the manufacturer. This identification code must be programmed into the Wireless Ignition Node (WIN) to be recognized by the SKIS as a valid key. The FOBIK transponder cannot be adjusted or repaired. If ineffective or damaged, the entire FOBIK and RKE transmitter unit must be replaced. OPERATION OPERATION

When the ignition switch is turned to the ON position, the Wireless Ignition Node (WIN) communicates through its antenna with the Sentry Key transponder within the FOB with Integrated Key (FOBIK) using a Low Frequency (LF) signal. The Sentry Key transponder chip is within the range of the WIN transceiver antenna ring when it is inserted into the ignition switch. The WIN determines whether a valid FOBIK is present in the ignition switch based upon the signal from the transponder. If a valid FOBIK is detected, that fact is communicated by the WIN to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows the engine to start. If the PCM receives an invalid key message, or receives no message from the WIN over the CAN data bus, the engine will be disabled. The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) will also respond to the invalid key message on the CAN data bus by flashing the security indicator ON and OFF. Each Sentry Key FOBIK has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the WIN has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key FOBIK is programmed into the memory of the WIN, the WIN stores the transponder identification code from the Sentry Key FOBIK and the Sentry Key FOBIK learns the Secret Key code from the WIN. Once the Sentry Key FOBIK learns the Secret Key code of the WIN, it is permanently stored in the memory of the transponder. Therefore, once a FOBIK has been programmed to a particular vehicle, it cannot be used on any other vehicle. Refer to RECEIVER, WIRELESS IGNITION NODE . The Sentry Key Immobilizer System (SKIS) performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in WIN memory if a Sentry Key FOBIK transponder problem is detected. The Sentry Key FOBIK transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic service information.

MODULE, SHAFT LOCK DESCRIPTION DESCRIPTION user Monday, June 04, 2012 9:49:30 AM

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Fig. 3: Shaft Lock Module Courtesy of CHRYSLER LLC A shaft lock module (1) is part of the premium version of the Sentry Key Immobilizer System (SKIS) in the Vehicle Theft Security System (VTSS). The premium version of the SKIS is only available in vehicles built for certain markets, where the additional features offered by this system are required. The shaft lock module is located in a bracket integral to the lower end of the steering column housing casting below the instrument panel in the passenger compartment. This unit is designed to work in conjunction with the Wireless Ignition Node (WIN), sometimes reffered to as the Sentry Key REmote Entry Module (SKREEM) to control a locking bolt (2) that engages a machined slot in the steering shaft to prevent shaft rotation whenever there is not a valid key present in the ignition lock cylinder on the instrument panel. Concealed within the module is the electronic circuitry of the module, and a bi-directional electric motor that actuates the locking bolt. The module is connected to the vehicle electrical system through the instrument panel wire harness. The mounting provisions for the shaft lock module are designed to resist unauthorized tampering. The module cannot be removed from the steering column while the locking bolt is in the locked position, or while the steering column is installed in the vehicle. The shaft lock module unit cannot be adjusted or repaired and, if ineffective or damaged, the entire steering column must be replaced. OPERATION OPERATION

The electronic circuitry within the shaft lock module contains all of the logic circuits and components to monitor and control the operation of the shaft locking bolt. The module uses a serial data bus for bi-directional communication with the Wireless Ignition Node (WIN) , sometimes referred to as the Sentry Key REmote Entry Module (SKREEM). If the module detects a problem with the positioning or operation of the locking bolt, it sends an error message to the WIN. The WINthen stores a Diagnostic Trouble Code (DTC) and sends an user Monday, June 04, 2012 9:49:30 AM

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electronic error message to the Instrument Cluster, sometimes referred to as the Cab Compartment Node (CCN), over the Controller Area Network (CAN) data bus. The shaft lock module continuously monitors inputs from the WIN and energizes the electric motor to move the locking bolt to the locked or unlocked position based upon that input. If the WIN indicates that the key present in the ignition lock cylinder is invalid, the locking bolt remains in the locked position. When the WIN indicates that a valid key is present in the ignition lock cylinder, the shaft lock module operates a motor to move the locking bolt to the unlocked position. However, to prevent inadvertent column locking due to a failure while the vehicle is being operated, the module cannot move the locking bolt from the unlocked position to the locked position as long as a key remains in the ignition lock cylinder. The shaft lock module receives ground at all times through a hard wired remote ground point. The module receives battery voltage to operate and to move the locking bolt in the unlocked direction on a B(+) circuit, and receives battery voltage to operate the locking bolt in the locked direction only when the key is removed from the ignition switch. These connections allow the module to remain operational, regardless of the ignition switch position. For added system security, the shaft lock module learns a unique Secret Key code from the WIN over the serial data bus upon initialization. This code is stored in the memory of the module and cannot be changed. Therefore, if the WIN requires service replacement, a new shaft lock module will also be required. Another security code, called a PIN, is used to gain access to the WIN Secured Access Mode. The Secured Access Mode is required during service to initialize a new shaft lock module. The shaft lock module is not available for separate service replacement. It is integral to the steering column so a complete column must be installed if the module is damaged or inoperative. Refer to Steering/Column - Removal . REMOVAL REMOVAL

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE:

The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, insert a valid FOB with Integrated Key (FOBIK) into the ignition switch, then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the FOBIK in the ignition switch until service has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and

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both the module and the steering column must be replaced with new units.

Fig. 4: Identifying Shaft Lock Module Courtesy of CHRYSLER LLC 1. Insert a FOB with Integrated Key (FOBIK) into the ignition switch to move the shaft lock module locking bolt to the unlocked position. Leave the FOBIK in the ignition switch while the shaft lock module service is being completed. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the instrument panel wire harness connector (3) from the shaft lock module (2) connector receptacle. 4. Remove the steering column from the vehicle. Refer to Steering/Column - Removal . 5. Depress the two spring clips that secure the shaft lock module to the mounting bracket on the steering column by inserting a suitable drift or punch into the release holes (1) on the upper surface of the bracket opposite the module. 6. While holding both of the spring clips depressed, slide the module toward the base of the column far enough to disengage the engagement tabs and slide tabs on the module from the slots and channels in the bracket. 7. Remove the module from the steering column bracket. INSTALLATION INSTALLATION

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system user Monday, June 04, 2012 9:49:30 AM

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capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.

Fig. 5: Shaft Lock Module Components Courtesy of CHRYSLER LLC 1. Be certain that a valid FOB with Integrated Key (FOBIK) is still present in the ignition switch. Leave the FOBIK in the ignition switch while the shaft lock module service is being completed. 2. Align the engagement and slide tabs integral to the housing of the shaft lock module (1) with the slots and channels in the mounting bracket (3) on the steering column. 3. Slide the module toward the top of the column far enough for the spring clips (2) on the module to engage the bracket. 4. Reinstall the steering column into the vehicle. Refer to Steering/Column - Installation . 5. Reconnect the instrument panel wire harness connector to the shaft lock module connector receptacle. 6. Reconnect the battery negative cable. NOTE:

If the shaft lock module has been replaced with a new unit, the Wireless Ignition Node (WIN) MUST also be replaced. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/RECEIVER, Wireless Ignition Node - Removal . Also, a diagnostic scan tool MUST be used to initialize the new module before the vehicle can be operated. See Standard Procedure .

SWITCH, HOOD AJAR DESCRIPTION DESCRIPTION user Monday, June 04, 2012 9:49:30 AM

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Fig. 6: Hood Ajar Switch Courtesy of CHRYSLER LLC The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. OPERATION OPERATION

The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is user Monday, June 04, 2012 9:49:30 AM

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a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic service information. REMOVAL SWITCH

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Fig. 7: Switch Connector Receptacle Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Unlatch and open the hood. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector (3) from the switch connector receptacle. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. INSTALLATION SWITCH

Fig. 8: Switch Connector Receptacle user Monday, June 04, 2012 9:49:30 AM

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Courtesy of CHRYSLER LLC NOTE:

1. 2. 3. 4. 5.

Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit.

Position the hood ajar switch (1) above the hole in the mounting bracket (2). Press the switch into the mounting hole until the integral switch latch tabs lock it into place. Connect the harness connector (3) to the switch connector receptacle. Reconnect the battery negative cable. Close and latch the hood.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Chime/Buzzer - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Chime/Buzzer - Service Information - Journey

DESCRIPTION DESCRIPTION The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the circuit board of the instrument cluster also known as the Cab Compartment Node (CCN) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The CCN also includes the necessary hardware and software to serve as the vehicle's electronic body control module. The electromechanical transducer generates chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based CCN utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard-wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the CCN allow it to control the audible outputs that are produced through its on-board transducer and relay. The CCN is capable of producing the following audible outputs: z

z

z z

Slow Rate Repetitive Click - Repeated click tones that are issued at a slow rate of about 90 clicks per minute. Fast Rate Repetitive Click - Repeated click tones that are issued at a fast rate of more than about 180 clicks per minute. Single Chime Tone - A single chime tone. Continuous Repetitive Chime Tone - Repeated chime tones that are issued continuously.

Hard-wired circuitry connects the CCN and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hard-wired circuits are integral to several wire harnesses that are routed throughout the vehicle and they are retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system, and to the CCN through a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, procedures for proper wire and connector repair, further details on wire harness routing and retention, and pin-out and location views for the various wire harness connectors, splices, and grounds. The chime warning system circuits and components cannot be adjusted or repaired. If the CCN circuitry, the onboard transducer, or the relay is damaged or ineffective, the instrument cluster assembly must be replaced.

OPERATION OPERATION user Monday, June 04, 2012 9:29:09 9:29:06 AM

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DOOR AJAR CHIME

The Cab Compartment Node (CCN) will sound an audible chime when the key is in the ignition and the driver's door is open. This is to prevent partial closing of vehicle doors. An audible chime will sound when the vehicle begins to move and the transmission range indicator display will indicate DOOR. ENHANCED SEAT BELT REMINDER

If all the following are met after sixty seconds with the engine ON, then the enhanced seat belt reminder feature will be activated. z z z

Driver seat belt is unbuckled for ten seconds or more. Vehicle speed is greater than five mph (8 km/h). The gear positioning is not in REVERSE (except in MTX vehicles where the reverse position cannot be detected).

The seat belt indicator will periodically blink, accompanied with a continuous chime for approximately ninetysix seconds or until the driver seat belt is buckled. When the enhanced seat belt feature is not initiated or if the feature is disabled, the seat belt indicator will be turned ON continuously until the driver seat belt is buckled. In the same ignition cycle, if the seat belt is again unbuckled for more than ten seconds with the vehicle speed greater than five mph (8 km/h), the enhanced seat belt reminder feature will again be initiated. The enhanced seat belt reminder feature is customer programmable and can be enabled/disabled with the use of a Scan Tool, or by the customer completing a sequence of steps. CUSTOMER PROGRAMMING OF ENHANCED SEAT BELT REMINDER FEATURE

1. With the ignition not in RUN or START, buckle the driver seat belt. 2. Turn the ignition switch to the RUN or START position and wait for the seat belt reminder check to be completed. 3. Unbuckle and then re-buckle the driver seat belt causing the indicator to go ON and OFF three or more times ending with the seat belt buckled. 4. Return the ignition switch back to a non-RUN or no-START position (the feature will toggle from the current status) and a confirmation chime will sound indicating to the customer the proper sequence to enable/disable the feature was performed. EXTERIOR LAMPS LEFT ON

An audible chime tone that indicates the exterior lamps were left on. FASTEN SEAT BELTS

At power up, the instrument cluster will conduct a seat belt lamp bulb check. If the driver side seat belt buckle user Monday, June 04, 2012 9:29:06 AM

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is unbuckled during the bulb check, an accompanying chime will sound within the duration of the bulb check. KEY LEFT IN IGNITION

An audible chime tone that indicates the key was left in ignition. SINGLE WARNING CHIME

After a bulb check at power-up, if any of the following indicators are still activated, the CCN will sound a single chime tone. ABS, Air Bag, Check Engine, Charging System, Engine Temperature, Low Fuel (after 10 seconds for accurate fuel information), and BRAKE (if speed is greater than 2 mph).

DIAGNOSIS AND TESTING CHIME WARNING SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard-wired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information, and location views for the various wire harness connectors, splices, and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Wipers/Washers - Service Information - Journey

2009 ACCESSORIES AND EQUIPMENT Wipers/Washers - Service Information - Journey

DESCRIPTION FRONT

Fig. 1: Intermittent Front Wiper & Washer System Courtesy of CHRYSLER LLC An electrically operated intermittent front wiper and washer system is standard factory-installed safety equipment on this vehicle. The wiper and washer system includes the following major components, which are described in further detail elsewhere in this service information: z

z

z

ElectroMechanical Instrument Cluster - The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is located on the instrument panel directly in front of the driver. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Front Washer Nozzle (3) - Two fluidic front washer nozzles with integral check valves are secured by latch features to dedicated openings in the hood panel near the base of the windshield. Front Washer Plumbing - The plumbing for the washer system consists of rubber hoses, plastic tubes and molded rubber or plastic fittings. The plumbing is routed through the engine compartment from the washer reservoir. The front washer hose is routed along the left fender ledge to the hood hinge, then across the underside of the inner hood panel reinforcement to the washer nozzles.

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z

z

z

z

z

z

z

Front Wiper Arms And Blades (5) - The two front wiper arms are secured with nuts to the threaded ends of the two wiper pivot shafts, which extend through the cowl plenum cover/grille panel located near the base of the windshield. The two front wiper blades are each secured to their wiper arm with an integral latch, and are parked on the glass near the bottom of the windshield when the front wiper system is not in operation. The left and right wiper arms and wiper blades are unique and are not interchangeable. Front Wiper Module (4) - The wiper pivot shafts are the only visible components of the front wiper module. The remainder of the module is concealed within the cowl plenum beneath the cowl plenum cover/grille panel. The wiper module includes the wiper module bracket, three rubber-isolated wiper module mounts, the wiper motor, the wiper motor crank arm, the two wiper drive links and the two wiper pivots. Right Multi-Function Switch (6) - The right (wiper) multi-function switch and the left (lighting) multifunction switch are secured to brackets integral to the clockspring housing on the top of the steering column just below the steering wheel. The right multi-function switch is connected by a short jumper harness to the Steering Control Module (SCM), which is internal to the left multi-function switch housing. Only the switch control stalk extending from the right side of the steering column is visible, while the remainder of the switch is concealed beneath the steering column shrouds. The right multifunction switch is dedicated to providing all of the driver controls for both the front and rear wiper and washer systems. Steering Control Module - The Steering Control Module (SCM) is internal to the left multi-function switch housing, which is secured to a bracket integral to the left side of the clockspring housing on the top of the steering column just below the steering wheel. Only the left switch control stalk extending from the left side of the steering column is visible, while the remainder of the switch housing containing the SCM is concealed beneath the steering column shrouds. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Steering Column - Description . Totally Integrated Power Module (2) - The Totally Integrated Power Module (TIPM) is located in the engine compartment, near the battery. Refer to Electrical - Wiring/Power Distribution/MODULE, Totally Integrated Power (TIPM) - Description . Washer Pump/Motor - The reversible electric washer pump/motor unit is located in a dedicated hole in a sump area on the lower, rearward facing surface of the washer reservoir, on the back of the cooling module just to the left of center. This single reversible washer pump/motor provides washer fluid to either the front or rear washer system plumbing, depending upon the direction of the pump motor rotation. Washer Reservoir (1) - The washer reservoir is located in the engine compartment on the back of the cooling module just to the left of center. The cap is accessed from the front of the engine compartment.

Hard wired circuitry connects the front wiper and washer system components to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the front wiper and washer system components through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds. HEADLAMP An electrically operated headlamp washer system is optional factory-installed equipment on this vehicle when it user Monday, June 04, 2012 9:17:15 AM

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is manufactured for certain export markets. The headlamp washer system includes the following major components, which are described in further detail elsewhere in this service information: z

z

z

z

z

z

z

z

z

ElectroMechanical Instrument Cluster - The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is located on the instrument panel directly in front of the driver. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Headlamp Washer Nozzle - A headlamp washer nozzle is secured to the front fascia beneath each front lamp unit. Headlamp Washer Pump/Motor - The electric headlamp washer pump/motor unit is located in a dedicated hole on the rearward facing side of the washer reservoir, on the left side of the cooling module in the engine compartment. This high pressure pump is located above and to the left of the reversible front and rear washer pump/motor unit on the reservoir. Headlamp Washer Plumbing - The plumbing for the headlamp washer system consists of large diameter rubber hoses and molded plastic fittings. The plumbing is routed to the washer nozzles on the front fascia from the washer reservoir. The connections at the headlamp washer pump and the two headlamp washer nozzles feature unique quick-connect fittings. Headlamp Washer Relay - The headlamp washer relay is an International Standards Organization (ISO) relay that is located near the Totally Integrated Power Module (TIPM) in the engine compartment near the battery. Right Multi-Function Switch - The right (wiper) multi-function switch and the left (lighting) multifunction switch are secured to brackets integral to the clockspring housing on the top of the steering column just below the steering wheel. The right multi-function switch is connected by a short jumper harness to the Steering Control Module (SCM), which is internal to the left multi-function switch housing. Only the switch control stalk extending from the right side of the steering column is visible, while the remainder of the switch is concealed beneath the steering column shrouds. The right multifunction switch is dedicated to providing all of the driver controls for both the front and rear wiper and washer systems. Steering Control Module - The Steering Control Module (SCM) is internal to the left multi-function switch housing, which is secured to a bracket integral to the left side of the clockspring housing on the top of the steering column just below the steering wheel. Only the left switch control stalk extending from the left side of the steering column is visible, while the remainder of the switch housing containing the SCM is concealed beneath the steering column shrouds. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Steering Column - Description . Totally Integrated Power Module - The Totally Integrated Power Module (TIPM) is located in the engine compartment, near the battery. Refer to Electrical - Wiring/Power Distribution/MODULE, Totally Integrated Power (TIPM) - Description . Washer Reservoir - A unique washer reservoir is used on vehicles with the optional headlamp washer system, which has dedicated provisions for the headlamp washer pump and plumbing. This reservoir is mounted in the same location and using the same mounting hardware as is used for vehicles without the headlamp washers. The reservoir is located on the left side of the cooling module in the engine compartment.

Hard wired circuitry connects the headlamp washer system components to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical user Monday, June 04, 2012 9:17:15 AM

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system and to the headlamp washer system components through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds. REAR

Fig. 2: Intermittent Rear Wiper & Washer System Courtesy of CHRYSLER LLC An electrically operated fixed interval intermittent rear wiper and washer system is standard factory-installed equipment on this vehicle. The rear wiper and washer system includes the following major components, which are described in further detail elsewhere in this service information: z

z

z

ElectroMechanical Instrument Cluster - The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is located on the instrument panel directly in front of the driver. Refer to Electrical - Instrument Cluster/Instrument Cluster - Description . Rear Washer Nozzle (4) - The fluidic rear washer nozzle with an integral check valve is secured by integral latch features to a mounting hole on the lower surface of the rear spoiler formation on the liftgate outer panel above the liftgate glass. Rear Washer Plumbing - The plumbing for the rear washer system consists of rubber hoses and molded plastic fittings. The plumbing is routed along the left side of the engine compartment from the washer reservoir on the cooling module through the dash into the passenger compartment. It is then routed within the body wiring harness along the left side of the floor to the left rear inner wheel housing, then up the

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z

z

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wheel housing to the D-pillar. It exits the wire harness near the top of the D-pillar and connects to the liftgate washer hose, which is routed along the liftgate opening upper reinforcement to the center of the vehicle then through the upper liftgate opening to the rear washer nozzle on the upper liftgate. Rear Wiper Arm And Blade (6) - The single rear wiper arm is secured by a nut directly to the rear wiper motor output shaft, which extends through a rubber grommet inserted into a hole in the liftgate outer panel at the base of the liftgate glass. The rear wiper blade is secured to the rear wiper arm with an integral latch feature, and is parked near the base of the glass when the rear wiper system is not in operation. Rear Wiper Motor (5) - The rear wiper motor includes the motor bracket and three rubber-isolated wiper motor mounts. The wiper motor output shaft is the only visible component of the rear wiper motor. The remainder of the motor is concealed by the inner liftgate trim on the inside of the liftgate beneath the liftgate glass opening. Right Multi-Function Switch (3) - The right (wiper) multi-function switch and the left (lighting) multifunction switch are secured to brackets integral to the clockspring housing, on the top of the steering column just below the steering wheel. The right multi-function switch is connected to the Steering Control Module (SCM) by a short jumper harness. The SCM is internal to the left multi-function switch housing. Only the switch control stalk extending from the right side of the steering column is visible, while the remainder of the switch is concealed beneath the steering column shrouds. The right multifunction switch is dedicated to providing all of the driver controls for both the front and rear wiper and washer systems. Steering Control Module - The Steering Control Module (SCM) is internal to the left multi-function switch housing, which is secured to a bracket integral to the left side of the clockspring housing on the top of the steering column just below the steering wheel. Only the left switch control stalk extending from the left side of the steering column is visible, while the remainder of the switch housing containing the SCM is concealed beneath the steering column shrouds. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Steering Column - Description . Totally Integrated Power Module (2) - The Totally Integrated Power Module (TIPM) is located in the engine compartment, near the battery. Refer to Electrical - Wiring/Power Distribution/MODULE, Totally Integrated Power (TIPM) - Description . Washer Reservoir (1) - The rear washer system shares a single reservoir and reversible pump with the front washer system, but has its own dedicated plumbing. The washer reservoir is located in the engine compartment attached to the FEM (Front End Module). The filler neck and cap are accessed from the right front corner of the engine compartment.

Hard wired circuitry connects the rear wiper and washer system components to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the rear wiper and washer system components through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, 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 harness connectors, splices and grounds.

OPERATION FRONT user Monday, June 04, 2012 9:17:15 AM

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Fig. 3: Right (Wiper) Multi-Function Switch Courtesy of CHRYSLER LLC The front wiper and washer system is designed to provide the vehicle operator with a convenient, safe, and reliable means of maintaining visibility through the windshield glass. The various components of this system are designed to convert electrical energy produced by the vehicle electrical system into the mechanical action of the wiper blades to wipe the outside surface of the glass, as well as into the hydraulic action of the washer system to apply washer fluid stored in an on-board reservoir to the area of the glass to be wiped. When combined, these components provide the means to effectively maintain clear visibility for the vehicle operator by removing excess accumulations of rain, snow, bugs, mud, or other minor debris from the outer surface of the windshield glass that might be encountered while driving the vehicle under numerous types of inclement operating conditions. The vehicle operator initiates all front and rear wiper and washer system functions with the control stalk of the right (wiper) multi-function switch (1) that extends from the right side of the steering column, just below the steering wheel. Rotating the control knob (2) on the end of the control stalk, selects the OFF, DELAY, LOW, or HIGH front wiper system operating modes. In the DELAY mode, the control knob also allows the vehicle operator to select from one of five intermittent wipe delay intervals. Pulling the control stalk rearward actuates the momentary front washer system switch, which selects the WASH and WIPE-AFTER-WASH modes, depending upon when and how long the switch is held closed. Pushing the control stalk downward actuates a momentary switch and selects the MIST mode, which cycles the wiper blades for as long as the switch is held closed then completes the current cycle and parks the blades at the base of the windshield after the switch is released. The right multi-function switch provides hard wired analog and resistor multiplexed inputs to the Steering Control Module (SCM) internal to the left (lighting) multi-function switch housing for all of the wiper and washer system functions. The SCM then sends electronic wiper and washer switch status messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), over a Local Interface Network (LIN) data bus. The EMIC responds to the SCM inputs by sending electronic wiper and user Monday, June 04, 2012 9:17:16 AM

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washer system request messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus requesting the appropriate wiper and washer system operating modes. Front wiper and washer system operation is completely controlled by the SCM, EMIC and TIPM logic circuits, and that logic will only allow these systems to operate when the ignition switch is in the ACCESSORY or ON positions. The TIPM uses intelligent, high current, self-protected high side switches to control wiper system operation by energizing or de-energizing the wiper motor low and high speed brushes. The TIPM uses an Hbridge circuit to control the operation of the reversible washer pump/motor unit. The right multi-function switch circuitry receives battery current and a clean ground output from the SCM, then provides analog and multiplexed inputs to the SCM to indicate the selected front wiper and front washer system mode. The hard wired circuits and components of the front wiper and washer system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the front wiper and washer system. The most reliable, efficient, and accurate means to diagnose the front wiper and washer system or the electronic controls and communication related to front wiper and washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. OPERATING MODES

Following are paragraphs that briefly describe the operation of each of the front wiper and washer system operating modes. CONTINUOUS WIPE MODE

When the LOW position of the control knob on the control stalk of the right (wiper) multi-function switch is selected, the SCM sends an electronic wiper switch low status message to the EMIC over the LIN data bus. The EMIC then relays an electronic wiper switch low request message to the TIPM over the CAN data bus. The TIPM then directs battery current to the low speed brush of the wiper motor, causing the wipers to cycle at low speed. When the HIGH position of the control knob is selected, the SCM sends an electronic wiper switch high status message to the EMIC. The EMIC then relays an electronic wiper switch high request message to the TIPM. The TIPM then directs battery current to the high speed brush of the wiper motor, causing the wipers to cycle at high speed. When the OFF position of the multi-function switch control knob is selected, the SCM sends an electronic wiper switch off status message to the EMIC, the EMIC relays an electronic wiper switch off request message to the TIPM, then one of two events will occur. The event that occurs depends upon the position of the wiper blades on the windshield at the moment that the control knob 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, which provides a hard wired park switch sense input to the TIPM. The TIPM then de-energizes the wiper motor and the wiper motor ceases to operate. If the wiper blades are not in the down position on the windshield at the moment the OFF position is selected, the park switch is an open circuit and the TIPM continues running the wiper motor at low speed until the wiper blades are in the down position on the windshield and the park switch input to the TIPM is again closed to user Monday, June 04, 2012 9:17:16 AM

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ground. INTERMITTENT WIPE MODE

When the control knob on the control stalk of the right (wiper) multi-function switch is moved to one of the five DELAY interval positions, the SCM sends an electronic wiper switch delay interval status message to the EMIC. The EMIC then relays an electronic wiper switch delay interval request message to the TIPM. The TIPM's electronic intermittent wipe logic circuit responds by calculating the correct length of time between wiper sweeps based upon the selected delay interval input. The TIPM monitors the changing state of the wiper motor park switch through a hard wired park switch sense input. This input allows the TIPM to determine the proper intervals at which to energize and de-energize the wiper motor intermittently for one low speed cycle at a time. The TIPM logic is also programmed to provide vehicle speed sensitivity to the selected intermittent wipe delay intervals. In order to provide this feature, the TIPM monitors electronic vehicle speed messages from the Controller Antilock Brake (CAB) and doubles the selected delay interval whenever the vehicle speed is about 16 kilometers-per-hour (10 miles-per-hour) or less. MIST WIPE MODE

When the control stalk of the right (wiper) multi-function switch is moved downward to the momentary MIST position, the SCM sends an electronic wiper mist mode status message to the EMIC, the EMIC relays an electronic wiper mist mode request message to the TIPM, then the TIPM energizes the low speed brush of the wiper motor for as long as the switch is held closed, then de-energizes the motor when the state of the switch changes to open, parking the wiper blades near the base of the windshield. The TIPM can operate the front wiper motor in this mode for only one low speed cycle at a time, or for an indefinite number of sequential low speed cycles, depending upon how long the switch is held closed. WASH MODE

When the control stalk of the right (wiper) multi-function switch is pulled rearward to the front momentary WASH position for more than about one-half second with the wiper system operating, the SCM sends an electronic washer switch status message to the EMIC, the EMIC relays an electronic washer switch request message to the TIPM, then the TIPM directs battery current and ground to the washer pump/motor. This will cause the washer pump/motor to be energized in the front wash direction for as long as the switch is held closed (up to approximately 10 seconds) and to be de-energized when the control stalk is released. When the control stalk is pulled rearward to the front momentary WASH position while the front wiper system is operating in one of the DELAY interval positions, the washer pump/motor operation is the same. However, the TIPM also overrides the selected delay interval and operates the front wiper motor in a continuous low speed mode for as long as the control stalk is held in the front momentary WASH position, then reverts to the selected delay interval several wipe cycles after the control stalk is released. If the WASH switch is held closed for more than approximately 10 seconds, the TIPM will suspend washer pump/motor operation until the control stalk is released for about 2 seconds and then cycled back to the WASH position. WIPE-AFTER-WASH MODE

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When the control stalk of the right (wiper) multi-function switch is pulled rearward to the front momentary WASH position for more than about one-half second while the wiper system is not operating, the SCM sends an electronic washer switch status message to the EMIC, the EMIC relays an electronic washer switch request message to the TIPM, and the TIPM directs battery current and ground to the washer pump/motor and energizes the wiper motor in a continuous low speed mode for as long as the switch is held closed (up to approximately 10 seconds). When the control stalk is released, the TIPM de-energizes the washer pump/motor immediately, but allows the wiper motor to operate for two or three additional wipe cycles before it de-energizes the wiper motor and parks the wiper blades near the base of the windshield. If the control stalk is held rearward for more than about 10 seconds, the TIPM will suspend washer pump/motor operation until the stalk is released for about 2 seconds and then cycled back to the WASH position; however, the wipers will continue to operate for as long as the switch is held closed. The TIPM monitors the changing state of the wiper motor park switch through a hard wired wiper park switch sense circuit input. This input allows the TIPM to count the number of wipe cycles that occur after the control stalk is released, and to determine the proper interval at which to de-energize the wiper motor to complete the WIPE-AFTER-WASH mode cycle. HEADLAMP The headlamp washer system is designed to provide the vehicle operator with a convenient, safe, and reliable means of maintaining headlamp lighting performance. The various components of this system are designed to convert electrical energy produced by the vehicle electrical system into the hydraulic action of the washer system to apply washer fluid stored in an on-board reservoir to the lenses of the two front lamp units, removing excess accumulations of snow, ice, bugs, mud, or other minor debris from the front lamps that might be encountered while driving the vehicle under numerous types of inclement operating conditions. The vehicle operator initiates the headlamp washer system function using the control knob on the end of the right multi-function switch control stalk that extends from the right side of the steering column, just below the steering wheel. While the headlamps are turned ON and the engine is running, pushing the knob on the end of the control stalk towards the steering column beyond the actuation point for more than about 100 milliseconds (0.10 second) activates the headlamp washer pump/motor in combination with the front washer pump/motor. When the headlamp washer pump/motor unit is energized, hydraulic pressure builds within the headlamp washer system plumbing against the pressure of the control valve in each headlamp washer nozzle. Sufficient pressure causes the headlamp washer nozzles to dispense high pressure washer fluid onto the lenses of both front lamp units for about 1600 milliseconds (1.6 seconds). Headlamp washer system operation is completely controlled by the Totally Integrated Power Module (TIPM) logic circuits based upon electronic wash command message inputs received from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC monitors electronic wash switch status and lighting switch status message inputs received over the Local Interface Network (LIN) data bus from the Steering Control Module (SCM) (also known as the steering column module) based upon the right and left multi-function switch positions. The TIPM will only allow this system to operate when the engine is running and the headlamp low beams are turned ON. The TIPM uses a low side driver to energize or de-energize the headlamp washer system relay which, in turn, controls the operation of the headlamp washer pump/motor unit. The hard wired circuits and components of the headlamp washer system may be diagnosed using conventional user Monday, June 04, 2012 9:17:16 AM

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diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer system or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REAR

Fig. 4: Right (Wiper) Multi-Function Switch Courtesy of CHRYSLER LLC The rear wiper and washer system is designed to provide the vehicle operator with a convenient, safe, and reliable means of maintaining visibility through the liftgate glass. The various components of this system are designed to convert electrical energy produced by the vehicle electrical system into the mechanical action of the wiper blade to wipe the outside surface of the glass, as well as into the hydraulic action of the washer system to apply washer fluid stored in an on-board reservoir to the area of the glass to be wiped. When combined, these components provide the means to effectively maintain clear visibility for the vehicle operator by removing excess accumulations of rain, snow, bugs, mud, or other minor debris from the outer surface of the liftgate glass that might be encountered while driving the vehicle under numerous types of inclement operating conditions. The vehicle operator initiates all front and rear wiper and washer system functions with the control stalk (1) of the right (wiper) multi-function switch that extends from the right side of the steering column, just below the steering wheel. Rotating the control sleeve (3) on the control stalk to the OFF or INTERMITTENT detent positions or the momentary WASH position selects the rear wiper and washer system operating modes. The right multi-function switch provides hard wired analog and resistor multiplexed inputs to the Steering Control Module (SCM) integral to the left (lighting) multi-function switch for all of the wiper and washer system functions. The SCM then sends electronic rear wiper/washer switch status messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over a Local user Monday, June 04, 2012 9:17:16 AM

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Interface Network (LIN) data bus. The EMIC then sends electronic rear wiper/washer switch request messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus requesting the appropriate rear wiper and washer system operating modes. Rear wiper and washer system operation is completely controlled by the SCM, EMIC and TIPM logic circuits, and that logic will only allow these systems to operate when the ignition switch is in the ACCESSORY or ON positions. The TIPM uses intelligent, high current, self-protected high side switches to control wiper system operation by energizing or de-energizing the rear wiper motor. The TIPM uses an H-bridge circuit to control the operation of the reversible washer pump/motor unit. The right multi-function switch circuitry receives a clean ground output from the SCM on a multi-function switch return circuit, then provides analog and resistor multiplexed inputs to the SCM to indicate the selected rear wiper and rear washer system mode. The hard wired circuits and components of the rear wiper and washer system may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper and washer system or the electronic controls and communication related to rear wiper and washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. OPERATING MODES

Following are paragraphs that briefly describe the operation of each of the rear wiper and washer system operating modes. INTERMITTENT WIPE MODE

When the INTERMITTENT WIPE position of the control sleeve on the control stalk of the right multi-function switch is selected, the SCM sends an electronic rear wiper switch status message to the EMIC over the LIN data bus, then the EMIC relays an electronic rear wiper switch request message to the TIPM over the CAN data bus, and the TIPM directs battery current to the rear wiper motor at fixed delay intervals to enable the rear wiper motor intermittent wipe mode. WASH MODE

When the control sleeve of the right multi-function switch is rotated counterclockwise past the INTERMITTENT detent position to the momentary rear WASH position, the SCM sends an electronic rear washer switch status message to the EMIC over the LIN data bus, then the EMIC relays an electronic rear washer switch request message to the TIPM over the CAN data bus, and the TIPM directs battery current to the rear wiper motor and directs battery current and ground to the washer pump/motor unit. These outputs will cause the washer pump motor and the rear wiper motor to operate continuously for as long as the switch is held closed up to approximately 10 seconds. The washer pump is de-energized as soon as the control sleeve is released, but the rear wiper motor continues to operate for two to three continuous cycles before reverting to the fixed delay interval operation. The TIPM uses a hard wired output from a park switch internal to the rear wiper motor as an additional logic input to monitor the position of the rear wiper blade on the glass and to control the number of continuous wiper sweeps following washer operation.

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DIAGNOSIS AND TESTING FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. If the front wiper motor operates, but the wipers do not move on the windshield, replace the ineffective front wiper module. If the washer pump/motor operates, but no washer fluid is dispensed on the glass; or, if the wipers operate, but chatter, lift, or do not clear the glass, clean and inspect the front wiper and washer system components as required. See Electrical - Wipers/Washers/Wipers/Washers - Cleaning and. See Electrical Wipers/Washers/Wipers/Washers - Inspection. The hard wired front wiper and washer system circuits and components may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the front wiper and washer system. The most reliable, efficient, and accurate means to diagnose the front wiper and washer system or the electronic controls and communication related to front wiper and washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. NOTE:

The front wiper and washer switches are integral to the right multi-function switch. The right multi-function switch is hard wired to the left multi-function switch/Steering Control Module (SCM), which communicates with the ElectroMechanical Instrument Cluster (EMIC)/Cab Compartment Node (CCN) over the Local Interface Network (LIN) data bus. Before performing any of the following tests, determine whether the other functions of the right and left multifunction switch/SCM are operational. If only the right multi-function switch functions are inoperative, test and repair the right multi-function switch or the jumper harness between the right and left multi-function switches before attempting to repair the Front Wiper and Washer System. If both the right and left multi-function switch/SCM functions are ineffective, diagnose and repair that problem before attempting to repair the Front Wiper and Washer System.

CONDITION POSSIBLE CAUSES WIPER MOTOR DOES NOT 1. Ineffective motor ground OPERATE IN ANY SWITCH circuit.

CORRECTION 1. Test and repair open wiper motor ground circuit if required.

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POSITION

2. Test and repair low speed and high speed feed circuits between TIPM and front wiper motor if required. 3. Ineffective right multi3. Test and replace ineffective right function switch. multi-function switch if required. 4. Use a diagnostic scan tool to test the 4. Ineffective SCM inputs or SCM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 5. Use a diagnostic scan tool to test the 5. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 6. Use a diagnostic scan tool to test the 6. Ineffective TIPM inputs or TIPM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 7. Ineffective wiper motor. 7. Test and replace open or shorted wiper motor as required. 1. Ineffective wiper motor park 1. Test and repair wiper park switch input circuit between TIPM and front wiper switch input circuit. motor if required. WIPERS DO NOT PARK 2. Use a diagnostic scan tool to test the 2. Ineffective TIPM inputs or TIPM inputs and outputs. Refer to the CORRECTLY outputs. appropriate diagnostic information. 3. Ineffective wiper motor park 3. Test and replace ineffective wiper switch. motor if required. WIPER MOTOR OPERATES 1. Ineffective wiper motor. 1. Check amperage draw with linkage SLOWLY IN ALL SWITCH disconnected from wiper motor crank POSITIONS arm. Correct draw should be about 6 amperes. If incorrect, refer to the appropriate Possible Cause that follows: 2. Test and repair shorted low and high 2. Amperage draw too low. speed feed circuits if required. 3. Amperage draw too high. 3. With linkage disconnected from wiper motor crank arm check linkage and pivots for binding. If binding is detected, repair or replace front wiper module if required. If no linkage binding detected, replace the front wiper motor if required. WIPERS RUN AT HIGH 1. Ineffective motor feed 1. Test and repair low speed and high SPEED WITH SWITCH LOW circuit wiring. speed feed circuits between TIPM and SPEED SELECTED OR AT front wiper motor if required. LOW SPEED WITH SWITCH HIGH SPEED SELECTED 1. Ineffective washer pump 1. Test and repair open washer pump ground circuit. ground circuit if required. 2. Test and repair washer pump feed circuits between TIPM and washer pump 2. Ineffective washer pump 2. Ineffective motor feed circuits.

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feed circuits. 3. Ineffective right multifunction switch. 4. Ineffective SCM inputs or outputs. WASHER PUMP DOES NOT 5. Ineffective EMIC (CCN) OPERATE inputs or outputs. 6. Ineffective TIPM inputs or outputs. 7. Ineffective washer pump.

if required. 3. Test and replace ineffective right multi-function switch if required. 4. Use a diagnostic scan tool to test the SCM inputs and outputs. Refer to the appropriate diagnostic information. 5. Use a diagnostic scan tool to test the EMIC (CCN) inputs and outputs. Refer to the appropriate diagnostic information. 6. Use a diagnostic scan tool to test the TIPM inputs and outputs. Refer to the appropriate diagnostic information. 7. Test and replace open or shorted washer pump if required.

HEADLAMP WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. Before attempting to diagnose the headlamp washer system, confirm whether the front washer system operates satisfactorily. If the front washer system is ineffective or operates improperly, diagnose and repair that problem before attempting to repair the headlamp washer system. If the front washer system operates satisfactorily and the headlamp washer pump/motor unit operates, but no washer fluid is dispensed on the front lamp unit lenses, inspect the headlamp washer plumbing for pinched or leaking hoses and fittings. If the headlamp washer pump/motor unit does not operate, check the headlamp washer system fuse. The hard wired headlamp washer system circuits and components may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer system or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REAR user Monday, June 04, 2012 9:17:16 AM

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WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment, possible personal injury, or death. If the rear wiper motor operates, but the wiper motor output shaft does not move, replace the ineffective rear wiper motor. If the washer pump/motor operates, but no washer fluid is dispensed on the glass; or, if the wiper operates, but chatters, lifts, or does not clear the glass, clean and inspect the rear wiper and washer system components as required. See Electrical - Wipers/Washers/Wipers/Washers - Cleaning and. See Electrical Wipers/Washers/Wipers/Washers - Inspection. The hard wired rear wiper and washer system circuits and components may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . 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 connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper and washer system or the electronic controls and communication related to rear wiper and washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. NOTE:

The rear wiper and washer switches are integral to the right multi-function switch. The right multi-function switch is hard wired to the left multi-function switch/Steering Control Module (SCM), which communicates with the ElectroMechanical Instrument Cluster (EMIC)/Cab Compartment Node (CCN) over the Local Interface Network (LIN) data bus. Before performing any of the following tests, determine whether the other functions of the right and left multifunction switch/SCM are operational. If only the right multi-function switch functions are inoperative, test and repair the right multi-function switch or the jumper harness between the right and left multi-function switches before attempting to repair the Rear Wiper and Washer System. If both the right and left multi-function switch/SCM functions are ineffective, diagnose and repair that problem before attempting to repair the Rear Wiper and Washer System.

CONDITION POSSIBLE CAUSES WIPER MOTOR DOES NOT 1. Ineffective motor ground OPERATE IN ANY SWITCH circuit. POSITION 2. Ineffective motor feed circuits.

CORRECTION 1. Test and repair open wiper motor ground circuit if required. 2. Test and repair motor feed circuit between TIPM and rear wiper motor if required.

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3. Ineffective right multifunction switch.

3. Test and replace ineffective right multi-function switch if required. 4. Use a diagnostic scan tool to test the 4. Ineffective SCM inputs or SCM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 5. Use a diagnostic scan tool to test the 5. Ineffective EMIC (CCN) EMIC (CCN) inputs and outputs. Refer to inputs or outputs. the appropriate diagnostic information. 6. Use a diagnostic scan tool to test the 6. Ineffective TIPM inputs or TIPM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 7. Ineffective wiper motor. 7. Test and replace open or shorted wiper motor if required. 1. Test and repair wiper park switch input 1. Ineffective wiper motor park circuit between TIPM and front wiper switch input circuit. motor if required. WIPER DOES NOT PARK 2. Ineffective TIPM inputs or 2. Use a diagnostic scan tool to test the CORRECTLY TIPM inputs and outputs. Refer to the outputs. appropriate diagnostic information. 3. Ineffective wiper motor park 3. Test and replace ineffective wiper switch. motor if required. WIPER MOTOR OPERATES 1. Ineffective wiper motor. 1. Check amperage draw with wiper arm SLOWLY disconnected from rear wiper motor output shaft. Correct draw should be about 6 amperes. If incorrect, refer to the appropriate Possible Cause that follows: 2. Test and repair shorted rear wiper motor signal and fused ignition switch 2. Amperage draw too low. output (run - accessory) circuits if required. 3. Amperage draw too high. 3. With wiper arm disconnected from wiper motor output shaft check for binding between output shaft and rubber grommet in liftgate. If binding is detected, lubricate or replace grommet if required. If no binding is detected, replace the wiper motor if required. 1. Ineffective washer pump 1. Test and repair open washer pump ground circuit. ground circuit if required. 2. Test and repair washer pump feed 2. Ineffective washer pump circuits between TIPM and washer pump feed circuits. if required. 3. Ineffective right multi3. Test and replace ineffective right function switch. multi-function switch if required. 4. Use a diagnostic scan tool to test the WASHER PUMP DOES NOT 4. Ineffective SCM inputs or SCM inputs and outputs. Refer to the user Monday, June 04, 2012 9:17:16 AM

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OPERATE

outputs. 5. Ineffective EMIC (CCN) inputs or outputs. 6. Ineffective TIPM inputs or outputs. 7. Ineffective washer pump.

appropriate diagnostic information. 5. Use a diagnostic scan tool to test the EMIC (CCN) inputs and outputs. Refer to the appropriate diagnostic information. 6. Use a diagnostic scan tool to test the TIPM inputs and outputs. Refer to the appropriate diagnostic information. 7. Test and replace open or shorted washer pump if required.

CLEANING FRONT WIPER SYSTEM

CAUTION: Protect the rubber squeegees of the wiper blades from any petroleumbased cleaners, solvents, or contaminants. These products can rapidly deteriorate the rubber squeegees. The squeegees of wiper blades exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove any deposits of salt or road film. The wiper blades, arms, and windshield glass should only be cleaned using a sponge or soft cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the wiper blades continue to leave streaks, smears, hazing, or beading on the glass after thorough cleaning of the squeegees and the glass, the entire wiper blade assembly must be replaced. WASHER SYSTEM

CAUTION: Never introduce petroleum-based cleaners, solvents, or contaminants into the washer system. These products can rapidly deteriorate the rubber seals and hoses of the washer system, as well as the rubber squeegees of the wiper blades. CAUTION: Never use compressed air to flush the washer system plumbing. Compressed air pressures are too great for the washer system plumbing components and will result in further system damage. Never use sharp instruments to clear a plugged washer nozzle or damage to the nozzle orifice and improper nozzle spray patterns will result. If the washer system is contaminated with foreign material, drain the washer reservoir by removing the washer pump/motor unit from the reservoir. Clean foreign material from the inside of the washer pump inlet filter screen and the washer reservoir using clean washer fluid, a mild detergent, or a non-abrasive cleaner. Flush foreign material from the washer system plumbing by first disconnecting the washer hose from the washer nozzle, then running the washer pump/motor to run clean washer fluid or water through the system. A plugged user Monday, June 04, 2012 9:17:16 AM

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or restricted washer nozzle should be carefully back-flushed using compressed air. If the washer nozzle obstruction cannot be cleared, replace the washer nozzle. REAR WIPER SYSTEM

CAUTION: Protect the rubber squeegee of the wiper blade from any petroleum-based cleaners, solvents, or contaminants. These products can rapidly deteriorate the rubber squeegee. The squeegee of a wiper blade exposed to the elements for a long time tends to lose its wiping effectiveness. Periodic cleaning of the squeegee is suggested to remove any deposits of salt or road film. The wiper blade, arm, and liftgate glass should only be cleaned using a sponge or soft cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the wiper blade continues to leave streaks, smears, hazing, or beading on the glass after thorough cleaning of the squeegees and the glass, the entire wiper blade assembly must be replaced. WASHER SYSTEM

CAUTION: Never introduce petroleum-based cleaners, solvents, or contaminants into the washer system. These products can rapidly deteriorate the rubber seals and hoses of the washer system, as well as the rubber squeegee of the wiper blade. CAUTION: Never use compressed air to flush the washer system plumbing. Compressed air pressures are too great for the washer system plumbing components and will result in further system damage. Never use sharp instruments to clear a plugged washer nozzle or damage to the nozzle orifice and improper nozzle spray patterns will result. If the washer system is contaminated with foreign material, drain the washer reservoir by removing the washer pump/motor from the reservoir. Clean foreign material from the inside of the washer pump/motor inlet filter screen and the washer reservoir using clean washer fluid, a mild detergent, or a non-abrasive cleaner. Flush foreign material from the washer system plumbing by first disconnecting the washer hose from the rear washer nozzle, then running the washer pump/motor to run clean washer fluid or water through the system. A plugged or restricted rear washer nozzle should be carefully back-flushed using compressed air. If the washer nozzle obstruction cannot be cleared, replace the rear washer nozzle.

INSPECTION FRONT WIPER SYSTEM

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Fig. 5: Inspecting Wiper Blades Courtesy of CHRYSLER LLC The wiper blades and wiper arms should be inspected periodically, not just when wiper performance problems are experienced. This inspection should include the following points: 1. Carefully inspect the wiper blades for any indications of worn or uneven edges (1), foreign material deposits (2), hardening or cracking (3), deformation or fatigue (4), or splitting (5). Inspect the wiper blade support components and the wiper arms for damage (6) or corrosion. If the wiper arms and blades are contaminated with any foreign material, clean them and the glass as required. See Electrical Wipers/Washers/Wipers/Washers - Cleaning. If a wiper blade or arm is damaged, or if corrosion is evident, replace the affected wiper arm or blade with a new unit. Do not attempt to repair a wiper arm or blade 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 arm should pivot freely at the hinge, but with no lateral looseness evident. If there is any binding evident in the wiper arm hinge, or if there is evident lateral play in the wiper arm hinge, replace the wiper arm. CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. 3. Once proper hinge action of the wiper arm is confirmed, check the hinge for proper spring tension. Remove the wiper blade from the wiper arm. Either place a small postal scale between the blade end of the wiper arm and the glass, or carefully lift the blade end of the arm away from the glass using a small fish scale. On vehicles with unequal wiper arm lengths, be certain that measurements on both arms are user Monday, June 04, 2012 9:17:16 AM

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taken at a point an equal distance from their wiper arm hinge pins. Compare the scale readings between the right and left wiper arms. Replace a wiper arm if it has comparatively lower spring tension, as evidenced by a lower scale reading. 4. After cleaning and inspecting the wiper components and the glass, if the wiper blade still fails to clear the glass without smearing, streaking, chattering, hazing, or beading, replace the wiper blade. WASHER SYSTEM

The washer system components should be inspected periodically, not just when washer performance problems are experienced. This inspection should include the following points: 1. Check for ice or other foreign material in the washer reservoir. If contaminated, clean and flush the washer system. See Electrical - Wipers/Washers/Wipers/Washers - Cleaning. 2. Inspect the washer plumbing for pinched, leaking, deteriorated, or incorrectly routed hoses and damaged or disconnected hose fittings. Replace damaged or deteriorated hoses and hose fittings. Leaking washer hoses can sometimes be repaired by cutting the hose at the leak and splicing it back together using an inline connector fitting. Similarly, sections of deteriorated hose can be cut out and replaced by splicing in new sections of hose using inline connector fittings. Whenever routing a washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts. Also, sharp bends that might pinch the washer hose must be avoided. REAR WIPER SYSTEM

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Fig. 6: Inspecting Wiper Blades Courtesy of CHRYSLER LLC The rear wiper blade and wiper arm should be inspected periodically, not just when wiper performance problems are experienced. This inspection should include the following points: 1. Carefully inspect the wiper blade for any indications of worn or uneven edges (1), foreign material deposits (2), hardening or cracking (3), deformation or fatigue (4), or splitting (5). Inspect the wiper blade support components and the wiper arm for damage (6). If the wiper arm and blade are contaminated with any foreign material, clean them and the glass as required. See Electrical Wipers/Washers/Wipers/Washers - Cleaning. If the wiper blade or arm is damaged, replace it with a new unit. Do not attempt to repair a wiper arm or blade 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 arm should pivot freely at the hinge, but with no lateral looseness evident. If there is any binding evident in the wiper arm hinge, or there is evident lateral play in the wiper arm hinge, replace the wiper arm. CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. 3. Once proper hinge action of the wiper arm is confirmed, check the hinge for proper spring tension. The spring tension of the wiper arm should be sufficient to cause the rubber squeegee to conform to the curvature of the glass. Replace a wiper arm if it has insufficient spring tension to maintain contact between the squeegee and the glass. 4. After cleaning and inspecting the wiper components and the glass, if the wiper blade still fails to clear the glass without smearing, streaking, chattering, hazing, or beading, replace the wiper blade. WASHER SYSTEM

The washer system components should be inspected periodically, not just when washer performance problems are experienced. This inspection should include the following points: 1. Check for ice or other foreign material in the washer reservoir. If contaminated, clean and flush the washer system. See Electrical - Wipers/Washers/Wipers/Washers - Cleaning. 2. Inspect the washer plumbing for pinched, leaking, deteriorated, or incorrectly routed hoses and damaged or disconnected hose fittings. Replace damaged or deteriorated hoses and hose fittings. Leaking washer hoses can sometimes be repaired by cutting the hose at the leak and splicing it back together using an inline connector fitting. Similarly, sections of deteriorated hose can be cut out and replaced by splicing in new sections of hose using inline connector fittings. Whenever routing a washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts. Also, sharp bends that might pinch the washer hose must be avoided.

SPECIFICATIONS SPECIFICATIONS user Monday, June 04, 2012 9:17:16 AM

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TORQUE SPECIFICATIONS DESCRIPTION Right Multi-Function Switch Mounting Screw Front Wiper Arm Mounting Nuts Rear Wiper Arm Mounting Nut Front Wiper Module Mounting Screws Front Wiper Motor Mounting Screws Rear Wiper Motor Bracket Mounting Screws

N.m 1

Ft. Lbs. -

In. Lbs. 10

24

18

-

9

-

80

10

-

90

9

-

80

5

-

44

ARM, WIPER DESCRIPTION FRONT

Fig. 7: Front Wiper Arm Courtesy of CHRYSLER LLC The front wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arm has a die cast metal pivot end (4) with a large tapered mounting hole (5) at one end. A molded user Monday, June 04, 2012 9:17:16 AM

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black plastic cap fits over the wiper arm retaining nut to conceal the nut and this mounting hole following wiper arm installation. The wide end of a tapered, stamped steel channel (3) hinges on and is secured with a hinge pin (6) to the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap (2) with a small hole near its pivot end is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long tension spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. The right and left wiper arms are unique and are not interchangeable. A wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. REAR

Fig. 8: Rear Wiper Arm Courtesy of CHRYSLER LLC The rear wiper arm is the rigid member located between the rear wiper motor output shaft that protrudes through the liftgate outer panel below the center of the liftgate glass opening and the wiper blade on the outside of the glass. The wiper arm is constructed of molded black plastic. A hinged pivot end is also molded plastic. A molded black plastic nut cover (2) with two pivot pins on one end and a snap feature on the other fits over the wiper arm retaining nut to conceal the nut and mounting hole following wiper arm installation. The wiper arm hinge and tension spring are concealed on the underside of the wide end of the arm (1), while an integral latch feature (3) concealed on the underside of the narrow end of the wiper arm accepts the pivot pin of the matching molded plastic wiper blade unit. The rear wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. user Monday, June 04, 2012 9:17:16 AM

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OPERATION FRONT

The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The tapered mounting hole in the wiper arm pivot end interlocks with the serrations on the tapered outer circumference of the wiper pivot shaft, allowing positive engagement and finite adjustment of this connection. The mounting nuts lock the wiper arms to the threaded studs of the wiper pivot shafts. 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 cradle for securing and latching the wiper blade pivot block to the wiper arm. REAR

The rear wiper arm is designed to mechanically transmit the motion from the rear wiper motor output shaft to the rear wiper blade. The wiper arm must be properly indexed to the motor output shaft in order to maintain the proper wiper blade travel on the glass. The tapered hole in the wiper arm pivot end interlocks with the serrations on the outer circumference of the tapered motor output shaft, allowing positive engagement and finite adjustment of this connection. A hex nut secures the wiper arm pivot end to the threads on the rear wiper motor output shaft and the plastic cover snaps over this connection for a neat appearance. The spring-loaded wiper arm hinge controls the downforce applied through the tip of the wiper arm to the wiper blade on the glass. The latch formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot pin to the wiper arm. REMOVAL FRONT

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Fig. 9: Removing/Installing Wiper Arm Courtesy of CHRYSLER LLC 1. Lift the front wiper arm (1) to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to pivot shaft connection. 2. Carefully pry the plastic nut cap (2) off of the pivot end of the wiper arm. 3. Remove the nut (3) that secures the wiper arm to the wiper pivot shaft.

Fig. 10: Disengaging Wiper Arm From Pivot Shaft Courtesy of CHRYSLER LLC 4. If necessary, use a suitable battery terminal puller (3) to disengage the wiper arm (1) from the pivot shaft (2). 5. Remove the front wiper arm pivot end from the pivot shaft. REAR user Monday, June 04, 2012 9:17:16 AM

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Fig. 11: Rear Wiper Motor Output Shaft Courtesy of CHRYSLER LLC 1. Unsnap and swing the molded plastic nut cover (2) off of the pivot end of the wiper arm (1). 2. Remove the nut (4) that secures the wiper arm to the rear wiper motor output shaft (3). CAUTION: The use of a battery terminal puller when removing the rear wiper arm is NOT recommended as this may damage the rear wiper arm. 3. Use a slight rocking action to disengage the rear wiper arm pivot end from the output shaft and remove the wiper arm. INSTALLATION FRONT

NOTE:

Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the ON position and move the right (wiper) multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The front wiper motor is now in its park position.

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Fig. 12: Removing/Installing Wiper Arm Courtesy of CHRYSLER LLC 1. The front wiper arms (1) must be indexed to the pivot shafts with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot ends onto the wiper pivot shafts so that the tip of the wiper blade is aligned with the wiper alignment lines located within the lower margin (blackout area) of the windshield glass. 2. Once the wiper blade is aligned, lift the wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot end of the wiper arm down firmly and evenly over the pivot shaft. 3. Install and tighten the nut (3) that secures the wiper arm to the pivot shaft. Tighten the nut to 24 N.m (18 ft. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the front wipers OFF, then check for the correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap (2) onto the wiper arm pivot nut. INSTALLATION

NOTE:

Be certain that the rear wiper motor is in the park position before attempting to install the rear wiper arm. Turn the ignition switch to the ON position and move the rear wiper switch to its OFF position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position.

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Fig. 13: Rear Wiper Motor Output Shaft Courtesy of CHRYSLER LLC 1. The rear wiper arm (1) must be indexed to the rear wiper motor output shaft with the motor in the park position to be properly installed. Position the wiper arm pivot end onto the output shaft (3) so that the tip of the wiper blade is aligned with the second rear window defogger grid line from the bottom of the liftgate glass. 2. With the rear wiper arm properly indexed, push the tapered mounting hole on the pivot end of the wiper arm down over the output shaft. 3. Install and tighten the nut (4) that secures the rear wiper arm to the output shaft. Tighten the nut to 9 N.m (80 in. lbs.). 4. Fold and snap the molded plastic nut cover (2) over the nut on the pivot end of the rear wiper arm. 5. Wet the lift glass and operate the rear wiper. Turn the rear wiper switch to the OFF position, then check for correct wiper arm position and readjust as required.

BLADE, WIPER DESCRIPTION FRONT

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Fig. 14: Identifying Wiper Blade Components Courtesy of CHRYSLER LLC Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: z

z

z

Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations (6) that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure.

The passenger side wiper blades are 47.50 centimeters (18.70 inches) long. The driver side wiper blades are 60 centimeters (23.62 inches) long. They have non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. REAR

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Fig. 15: Rear Wiper Blade Is Secured By An Integral Pivot Pin Courtesy of CHRYSLER LLC The rear wiper blade is secured by an integral pivot pin (2) to a receptacle at the tip of the rear wiper arm, and rests near the base of the liftgate glass when the wiper is not in operation. The rear wiper blade consists of the following components: z

z

z

Superstructure (1) - The superstructure includes a molded black plastic bridge and plastic links with claw formations that grip the wiper blade element. Also included in this unit is the pivot pin that secures the superstructure to the wiper arm. Element (3) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure.

The rear wiper blade is 30.50 centimeters (12.00 inches) long with a non-replaceable element (squeegee). The wiper blade superstructure cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. OPERATION FRONT

The wiper blades are moved back and forth across 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 and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the user Monday, June 04, 2012 9:17:16 AM

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glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. REAR

The rear wiper blade is moved back and forth across the liftgate glass by the wiper arm when the rear wiper system is in operation. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. REMOVAL FRONT

CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged.

Fig. 16: Removing/Installing Wiper Blade Courtesy of CHRYSLER LLC NOTE:

The notched end of the wiper element flexor should always be oriented towards

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the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. REAR

Fig. 17: Rear Wiper Arm Pivot Cap Courtesy of CHRYSLER LLC 1. Lift the rear wiper arm pivot cap (2) upward to allow the rear wiper blade to be raised off of the glass. NOTE:

The rear wiper arm cannot be raised to its over-center hinge position unless the pivot cover is raised first.

2. Lift the rear wiper arm to its over-center hinge position to raise the wiper blade and element off of the liftgate glass.

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Fig. 18: Removing/Installing Wiper Blade From Wiper Arm Courtesy of CHRYSLER LLC 3. To remove the wiper blade (1) from the wiper arm (3), grasp the end of the blade nearest to the motor output shaft, then over-rotate it out from under the arm and past its stop far enough to unsnap the blade pivot pin (2) from the receptacle (4) on the end of the arm. 4. Gently lower the tip of the wiper arm onto the glass. INSTALLATION FRONT

CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged.

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Fig. 19: Removing/Installing Wiper Blade Courtesy of CHRYSLER LLC NOTE:

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

1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. REAR

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Fig. 20: Rear Wiper Arm Pivot Cap Courtesy of CHRYSLER LLC 1. Lift the rear wiper arm pivot cap (2) upward to allow the rear wiper arm to be raised off of the glass. NOTE:

The rear wiper arm cannot be raised to its over-center hinge position unless the pivot cover is raised first.

2. Lift the rear wiper arm to its over-center hinge position and off of the liftgate glass.

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Fig. 21: Removing/Installing Wiper Blade From Wiper Arm Courtesy of CHRYSLER LLC 3. Position the rear wiper blade (1) with the pivot pin (2) aligned with the opening of the receptacle (4) on the tip of the wiper arm (3). 4. Using hand pressure, press the wiper blade pivot pin firmly and evenly into the wiper arm receptacle until it snaps into place. 5. Lower the wiper blade onto the glass and snap the pivot cover back into place.

CHECK VALVE, WASHER DESCRIPTION DESCRIPTION

Diaphragm-type washer system check valves are standard equipment in this vehicle. The check valves for both the front and rear washer systems are integral to their respective washer nozzles. The check valve for the headlamp washer system, which is optional equipment only on vehicles manufactured for certain export markets, is integral to the headlamp washer hose tee fitting. The headlamp washer tee fitting is located behind the front fascia near the left headlamp washer nozzle. Each diaphragm-type check valve consists of a molded plastic valve body where a small diaphragm is held against the lip of an integral sump well by a small plastic piston and a coiled spring. The front and rear check valves cannot be adjusted or repaired and, if ineffective or damaged, the washer nozzle unit must replaced. The headlamp washer system tee fitting with the integral check valve also cannot be adjusted or repaired, and is serviced only as a unit with the headlamp washer hose assembly. OPERATION OPERATION

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Fig. 22: Cutaway View Of Washer System Check Valve Courtesy of CHRYSLER LLC Diaphragm-type washer system check valves provide more than one function. First, they prevent washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer system is activated until washer fluid was dispensed through the washer nozzles because the washer pump would have to refill the washer plumbing from the reservoir to the nozzle. Such a drain-back condition could also result in water, dirt, or other outside contaminants being drawn into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning out through the washer nozzle after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing (5), the fluid pressure unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to it by a piston (2) and coiled spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the washer nozzle (4). 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.

HOSES AND TUBES, WASHER DESCRIPTION FRONT

Fig. 23: Front Washer Plumbing Components Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:17:16 AM

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The front washer plumbing consists of a small diameter rubber hose (2) that is routed along the left front fender ledge (4) from the washer reservoir hose (5) located at the left front corner of the engine compartment. The reservoir hose is attached to the front outlet nipple of the washer pump/motor unit near the bottom of the reservoir. The hose is then secured by plastic push-in type retainers to the left fender ledge within the engine compartment to the left side of the cowl plenum. From the cowl plenum, the front hose is routed up toward the inner hood panel reinforcement (1). The hose is secured to the left hood hinge and the left side of the inner hood panel reinforcement by plastic push-in type retainers, then is routed through the rear hood silencer brackets across the underside of the inner hood panel. Plastic inline fittings, a molded rubber tee and a molded rubber elbow provide the take outs for the two front washer nozzles. Washer hose is available for service as roll stock, which may be cut to length. The molded plastic or rubber washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they must be replaced. HEADLAMP

Fig. 24: Headlamp Washer System Plumbing Components Courtesy of CHRYSLER LLC The headlamp washer system plumbing consists of a large diameter high pressure rubber hose (3) that is routed from the outlet nipple of the headlamp washer pump/motor unit on the washer reservoir to the barbed nipple of a tee fitting with an integral check valve located near the left headlamp washer nozzle on the back side of the front fascia (1). The other two barbed nipples of the tee fitting are connected to one short and one long length of hose that each terminate at a headlamp washer nozzle (2) behind the fascia and below the two front lamp units. The hose is secured and routed from left to right behind the fascia and above the fascia reinforcement by several routing clips. The hose connections at the nozzles and the washer pump are secured using molded plastic quickconnect fittings. The headlamp washer hose is serviced only as a complete unit. The molded plastic washer hose fittings and user Monday, June 04, 2012 9:17:16 AM

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check valve cannot be repaired. If these fittings or the check valve are ineffective or damaged, the entire headlamp washer hose unit must be replaced. REAR

Fig. 25: Front Washer Plumbing Components Courtesy of CHRYSLER LLC The rear washer plumbing consists of a small diameter rubber hose (3) that is routed along the left front fender shield (6) from the washer reservoir hose (5) located at the left front corner of the engine compartment. The reservoir hose is attached to the rear outlet nipple of the washer pump/motor unit near the bottom of the reservoir. The hose is then secured by a plastic clip retainer to the front end sheet metal within the engine compartment and routed to just behind the left strut tower, where it connects to the unibody hose (7).

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Fig. 26: Unibody Hose Courtesy of CHRYSLER LLC The unibody hose (1) passes from the engine compartment through a hole with a rubber grommet in the dash panel into the passenger compartment where it enters the body wire harness. The hose and wire harness bundle is routed along the floor panel (3) near the left sill back to the base of the left rear inner wheel house (2). The hose and wiring bundle is then routed over the wheel house and along the quarter inner panel near the belt line, then up the D-pillar.

Fig. 27: Liftgate Washer Hose user Monday, June 04, 2012 9:17:16 AM

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Courtesy of CHRYSLER LLC The unibody hose (3) exits the body wire harness near the top of the D-pillar, where it is connected to the liftgate washer hose (2) by a quick connect fitting. The liftgate washer hose is routed up the D-pillar to the upper liftgate opening header panel, then to the center of the upper liftgate opening. The liftgate hose is routed through a hole with a rubber grommet in the upper liftgate opening header panel and passes through another hole with a rubber grommet in the upper liftgate panel (1) to the rear washer nozzle on the upper liftgate. Washer hose is available for service as roll stock, which may be cut to length. The unibody washer hose is integral to the body wire harness. The molded plastic washer hose fittings and routing clips cannot be repaired. If these fittings or clips are ineffective or damaged, they must be replaced. OPERATION FRONT

Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the front washer system plumbing and fittings to the two front washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. HEADLAMP

Washer fluid in the washer reservoir is pressurized and fed by the headlamp washer pump/motor unit through the headlamp washer system plumbing and fittings to the two headlamp washer nozzles. Whenever routing the washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. REAR

Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the rear washer system plumbing and fittings to the rear washer nozzle. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided.

LINKAGE, WIPER ARM DESCRIPTION DESCRIPTION

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Fig. 28: Front Wiper Linkage Module Courtesy of CHRYSLER LLC The front wiper linkage module is secured by three screws through three rubber grommet-type insulators to two brackets and weld nuts on the cowl plenum panel and one bracket and weld nut on the driver side strut tower. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades and are the only visible components of the front wiper linkage module. The front wiper linkage module consists of the following major components: z

z

z

z

Bracket - The front wiper module bracket consists of a long tubular steel main member that has a die cast pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting bracket for the wiper motor is secured near the center of the main member. Each of the two wiper pivot brackets secures the module to the cowl plenum with a screw through a rubber insulator (4), and a third rubber insulator on the motor bracket secures the module with a screw in the bracket on the driver side strut tower. Crank Arm - The front wiper motor crank arm (6) is a stamped steel unit with a hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a long ball stud secured to the drive end to accept the wiper linkage. Linkage - Two stamped steel drive links (3) connect the wiper motor crank arm to the wiper pivot lever arms. The right side drive link has a plastic socket-type bushing on each end. The left side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The sockettype bushing on one end of each drive link is snap-fit over the ball stud on the lever arm of its respective pivot. The left side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the right side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. Motor - The front wiper motor (1) features a transmission housing from which the wiper motor output shaft exits, and has three mounting bosses with internal threads to which the motor is mounted to the

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z

center wiper linkage module bracket with screws. is secured with three screws near the center of the main tubular member of the wiper module bracket. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector (5) connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. Pivots - The two front wiper pivots (2) are secured within the die cast pivot brackets on the outboard ends of the wiper linkage module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a finely splined and tapered driver with a threaded stud extending from the top. The lower ends of the pivot shafts are installed through permanently lubricated bushings in the pivot brackets.

The front wiper linkage module cannot be adjusted or repaired. The wiper motor is available for separate service replacement. If any other component of the linkage module is ineffective or damaged, the entire wiper linkage module unit must be replaced. OPERATION OPERATION

The front wiper linkage module operation is controlled by the battery current inputs received by the wiper motor from the Totally Integrated Power Module (TIPM). The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The hard wired inputs and outputs of the wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the wiper system. The most reliable, efficient, and accurate means to diagnose the wiper system or the electronic controls and communication related to wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL REMOVAL

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Fig. 29: Front Wiper Linkage Module Wiper Motor Courtesy of CHRYSLER LLC NOTE:

The front wiper linkage module includes the wiper motor. The wiper motor is also available for separate service replacement and can be removed from the wiper linkage module without removing the module from the vehicle. See Electrical - Wipers/Washers/Wipers/Washers/MOTOR, Wiper - Removal.

1. Remove both front wiper arms from the wiper pivots. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Removal. 2. Disconnect and isolate the battery negative cable. 3. Remove the outer and inner cowl plenum cover/grille panels from the vehicle. Refer to Body/Exterior/COVER, Cowl Panel - Removal . 4. Disconnect the headlamp and dash wire harness connector (2) from the wiper motor pigtail wire connector. 5. Remove the three screws (1) that secure the front wiper linkage module (4) to the driver side strut tower bracket (3) and the two cowl brackets (5). 6. Remove the front wiper linkage module from the vehicle as a unit. INSTALLATION INSTALLATION

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Fig. 30: Front Wiper Linkage Module Wiper Motor Courtesy of CHRYSLER LLC NOTE:

The front wiper linkage module includes the wiper motor. The wiper motor is also available for separate service replacement and can be removed from the wiper linkage module without removing the module from the vehicle. See Electrical - Wipers/Washers/Wipers/Washers/MOTOR, Wiper - Removal.

1. Position the front wiper linkage module (4) into the vehicle as a unit. 2. Reconnect the headlamp and dash wire harness connector (2) to the wiper motor pigtail wire connector. Be certain to route the wire harness take out under the wiper linkage module. 3. Install but do not tighten the three screws (1) that secure the front wiper linkage module to the driver side strut tower bracket (3) and the two cowl brackets (5). 4. Starting on the driver side and working toward the passenger side, tighten each of the three screws. Tighten the screws to 10 N.m (90 in. lbs.). 5. Reinstall the inner and outer cowl plenum cover/grille panels. Refer to Body/Exterior/COVER, Cowl Panel - Installation . 6. Reconnect the battery negative cable. 7. Reinstall both front wiper arms onto the wiper pivots. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Installation.

MOTOR, WIPER DESCRIPTION REAR user Monday, June 04, 2012 9:17:16 AM

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Fig. 31: Rear Wiper Motor Courtesy of CHRYSLER LLC The rear wiper motor is concealed within the liftgate, below the liftgate glass and behind the liftgate inner trim panel. The end of the motor output shaft (1) that extends through the liftgate outer panel to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber bezel and grommet is engaged within the output shaft hole of the liftgate outer panel and seals the output shaft where it passes through the panel. An integral connector receptacle (4) connects the rear wiper motor to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. The rear wiper motor consists of the following major components: z

z

Bracket (5) - The rear wiper motor bracket consists of a stamped metal mounting plate for the wiper motor that is secured with screws to the wiper motor transmission housing, and through three rubber isolators (2) to the liftgate inner panel. Motor (3) - The single-speed permanent magnet rear wiper motor is secured with screws to the rear wiper motor transmission, which is secured to the motor bracket with screws. The wiper motor includes the integral transmission, the motor output shaft, an automatic resetting circuit breaker, and the rear wiper motor park switch that parks the rear wiper blade near the base of the liftgate glass.

The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or damaged, the entire rear wiper motor unit must be replaced. The output shaft bezel and grommet unit is available for individual service replacement. OPERATION REAR

The rear wiper motor operation is controlled by the Totally Integrated Power Module (TIPM), which uses intelligent, high current, self-protected high side switches to control rear wiper system operation for energizing or de-energizing the rear wiper motor. The TIPM uses internal programming and electronic messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also user Monday, June 04, 2012 9:17:16 AM

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known as the Cab Compartment Node/CCN) to provide the appropriate rear wiper and washer system operating modes. The EMIC uses electronic messages received from the Steering Control Module (SCM) over a Local Interconnect Network (LIN) data bus to determine when to send electronic rear wiper system requests to the TIPM. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor electronic control logic circuitry of the TIPM, depending upon the position of the rear wiper blade on the liftgate glass. This input allows the electronic logic circuits of the TIPM to control all of the electronic features of rear wiper motor operation and to keep the motor energized long enough to complete its current wipe cycle and park the wiper blade after the wiper system or the ignition switch has been turned OFF. The rear wiper motor is grounded at all times through a take out in the body wire harness that is secured to a remote ground location. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper system or the electronic controls and communication related to rear wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL FRONT

CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing a drive link from, or installing a drive link onto the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper linkage module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper motor and crank arm unit MUST be replaced.

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Fig. 32: Wiper Pivots Courtesy of CHRYSLER LLC 1. Unlatch and open the hood. 2. Remove both front wiper arms from the wiper pivots. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Removal. 3. Disconnect and isolate the battery negative cable. 4. Remove the outer and inner cowl plenum cover/grille panels from the vehicle. Refer to Body/Exterior/COVER, Cowl Panel - Removal . 5. Disconnect the headlamp and dash wire harness connector from the wiper motor pigtail wire connector (3). 6. Disengage the socket bushing (2) of the right wiper drive link from the ball stud on the wiper motor crank arm using two large screwdrivers, one on each side of the ball stud. Pry between the crank arm and the metal portion of the drive link until the socket unsnaps from the ball. 7. Disengage the sleeve bushing of the left wiper drive link from the ball stud on the wiper motor crank arm using two large screwdrivers, one on each side of the ball stud. Pry between the crank arm and the metal portion of the drive link until the sleeve unsnaps from the ball. 8. Remove the three screws (1) that secure the wiper motor to the center bracket (4) of the wiper linkage module. 9. Remove the wiper motor from under the wiper linkage module bracket and out of the cowl plenum. REAR

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Fig. 33: Rear Wiper Motor Output Shaft Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the rear wiper arm (3) from the rear wiper motor output shaft. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Removal. NOTE:

The output shaft bezel and grommet (4) does not have to be removed to remove the rear wiper motor from the liftgate.

3. Remove the trim panel from the liftgate inner panel (2). Refer to Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Removal . 4. Disconnect the wire harness connector (7) from the rear wiper motor (1). 5. Remove the three screws (6) that secure the motor mounting bracket to the liftgate inner panel. 6. Remove the motor from the liftgate. 7. Remove the bezel and rubber grommet on the outer liftgate panel from the output shaft clearance hole. Be certain to take proper precautions to protect the outer liftgate panel and its paint finish from damage during this procedure. INSTALLATION FRONT

CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing a drive link from, or installing a drive link onto the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal user Monday, June 04, 2012 9:17:16 AM

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portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper linkage module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper motor and crank arm unit MUST be replaced.

Fig. 34: Wiper Pivots Courtesy of CHRYSLER LLC 1. Position the front wiper motor to the center bracket (4) of the wiper linkage module from the underside of the bracket. 2. Install and tighten the three screws (1) that secure the motor to the bracket. Tighten the screws to 9 N.m (80 in. lbs.). 3. Reconnect the headlamp and dash wire harness connector to the wiper motor pigtail wire connector (3). Be certain to route the wire harness take out under the wiper linkage module. 4. Reconnect the battery negative cable. 5. Turn the ignition switch (also known as the Wireless Ignition Node/WIN) to the ON position. WARNING: To avoid serious or fatal injury and vehicle damage, be certain there are no objects including hands or fingers in the rotational path of the wiper motor crank arm. The following step will activate the front wiper motor to ensure it is in the Park position, and may cause the motor crank arm to complete up to one complete revolution. user Monday, June 04, 2012 9:17:16 AM

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6. Turn the front wiper system ON, then back to OFF using the right (wiper) multi-function switch control knob. 7. Wait until the wiper motor stops moving, then turn the ignition switch back to the OFF position. 8. Position the sleeve bushing of the left wiper drive link onto the ball stud on the end of the motor crank arm. Place a short 19 millimeter or 3/4 inch socket over the bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushing.

Fig. 35: Motor Crank Arm Ball Stud Courtesy of CHRYSLER LLC CAUTION: Carefully inspect the installed sleeve bushing (2) to be certain it is centered over the lower ball of the ball stud (3), and not trapped between the lower ball and the crank arm (1). There should be a visible clearance between the lower surface of the sleeve bushing and the crank arm. Refer to the accompanying illustration. The sleeve bushing must be able to swivel freely on the lower ball during wiper operation. If the bushing is trapped between the lower ball and the crank arm, the bushing and the drive link (4) may be damaged. 9. Position the socket bushing of the right wiper drive link over the ball stud on the crank arm. Place a short 19 millimeter or 3/4 inch socket over the bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushing. 10. Reinstall the inner and outer cowl plenum cover/grille panels. Refer to Body/Exterior/COVER, Cowl Panel - Installation . 11. Reinstall both front wiper arms onto the wiper pivots. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Installation. user Monday, June 04, 2012 9:17:16 AM

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REAR

Fig. 36: Rear Wiper Motor Output Shaft Courtesy of CHRYSLER LLC 1. If the output shaft bezel and grommet (4) were removed from the outside of the liftgate, install the rubber bezel and grommet into the clearance hole of the liftgate outer panel. Be certain the arrow (5) molded onto the grommet is oriented upward. 2. Position the rear wiper motor and bracket unit (1) onto the liftgate inner panel (2) as a unit. 3. Install and tighten the three screws (6) that secure the mounting bracket to the liftgate. Tighten the screws to 5 N.m (44 in. lbs.). 4. Reconnect the wire harness connector (7) to the motor connector receptacle. 5. Reinstall the trim panel onto the liftgate inner panel. Refer to Body/Decklid/Hatch/Liftgate/Tailgate/PANEL, Trim - Installation . 6. Reinstall the rear wiper arm (3) onto the output shaft. See Electrical Wipers/Washers/Wipers/Washers/ARM, Wiper - Installation. 7. Reconnect the battery negative cable.

NOZZLE, WASHER DESCRIPTION FRONT

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Fig. 37: Front Washer Nozzle Courtesy of CHRYSLER LLC The fluidic front washer nozzles (2) are constructed of molded plastic and include an integral check valve. Each nozzle has two integral latches (3) that secure them in dedicated holes in the hood panel near the base of the windshield. The domed upper surface of the washer nozzle is visible on the outside of the hood panel, and the two nozzle orifices (1) are oriented towards the windshield glass. An integral diaphragm type check valve is contained within the body of each nozzle. The washer plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the engine compartment. The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced. HEADLAMP

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Fig. 38: Headlamp Washer Nozzles Courtesy of CHRYSLER LLC Vehicles equipped with the optional headlamp washer system have two fixed headlamp washer nozzles (1), one secured to the front fascia beneath each front lamp unit.

Fig. 39: Integral Mounting Bezel Is Secured By Two Integral Latch Courtesy of CHRYSLER LLC user Monday, June 04, 2012 9:17:16 AM

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Each nozzle includes two orifices (1) to ensure complete headlamp lens coverage by the fluid streams emitted from the nozzle. The fixed body of the molded plastic nozzle is located below the front fascia. An integral mounting bezel (2) is secured by two integral latch features (3) within the mounting hole in the front fascia. A large diameter high pressure washer fluid supply hose from the dedicated headlamp washer pump/motor unit is routed to the nozzle, where it is secured by a quick connect fitting to the nipple fitting (4) at the base of the nozzle. The headlamp washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, the entire nozzle and mounting bezel must be replaced with a new unit. REAR

Fig. 40: Center High-Mounted Stop Lamp Courtesy of CHRYSLER LLC The fluidic rear washer nozzle is constructed of molded plastic and includes an integral check valve. The rear washer nozzle is secured by two integral latch features (3) within a mounting hole to the left of the Center HighMounted Stop Lamp (CHMSL) in the lower surface of the brow above the liftgate glass opening in the outer liftgate panel. The outer surface of the washer nozzle is visible on the lower exterior surface of the liftgate, and a rubber gasket (1) seals the nozzle to the spoiler mounting hole. The nozzle orifice (2) is oriented downward towards the liftgate glass. The washer plumbing fitting (4) is concealed between the liftgate inner and outer panels. The rear washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. OPERATION FRONT

The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer user Monday, June 04, 2012 9:17:16 AM

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pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the inner hood panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in each nozzle prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. HEADLAMP

When the headlamp washer pump/motor unit is activated, pressure builds within the high pressure hoses to each headlamp washer nozzle. Driven by this pressure, a control valve integral to each nozzle allows a precisely metered quantity of washer fluid to be sprayed in several high pressure streams against the lenses of both front lamp units. When the pressure drops, the control valve closes and the nozzle spray ceases. The headlamp washer system only operates when the engine is running and the headlamps are turned ON. When those conditions have been met, the headlamp washer system operates whenever the front (windshield) washer system is activated. REAR

The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer pump/motor through a single hose, which is attached to a barbed nipple on the back of the nozzle. A fluidic matrix within the nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in the nozzle prevents washer fluid from draining out of the washer supply hose back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzle because the washer pump would have to refill the washer plumbing from the reservoir to the nozzle. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzle after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, user Monday, June 04, 2012 9:17:16 AM

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the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. REMOVAL FRONT

Fig. 41: Washer Nozzle Hose Courtesy of CHRYSLER LLC 1. From the underside of the hood (3), remove the push-in retainers that secure the rear edge of the hood silencer pad to the inner hood reinforcement as necessary to access the washer nozzle hose (2) connections. 2. From the underside of the hood, disconnect the washer nozzle hose from the barbed nipple (1) of the washer nozzle.

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Fig. 42: Washer Nozzle Courtesy of CHRYSLER LLC 3. From the underside of the hood, release the integral latch features of the washer nozzle (1) and push the nozzle out through the mounting hole toward the top side of the hood. 4. Remove the washer nozzle from the top of the hood panel. HEADLAMP

CAUTION: Take proper precautions to ensure there is no cosmetic damage done to the paint finish of the headlamp washer nozzle bezel or the front fascia during the following procedure.

Fig. 43: Integral Latches Of Washer Nozzle Bezel user Monday, June 04, 2012 9:17:16 AM

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Courtesy of CHRYSLER LLC 1. Raise and support the vehicle. 2. Remove the push pin retainers that secure the lower front edge of the front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash - Removal . 3. Reach up behind the front fascia to access and securely clamp the headlamp washer supply hose to prevent the contents of the washer reservoir from draining during the following procedure. 4. From behind the front fascia, depress the two integral latches (1) of the washer nozzle bezel and push the nozzle out through the face of the fascia.

Fig. 44: Removing/Installing Hose At Headlamp Washer Nozzle Nipple Courtesy of CHRYSLER LLC 5. From the face of the front fascia, pull the nozzle out from the mounting hole far enough to access the headlamp washer nozzle supply hose (1) quick connect fitting (4). 6. Pull the molded plastic lock (2) away from the quick connect fitting far enough to disengage the hose from the washer nozzle nipple (3). 7. Remove the nozzle from the front fascia. REAR

NOTE:

The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit.

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Fig. 45: Rear Washer Nozzle Courtesy of CHRYSLER LLC 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry the rear washer nozzle (3) to release the latch features that secure it in the mounting hole of the liftgate outer panel (1). 2. Pull the rear washer nozzle out from the liftgate outer panel far enough to access the washer supply hose (2). 3. Disconnect the hose from the barbed nipple on the back of the nozzle. 4. Cut 4 to 6 millimeters (0.15 to 0.23 inch) from the end of the hose to ensure a good fit to the barbed nipple of the replacement rear washer nozzle. 5. Discard the removed nozzle. INSTALLATION FRONT

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Fig. 46: Washer Nozzle Courtesy of CHRYSLER LLC 1. From the top of the hood, position the washer nozzle (1) to the mounting hole on the outside of the hood panel (2). 2. Align the anti-rotation tabs of the nozzle with the anti-rotation notches in the mounting hole. 3. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features lock into place on the underside of the hood.

Fig. 47: Washer Nozzle Hose Courtesy of CHRYSLER LLC 4. From the underside of the hood (3), reconnect the washer hose (2) fitting to the barbed nipple (1) of the user Monday, June 04, 2012 9:17:16 AM

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washer nozzle. 5. Reinstall the washer nozzle hose into its routing clips as necessary on the underside of the hood. 6. Reinstall the push-in retainers that secure the rear edge of the hood silencer pad to the inner hood reinforcement. HEADLAMP

CAUTION: Take proper precautions to ensure there is no cosmetic damage done to the paint finish of the headlamp washer nozzle bezel or the front fascia during the following procedure.

Fig. 48: Removing/Installing Hose At Headlamp Washer Nozzle Nipple Courtesy of CHRYSLER LLC 1. Pull the washer nozzle supply hose (1) quick connect fitting (4) out through the mounting hole of the front fascia far enough to seat the molded plastic lock (2) onto the fitting. 2. Push the quick connect fitting onto the headlamp washer nozzle nipple (3) until it snaps into place with an audible click.

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Fig. 49: Integral Latches Of Washer Nozzle Bezel Courtesy of CHRYSLER LLC 3. Position the headlamp washer nozzle into the mounting hole in the front fascia. 4. Align the washer nozzle bezel with the mounting hole in the front fascia. 5. Using hand pressure, push the bezel down into the fascia mounting hole until both bezel latch features are fully engaged on the back side of the fascia. 6. Reach up behind the front fascia to access and remove the clamp from the washer supply hose. 7. Reinstall the push pin retainers that secure the lower front edge of the front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash - Installation . REAR

NOTE:

The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit.

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Fig. 50: Rear Washer Nozzle Courtesy of CHRYSLER LLC 1. Position the new rear washer nozzle (3) to the mounting hole in the liftgate outer panel (1). Be certain that the rubber gasket is in position on the back of the nozzle. 2. Reconnect the washer supply hose (2) to the barbed nipple on the back of the nozzle. 3. Push the hose and nozzle nipple into the mounting hole in the liftgate outer panel and align the antirotation tab to the mounting hole. 4. Using hand pressure, push firmly and evenly on the nozzle until both integral latch features are fully engaged on the back side of the outer panel.

PUMP, WINDSHIELD WASHER DESCRIPTION FRONT AND REAR

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Fig. 51: Washer Pump/Motor Courtesy of CHRYSLER LLC The washer pump/motor unit is located on the top of a sump area on the rearward facing side of the washer reservoir, which is located on the upper left corner of the cooling module in the engine compartment. A small permanently lubricated and sealed reversible electric motor (3) is coupled to the rotor-type washer pump (4). The use of an integral valve body (7) allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer systems, depending upon the direction of the motor/pump impeller rotation. An inlet nipple (6) on the pump housing passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir sump. The filter screen prevents most debris from entering the pump housing. When the pump is installed in the reservoir the front barbed outlet nipple (5) on the pump valve body housing connects the unit to the front washer hose, and the rear barbed outlet nipple (8) connects the unit to the rear washer hose. The letters F and R molded into the valve body housing adjacent to each nipple provide further clarification of the nipple assignments. The washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap fit between the motor housing and a receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (1) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. Service replacement washer pumps may also include a snap post (2) at the top of the pump motor housing, but this feature is not used in this application. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. HEADLAMP

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Fig. 52: Headlamp Washer Pump/Motor Unit Courtesy of CHRYSLER LLC The headlamp washer pump/motor unit (1) of vehicles so equipped is located on the top of a sump area just above and outboard of the reversible front and rear washer pump on the rearward facing side of the washer reservoir, on the upper left corner of the cooling module in the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. An inlet nipple (4) on the bottom of the pump housing (3) passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir. When the pump is installed in the reservoir the quick connect outlet nipple (5) on the pump housing points toward the left side of the vehicle and connects the unit to the headlamp washer hose. The headlamp washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by a light snap fit into a receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (2) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The headlamp washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire headlamp washer pump/motor unit must be replaced. OPERATION FRONT AND REAR

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Fig. 53: Washer Pump/Motor Operation Courtesy of CHRYSLER LLC The washer pump/motor unit features a reversible electric motor. The direction of the motor is controlled by hard wired outputs from the Totally Integrated Power Module (TIPM). When battery current and ground are applied to the two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through one of the two pump outlet nipples, and into the front or rear washer plumbing. The TIPM controls the hard wired outputs to the pump motor based upon electronic washer request messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC receives electronic washer switch status messages over a Local Interface Network (LIN) bus connection from the Steering Control Module (SCM) within the left (lighting) multi-function switch housing. The SCM monitors hard wired analog and multiplex inputs from the washer switch circuitry contained within the right (wiper) multi-function switch to determine the proper electronic messages to send. Washer fluid is drawn through the pump inlet nipple from the washer reservoir to the inlet port of the washer pump housing. An integral valve body is located in a housing on the outlet port side (2) of the pump housing. A diaphragm (4) in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump impeller (1) rotates in the counterclockwise direction (viewed from the bottom), the biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid is pushed out through the pump front outlet port and the front washer outlet nipple (5). When the pump impeller rotates in the clockwise direction (viewed from the bottom), pressurized washer fluid is pushed out through the pump rear outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple (3). The washer pump/motor unit and the hard wired motor control circuits from the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation user Monday, June 04, 2012 9:17:17 AM

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requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. HEADLAMP

Headlamp washer pump/motor unit operation is completely controlled by the Totally Integrated Power Module (TIPM) logic circuits based upon electronic wash request and lighting request message inputs received from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC monitors electronic washer switch and lighting switch status messages received over the Local Interface Network (LIN) data bus from the Steering Control Module (SCM). The SCM monitors analog and resistor multiplexed inputs from the front washer switch circuitry contained within the right (wiper) multi-function switch and the exterior lighting switch circuitry of the left (lighting) multi-function switch to determine the proper washer switch and lighting switch status messages to send. The headlamp washer relay control coil operates on battery voltage received from the run relay, so it is only functional while the engine is running. In addition, the TIPM will only allow the headlamp washers to operate when the headlamps are turned ON. The TIPM uses a low side driver to energize or de-energize the headlamp washer relay which, in turn, controls the operation of the headlamp washer pump/motor unit. The hard wired circuits and components of the headlamp washer pump/motor unit may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the headlamp washer pump/motor or the electronic controls or communication between other modules and devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer pump/motor unit or the electronic controls and communication related to headlamp washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL FRONT AND REAR

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Fig. 54: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. Remove the washer reservoir from the cooling module. See Electrical Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Removal. 4. Pull lightly outward on the top of the washer pump/motor housing (2), away from the washer reservoir to disengage the top of the motor from the receptacle in the reservoir. 5. Using hand pressure, firmly grasp and pull the washer pump upward far enough to disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the washer pump/motor unit from the washer reservoir. 7. Remove the rubber grommet seal/filter screen from the washer pump mounting hole in the reservoir and discard. HEADLAMP

Fig. 55: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. Remove the washer reservoir from the cooling module. See Electrical Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Removal. 4. Pull lightly outward on the top of the washer pump/motor housing (1), away from the washer reservoir to disengage the top of the motor from the receptacle in the reservoir. 5. Using hand pressure, firmly grasp and pull the washer pump upward far enough to disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage user Monday, June 04, 2012 9:17:17 AM

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the reservoir. 6. Remove the rubber grommet seal/filter screen from the pump mounting hole in the washer reservoir and discard. INSTALLATION FRONT AND REAR

Fig. 56: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Install a new rubber grommet seal/filter screen into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal/filter screen on the reservoir. 2. Position the inlet nipple on the base of the pump housing of the washer pump/motor unit (2) to the rubber grommet seal/filter screen in the reservoir. 3. Using hand pressure, press firmly and evenly downward on the top of washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Align the top of the washer pump/motor unit housing with the receptacle in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the motor housing snaps into the receptacle. 6. Reinstall the washer reservoir onto the cooling module. See Electrical Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Installation. 7. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 8. Reconnect the battery negative cable. HEADLAMP

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Fig. 57: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Install a new rubber grommet seal/filter screen into the headlamp washer pump/motor unit mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the inlet nipple of the headlamp washer pump/motor unit (1) to the rubber grommet seal/filter screen in the reservoir. 3. Using hand pressure, press firmly and evenly downward on the washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Align the top of the washer pump/motor unit housing with the receptacle in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the motor housing snaps into the receptacle. 6. Reinstall the washer reservoir onto the cooling module. See Electrical Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Installation. 7. Refill the washer reservoir with the washer fluid drained during removal. 8. Reconnect the battery negative cable.

RELAY, HEADLAMP WASHER DESCRIPTION DESCRIPTION

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Fig. 58: Headlamp Washer Relay Courtesy of CHRYSLER LLC The headlamp washer relay (1) is a conventional International Standards Organization (ISO) skirted relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns (2), and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The headlamp washer relay is located in a dedicated connector on a take out of the Front End Module (FEM) wire harness, and is secured to the radiator closure panel to the left of the washer reservoir in front of the Totally Integrated Power Module (TIPM) in the engine compartment, near the battery. The headlamp washer relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. OPERATION OPERATION

The headlamp washer relay is an electromechanical switch that uses a low current input from the Totally Integrated Power Module (TIPM) to control a high current output to the headlamp washer pump/motor unit. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The headlamp washer relay terminals are connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The inputs and outputs of the headlamp washer relay include: user Monday, June 04, 2012 9:17:17 AM

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z

z

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z

Common Feed Terminal - The common feed terminal (30) is connected to battery current on a fused B (+) circuit from a fuse in the Totally Integrated Power Module (TIPM) at all times. Coil Ground Terminal - The coil ground terminal (85) is connected to battery current on a fused run relay output circuit from a fuse in the TIPM at all times. This circuit is energized by the run relay only while the engine is running. Coil Battery Terminal - The coil battery terminal (86) is connected to a low side driver output from the TIPM on a headlamp washer relay control circuit. The TIPM controls headlamp washer system operation through this relay connection. Normally Open Terminal - The normally open terminal (87) is connected through a headlamp washer relay output circuit to the headlamp washer pump/motor unit at all times. When the relay is energized, the normally open terminal of the relay is connected to battery current from the fuse in the TIPM. Normally Closed Terminal - The normally closed terminal (87A) is not connected to any circuit in this application, but will have battery current present whenever the headlamp washer relay coil is not energized.

The headlamp washer relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or the communication between modules and other devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer relay or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.

RESERVOIR, WINDSHIELD WASHER DESCRIPTION DESCRIPTION

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Fig. 59: Molded Plastic Washer Fluid Reservoir Courtesy of CHRYSLER LLC The molded plastic washer fluid reservoir (1) is mounted on the upper left corner of the cooling module on the back of the Front End Module (FEM) carrier (also known as the radiator closure). The filler neck for the reservoir extends upward just past the upper radiator closure member and through the upper radiator seal. This reservoir is constructed of opaque black plastic, which does not allow the fluid level to be inspected without removing the reservoir filler cap (2). The bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon for Windshield Washer molded into it snaps over the open end of the washer reservoir filler neck. The cap hinges on and is secured to an integral molded hook formation on the top of the reservoir just to the left of the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. The washer reservoir is secured to the cooling module through integral mounting brackets at the top on the inboard and outboard sides by two screws. In addition, integral mounting tab provisions on the bottom of the washer reservoir engage through slots or slotted loops integral to the cooling module to secure the lower end of the reservoir. There is a dedicated mounting hole in the top of the sump area on the rearward facing side of the reservoir with a receptacle provided for the mounting of the reversible washer/pump motor unit (3) without the use of fasteners. A separate dedicated mounting hole is provided in the rearward facing side of the reservoir for the washer fluid level switch (4). An integral molded routing trough for the washer hose and washer pump/motor unit wiring routes the hose and wiring bundle from the washer pump to the outboard side of the reservoir. A unique reservoir is used for vehicles manufactured for export markets with the optional headlamp washer system. This reservoir has a dedicated sump area and mounting receptacle for the high pressure headlamp washer pump (5) near the outboard side of the reservoir, directly above the washer fluid level switch location. The location and mounting provisions for this reservoir are the same as for those vehicles without the headlamp user Monday, June 04, 2012 9:17:17 AM

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washer system. A washer reservoir cannot be repaired and, if ineffective or damaged, the unit must be replaced. The reversible washer pump/motor unit, the washer fluid level switch, the headlamp washer pump/motor unit, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. OPERATION OPERATION

The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front, rear and, if equipped, headlamp washer systems. The washer reservoir filler cap provides a clearly marked and readily accessible point at 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 reservoir becomes depleted. The washer fluid level switch is mounted far enough above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. REMOVAL REMOVAL

Fig. 60: Removing/Installing Hose At Headlamp Washer Nozzle Nipple Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. If equipped with certain optional engines, it may be necessary to remove the air filter housing for access user Monday, June 04, 2012 9:17:17 AM

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to the washer reservoir mounting provisions and connections. Refer to Engine/Air Intake System/BODY, Air Cleaner - Removal . 4. If the vehicle is so equipped, disconnect the Front End Module (FEM) wire harness connector (2) and headlamp washer supply hose (1) from the headlamp washer pump/motor unit (3). To disconnect the quick connect fitting (4), pull the molded plastic lock (2) away from the headlamp washer supply hose quick connect fitting far enough to disengage the hose from the washer pump nipple.

Fig. 61: Front End Module Wire Harness Connector Courtesy of CHRYSLER LLC 5. Disconnect the FEM wire harness connector (5) from the washer fluid level switch connector receptacle on the back of the reservoir. 6. Disconnect the FEM wire harness connector (3) and the front and rear washer supply hoses (4) from the reversible washer pump/motor unit. 7. Disengage each of the FEM wire harness takeouts and washer supply hoses from the integral routing provisions of the washer reservoir.

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Fig. 62: Washer Reservoir Screws Courtesy of CHRYSLER LLC 8. Remove the two screws (1) that secure the washer reservoir inboard and outboard mounting brackets to the back of the cooling module. 9. Lift the washer reservoir straight up to disengage the mounting tabs from the cooling module. 10. Remove the washer reservoir from the left side of the cooling module. INSTALLATION INSTALLATION

Fig. 63: Washer Reservoir Screws user Monday, June 04, 2012 9:17:17 AM

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Courtesy of CHRYSLER LLC 1. Position the washer reservoir to the left side of the cooling module. 2. Engage the mounting provisions at the bottom of the washer reservoir with the cooling module. 3. Install and tighten the two screws (1) that secure the washer reservoir inboard and outboard mounting brackets to the back of the cooling module. Tighten the screws securely. 4. Engage each of the Front End Module (FEM) wire harness takeouts and washer supply hoses into the integral routing provisions of the washer reservoir.

Fig. 64: Front End Module Wire Harness Connector Courtesy of CHRYSLER LLC 5. Reconnect the FEM wire harness connector (3) and the front and rear washer supply hoses (4) to the reversible washer pump/motor unit. 6. Reconnect the FEM wire harness connector (5) to the washer fluid level switch connector receptacle on the back of the reservoir.

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Fig. 65: Removing/Installing Hose At Headlamp Washer Nozzle Nipple Courtesy of CHRYSLER LLC 7. If the vehicle is so equipped, reconnect the FEM wire harness connector and headlamp washer supply hose (1) to the headlamp washer pump/motor unit. To reconnect the quick connect fitting (4), first seat the molded plastic lock (2) onto the washer supply hose quick connect fitting. Next, push the quick connect fitting onto the headlamp washer pump/motor unit outlet nipple (3) until it snaps into place with an audible click. 8. If removed, reinstall the air filter housing. Refer to Engine/Air Intake System/BODY, Air Cleaner Installation . 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable.

SWITCH, MULTIFUNCTION, RIGHT DESCRIPTION DESCRIPTION

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Fig. 66: Right (Wiper) Multi-Function Switch Courtesy of CHRYSLER LLC The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds.

Fig. 67: Identifying Steering Control Module Components Courtesy of CHRYSLER LLC The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has user Monday, June 04, 2012 9:17:17 AM

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white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: z

z

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z

Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. Rear Washer Mode - The right multi-function switch control sleeve provides one momentary switch positions for control of rear washer system operation.

The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. OPERATION OPERATION

The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional analog switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a fail-safe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current user Monday, June 04, 2012 9:17:17 AM

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ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard-wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: z

z

z

z

z

Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle.

DIAGNOSIS AND TESTING RIGHT MULTI-FUNCTION SWITCH

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering user Monday, June 04, 2012 9:17:17 AM

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wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment.

Fig. 68: Right Multi-Function Switch Connector Courtesy of CHRYSLER LLC The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See Electrical - Wipers/Washers/Wipers/Washers/SWITCH, Multifunction - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables below. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). CONTROL STALK FUNCTION TESTS PINS FUNCTION RESISTANCE 1 7 Front Wash X X 10000 Ohms Front Mist X X 5490 Ohms CONTROL KNOB FUNCTION TESTS BETWEEN PIN 7 (GROUND) AND PINS FUNCTION 4 5 6 Off CLOSED CLOSED OPEN user Monday, June 04, 2012 9:17:17 AM

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Front Delay 1 Front Delay 2 Front Delay 3 Front Delay 4 Front Delay 5 Front Wiper Low Front Wiper High

CLOSED CLOSED OPEN OPEN OPEN OPEN CLOSED

CLOSED OPEN OPEN CLOSED CLOSED OPEN OPEN

CLOSED CLOSED CLOSED CLOSED OPEN OPEN OPEN

CONTROL SLEEVE FUNCTION TESTS BETWEEN PIN 7 (GROUND) AND PINS FUNCTION 2 3 Off CLOSED OPEN Rear Wipe CLOSED CLOSED Rear Wash OPEN CLOSED 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. REMOVAL REMOVAL

WARNING: To avoid personal or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 precautions could result in accidental airbag deployment.

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Fig. 69: Removing/Installing Right Multi-Function Switch Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. Refer to Steering/Column/SHROUD, Steering Column - Removal . 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket.

Fig. 70: Right Multi-Function Switch Harness Connector Courtesy of CHRYSLER LLC 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). user Monday, June 04, 2012 9:17:17 AM

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6. Remove the switch from the clockspring (3). INSTALLATION INSTALLATION

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment.

Fig. 71: Right Multi-Function Switch Harness Connector Courtesy of CHRYSLER LLC 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated.

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Fig. 72: Removing/Installing Right Multi-Function Switch Courtesy of CHRYSLER LLC 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). Tighten the screw to 1 N.m (10 in. lbs.). 4. Reinstall the upper and lower shrouds onto the steering column. Refer to Steering/Column/SHROUD, Steering Column - Installation . 5. Reconnect the battery negative cable.

SWITCH, WASHER FLUID LEVEL DESCRIPTION DESCRIPTION

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Fig. 73: Washer Fluid Level Switch Courtesy of CHRYSLER LLC The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir on the upper left corner of the cooling module on the Front End Module (FEM). Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two overmolded pins or electrodes (2) extend from the back of the nipple formation. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the FEM wire harness. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. OPERATION OPERATION

The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON request user Monday, June 04, 2012 9:17:17 AM

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message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to SYSTEM WIRING DIAGRAMS . However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level indicator or the electronic controls or communication between other modules and devices that provide some features of the washer system. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. REMOVAL REMOVAL

Fig. 74: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Disconnect and isolate the battery negative cable. 2. Remove the washer reservoir from the back of the cooling module on the Front End Module (FEM). See Electrical - Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Removal. 3. Disconnect the FEM wire harness connector from the washer fluid level switch connector receptacle (3) on the back of the reservoir. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir. Care must be taken not to damage the reservoir. user Monday, June 04, 2012 9:17:17 AM

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5. Remove the switch from the washer reservoir. 6. Remove the rubber grommet seal from the switch mounting hole in the washer reservoir and discard. INSTALLATION INSTALLATION

Fig. 75: Washer Pump/Motor Housing Courtesy of CHRYSLER LLC 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented upward. 4. Reconnect the Front End Module (FEM) wire harness connector (3) to the switch connector receptacle. 5. Reinstall the washer reservoir onto the back of the cooling module on the FEM. See Electrical Wipers/Washers/Wipers/Washers/RESERVOIR, Windshield Washer - Installation. 6. Reconnect the battery negative cable.

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2009 ACCESSORIES AND EQUIPMENT Wiring Harness - Service Information - Journey

GROMMET REMOVAL GROMMET - A PILLAR

Fig. 1: A Pillar Grommet Courtesy of CHRYSLER LLC 1. Peel the A Pillar grommet (1) off of the connector/retainer and move it up the wire harness. 2. Grasp the wire harness (2) by the convolute section of the grommet and gently pull the wire harness down towards the floor to expose the connector lock tabs. CAUTION: Do not force the locking tab past the connector body, as damage to the connector may occur. 3. While still pulling down on the harness, use a small slotted screw driver (3) to gently push one of the top lock tabs until the lock feature is flush with the connector/retainer body. 4. Repeat the step 3 for the remaining top lock tab. 5. The connector should now be able to rock out of the sheet metal hole without causing any damage to the connector or sheet metal.

TRAILER TOW STANDARD PROCEDURE TRAILER TOW HARNESS INSTALLATION

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Fig. 2: Push Pin Fasteners & Rear Tail Lamp Assemblies Courtesy of CHRYSLER LLC 1. Remove the push pin fasteners (2) and separate the rear tail lamp assemblies (1).

Fig. 3: Tail Lamp Electrical Connectors & Tail Lamp Assemblies Courtesy of CHRYSLER LLC 2. Disconnect the tail lamp electrical connectors (2 and 3).

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Fig. 4: Tail Lamp Electrical Connectors Courtesy of CHRYSLER LLC 3. Connect the harness (2) to the left side tail lamp electrical connectors (1).

Fig. 5: Harness & Support Clips Courtesy of CHRYSLER LLC 4. Position the harness (1) through the tail lamp opening and down the side of the fender. 5. Secure the support clips (2) to the body seem.

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Fig. 6: Harness & Push Pin Fasteners Courtesy of CHRYSLER LLC 6. Position the harness (1) over the exhaust and fasten the push pin fasteners (2) to the under side of the rear bumper in the existing holes.

Fig. 7: Harness & Right Tail Lamp Courtesy of CHRYSLER LLC 7. Position the harness (1) up the right side of the vehicle to the right tail lamp opening and secure the clips user Monday, June 04, 2012 5:01:53 PM

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Wiring Harness - Service Information - Journey

(2) to the body seem.

Fig. 8: Right Side Tail Lamp Electrical Connectors Courtesy of CHRYSLER LLC 8. Connect the harness (1) to the right side tail lamp electrical connectors (2).

Fig. 9: Tail Lamp Electrical Connectors & Tail Lamp Assemblies Courtesy of CHRYSLER LLC 9. Connect the tail lamp electrical connectors (2 and 3) to the tail lamp assemblies (1).

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2009 Dodge Journey SE 2009 ACCESSORIES AND EQUIPMENT Wiring Harness - Service Information - Journey

Fig. 10: Push Pin Fasteners & Rear Tail Lamp Assemblies Courtesy of CHRYSLER LLC 10. Install tail lamps assemblies (1) and install the push pin fasteners (2) fully.

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2009 Dodge Journey SE 2009 BRAKES Base - Service Information - Journey

2009 BRAKES Base - Service Information - Journey

DESCRIPTION DESCRIPTION The base brake system consists of the following components: z z z z z z z z

Brake pedal Power brake booster Master cylinder Brake tubes and hoses Disc brakes (four-wheel) Brake lamp switch Brake fluid level switch Parking brakes

Antilock brakes with traction control and Electronic Stability Program (ESP) are standard equipment on this vehicle. ABS and ESP components are described in detail in ABS SERVICE INFORMATION. For information on the brake lamp switch. Refer to Electrical - Lamps and Lighting/Lamps/Lighting Exterior/SWITCH, Stop Lamp - Description

WARNING WARNING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris.

CAUTION CAUTION CAUTION: During service procedures, grease or any other foreign material must be user Monday, June 04, 2012 10:08:32 10:08:22 AM

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2009 Dodge Journey SE 2009 BRAKES Base - Service Information - Journey

kept off brake shoes and braking surfaces of brake rotor or drum, and external surfaces of hub and bearing assembly. CAUTION: Brake rotor and caliper handling must be done in such a way as to avoid damage to the rotor, especially the machined surfaces, and scratching or nicking of the brake linings. CAUTION: Only the recommended jacking or hoisting procedures for this vehicle are to be used whenever it is necessary to lift a vehicle. Failure to raise a vehicle utilizing the recommended lift points can result in damage to the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .

DIAGNOSIS AND TESTING BASE BRAKE SYSTEM NOTE:

There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR LAMP, BRAKE NOISE and OTHER BRAKE CONDITIONS.

RED BRAKE WARNING INDICATOR LAMP

CONDITION POSSIBLE CAUSES RED BRAKE WARNING LAMP 1. Parking brake lever not ON fully released. 2. Parking brake warning lamp switch on parking brake lever. 3. Brake fluid level low in reservoir. 4. Brake fluid level switch.

CORRECTION 1. Release parking brake lever. 2. Inspect and replace switch as necessary. 3. Fill reservoir. Check entire system for leaks. Repair or replace as required. 4. Disconnect switch wiring connector. If lamp goes out, replace switch. 5. Refer to appropriate Diagnostic information. 6. Refer to appropriate Diagnostic information.

5. Mechanical instrument cluster (MIC) problem. 6. Amber ABS Warning Indicator Lamp also illuminated. BRAKE NOISE

CONDITION POSSIBLE CAUSES CLICK OR SQUAWK ON PEDAL 1. Brake lamp switch. APPLICATION 2. Brake Transmission Shift Interlock Linkage. 3. Pedal pivot bushings

CORRECTION 1. Replace switch. 2. Lubricate BTSI linkage. 3. Lubricate pivot bushings. Replace

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DISC BRAKE CHIRP

1. Excessive brake rotor runout. 2. Lack of lubricant on brake caliper slides. 3. Caliper/shoes not fully seated. DISC BRAKE RATTLE OR 1. Broken or missing antiCLUNK rattle spring clips. 2. Caliper guide pins/bolts loose. DISC BRAKE SQUEAK AT LOW 1. Brake shoe linings. SPEED (WHILE APPLYING LIGHT BRAKE PEDAL EFFORT) SCRAPING (METAL-TO1. Foreign object interference METAL). with brakes. 2. Brake shoes worn out.

if necessary. 1. Follow brake rotor diagnosis and testing. Correct as necessary. 2. Lubricate brake caliper slides. 3. Reseat caliper/shoes. 1. Replace anti-rattle spring clips. 2. Tighten guide pins/bolts. 1. Replace brake shoes. 1. Inspect brakes and remove foreign object. 2. Replace brake shoes. Inspect rotors. Reface or replace as necessary.

OTHER BRAKE CONDITIONS

CONDITION BRAKES CHATTER BRAKES DRAG (FRONT OR ALL)

BRAKES DRAG (REAR ONLY)

BRAKES GRAB

POSSIBLE CAUSES CORRECTION 1. Disc brake rotor has 1. Isolate condition as rear or excessive thickness variation. front. Reface or replace brake rotors as necessary. 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all system components containing rubber. 2. Binding caliper pins or 2. Replace pins and bushings. bushings. 3. Binding master cylinder. 3. Replace master cylinder. 4. Binding brake pedal. 4. Replace brake pedal. 5. Brake lamp switch not 5. Straighten mounting bracket adjusted properly and and replace brake lamp switch. mounting bracket is bent. 1. Parking brake cables 1. Check cable routing. Replace binding or froze up. cables as necessary. 2. Parking brake cable return 2. Replace cables as necessary. spring not returning shoes. 3. Rear disc brake parking 3. Adjust parking brake shoes. brake not properly adjusted. 1. Contaminated brake shoe 1. Inspect and clean, or replace linings. shoes. Repair source of contamination.

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EXCESSIVE PEDAL EFFORT

EXCESSIVE PEDAL TRAVEL (VEHICLE STOPS OK) EXCESSIVE PEDAL TRAVEL (ONE FRONT WHEEL LOCKS UP DURING HARD BRAKING) PEDAL PULSATES/SURGES DURING BRAKING

2. Improper power brake 2. Refer to BOOSTER, Power booster assist. Brake. 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction. 2. Low power brake booster 2. Refer to BOOSTER, Power Brake. assist (vacuum leak). 3. Glazed brake linings. 3. Reface or replace brake rotors as necessary. Replace brake shoes. 4. Brake shoe lining transfer 4. Reface or replace brake to brake rotor. rotors as necessary. Replace brake shoes. 1. Air in brake lines. 1. Bleed brakes. 1. One of the two hydraulic circuits to the front brakes is malfunctioning. 1. Disc brake rotor has excessive thickness variation.

PEDAL IS SPONGY

1. Air in brake lines. 2. Power brake booster runout (vacuum assist).

PREMATURE WHEEL LOCKUP

1. Contaminated brake shoe linings.

STOP/BRAKE LAMPS STAY ON

2. Antilock brake system function issue. 1. Brake lamp switch out of adjustment. 2. Brake pedal binding.

3. Obstruction in pedal linkage. 4. Power Brake Booster not allowing pedal to return completely. VEHICLE PULLS TO RIGHT OR LEFT 1. Frozen brake caliper ON BRAKING piston. 2. Contaminated brake shoe lining. 3. Pinched brake lines.

1. Inspect system for leaks. Check master cylinder for internal malfunction. 1. Isolate condition as rear or front. Reface or replace brake rotors as necessary. 1. Bleed brakes. 2. Check booster vacuum hose and engine tune for adequate vacuum supply. Refer to BOOSTER, Power Brake. 1. Inspect and clean, or replace shoes. Repair source of contamination. 2. Refer to appropriate antilock brake diagnostic information. 1. Replace brake lamp switch. 2. Inspect and replace as necessary. 3. Remove obstruction. 4. Replace power brake booster. 1. Replace frozen piston or caliper. Bleed brakes. 2. Inspect and clean, or replace shoes. Repair source of contamination. 3. Replace pinched line.

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2009 Dodge Journey SE 2009 BRAKES Base - Service Information - Journey

4. Leaking piston seal. 5. Suspension problem. PARKING BRAKE - EXCESSIVE LEVER TRAVEL

4. Replace piston seal or brake caliper. 5. Refer to FRONT SUSPENSION or REAR SUSPENSION . 1. Replace broken cable. 2. Replace binding cable.

1. Broke cable. 2. Binding cable. 3. Damaged lever at rear 3. Replace rear brake caliper. brake caliper. 4. Binding/frozen rear brake 4. Replace rear brake caliper. caliper piston.

STANDARD PROCEDURE BASE BRAKE BLEEDING NOTE:

This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system. See Brakes - Standard Procedure CAUTION: Before removing the master cylinder reservoir cap, thoroughly clean the cap and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir.

NOTE:

z z z z

The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system.

Left Rear Wheel Right Front Wheel Right Rear Wheel Left Front Wheel

NOTE:

When bleeding the brake system, some air may be trapped in the brake lines far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.

Pressure bleeding the brakes is recommended, although the brakes may be manually bled or pressure bled. Refer to the appropriate following procedure. PRESSURE BLEEDING PROCEDURE

Follow the pressure bleeder manufacturer's instructions for use of the pressure bleeding equipment. user Monday, June 04, 2012 10:08:22 AM

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Fig. 1: BLEED HOSE SET UP Courtesy of CHRYSLER LLC 1. Install Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the master cylinder fluid reservoir. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 3. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 4. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an airfree flow is maintained in the clear plastic hose and jar, close the bleeder screw. 5. Repeat this procedure at all the remaining bleeder screws. 6. Check and adjust brake fluid level to the FULL mark on the reservoir. 7. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. MANUAL BLEEDING PROCEDURE

NOTE:

To bleed the brakes manually, the aid of a helper will be required.

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Fig. 2: BLEED HOSE SET UP Courtesy of CHRYSLER LLC 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. IPB CALIPER BRAKE BLEEDING PROCEDURE

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Fig. 3: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC NOTE:

The following procedure is normally only necessary if a rear brake caliper has been removed and installed, or replaced.

Perform the following procedure on each rear brake caliper as necessary. 1. Raise and support vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).

Fig. 4: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:22 AM

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3. Remove the brake caliper lower guide pin bolt (1). 4. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket.

Fig. 5: REAR BRAKE PADS Courtesy of CHRYSLER LLC 5. Remove the outboard pad (5) from the adapter bracket. 6. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 7. Slowly pump the brake pedal until the caliper fingers touch the outboard surface of the brake rotor. Release the pedal. 8. Remove the brake caliper lower guide pin bolt. 9. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 10. Reinstall the outboard pad in the adapter bracket. 11. Open the caliper bleeder screw at least one full turn.

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Fig. 6: SEATING PISTON WITH SPECIAL TOOL Courtesy of CHRYSLER LLC 12. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 13. Close the bleeder screw. 14. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 15. Have a helper pump the brake pedal three or four times and hold it in the down position. 16. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 17. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 18. Repeat the previous three steps until all trapped air is removed. 19. Tighten the guide pin bolt to 35 N.m (26 ft. lbs.). 20. Repeat the above procedure on the opposite rear brake caliper as necessary. 21. Check brake pedal travel and feel. If pedal travel is still excessive or if the pedal feels excessively spongy, repeat the entire procedure as necessary. 22. Install the tire and wheel assembly. Refer to Tires and Wheels - Installation . Install and tighten wheel mounting nuts to 135 N.m (100 ft. lbs.). 23. Lower the vehicle. user Monday, June 04, 2012 10:08:22 AM

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24. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.

SPECIFICATIONS BRAKE FASTENER TORQUE BRAKE FASTENER TORQUE DESCRIPTION ABS ABM Mounting Screws (To HCU) ABS ICU Mounting Bolt (To Bracket) ABS ICU Mounting Pins ABS ICU Mounting Bracket Screws (To Frame) ABS ICU Mounting Bracket Screw And Nut (To Body) - Right-Hand-Drive ABS Wheel Speed Sensor Head Mounting Bolt - Front ABS Wheel Speed Sensor Head Mounting Bolt - Rear ABS Wheel Speed Sensor Routing Bracket Screws Front ABS Wheel Speed Sensor Routing Bracket Screws Rear Brake Tube Nuts Brake Hose Bracket Bolt Brake Hose Caliper Banjo Bolt Brake Shield Mounting Screws Disc Brake Caliper Adapter Mounting Bolts - Front Disc Brake Caliper Adapter Mounting Bolts - Rear Disc Brake Caliper Guide Pin Bolts - Front Disc Brake Caliper Guide Pin Bolts - Rear Disc Brake Caliper Bleeder Screw Dynamics (ESP) Sensor Mounting Nuts Master Cylinder Mounting Nuts Pedal Bracket Upper Mounting Nuts Power Brake Booster Mounting Nuts Parking Brake Cable Mounting Screws to Hand Lever Front Parking Brake Cable Routing Clamp Screws/Nuts Parking Brake Cable Routing Loop Mounting Nuts Parking Brake Lever Mounting Nuts - Foot Lever System Parking Brake Lever Mounting Nuts - Hand Lever System Wheel Mounting (Lug) Nuts

N.m 2 11 11 23

Ft. Lbs. 8 8 17

In. Lbs. 17 97 97 203

23

17

203

12 6

9 4.5

106 55

20

15

177

20

15

177

17 18 26 8 169 100 35 35 10 9 25 28 28

12.5 13 19 6 125 74 26 26 7 6.5 19 21 21

150 160 230 71 88 80 225 250 250

28

21

250

6 6

4.5 4.5

55 55

28

21

250

20

15

177

135

100

-

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SPECIAL TOOLS SPECIAL TOOLS

Fig. 7: Adapter, Master Cylinder Pressure Bleed Cap 6921 Courtesy of CHRYSLER LLC

Fig. 8: Bleeder Tubes 8358A Courtesy of CHRYSLER LLC

Fig. 9: Retractor, Rear Caliper Piston 8807 Courtesy of CHRYSLER LLC

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Fig. 10: Dial Indicator 9524 Courtesy of CHRYSLER LLC

Fig. 11: Dial Indicator C-3339A Courtesy of CHRYSLER LLC

ELECTRICAL SWITCH, BRAKE FLUID LEVEL Description DESCRIPTION

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Fig. 12: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC The brake fluid level switch (2) is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. Removal REMOVAL

Fig. 13: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:22 AM

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NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir.

Fig. 14: LEVEL SWITCH RETAINING TABS Courtesy of CHRYSLER LLC 2. Push together the retaining tabs (1) that hold the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Installation INSTALLATION

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Fig. 15: LEVEL SWITCH RETAINING TABS Courtesy of CHRYSLER LLC 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place.

Fig. 16: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC 2. Connect the wiring harness connector (1) to the switch (2).

HYDRAULIC/MECHANICAL user Monday, June 04, 2012 10:08:22 AM

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DESCRIPTION DESCRIPTION

Four-wheel disc brakes are standard on this vehicle. Each disc brake assembly consists of the following major components: z z z z

Caliper Caliper adapter bracket Pads (Shoe and lining assemblies) Rotor

FRONT DISC BRAKES Each front disc brake features a single 2.6 in. (66 mm) piston floating caliper acting on a 11.9 x 1.1 in. (302 x 28 mm) vented rotor. The brake caliper is a low-drag type. The vented rotor utilizes an inverted hat construction (vent openings are on the outboard side of the rotor versus inboard side) to improve cooling and minimize hightemperature deformation for long-term smooth operation. The front brake caliper piston and seals are serviceable. REAR DISC BRAKES Each rear disc brake features a single 1.7 in. (43 mm) piston floating caliper acting on a 12.0 x.47 in. (305 x 12 mm) solid rotor. The brake caliper used features an Integral Parking Brake (IPB) mechanism which combines a mechanical parking brake function with a conventional rear caliper. Refer to Parking Brake for additional information on this feature. The rear brake caliper with integrated parking brake is not serviceable. All brake calipers are coated in zinc nickel and dipped after machining with clear coat for excellent corrosion protection and a neat appearance. They use adapter bracket mounted guide pins for caliper slide functions. All rotors are made from high-carbon, damped iron for quiet operation. They are fully coated with zinc dust water-soluble, environmental friendly corrosion preventive. Both the friction surfaces and the vents are coated. During initial brake applications, the brake pads scrub the coating off the friction surfaces, ensuring that the remainder will be rust free. Coating the vents also maintains their heat capacity over time. Front disc brakes are equipped with an audible wear indicator on the left side inboard brake pad only. The right side pads do not include an audible wear indicator. Rear disc brakes are equipped with audible wear indicators on both left side and right side inboard brake pads. When the brake pads are replaced, only brake pads meeting the Original Equipment Manufacturer (OEM) formulation (such as Mopar® replacement parts) should be used. BOOSTER, POWER BRAKE Description user Monday, June 04, 2012 10:08:22 AM

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DESCRIPTION

Fig. 17: PEDAL AND BOOSTER MOUNTING - LHD Courtesy of CHRYSLER LLC The power brake booster (3) is mounted to the engine side of the dash panel. The master cylinder is bolted to the front of the booster. A vacuum check valve is also mounted on the front of the booster. A vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dash panel and connects to the brake pedal. This vehicle uses a tandem diaphragm, single rate vacuum power brake booster with 203 and 229 mm (8 and 9 in.) diaphragms. Power brake boosters are internally tuned differently depending on whether the vehicle is equipped with ABS or without ABS. If the power brake booster requires replacement, be sure it is replaced with the correct part. The power brake booster can be identified by the tag attached to the body of the booster. This tag contains the following information: z z z

The production part number The date it was built, and The booster manufacturer.

Diagnosis and Testing POWER BRAKE BOOSTER BASIC TEST

1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. user Monday, June 04, 2012 10:08:22 AM

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2. Depress and hold the pedal with light effort (15 to 25 lbs. (6.8 to 11.3 kg) pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST

1. 2. 3. 4.

Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. Start the engine. Allow the engine to warm up to normal operating temperature and engine idle. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test.

5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. (6.8 kg) of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 7. Have an assistant reattach the pliers to the vacuum supply hose. 8. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. user Monday, June 04, 2012 10:08:22 AM

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Removal LEFT-HAND-DRIVE

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.

1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable.

Fig. 18: COWL TOP SCREEN Courtesy of CHRYSLER LLC 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

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Fig. 19: COWL SCREEN Courtesy of CHRYSLER LLC 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3).

Fig. 20: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 7. Remove the wheelhouse brace (2). 8. Remove the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Removal user Monday, June 04, 2012 10:08:23 AM

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Fig. 21: REAR BRAKE TUBES AT JUNCTION BLOCK Courtesy of CHRYSLER LLC 9. Disconnect the rear brake tubes (1) at the junction block (2). Install plugs at all of the open brake tubes.

Fig. 22: VACUUM HOSE AT BOOSTER - LHD Courtesy of CHRYSLER LLC 10. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. 11. If equipped, remove the silencer pad below the steering column opening cover.

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Fig. 23: STOP LAMP SWITCH REMOVAL Courtesy of CHRYSLER LLC 12. Remove the stop lamp switch (2). Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008. . Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp Removal

Fig. 24: BRAKE PEDAL CLIP Courtesy of CHRYSLER LLC 13. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the user Monday, June 04, 2012 10:08:23 AM

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2009 Dodge Journey SE 2009 BRAKES Base - Service Information - Journey

clip. Do not reuse the clip. 14. Slide the booster push rod (1) off the brake pedal pin (3).

Fig. 25: PEDAL AND BOOSTER MOUNTING - LHD Courtesy of CHRYSLER LLC 15. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 16. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. RIGHT-HAND-DRIVE

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution. CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.

1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Remove the engine appearance cover.

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Fig. 26: COWL TOP SCREEN Courtesy of CHRYSLER LLC 4. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 5. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

Fig. 27: COWL SCREEN Courtesy of CHRYSLER LLC 6. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). user Monday, June 04, 2012 10:08:23 AM

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Fig. 28: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 7. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 8. Remove the wheelhouse brace (2).

Fig. 29: MODULE -WIPER Courtesy of CHRYSLER LLC 9. Disconnect the electrical connector (2) from the wiper motor. 10. Remove three bolts (1) from the wiper module. 11. Remove the wiper module from the vehicle.

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Fig. 30: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 12. Remove the booster vacuum hose routing clip (4) from the master cylinder mounting stud. 13. Remove the vacuum hose routing clip (3) from the stud on the dash panel. 14. Remove the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Removal

Fig. 31: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 15. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from the power brake booster. user Monday, June 04, 2012 10:08:23 AM

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16. Remove both brake tube routing clips with tubes from the studs on the dash panel. Do not bend the brake tubes.

Fig. 32: STOP LAMP SWITCH REMOVAL Courtesy of CHRYSLER LLC 17. Remove the stop lamp switch (2).Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008. . Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp Removal

Fig. 33: BRAKE PEDAL CLIP - RHD Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:23 AM

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18. Remove the retaining clip (1) securing the power brake booster push rod (2) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 19. Slide the booster push rod (2) off the brake pedal pin (3). 20. If equipped with a manual transaxle, remove the clutch master cylinder from the pedal bracket assembly and dash panel. Refer to Clutch/CYLINDER, Clutch Master - Removal

Fig. 34: PEDAL AND BOOSTER MOUNTING - RHD Courtesy of CHRYSLER LLC 21. Remove the four nuts (4) attaching the power brake booster (1) to the dash panel. 22. Slide the power brake booster (1) forward clearing the dash panel, then remove it from the vehicle. Installation LEFT-HAND-DRIVE

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Fig. 35: BOOSTER SEAL Courtesy of CHRYSLER LLC NOTE:

Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Fig. 36: PEDAL AND BOOSTER MOUNTING - LHD Courtesy of CHRYSLER LLC 1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. user Monday, June 04, 2012 10:08:23 AM

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Fig. 37: MOUNTING NUT TORQUE SEQUENCE Courtesy of CHRYSLER LLC CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).

Fig. 38: BRAKE PEDAL CLIP Courtesy of CHRYSLER LLC 4. Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). user Monday, June 04, 2012 10:08:23 AM

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5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.

Fig. 39: STOP LAMP SWITCH AND PEDAL CLIP Courtesy of CHRYSLER LLC CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 6. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation 7. If equipped, install the silencer pad below the instrument panel.

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Fig. 40: VACUUM HOSE AT BOOSTER - LHD Courtesy of CHRYSLER LLC CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 8. Connect the vacuum hose (2) to the vacuum check valve (1).

Fig. 41: REAR BRAKE TUBES AT JUNCTION BLOCK Courtesy of CHRYSLER LLC 9. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 N.m (150 in. lbs.). user Monday, June 04, 2012 10:08:23 AM

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10. Install the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Installation

Fig. 42: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Fig. 43: COWL SCREEN Courtesy of CHRYSLER LLC 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and user Monday, June 04, 2012 10:08:23 AM

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cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Installation

Fig. 44: COWL TOP SCREEN Courtesy of CHRYSLER LLC 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Connect the battery negative cable to its post on the battery. 16. Bleed the base brake system. See Brakes - Standard Procedure 17. Road test the vehicle to ensure proper operation of the brakes. RIGHT-HAND-DRIVE

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Fig. 45: BOOSTER SEAL Courtesy of CHRYSLER LLC NOTE:

Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Fig. 46: PEDAL AND BOOSTER MOUNTING - RHD Courtesy of CHRYSLER LLC 1. Install the power brake booster (1) into the engine compartment using the reverse version of how it was removed. Slide the power brake booster push rod and studs through the dash panel and into mounting position. 2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, user Monday, June 04, 2012 10:08:23 AM

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refer to the following step.

Fig. 47: MOUNTING NUT TORQUE SEQUENCE - RHD Courtesy of CHRYSLER LLC CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 3. Tighten the four brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.). 4. If equipped with a manual transaxle, install the clutch master cylinder on the dash panel and clutch pedal bracket assembly. Refer to Clutch/CYLINDER, Clutch Master - Installation

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Fig. 48: BRAKE PEDAL CLIP - RHD Courtesy of CHRYSLER LLC 5. Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (2). 6. Install the power brake booster push rod (2) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (1) on the end of the pin. Do not reuse the old clip.

Fig. 49: STOP LAMP SWITCH AND PEDAL CLIP Courtesy of CHRYSLER LLC CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation 8. Install the brake tube routing clips with tubes onto the studs on the dash panel.

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Fig. 50: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 9. Connect the vacuum hose (2) to the check valve (1) on the power brake booster. 10. Install the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Installation

Fig. 51: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 11. Install the booster vacuum hose routing clip (4) onto the master cylinder mounting stud. 12. Install the vacuum hose routing clip (3) onto the stud on the dash panel. user Monday, June 04, 2012 10:08:23 AM

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Fig. 52: MODULE -WIPER Courtesy of CHRYSLER LLC 13. Place the wiper module into position, install the three mounting bolts (1), Tighten bolts to 11 N.m (97 in. lbs.). 14. Connect the electrical connector (2) to the wiper motor.

Fig. 53: WHEELHOUSE BRACE Courtesy of CHRYSLER LLC 15. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

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Fig. 54: COWL SCREEN Courtesy of CHRYSLER LLC 16. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 17. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Installation

Fig. 55: COWL TOP SCREEN Courtesy of CHRYSLER LLC 18. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. user Monday, June 04, 2012 10:08:23 AM

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Install the remaining push-pins (2). 19. Install the engine appearance cover. 20. Connect the battery negative (ground) cable to its post on the battery. 21. Bleed the base brake system as necessary. See Brakes - Standard Procedure WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. 22. Road test the vehicle to ensure proper operation of the brakes. CALIPER, DISC BRAKE, FRONT Removal REMOVAL

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

Fig. 56: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 57: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly.

Fig. 58: BRAKE HOSE MOUNTING TO CALIPER Courtesy of CHRYSLER LLC 4. Remove the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). There are two washers (4) that will come off with the banjo bolt. Discard the washers. They should not be reused.

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Fig. 59: CALIPER GUIDE PIN BOLTS Courtesy of CHRYSLER LLC CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Disassembly DISASSEMBLY

NOTE:

Before disassembling the brake caliper, remove it from the vehicle. See Brakes/Hydraulic/Mechanical/CALIPER, Disc Brake - Removal

NOTE:

Before disassembling the brake caliper, clean and inspect it. See Brakes/Hydraulic/Mechanical/CALIPER, Disc Brake - Cleaning. See Brakes/Hydraulic/Mechanical/CALIPER, Disc Brake - Inspection WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion.

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1. Mount the caliper in a vise equipped with protective jaws.

Fig. 60: Piston Removal Courtesy of CHRYSLER LLC 1 - WOOD BLOCK WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it.

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Fig. 61: Piston Seal Removal Courtesy of CHRYSLER LLC 1 - TRIM STICK 2 - SEAL CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Cleaning CLEANING

WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar® Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing user Monday, June 04, 2012 10:08:23 AM

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mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION

Inspect the disc brake caliper for the following: z z

Brake fluid leaks in and around piston boot area Ruptures, brittleness or damage to the piston dust boot

If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Assembly ASSEMBLY

NOTE:

Always have clean hands when assembling a brake caliper.

NOTE:

Always use fresh, clean brake fluid when assembling a brake caliper.

Fig. 62: New Piston Seal Installation Courtesy of CHRYSLER LLC 1 - SEAL 2 - GROOVE NOTE:

Never use an old piston seal.

1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. user Monday, June 04, 2012 10:08:23 AM

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Fig. 63: Boot Installation Courtesy of CHRYSLER LLC 2. 3. 4. 5.

Coat the NEW piston with clean brake fluid. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. Position the dust boot over the lower section of the piston. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore.

Fig. 64: Piston Installation Courtesy of CHRYSLER LLC 1PISTON GROOVE CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. user Monday, June 04, 2012 10:08:23 AM

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6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure . Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. See Brakes/Hydraulic/Mechanical/CALIPER, Disc Brake - Installation Installation INSTALLATION

1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.

Fig. 65: CALIPER GUIDE PIN BOLTS Courtesy of CHRYSLER LLC CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 35 N.m (26 ft. lbs.). user Monday, June 04, 2012 10:08:23 AM

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Fig. 66: BRAKE HOSE MOUNTING TO CALIPER Courtesy of CHRYSLER LLC 4. Install the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). Install NEW brake hose washers (4) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 N.m (19 ft. lbs.).

Fig. 67: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 5. Install the tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 6. Lower the vehicle. user Monday, June 04, 2012 10:08:23 AM

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Fig. 68: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 7. Remove the brake pedal holding tool.

Fig. 69: BLEED HOSE SET UP Courtesy of CHRYSLER LLC 8. Bleed the caliper as necessary. See Brakes - Standard Procedure 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. CALIPER, DISC BRAKE, REAR Removal user Monday, June 04, 2012 10:08:23 AM

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REMOVAL

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Disconnect and isolate battery negative cable from battery post.

Fig. 70: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 2. Using a brake pedal holding tool as shown, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. 3. Raise and support vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 71: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 4. Remove wheel mounting nuts (3), then tire and wheel assembly (1). 5. Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure

Fig. 72: PARKING BRAKE CABLE AT BRACKET Courtesy of CHRYSLER LLC 6. Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1).

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Fig. 73: PARKING BRAKE CABLE AT LEVER Courtesy of CHRYSLER LLC 7. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2).

Fig. 74: BRAKE HOSE MOUNTING TO CALIPER Courtesy of CHRYSLER LLC 8. Remove the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). There are two washers (2) that will come off with the banjo bolt. Discard the washers. They should not be reused.

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Fig. 75: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 9. Remove two caliper guide pin bolts (1). 10. Slide the disc brake caliper (2) from the disc brake adapter bracket (3) and brake pads. Cleaning CLEANING

WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar® Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Inspection INSPECTION

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Inspect the disc brake caliper for the following: z z

Brake fluid leaks in and around piston boot area Ruptures, brittleness or damage to the piston dust boot

If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Installation INSTALLATION

CAUTION: When installing a NEW brake caliper it is necessary to bleed the brakes using a special procedure which has been integrated to this installation procedure.

Fig. 76: REAR BRAKE PADS Courtesy of CHRYSLER LLC 1. Remove the outboard pad (5) from the adapter bracket.

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Fig. 77: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots. 2. Install the disc brake caliper (2) over the inboard brake pad on the brake caliper adapter bracket and the brake rotor. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Lightly tighten the guide pin bolts at this time.

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Fig. 78: BRAKE HOSE MOUNTING TO CALIPER Courtesy of CHRYSLER LLC 4. Install the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). Be sure to install a NEW brake hose washer (2) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 N.m (19 ft. lbs.).

Fig. 79: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 5. Access the interior of the vehicle, remove the brake pedal holder, then slowly pump the brake pedal until the rear caliper fingers touch the outboard surface of the brake rotor where the brake pad was removed. Release the pedal. user Monday, June 04, 2012 10:08:23 AM

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Fig. 80: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 6. Remove two caliper guide pin bolts (1). 7. Slide the disc brake caliper (2) from the disc brake adapter bracket (3).

Fig. 81: REAR BRAKE PADS Courtesy of CHRYSLER LLC 8. Reinstall the outboard pad (5) in the adapter bracket (3). user Monday, June 04, 2012 10:08:23 AM

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9. Open the caliper bleeder screw at least one full turn.

Fig. 82: SEATING PISTON WITH SPECIAL TOOL Courtesy of CHRYSLER LLC 10. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 11. Close the bleeder screw.

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Fig. 83: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 12. Return the brake caliper back down over the adapter bracket into mounted position and install the guide pin bolts (1). Tighten both guide pin bolts to 35 N.m (26 ft. lbs.). NOTE:

While bleeding air from the brake caliper in the following steps, be sure to monitor the fluid level in the master cylinder reservoir making sure it does not go dry.

13. Have a helper pump the brake pedal three or four times and hold it in the down position. 14. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 15. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 16. Repeat the previous three steps as necessary until all trapped air is removed. 17. If necessary, bleed remaining wheel circuits as necessary using normal bleeding procedure. See Brakes Standard Procedure

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Fig. 84: PARKING BRAKE CABLE AT LEVER Courtesy of CHRYSLER LLC 18. Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2).

Fig. 85: PARKING BRAKE CABLE AT BRACKET Courtesy of CHRYSLER LLC 19. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket.

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Fig. 86: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 20. Install tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 21. Reconnect the parking brake cable equalizer and reset the cable tension. See Brakes/Parking Brake Standard Procedure 22. Lower vehicle. 23. Connect battery negative (-) cable to battery post. 24. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake pads. FLUID Diagnosis and Testing BRAKE FLUID CONTAMINATION

Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Standard Procedure user Monday, June 04, 2012 10:08:23 AM

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BRAKE FLUID LEVEL CHECKING

NOTE:

Brake fluid level should be checked a minimum of twice a year.

Master cylinder reservoirs are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar® Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. See Brakes/Hydraulic/Mechanical/FLUID - Specifications NOTE:

Although there is a range, the preferred level is FULL.

1. Remove the cap. 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir as necessary. Do not overfill the system. 3. Install the cap. Specifications BRAKE FLUID

The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar® Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. MASTER CYLINDER, BRAKE Description DESCRIPTION

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Fig. 87: PRIMARY AND SECONDARY BRAKE TUBES Courtesy of CHRYSLER LLC All master cylinders (2) are a two-outlet design and the brake tubes from these primary and secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel brake. All master cylinders mount to the power brake booster in the same manner. The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required. On manual transmission model vehicles the brake fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of see-through plastic and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the right side. Operation OPERATION

When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through the chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. The master cylinder's outlet ports supply hydraulic pressure to the Integrated Control Unit (ICU) where it is distributed to the individual wheel brakes. The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the diaphragm. Standard Procedure user Monday, June 04, 2012 10:08:23 AM

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MASTER CYLINDER BLEEDING

1. Clamp the master cylinder in a vise with soft-jaw caps.

Fig. 88: BLEEDING MASTER CYLINDER WITH ABS Courtesy of CHRYSLER LLC 2. Thread a Bleeder Tube (2), Special Tool 8358-1, into the primary and secondary ports. Tighten bleeder tube nuts to 17 N.m (150 in. lbs.). 3. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. NOTE:

Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure.

4. Fill the brake fluid reservoir with fresh Mopar® Brake Fluid DOT 3 Motor Vehicle, or equivalent. See Brakes/Hydraulic/Mechanical/FLUID - Specifications

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Fig. 89: BLEEDING MASTER CYLINDER WITH ABS Courtesy of CHRYSLER LLC 5. Using an appropriately sized wooden dowel as a pushrod (1), slowly press the pistons inward discharging brake fluid through the Bleeder Tubes (2), then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation Removal LEFT-HAND-DRIVE

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution. CAUTION: The vacuum in the power brake booster must be depleted before removing the master cylinder to avoid damaging the master cylinder and to prevent inhalation of the o-ring or any other contamination into the booster. The preferred method is to pump the brake pedal while the engine is not running until the brake pedal becomes firm. An alternative method is to remove and immediately reinstall the check valve located on the booster. If the check valve is removed, special care should be taken to ensure that the grommet is not damaged and remains seated, the check valve is dry and free of debris, and that contaminates cannot be ingested during removal.

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1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable.

Fig. 90: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC 3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir.

Fig. 91: PRIMARY AND SECONDARY BRAKE TUBES Courtesy of CHRYSLER LLC 4. Disconnect the primary (1) and secondary (3) brake tubes at the master cylinder (2) outlet ports. Install user Monday, June 04, 2012 10:08:23 AM

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plugs at all of the open brake tube outlets on the master cylinder.

Fig. 92: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER Courtesy of CHRYSLER LLC 5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1).

Fig. 93: MASTER CYLINDER MOUNTING NUTS Courtesy of CHRYSLER LLC 6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar® Brake Parts Cleaner or an equivalent. 7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). user Monday, June 04, 2012 10:08:23 AM

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8. Slide the master cylinder straight out of the power brake booster. RIGHT-HAND-DRIVE

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution. CAUTION: The vacuum in the power brake booster must be depleted before removing the master cylinder to avoid damaging the master cylinder and to prevent inhalation of the o-ring or any other contamination into the booster. The preferred method is to pump the brake pedal while the engine is not running until the brake pedal becomes firm. An alternative method is to remove and immediately reinstall the check valve located on the booster. If the check valve is removed, special care should be taken to ensure that the grommet is not damaged and remains seated, the check valve is dry and free of debris, and that contaminates cannot be ingested during removal.

1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Remove the engine appearance cover.

Fig. 94: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER Courtesy of CHRYSLER LLC 4. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1).

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Fig. 95: PRIMARY AND SECONDARY BRAKE TUBES - RHD Courtesy of CHRYSLER LLC 5. Disconnect the primary (2) and secondary (1) brake tubes at the master cylinder outlet ports. Install plugs at both of the open brake tube outlets on the master cylinder (3).

Fig. 96: MASTER CYLINDER MOUNTING NUTS Courtesy of CHRYSLER LLC 6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar® Brake Parts Cleaner or an equivalent.

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Fig. 97: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 7. Remove the booster vacuum hose routing clip (4) from the master cylinder mounting stud.

Fig. 98: MASTER CYLINDER MOUNTING NUTS Courtesy of CHRYSLER LLC 8. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1).

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Fig. 99: BRAKE FLUID LEVEL SWITCH CONNECTOR - RHD Courtesy of CHRYSLER LLC 9. Slide the master cylinder straight out of the power brake booster, then disconnect the wiring harness connector (1) from the brake fluid level switch (2). 10. Remove the master cylinder from the engine compartment. Disassembly DISASSEMBLY

NOTE:

If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir.

1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar® Brake Parts Cleaner or equivalent. 2. Remove the brake fluid reservoir cap. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir.

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Fig. 100: REMOVING RESERVOIR FROM MASTER CYLINDER PINS Courtesy of CHRYSLER LLC 3. Remove the four reservoir retaining tabs from the mounting posts on the master cylinder housing. 4. Pull the reservoir straight up and remove it from the grommet seals in master cylinder housing.

Fig. 101: SEAL ON REAR OF MASTER CYLINDER Courtesy of CHRYSLER LLC 5. Remove the vacuum O-ring seal (2) from the master cylinder mounting flange (1). Assembly ASSEMBLY

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NOTE:

If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir.

Fig. 102: SEAL ON REAR OF MASTER CYLINDER Courtesy of CHRYSLER LLC 1. Install a NEW vacuum O-ring seal (2) on the master cylinder mounting flange (1) making sure the O-ring fits evenly against the mounting flange.

Fig. 103: Grommet Seals Courtesy of CHRYSLER LLC 2. Lubricate the reservoir mounting area with fresh clean brake fluid. With the grommet seals (2) on the fluid reservoir spigots, place the reservoir in position over the master cylinder. Install the fluid reservoir by firmly pressing down on the fluid reservoir. Once installed, make sure the fluid reservoir is touching user Monday, June 04, 2012 10:08:23 AM

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the top of both grommet seals. 3. Push the reservoir retaining tabs over the mounting posts on the master cylinder housing. Make sure the retaining tabs are securely engaged. 4. Fill and thoroughly bleed the master cylinder before installing it. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Standard Procedure 5. Install the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Installation Installation LEFT-HAND-DRIVE

NOTE:

The master cylinder must be bled before installing it on the vehicle.

1. Bench bleed the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Standard Procedure 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster.

Fig. 104: SEAL ON REAR OF MASTER CYLINDER Courtesy of CHRYSLER LLC CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum Oring seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum O-ring seal (2) on the mounting flange (1), remove it. Install a NEW vacuum O-ring seal on the master cylinder mounting flange making sure the O-ring fits evenly against the mounting flange. user Monday, June 04, 2012 10:08:23 AM

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CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.

Fig. 105: MASTER CYLINDER MOUNTING NUTS Courtesy of CHRYSLER LLC 5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 N.m (18 ft. lbs.).

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Fig. 106: CUT AND REMOVE CLUTCH PORT PLUG Courtesy of CHRYSLER LLC 6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3).

Fig. 107: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER Courtesy of CHRYSLER LLC 7. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port.

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Fig. 108: PRIMARY AND SECONDARY BRAKE TUBES Courtesy of CHRYSLER LLC 8. Connect the primary (1) and secondary (3) brake tubes to the master cylinder (2) outlet ports. Tighten the tube nuts to 17 N.m (150 in. lbs.).

Fig. 109: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC 9. Connect the wiring harness connector (1) to the brake fluid level switch (2). 10. Connect the negative (ground) cable on the battery. 11. Fill the master cylinder reservoir to the proper level. See Brakes/Hydraulic/Mechanical/FLUID Standard Procedure WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. See Brakes Standard Procedure 12. Road test the vehicle to ensure proper operation of the brakes. RIGHT-HAND-DRIVE

NOTE:

The master cylinder must be bled before installing it on the vehicle.

1. Bench bleed the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake Standard Procedure 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster. user Monday, June 04, 2012 10:08:24 AM

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Fig. 110: SEAL ON REAR OF MASTER CYLINDER Courtesy of CHRYSLER LLC CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum Oring seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum O-ring seal (2) on the mounting flange (1), remove it. Install a NEW vacuum O-ring seal on the master cylinder mounting flange making sure the O-ring fits evenly against the mounting flange.

Fig. 111: BRAKE FLUID LEVEL SWITCH CONNECTOR - RHD Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:24 AM

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4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster, then connect the wiring harness connector (1) to the brake fluid level switch (2). CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 5. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.

Fig. 112: MASTER CYLINDER MOUNTING NUTS Courtesy of CHRYSLER LLC 6. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 N.m (18 ft. lbs.).

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Fig. 113: VACUUM HOSE AT BOOSTER - RHD Courtesy of CHRYSLER LLC 7. Install the booster vacuum hose routing clip (4) onto the master cylinder mounting stud.

Fig. 114: PRIMARY AND SECONDARY BRAKE TUBES - RHD Courtesy of CHRYSLER LLC 8. Connect the primary (2) and secondary (1) brake tubes to the master cylinder outlet ports. Tighten the tube nuts to 17 N.m (150 in. lbs.).

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Fig. 115: CUT AND REMOVE CLUTCH PORT PLUG Courtesy of CHRYSLER LLC 9. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3).

Fig. 116: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER Courtesy of CHRYSLER LLC 10. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. 11. Install the engine appearance cover. user Monday, June 04, 2012 10:08:24 AM

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12. Connect the negative (ground) cable on the battery. 13. Fill the master cylinder reservoir to the proper level. See Brakes/Hydraulic/Mechanical/FLUID Standard Procedure WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. See Brakes Standard Procedure 14. Road test the vehicle to ensure proper operation of the brakes. PADS, BRAKE, FRONT Removal REMOVAL

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure NOTE:

Perform 2 through 5 on each side of the vehicle to complete pad set removal.

Fig. 117: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). user Monday, June 04, 2012 10:08:24 AM

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Fig. 118: CALIPER GUIDE PIN BOLTS Courtesy of CHRYSLER LLC CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Remove the two brake caliper guide pin bolts (2, 3). 4. Remove the disc brake caliper (4) from the disc brake adapter bracket (1) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.

Fig. 119: FRONT BRAKE PADS user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 5. Remove the brake pads (4, 5) from the caliper adapter bracket (2). Cleaning CLEANING

WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Inspection INSPECTION

Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle.

Fig. 120: Brake pad Friction Material Thickness Measurement Courtesy of CHRYSLER LLC 1 - BRAKE SHOE ASSEMBLY FRICTION MATERIAL THICKNESS IS TO BE MEASURED AT THE THINNEST POINT. 2 - BRAKE Shoe ASSEMBLY FRICTION MATERIAL user Monday, June 04, 2012 10:08:24 AM

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3 - BRAKE SHOE ASSEMBLY BACKING PLATE Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE:

It is important to inspect both front and rear brake pads during the same inspection.

Installation INSTALLATION

NOTE:

Perform 1 through 5 on each side of the vehicle to complete pad set installation, then proceed to 6.

NOTE:

Make sure that the audible wear indicator (if equipped) is placed toward the top when the inboard brake pad is installed on each side of the vehicle.

Fig. 121: FRONT BRAKE PADS Courtesy of CHRYSLER LLC NOTE:

If the brake pads have a protective paper on the rear face of the brake pad plate,

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it must be removed before pad installation. 1. Place the brake pads (4, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (2) as shown. Place the pad with the wear indicator (if equipped) attached on the inboard side (2). 2. Completely retract the caliper piston back into the bore of the caliper.

Fig. 122: CALIPER GUIDE PIN BOLTS Courtesy of CHRYSLER LLC CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the boots. 3. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 35 N.m (26 ft. lbs.).

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Fig. 123: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 5. Install tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. PADS, BRAKE, REAR Removal REMOVAL

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Raise and support vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure NOTE:

Perform 2 through 5 on each side of vehicle to complete pad set removal.

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Fig. 124: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

Fig. 125: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Remove two caliper guide pin bolts (1). user Monday, June 04, 2012 10:08:24 AM

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4. Remove the disc brake caliper (2) from the disc brake adapter bracket (3) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose or parking brake cable when doing this.

Fig. 126: REAR BRAKE PADS Courtesy of CHRYSLER LLC 5. Remove the brake pads (2, 5) from the caliper adapter bracket (3). Cleaning CLEANING

WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Inspection INSPECTION

Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. user Monday, June 04, 2012 10:08:24 AM

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Fig. 127: Brake pad Friction Material Thickness Measurement Courtesy of CHRYSLER LLC 1 - BRAKE SHOE ASSEMBLY FRICTION MATERIAL THICKNESS IS TO BE MEASURED AT THE THINNEST POINT. 2 - BRAKE Shoe ASSEMBLY FRICTION MATERIAL 3 - BRAKE SHOE ASSEMBLY BACKING PLATE Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE:

It is important to inspect both front and rear brake pads during the same inspection.

Installation INSTALLATION

NOTE:

Perform 1 through 6 on each side of vehicle to complete pad set installation, then proceed to 7. CAUTION: Anytime the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable

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method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism.

Fig. 128: SEATING PISTON WITH SPECIAL TOOL Courtesy of CHRYSLER LLC 1. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction.

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Fig. 129: REAR BRAKE PADS Courtesy of CHRYSLER LLC 2. Make sure abutment shims (4) are in place on both upper and lower slide abutments of caliper adapter (3). NOTE:

If the brake pads have a protective paper on the rear face of the brake pad plate, it must be removed before pad installation.

3. Place the brake pads (2, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (3) as shown.

Fig. 130: REAR CALIPER MOUNTING Courtesy of CHRYSLER LLC CAUTION: Use care when installing the caliper (2) onto the adapter bracket to user Monday, June 04, 2012 10:08:24 AM

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avoid damaging the guide pin boots. 4. Install the disc brake caliper (2) over the brake pads on the brake caliper adapter bracket (3). CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 5. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Tighten the guide pin bolts to 35 N.m (26 ft. lbs.).

Fig. 131: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 6. Install tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 7. Lower vehicle. 8. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle. 9. Check and adjust brake fluid level as necessary. 10. Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake pads. PEDAL(S), BRAKE AND/OR ACCELERATOR Removal LEFT-HAND-DRIVE

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NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column opening cover.

Fig. 132: STOP LAMP SWITCH WIRING CONNECTOR Courtesy of CHRYSLER LLC 3. Disconnect the wiring connector (4) at the stop lamp switch (3). 4. Remove the stop lamp switch wiring routing clip (1) from the brake pedal bracket (2).

Fig. 133: STOP LAMP SWITCH REMOVAL user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 5. Remove the stop lamp switch (2).Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008. . Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp Removal

Fig. 134: BRAKE PEDAL CLIP Courtesy of CHRYSLER LLC 6. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 7. Slide the booster push rod (1) off the brake pedal pin (3).

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Fig. 135: PEDAL AND BOOSTER MOUNTING - LHD Courtesy of CHRYSLER LLC 8. Remove the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. 9. Remove the remaining nut (5) attaching the brake pedal (1) to the dash panel. 10. Remove the brake pedal (1). RIGHT-HAND-DRIVE

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column opening cover.

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Fig. 136: STOP LAMP SWITCH WIRING CONNECTOR Courtesy of CHRYSLER LLC 3. Disconnect the wiring connector (4) at the stop lamp switch (3). 4. Remove the stop lamp switch wiring routing clip (1) from the brake pedal bracket (2).

Fig. 137: STOP LAMP SWITCH REMOVAL Courtesy of CHRYSLER LLC 5. Remove the stop lamp switch (2).Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008. . Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp Removal user Monday, June 04, 2012 10:08:24 AM

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Fig. 138: BRAKE PEDAL CLIP - RHD Courtesy of CHRYSLER LLC 6. Remove the retaining clip (1) securing the power brake booster push rod (2) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 7. Slide the booster push rod (2) off the brake pedal pin (3).

Fig. 139: PEDAL AND BOOSTER MOUNTING - RHD Courtesy of CHRYSLER LLC 8. Remove the four nuts (4) attaching the brake pedal (5) (and power brake booster) to the dash panel. user Monday, June 04, 2012 10:08:24 AM

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9. Remove the remaining nut (3) attaching the brake pedal (5) to the dash panel. 10. Remove the brake pedal (5). Installation LEFT-HAND-DRIVE

Fig. 140: PEDAL AND BOOSTER MOUNTING - LHD Courtesy of CHRYSLER LLC 1. Carefully install the brake pedal and bracket assembly (1) in the vehicle lining up the bracket with the power brake booster mounting studs and the stud (2) on the dash panel. 2. Install the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. Do not tighten the nuts at this time. 3. Install the remaining nut (5) attaching the brake pedal (1) to the dash panel. To tighten this nut (and the other four from the preceding step), refer to the following step.

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Fig. 141: MOUNTING NUT TORQUE SEQUENCE Courtesy of CHRYSLER LLC CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).

Fig. 142: BRAKE PEDAL CLIP Courtesy of CHRYSLER LLC 5. Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster push rod (1). user Monday, June 04, 2012 10:08:24 AM

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6. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.

Fig. 143: STOP LAMP SWITCH AND PEDAL CLIP Courtesy of CHRYSLER LLC CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation

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Fig. 144: STOP LAMP SWITCH WIRING CONNECTOR Courtesy of CHRYSLER LLC 8. 9. 10. 11. 12.

If not already performed, connect the wiring connector (4) at the stop lamp switch (3). Attach the stop lamp switch wiring routing clip (1) at the brake pedal bracket (2). If equipped, install the silencer pad below the instrument panel. Connect the battery negative cable to its post on the battery. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 13. Road test the vehicle to ensure proper operation of the brakes. RIGHT-HAND-DRIVE

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Fig. 145: PEDAL AND BOOSTER MOUNTING - RHD Courtesy of CHRYSLER LLC 1. Carefully install the brake pedal and bracket assembly (5) in the vehicle lining up the bracket with the power brake booster mounting studs and the stud (2) on the dash panel. 2. Install the four nuts (4) attaching the brake pedal (5) (and power brake booster) to the dash panel. Do not tighten the nuts at this time. 3. Install the remaining nut (3) attaching the brake pedal (5) to the dash panel. To tighten these nuts, refer to the following step.

Fig. 146: MOUNTING NUT TORQUE SEQUENCE - RHD Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:24 AM

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CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).

Fig. 147: BRAKE PEDAL CLIP - RHD Courtesy of CHRYSLER LLC 5. Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster push rod. 6. Install the power brake booster push rod (2) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (1) on the end of the pin. Do not reuse the old clip.

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Fig. 148: STOP LAMP SWITCH AND PEDAL CLIP Courtesy of CHRYSLER LLC CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation

Fig. 149: STOP LAMP SWITCH WIRING CONNECTOR Courtesy of CHRYSLER LLC 8. 9. 10. 11. 12.

If not already performed, connect the wiring connector (4) at the stop lamp switch (3). Attach the stop lamp switch wiring routing clip (1) at the brake pedal bracket (2). If equipped, install the silencer pad below the instrument panel. Connect the battery negative cable to its post on the battery. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 13. Road test the vehicle to ensure proper operation of the brakes. RESERVOIR, BRAKE MASTER CYLINDER Removal REMOVAL

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CAUTION: If at any time the master cylinder is loosened or removed, you must perform the master cylinder installation procedure to ensure that the seal (o-ring) is still on the hub of the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation. NOTE:

The brake fluid level switch is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. See Brakes/Electrical/SWITCH, Brake Fluid Level - Removal

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

Fig. 150: BRAKE FLUID LEVEL SWITCH CONNECTOR Courtesy of CHRYSLER LLC 1. Remove the outer and inner cowl covers. Refer to Body/Exterior/COVER, Cowl Panel - Removal 2. Remove the front wiper motor module. Refer to Electrical Wipers/Washers/Wipers/Washers/LINKAGE, Wiper Arm - Removal 3. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar® Brake Parts Cleaner or equivalent. 4. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 5. Remove the brake fluid reservoir cap. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir.

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Fig. 151: REMOVING RESERVOIR FROM MASTER CYLINDER PINS Courtesy of CHRYSLER LLC 6. Remove the four reservoir retaining tabs from the mounting posts on the master cylinder housing. 7. Pull the reservoir straight up and remove it from the grommet seals in master cylinder housing. Installation INSTALLATION

NOTE:

The brake fluid level switch is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. See Brakes/Electrical/SWITCH, Brake Fluid Level - Installation

Fig. 152: Grommet Seals Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:24 AM

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1. Lubricate the reservoir mounting area with fresh clean brake fluid. With the grommet seals (2) on the fluid reservoir spigots, place the reservoir in position over the master cylinder. Install the fluid reservoir by firmly pressing down on the fluid reservoir. Once installed, make sure the fluid reservoir is touching the top of both grommet seals. 2. Push the reservoir retaining tabs over the mounting posts on the master cylinder housing. Make sure the retaining tabs are securely engaged. 3. Fill the brake fluid reservoir with fresh Mopar® Brake Fluid DOT 3 Motor Vehicle, or equivalent. See Brakes/Hydraulic/Mechanical/FLUID - Specifications 4. Install the front wiper motor module. Refer to Electrical Wipers/Washers/Wipers/Washers/LINKAGE, Wiper Arm - Installation 5. Install the inner and outer cowl covers. Refer to Body/Exterior/COVER, Cowl Panel - Installation ROTOR, BRAKE Diagnosis and Testing BRAKE ROTOR

Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be inspected. BRAKING SURFACE INSPECTION

Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. See Brakes/Hydraulic/Mechanical/ROTOR, Brake - Standard Procedure. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS

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Fig. 153: MEASURING ROTOR THICKNESS Courtesy of CHRYSLER LLC Measure rotor thickness (1) at the center of the brake pad contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.

Fig. 154: Minimum Courtesy of CHRYSLER LLC 1 - ROTOR MINIMUM THICKNESS MARKING 2 - ROTOR Minimum thickness specifications are cast on the rotor's unmachined surface (1). Limits can also be found in Brakes/Hydraulic/Mechanical/ROTOR, Brake - Specifications user Monday, June 04, 2012 10:08:24 AM

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ROTOR THICKNESS VARIATION

Fig. 155: MEASURING ROTOR THICKNESS Courtesy of CHRYSLER LLC Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor (2) at 12 equal points around the rotor braking surface with a micrometer (1) at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary beyond the specification listed in the specification table. See Brakes/Hydraulic/Mechanical/ROTOR, Brake Specifications, the rotor should be refaced or replaced. See Brakes/Hydraulic/Mechanical/ROTOR, Brake Standard Procedure. ROTOR RUNOUT

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Fig. 156: MEASURING ROTOR RUNOUT Courtesy of CHRYSLER LLC On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the brake rotor (hub runout can be measured separately). To measure rotor runout on the vehicle: 1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure 2. Remove the tire and wheel assembly. Refer to Tires and Wheels - Removal 3. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross (star) pattern to 135 N.m (100 ft. lbs.). NOTE:

Dial Indicator, Special Tool 9524, can be used in conjunction with C-3339A to measure in millimeters instead of inches. Dial indicator 9524 includes a finer scale to measure lower, tighter tolerances.

4. Mount Dial Indicator (1), Special Tool C-3339A, with Wheel, Special Tool 25w, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 millimeters from the outer edge of the rotor (3). 5. Slowly rotate the brake rotor checking lateral runout, marking the low and high spots. Record these measurements. 6. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 7. Compare runout measurement to specifications. See Brakes/Hydraulic/Mechanical/ROTOR, Brake Specifications

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Fig. 157: WHEEL STUD AND ROTOR INDEX MARKED Courtesy of CHRYSLER LLC If runout is in excess of specifications, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor (1) and the one wheel stud (2) closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. 8. Remove the rotor from the hub. See Brakes/Hydraulic/Mechanical/ROTOR, Brake - Removal

Fig. 158: MEASURING HUB RUNOUT Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:24 AM

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NOTE:

Before measuring hub runout, clean the hub face surface with an appropriate cleaner. This provides a clean surface to get an accurate indicator reading.

NOTE:

Dial Indicator, Special Tool 9524, can be used in conjunction with C-3339A to measure in millimeters instead of inches. Dial indicator 9524 includes a finer scale to measure lower, tighter tolerances.

9. Mount Dial Indicator (2), Special Tool C-3339A, to the knuckle. Position the dial indicator stem so it contacts the hub face (1) near the outer diameter. Care must be taken to position the stem outside of the stud circle, but inside of the chamfer on the hub rim. 10. Slowly rotate the hub measuring runout. Hub runout should not exceed 0.01 mm (0.0004 inch). If runout exceeds this specification, the hub must be replaced. Refer to Front Suspension/Front/KNUCKLE, Steering - Removal . Refer to Rear Suspension/HUB AND BEARING - Removal

Fig. 159: ROTOR REINDEXED ON WHEEL STUDS Courtesy of CHRYSLER LLC 11. If hub runout does not exceed this specification, install the original rotor back on the hub, aligning the chalk mark on the rotor (2) with a wheel mounting stud, two studs apart from the original stud (1).

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Fig. 160: MEASURING ROTOR RUNOUT Courtesy of CHRYSLER LLC 12. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross (star) pattern to 135 N.m (100 ft. lbs.). 13. Mount the Dial Indicator (1), Special Tool C-3339A, and remeasure runout on both sides of the brake rotor as explained in earlier steps to see if runout is now within specifications. See Brakes/Hydraulic/Mechanical/ROTOR, Brake - Specifications 14. If runout is still not within specifications, reface or replace brake rotor. See Brakes/Hydraulic/Mechanical/ROTOR, Brake - Standard Procedure Standard Procedure BRAKE ROTOR MACHINING

NOTE:

Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen.

Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action.

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Fig. 161: On-Car Brake Lathe Courtesy of CHRYSLER LLC 1 - ON-CAR BRAKE LATHE If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (1), or replaced. The use of a hub-mounted on-car brake lathe (1) is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing.

Fig. 162: Minimum Brake Rotor Thickness (Typical) Courtesy of CHRYSLER LLC 1 - ROTOR MINIMUM THICKNESS MARKING 2 - ROTOR NOTE:

All brake rotors (2) have markings for minimum allowable thickness cast on an unmachined surface of the rotor (1) or stamped into the hat section. Minimum thickness specifications can also be found in

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Brakes/Hydraulic/Mechanical/ROTOR, Brake - Specifications Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be found in Brakes/Hydraulic/Mechanical/ROTOR, Brake - Specifications Removal FRONT

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 163: TIRE AND WHEEL MOUNTING user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE:

In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged.

Fig. 164: CALIPER/ADAPTER MOUNTING Courtesy of CHRYSLER LLC 3. Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering knuckle (2). 4. Remove the disc brake caliper and adapter bracket (1) from the knuckle (2) and rotor (4) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.

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Fig. 165: VENTED BRAKE ROTOR MOUNTING Courtesy of CHRYSLER LLC 5. Remove any clips retaining the brake rotor to the wheel mounting studs. 6. Slide the brake rotor (2) off the hub and bearing (1). REAR

NOTE:

Before proceeding. See Brakes - Warning. See Brakes - Caution.

1. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 166: TIRE AND WHEEL MOUNTING user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE:

In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged.

Fig. 167: REAR CALIPER ADAPTER MOUNTING Courtesy of CHRYSLER LLC 3. Remove two bolts (1) securing the disc brake caliper and adapter bracket ( 2) to the knuckle (3). 4. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.

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Fig. 168: SOLID BRAKE ROTOR MOUNTING Courtesy of CHRYSLER LLC 5. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). Installation FRONT

NOTE:

Inspect disc brake pads before installation. See Brakes/Hydraulic/Mechanical/PADS, Brake - Inspection.

Fig. 169: VENTED BRAKE ROTOR MOUNTING user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (2) over the studs on the hub and bearing.

Fig. 170: CALIPER/ADAPTER MOUNTING Courtesy of CHRYSLER LLC 3. Install the disc brake caliper and adapter bracket assembly (1) over the brake rotor (4) and knuckle (2). 4. Install the mounting bolts (3) securing the caliper adapter bracket to the knuckle (2). Tighten the bolts to 169 N.m (125 ft. lbs.).

Fig. 171: TIRE AND WHEEL MOUNTING user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 5. Install the tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. REAR

NOTE:

Inspect disc brake pads before installation. Replace as necessary.

Fig. 172: SOLID BRAKE ROTOR MOUNTING Courtesy of CHRYSLER LLC 1. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 2. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism.

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Fig. 173: SEATING PISTON WITH SPECIAL TOOL Courtesy of CHRYSLER LLC 3. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction.

Fig. 174: REAR CALIPER ADAPTER MOUNTING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:24 AM

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4. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 5. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 N.m (74 ft. lbs.).

Fig. 175: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 6. Install the tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). 7. Lower the vehicle. 8. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving vehicle. 9. Check and adjust the brake fluid level as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Specifications SPECIFICATIONS

NOTE:

When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning (machining) equipment is required.

LIMITS/SPECIFICATIONS Brake Rotor

Rotor Thickness

Front

27.87-28.13 mm 1.097-1.107 in.

Minimum Rotor Thickness 26.4 mm 1.040 in

Rotor Thickness Variation 0.009 mm 0.0004 in.

Rotor Runout * 0.050 mm 0.002 in.

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11.75-12.25 mm 10.4 mm 0.463-0.482 in. 0.409 in. * TIR Total Indicator Reading (Measured On Vehicle) Rear

0.009 mm 0.0004 in.

0.050 mm 0.002 in.

TUBES AND HOSES, BRAKE Description DESCRIPTION

The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end. The fitting at each brake caliper is the banjo-type and requires a special banjo bolt and copper washers. Operation OPERATION

The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle's suspension. Inspection INSPECTION

Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should be performed whenever the brake system is serviced and every 12,000 km (7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. NOTE:

This vehicle is equipped with more than one size (diameter) brake tube depending on location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as that being replaced. Never use under-size brake tubing.

PARKING BRAKE DESCRIPTION DESCRIPTION user Monday, June 04, 2012 10:08:24 AM

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The parking brake consists of the following components: z z z z

Foot-operated parking brake lever * Cables (front, left rear, right rear) Cable equalizer Caliper with Integral Parking Brake (IPB) * Right-Hand-Drive Export models feature a hand-operated parking brake lever.

The parking brake lever is an automatic-adjusting type that continuously applies minimal tension to the parking brake cables to keep them in adjustment at all times. The front cable extends from the lever to the parking brake cable equalizer. The equalizer joins the front cable to the left and right rear cables that extend to the individual rear calipers with Integral Parking Brake (IPB). The parking brake cables are made of flexible steel cable. The brake caliper used for the foundation brakes features an Integral Parking Brake (IPB) which combines a mechanical parking brake function with a conventional rear caliper. This caliper features a lever attached to a shaft on the outside of the caliper. The lever uses a ball-ramp mechanism to mechanically apply piston clamp force to the rear rotor when the parking brake lever is applied. As the lever and shaft rotate, the ball-ramp interface causes the shaft to lift and the piston to travel toward the rotor. The IPB includes an automatic adjuster mechanism that keeps the mechanical park brake mechanism in contact with the piston as the pads wear. The auto-adjuster is linked to the piston through a friction clutch that is used to detect pad wear. STANDARD PROCEDURE PARKING BRAKE CABLE TENSION RELEASE - FOOT LEVER

Use the following procedure to release the tension from the parking brake cables and the automatic adjuster in the parking brake lever (pedal) mechanism when required. 1. Release the parking brake. 2. Raise the vehicle to a comfortable working position and support. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 176: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 3. Wipe the parking brake cable strands (front and both rear) clean where visible at the intermediate bracket. CAUTION: Do not use any type of sharp instrument to hold the cable strand in place. Damage to the cable strand or coating can occur. 4. Pull rearward on the equalizer (4) until the front cable stops, then grasp the front cable (5) strand and hold it in this position. Disconnect the equalizer from the front cable strand. 5. Release the front cable strand allowing the lever automatic self-adjusting mechanism to pull the front cable strand forward. This action allows the adjuster mechanism to rotate around to its stop, removing tension from the adjuster and front parking brake cable. PARKING BRAKE CABLE TENSION RELEASE - HAND LEVER

1. Release the parking brake. 2. Block the tire and wheel assemblies so the vehicle does not move once the parking brake lever is released. 3. Release the parking brake.

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Fig. 177: HAND LEVER COVER MOUNTING Courtesy of CHRYSLER LLC 4. Remove the cover from the side of the parking brake lever. To remove the cover, unclip it at the top and rotate it counterclockwise.

Fig. 178: CABLE MOUNTING TO HAND LEVER Courtesy of CHRYSLER LLC 5. Place the parking brake lever (1) in the fully released (down) position. 6. Loosen the adjusting nut (2) on the end of the front parking brake cable. Back it off to the end of the cable. user Monday, June 04, 2012 10:08:24 AM

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Fig. 179: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC 7. If the cable equalizer/bent nail tensioner needs to be removed, perform the following: a. Raise the vehicle to a comfortable working position and support. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure b. Remove the parking brake cable equalizer/bent nail tensioner (4) from the three parking brake cables (2, 3, 5). PARKING BRAKE CABLE TENSION RESET - FOOT LEVER

1. Raise the vehicle to a comfortable working position and support. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 180: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 2. Wipe the front parking brake cable strand clean at the intermediate bracket (1) area. CAUTION: Do use any type of sharp instrument directly on the cable strand to hold it in place. Damage to the cable strand or coating can occur. 3. Clamp an appropriate pair of pliers on the front parking brake cable button (2) only and pull the cable stand rearward until it stops, then grasp the front cable strand and hold it in this position. Remove the pliers from the button.

Fig. 181: PARKING BRAKE CABLE EQUALIZER user Monday, June 04, 2012 10:08:24 AM

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Courtesy of CHRYSLER LLC 4. While holding the front cable in this position, install the equalizer (2) (attached to both rear cables) on the front parking brake cable. 5. Release the grasp on the front parking brake cable. 6. Lower the vehicle. 7. Apply and release the parking brake lever one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever mechanism to correctly tension the parking brake cables. PARKING BRAKE CABLE TENSION RESET - HAND LEVER

Fig. 182: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC 1. If the cable equalizer/bent nail tensioner needs to be installed on the cables, perform the following: a. Raise the vehicle to a comfortable working position and support. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure b. Connect the parking brake cable equalizer/bent nail tensioner (4) to the three parking brake cables (2, 3, 5). c. Remove any slack from the parking brake cables by pushing the front cable strand forward into the housing until slack is removed. d. Lower the vehicle. 2. If not installed during Step (1), make sure the parking brake cable equalizer/bent nail tensioner is attached to all three parking brake cables 3. Make sure that the front parking brake cable is properly aligned and installed on the cable track of the parking brake lever.

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Fig. 183: CABLE STUD-TO-NUT DIMENSION Courtesy of CHRYSLER LLC NOTE:

Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 1/4 inch (6 mm). This process will correctly set the parking brake cable tension.

4. Adjust parking brake cable tension using the following steps: a. Make sure the parking brake lever in the fully released (down) position. b. While maintaining tension on the cable, tighten the adjusting nut (2) on the front parking brake cable until 34 millimeters (1.34 in.) of thread (1) is out past the end of the adjustment nut. c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully released (down) position. 5. Raise the vehicle to a point where the rear wheels just clear the floor. 6. Check the rear wheels of the vehicle; they should rotate freely without dragging. 7. Apply the parking brake. Check the rear wheels of the vehicle. They should not rotate. 8. Return the parking brake lever to its fully released (down) position and check the rear wheels. They should rotate freely without dragging. 9. Apply the parking brake. 10. Lower the vehicle.

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Fig. 184: HAND LEVER COVER MOUNTING Courtesy of CHRYSLER LLC 11. Install the cover on the side of the parking brake lever. CABLE END CLEANING AND LUBRICATION

Periodic cleaning and lubrication can be done to ensure proper operation of the parking brake cables. This procedure applies to the trailing end of all parking brake cables. CAUTION: If a liquid cleaner is necessary, use a cleaner such as Mopar® NonChlorinated Brake Parts Cleaner or equivalent.

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Fig. 185: Areas To Be Cleaned And Lubricated Courtesy of CHRYSLER LLC 1 - STRAND AREA 2 - SEAL AREA 1. Using an appropriate bristle brush, clean the cable strand (1) in the area that retracts into the cable housing when the parking brake lever is applied. 2. Clean the cable seal area (2) at the end of the cable housing. 3. Lubricate the cleaned area with a general purpose grease lubricant. CABLE, PARKING BRAKE, FRONT Removal WITH FOOT LEVER

1. Release the parking brake. 2. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure 3. Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure

Fig. 186: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 4. Collapse the front cable retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the cable (5) forward and remove it from the intermediate bracket. 5. Push the front cable strand into the housing until it bottoms. user Monday, June 04, 2012 10:08:25 AM

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Fig. 187: CABLE MOUNTING TO UNDERBODY WITH FOOT LEVER Courtesy of CHRYSLER LLC 6. 7. 8. 9. 10. 11.

Remove the nuts (5) securing the front cable routing clamps (1) to the underbody of the vehicle. Remove the cable routing clamps (1) from the cable (4). Lower the vehicle. Remove the left front door opening sill scuff plate. Remove the lower cowl trim. Remove the steering column opening cover. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Removal .

Fig. 188: STEERING COLUMN COVER REINFORCEMENT Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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12. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 13. Pull the parking brake lever pedal up and hold it in this position.

Fig. 189: CABLE BUTTON LOCATED IN LEVER Courtesy of CHRYSLER LLC 14. Rotate the cable strand around at the lever mechanism until the strand lines up with the slot, then remove the cable end button (2) from the lever mechanism (1). NOTE:

Prior to removing cable from lever, note cable routing through lever for ease in reassembly.

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Fig. 190: CABLE HOUSING RETAINED IN LEVER Courtesy of CHRYSLER LLC 15. 16. 17. 18.

Collapse the front cable retainer fingers on the end of the cable housing (1) at the lever (2). Remove the cable from the parking brake lever (3). Lift back the carpet and pull the cable seal loose from the floor pan. Remove the front parking brake cable from the vehicle through the hole in the floor pan.

WITH HAND LEVER

Fig. 191: CENTER CONSOLE Courtesy of CHRYSLER LLC 1. Remove the floor center console. Refer to Body/Interior/CONSOLE, Center - Removal 2. Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure 3. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 192: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC 4. Remove the parking brake cable equalizer/bent nail tensioner (4) from the three parking brake cables (2, 3, 5). 5. Collapse the front cable retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the cable (5) forward and remove it from the intermediate bracket.

Fig. 193: CABLE MOUNTING TO UNDERBODY WITH HAND LEVER Courtesy of CHRYSLER LLC 6. Remove the screws (4) securing the front cable routing clamps (1, 5) to the underbody of the vehicle. 7. Remove the cable routing clamps (1, 5) from the cable (6). user Monday, June 04, 2012 10:08:25 AM

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8. Lower the vehicle.

Fig. 194: CABLE MOUNTING TO HAND LEVER Courtesy of CHRYSLER LLC 9. 10. 11. 12.

Remove the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). Remove the adjusting nut (2) from the end of the front parking brake cable. Remove the cable strand from the lever. Pull the cable seal loose from the floor pan and remove the front parking brake cable from the vehicle through the access hole in the floor pan.

Installation WITH FOOT LEVER

1. Pass most of the front parking brake cable down through the access hole in the floor pan from inside the vehicle.

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Fig. 195: CABLE HOUSING RETAINED IN LEVER Courtesy of CHRYSLER LLC 2. Insert the lever end of the front parking brake cable through the mounting hole in the parking brake lever (2). Slide it through until the cable retainer fingers on the end of the housing (1) lock in place. Make sure all fingers are engaged preventing removal of the cable from the bracket.

Fig. 196: CABLE BUTTON LOCATED IN LEVER Courtesy of CHRYSLER LLC 3. Pull the button on the end of cable strand out of housing and route the strand around the cable guide, then rotate the cable strand up and align the cable with the slot in lever mechanism (1). Slide the cable button (2) into the slot and rotate the cable down into mounted position with the cable inserted into the guide on user Monday, June 04, 2012 10:08:25 AM

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the mechanism. 4. Slide any extra cable back into the cable housing. This can be easily done by pulling on the trailing end of the front cable strand that is now under the vehicle. 5. Install the front parking brake cable floor pan seal into the access hole in the floor pan. 6. Reposition the carpeting back down on the floor.

Fig. 197: STEERING COLUMN COVER REINFORCEMENT Courtesy of CHRYSLER LLC 7. Install the steering column cover reinforcement (1) using the four mounting screws (2). 8. Install the steering column opening cover. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Installation 9. Install the lower cowl trim. 10. Install the left front door opening sill scuff plate. 11. Raise and support the vehicle.

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Fig. 198: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 12. Pass the end of the front cable (5) through the hole in the end of the intermediate bracket (1). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place.

Fig. 199: CABLE MOUNTING TO UNDERBODY WITH FOOT LEVER Courtesy of CHRYSLER LLC 13. Install the cable routing clamps (1) over the metal sleeves on the front cable (4). 14. Position the front cable routing clamps over the studs on the underbody of the vehicle and install the nuts (5). Tighten the nuts to 6 N.m (55 in. lbs.). user Monday, June 04, 2012 10:08:25 AM

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Fig. 200: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 15. Reconnect the parking brake cable equalizer (4) and reset the cable tension. See Brakes/Parking Brake Standard Procedure 16. Lower the vehicle. 17. Apply and release the parking brake lever (pedal) one time. This will seat the parking brake cables. 18. Check operation of parking brakes. WITH HAND LEVER

1. Pass most of the front parking brake cable down through the access hole in the floor pan from inside the vehicle. 2. Install the front parking brake cable floor pan seal into the access hole in the floor pan.

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Fig. 201: CABLE MOUNTING TO HAND LEVER Courtesy of CHRYSLER LLC 3. Install the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). Tighten the mounting screws to 28 N.m (21 ft. lbs.). 4. Route the cable strand around the lever cable guide and start the adjusting nut (2) on the end of the cable stud. Do not install the nut any further than having the threads flush with the top of the nut. Otherwise, cable equalizer/bent nail tensioner installation later in this procedure could be difficult. 5. Slide any extra cable back into the cable housing. 6. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 202: CABLE MOUNTING TO UNDERBODY WITH HAND LEVER Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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7. Install the cable routing clamps (1, 5) over the metal sleeves on the front cable (6). Be sure to place the correct length clamp at the appropriate location. 8. Position the front cable routing clamps over the studs on the underbody of the vehicle and install the screws (4). Tighten the screws to 6 N.m (55 in. lbs.).

Fig. 203: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC 9. Pass the end of the front cable (5) through the hole in the end of the intermediate bracket (1). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place. 10. Connect the parking brake cable equalizer/bent nail tensioner (4) to the three parking brake cables (2, 3, 5). 11. Remove any slack from the parking brake cables by pushing the front cable strand forward into the housing until slack is removed. 12. Lower the vehicle. 13. Reset the hand lever cable tension and verify check operation of the parking brake. See Brakes/Parking Brake - Standard Procedure

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Fig. 204: HAND LEVER COVER MOUNTING Courtesy of CHRYSLER LLC 14. Install the cover on the side of the parking brake lever.

Fig. 205: CENTER CONSOLE Courtesy of CHRYSLER LLC 15. Install the floor center console. Refer to Body/Interior/CONSOLE, Center - Removal CABLE, PARKING BRAKE, REAR Removal user Monday, June 04, 2012 10:08:25 AM

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REMOVAL

1. Release the parking brake. 2. Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure 3. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 206: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 4. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

Fig. 207: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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5. If not removed, remove the cable equalizer (4) (with foot lever) or equalizer/tensioner (with hand lever) from the front and rear cables. 6. Collapse the right rear cable (3) retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the right rear cable out of the intermediate bracket.

Fig. 208: PARKING BRAKE CABLE ROUTING LOOP Courtesy of CHRYSLER LLC 7. Pull the right rear cable (2) out of the cable routing loop (3).

Fig. 209: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 8. If servicing the left rear cable, collapse the left rear cable (2) retainer fingers at the end of the cable user Monday, June 04, 2012 10:08:25 AM

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housing where it contacts the intermediate bracket (1). Pull the left rear cable out of the intermediate bracket.

Fig. 210: PARKING BRAKE CABLE ROUTING LOOP Courtesy of CHRYSLER LLC 9. If servicing the left rear cable, remove the nuts (1) fastening the cable routing loop (3) to the vehicle underbody near the trailing link forward mounting point.

Fig. 211: RIGHT CABLE AT CROSSMEMBER Courtesy of CHRYSLER LLC 10. If servicing the right rear cable, remove the four screws securing the right rear cable to the rear crossmember.

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Fig. 212: CABLE AT RIGHT TRAILING LINK Courtesy of CHRYSLER LLC 11. If servicing the right rear cable, remove the upper bolt (1) securing the knuckle to the trailing link. This bolt also fastens the cable routing clamp (3) in place.

Fig. 213: CABLE AT LEFT TRAILING LINK Courtesy of CHRYSLER LLC 12. If servicing the left rear cable: a. Remove the upper bolt (1) securing the knuckle to the trailing link as well as the rear cable routing clamp (3). b. Remove the other bolt (2) fastening the rear cable (4) to the trailing arm.

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Fig. 214: PARKING BRAKE CABLE AT BRACKET Courtesy of CHRYSLER LLC 13. Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1).

Fig. 215: PARKING BRAKE CABLE AT LEVER Courtesy of CHRYSLER LLC 14. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2). 15. Remove the cable from the vehicle. Installation user Monday, June 04, 2012 10:08:25 AM

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INSTALLATION

1. Guide the trailing end of the parking brake cable along the inboard side of the axle trailing arm up to the rear brake caliper. Make sure the cable is routed between the brake line and the trailing arm.

Fig. 216: PARKING BRAKE CABLE AT LEVER Courtesy of CHRYSLER LLC 2. Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2).

Fig. 217: PARKING BRAKE CABLE AT BRACKET Courtesy of CHRYSLER LLC 3. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the user Monday, June 04, 2012 10:08:25 AM

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mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket.

Fig. 218: CABLE AT LEFT TRAILING LINK Courtesy of CHRYSLER LLC CAUTION: Before installing bolt (1) in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent. 4. If servicing the left rear cable, position the cable routing clamps (3) against the axle trailing link and: a. Install the upper mounting bolt (1) securing the trailing link (and cable routing clamp) to the knuckle. Tighten the mounting bolt to 60 N.m (44 ft. lbs.). b. Install the bolt (2) attaching the other cable routing clamp to the axle trailing link. Tighten the bolt to 28 N.m (21 ft. lbs.).

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Fig. 219: CABLE AT RIGHT TRAILING LINK Courtesy of CHRYSLER LLC CAUTION: Before installing bolt (1) in the following step, it is especially important to clean the threads and apply Mopar® Lock AND Seal Adhesive or equivalent. 5. If servicing the right rear cable, position the cable routing clamps (3) against the axle trailing link and install the upper mounting bolt (1) securing the trailing link (and cable routing clamp) to the knuckle. Tighten the mounting bolt to 60 N.m (44 ft. lbs.).

Fig. 220: RIGHT CABLE AT CROSSMEMBER Courtesy of CHRYSLER LLC 6. If servicing the right rear cable, route the cable over the rear axle (if equipped with AWD) along the front of the rear suspension crossmember. Position the four routing clamps on the rear crossmember and install user Monday, June 04, 2012 10:08:25 AM

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the screws. Tighten the screws to 6 N.m (55 in. lbs.).

Fig. 221: PARKING BRAKE CABLE ROUTING LOOP Courtesy of CHRYSLER LLC 7. If servicing the left rear cable, place the routing loop (3) over the studs on the vehicle underbody near the trailing link forward mounting point and install the mounting nuts. Tighten the nuts to 6 N.m (55 in. lbs.). 8. Insert the right rear cable (2) through the lower loop of the cable routing loop (3).

Fig. 222: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 9. Install tire and wheel assembly (1). Refer to Tires and Wheels - Installation . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.). user Monday, June 04, 2012 10:08:25 AM

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Fig. 223: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 10. If servicing the left rear cable, pass the leading end of the left rear cable (2) through the upper hole in the intermediate bracket (1). Press the cable housing through the hole until the fingers on the retainer lock it into place. 11. If servicing a vehicle equipped with a foot lever: a. Connect the parking brake cable equalizer (4) to the three parking brake cables (2, 3, 5) and reset the cable tension. See Brakes/Parking Brake - Standard Procedure b. Lower the vehicle.

Fig. 224: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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12. If servicing a vehicle equipped with a hand lever: a. Connect the parking brake cable equalizer/bent nail tensioner (4) to the three parking brake cables (2, 3, 5). b. Remove any slack from the parking brake cables by pushing the front cable strand forward into the housing until slack is removed. c. Lower the vehicle. d. Reset the hand lever cable tension and verify check operation of the parking brake. See Brakes/Parking Brake - Standard Procedure 13. Check operation of parking brakes. LEVER, PARKING BRAKE Removal FOOT OPERATED PARKING BRAKE LEVER

1. 2. 3. 4. 5. 6. 7. 8.

Release the parking brake. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure Push the front cable strand into the housing until it bottoms. Lower the vehicle. Remove the left front door opening sill scuff plate. Remove the lower cowl trim. Remove the steering column opening cover. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Removal .

Fig. 225: STEERING COLUMN COVER REINFORCEMENT Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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9. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 10. Pull the parking brake lever pedal up and hold it in this position.

Fig. 226: CABLE BUTTON LOCATED IN LEVER Courtesy of CHRYSLER LLC 11. Rotate the cable strand around at the lever mechanism until the strand lines up with the slot, then remove the cable end button (2) from the lever mechanism (1). NOTE:

Prior to removing cable from lever, note cable routing through lever for ease in reassembly.

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Fig. 227: CABLE HOUSING RETAINED IN LEVER Courtesy of CHRYSLER LLC 12. Collapse the front cable retainer fingers on the end of the cable housing (1) at the lever (2). 13. Remove the cable from the parking brake lever (3).

Fig. 228: WIRING AT PARKING BRAKE LEVER Courtesy of CHRYSLER LLC 14. Disconnect the wiring connector (2) at parking brake indicator lamp switch.

Fig. 229: FOOT LEVER MOUNTING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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15. Remove the three mounting nuts (2), then remove the parking brake lever (1) from the cowl (3). HAND OPERATED PARKING BRAKE LEVER

Fig. 230: CENTER CONSOLE Courtesy of CHRYSLER LLC 1. Remove the floor center console. Refer to Body/Interior/CONSOLE, Center - Removal 2. Manually release the parking brake cable tension. See Brakes/Parking Brake - Standard Procedure

Fig. 231: CABLE MOUNTING TO HAND LEVER Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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3. Remove the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). 4. Remove the adjusting nut (2) from the end of the front parking brake cable. 5. Remove the cable strand from the lever.

Fig. 232: HAND LEVER PARKING BRAKE SWITCH Courtesy of CHRYSLER LLC 6. Disconnect the wiring connector (2) at parking brake indicator lamp switch (1).

Fig. 233: HAND LEVER MOUNTING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:08:25 AM

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7. Remove the two horizontal (5) and one vertical (2) mounting bolts, then remove the parking brake lever (1) from the shifter bracket (4). Installation FOOT OPERATED PARKING BRAKE LEVER

Fig. 234: FOOT LEVER MOUNTING Courtesy of CHRYSLER LLC 1. Position the parking brake lever (1) over the mounting studs, against the left lower cowl (3). 2. Install the three mounting nuts (2). Tighten the nuts to 28 N.m (21 ft. lbs.).

Fig. 235: WIRING AT PARKING BRAKE LEVER user Monday, June 04, 2012 10:08:25 AM

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Courtesy of CHRYSLER LLC 3. Connect the wiring connector (2) at the parking brake indicator lamp switch on the parking brake lever (1).

Fig. 236: CABLE HOUSING RETAINED IN LEVER Courtesy of CHRYSLER LLC 4. Insert the lever end of the front parking brake cable through the mounting hole in the parking brake lever (2). Slide it through until the cable retainer fingers on the end of the housing (1) lock in place. Make sure all fingers are engaged preventing removal of the cable from the bracket.

Fig. 237: CABLE BUTTON LOCATED IN LEVER user Monday, June 04, 2012 10:08:25 AM

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Courtesy of CHRYSLER LLC 5. Pull the button on the end of cable strand out of housing and route the strand around the cable guide, then rotate the cable strand up and align the cable with the slot in lever mechanism (1). Slide the cable button (2) into the slot and rotate the cable down into mounted position with the cable inserted into the guide on the mechanism. 6. Slide any extra cable back into the cable housing. This can be easily done by pulling on the trailing end of the front cable strand that is now under the vehicle. 7. Install the front parking brake cable floor pan seal into the access hole in the floor pan. 8. Reposition the carpeting back down on the floor.

Fig. 238: STEERING COLUMN COVER REINFORCEMENT Courtesy of CHRYSLER LLC 9. Install the steering column cover reinforcement (1) using the four mounting screws (2). 10. Install the steering column opening cover. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Installation 11. Install the lower cowl trim. 12. Install the left front door opening sill scuff plate. 13. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

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Fig. 239: PARKING BRAKE CABLE EQUALIZER Courtesy of CHRYSLER LLC 14. If the original parking brake lever is being reinstalled, reconnect the parking brake cable equalizer (4) and reset the cable tension. See Brakes/Parking Brake - Standard Procedure 15. If a NEW parking brake lever is being installed, connect the parking brake cable equalizer to the cables, then remove the pin locking the lever mechanism spring tension at the lever. 16. Lower the vehicle. 17. Apply and release the parking brake lever (pedal) one time. This will seat the parking brake cables. 18. Check operation of parking brake lever and parking brakes. HAND OPERATED PARKING BRAKE LEVER

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Fig. 240: HAND LEVER MOUNTING Courtesy of CHRYSLER LLC 1. Position the parking brake lever (1) on the shifter bracket (4).

Fig. 241: HAND LEVER MOUNTING VERTICAL BOLT Courtesy of CHRYSLER LLC NOTE:

When installing the vertical mounting bolt in the following step make sure to capture the ground strap (2) with the mounting bolt (1) before installation.

Fig. 242: HAND LEVER MOUNTING user Monday, June 04, 2012 10:08:25 AM

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Courtesy of CHRYSLER LLC 2. Install the two horizontal (5) and one vertical (2) mounting bolts. Tighten the nuts to 20 N.m (15 ft. lbs.).

Fig. 243: HAND LEVER PARKING BRAKE SWITCH Courtesy of CHRYSLER LLC 3. Connect the wiring connector (2) at the parking brake indicator lamp switch (1).

Fig. 244: CABLE MOUNTING TO HAND LEVER Courtesy of CHRYSLER LLC 4. Install the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). user Monday, June 04, 2012 10:08:25 AM

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Tighten the mounting screws to 28 N.m (21 ft. lbs.). 5. Route the cable strand around the lever cable guide and start the adjusting nut (2) on the end of the cable stud. Do not install the nut any further than having the threads flush with the top of the nut before the next step is performed.

Fig. 245: CABLE EQUALIZER/TENSIONER Courtesy of CHRYSLER LLC 6. Make sure the cables (2, 3, 5) are connected to the cable equalizer/bent nail tensioner (4) at the intermediate bracket (1) under the vehicle. 7. Reset the hand lever cable tension and verify check operation of the parking brake. See Brakes/Parking Brake - Standard Procedure

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Fig. 246: HAND LEVER COVER MOUNTING Courtesy of CHRYSLER LLC 8. Install the cover on the side of the parking brake lever.

Fig. 247: CENTER CONSOLE Courtesy of CHRYSLER LLC 9. Install the floor center console. Refer to Body/Interior/CONSOLE, Center - Removal

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2009 BRAKES ABS - Service Information - Journey

DESCRIPTION ANTILOCK BRAKE SYSTEM WITH ELECTRONIC STABILITY PROGRAM

Fig. 1: Integrated Control Unit Courtesy of CHRYSLER LLC This vehicle uses the Continental Mk25e electronic brake control system. The system includes ABS (Anti-lock Brake System), EVBP (Electronic Variable Brake Proportioning), TCS (Traction Control System), BAS (Brake Assist System), Electronic Roll Mitigation (ERM) and ESP (Electronic Stability Program). These systems work together to enhance vehicle stability and control in various driving conditions and are commonly referred to as ESP. ESP is standard on this vehicle. This electronic brake control system uses the following components to operate: z

z z

z

z

Integrated Control Unit (ICU) - Hydraulic Control Unit (HCU) (2) and Antilock Brake Module (ABM) (1) Wheel Speed Sensors (WSS) - Four sensors (one sensor at each wheel) Dynamics Sensor - The Dynamics Sensor includes the Yaw Rate Sensor and the lateral Acceleration Sensor. Steering Angle Sensor (SAS) - The steering angle sensor is located in the Steering Column Control Module (SCCM) mounted on the steering column. Brake Pressure Sensor - The brake pressure sensor is located in the HCU and is not serviceable separate from the HCU.

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ABS

The purpose of the Antilock Brake System (ABS) is to prevent wheel lockup under braking conditions on virtually any type of road surface. Antilock braking is desirable because a vehicle that is stopped without locking the wheels retains directional stability and some steering capability. This allows the driver to retain greater control of the vehicle during braking. All vehicles equipped with ABS use Electronic Variable Brake Proportioning (EVBP) to balance front-to-rear braking when the brakes are applied in the partial braking range. ALL-SPEED TRACTION CONTROL

Fig. 2: Accessory Switch Bank Module Courtesy of CHRYSLER LLC The traction control system (TCS) is an all-speed traction control. All-Speed Traction Control enhances mobility and prevents wheel slip when accelerating on slippery surfaces. It also provides a measure of directional stability control. Using the wheel-speed sensors, it can detect excessive yaw and help keep the car on the intended course, as for instance, when accelerating around a curve. All-Speed Traction Control is effective up to 85 mph (137 km/h). The traction control system may be turned off or on by depressing the ESP Off switch button (2) located in the instrument panel switch pod located in center of the instrument panel. ELECTRONIC STABILITY PROGRAM

The Electronic Stability Program (ESP) enhances control and stability of the vehicle under various driving conditions. ESP corrects for over/under steering of the vehicle by applying the brake of the appropriate wheel to assist in counteracting the over/under steer condition. Engine power may also be reduced to help the vehicle maintain the desired path. ESP uses sensors in the vehicle to determine the vehicle path intended by the driver and compares it to the actual path of the vehicle. When the actual path does not match the intended path, ESP user Monday, June 04, 2012 10:04:48 AM

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applies the brake of the appropriate wheel to assist in counteracting the oversteer or understeer condition. z z

Oversteer - When the vehicle is turning more that appropriate for the steering wheel position. Understeer - When the vehicle is turning less than appropriate for the steering wheel position.

The "ESP/TCS" indicator light located in the instrument cluster starts to flash as soon as the tires lose traction and the ESP system becomes active. The "ESP/TCS" indicator light also flashes when the TCS is active. The ESP® default mode is Full-On with every key-on. Pressing the ESP Off button once activates what is referred to as Partial mode. In Partial mode, Traction Control is deactivated and ESP® operates at a higher threshold, therefore, it will not come on as aggressively as in the Full-On mode. The system can be returned to "normal" Full-On mode by pressing and releasing the ESP Off switch. The ESP function lamp is illuminated in the cluster whenever the ESP system is turned off. ELECTRONIC ROLL MITIGATION

Electronic Roll Mitigation (ERM) is a software feature in addition to ESP control that focuses on preventing wheel lift in NHTSA Fish Hook maneuvers. These very extreme situations are well out of normal everyday driving, but if by chance an extreme dynamic maneuver occurs, ERM can help reestablish vehicle stability and return control to the driver. ERM determines when a vehicle is in a potential roll over condition and applies the appropriate braking force to reduce the likelihood that such an event will occur. ERM will not aid vehicle stability in "trip" situations, such as when a vehicle slides sideways into a curb, etc. which could still cause the wheels opposite the curb to lift and the vehicle to roll. HILL START ASSIST

The Hill Start Assist (HSA) system is designed to assist the driver when starting a vehicle from a stop on a hill. HSA will maintain the level of brake pressure the driver applied for a short period of time after the driver takes his foot off of the brake pedal. TRAILER SWAY CONTROL

Trailer Sway Control (TSC) is safety feature made possible by ESP. TSC does not require driver input; it activates once the yaw sensor recognizes the unique vehicle motion associated with trailer sway and no steering input. It becomes clear that this motion has to be from a trailer and thus activates the brakes to eliminate the trailer sway. BRAKE ASSIST SYSTEM

The Brake Assist System (BAS) is designed to optimize the vehicle's braking capability during emergency braking maneuvers. The system detects an emergency braking situation by sensing the rate and amount of brake application and then applies optimum pressure to the brakes. This can help reduce braking distances. The BAS complements the antilock brake system (ABS). Applying the brakes very quickly results in the best BAS assistance. ELECTRONIC VARIABLE BRAKE PROPORTIONING

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Electronic Variable Brake Proportioning (EVBP) is used to balance front-to-rear braking in place of a traditional rear proportioning valve. The EVBP system uses the ABS system to control the slip of the rear wheels in partial braking range. The braking force of the rear wheels is controlled electronically by using the inlet and outlet valves located in the integrated control unit (ICU). EVBP activation is nearly invisible to the customer since there is no pump motor noise and minimal brake pedal feedback.

OPERATION ANTILOCK BRAKE SYSTEM WITH ELECTRONIC STABILITY PROGRAM ABS

There are a few performance characteristics of the Antilock Brake System (ABS) that may at first seem abnormal, but in fact are normal. These characteristics are described below. NORMAL BRAKING

Under normal braking conditions, the ABS functions the same as a standard base brake system with a diagonally split master cylinder and conventional vacuum assist. ABS BRAKING

ABS operation is available at all vehicle speeds above 3-5 mph (5-8 km/h) If a wheel locking tendency is detected during a brake application, the brake system enters the ABS mode. During ABS braking, hydraulic pressure in the four wheel circuits is modulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric solenoids to allow modulation. Wheel lockup may be perceived at the very end of an ABS stop and is considered normal. During an ABS event, the Integrated Control Unit (ICU) regulates hydraulic pressure at all four of the vehicle's wheels. The hydraulic pressure at each wheel is controlled independently (relative to the amount of slip at each wheel) in order to maximize the braking force generated by the front brakes. The system can build and release pressure at each wheel, depending on signals generated by the Wheel Speed Sensors (WSS) at each wheel and received at the Antilock Brake Module (ABM). NOISE AND BRAKE PEDAL FEEL

During ABS braking, some brake pedal movement may be felt. In addition, ABS braking will create ticking, popping, or groaning noises heard by the driver. This is normal and is due to pressurized fluid being transferred between the master cylinder and the brakes. If ABS operation occurs during hard braking, some pulsation may be felt in the vehicle body due to fore and aft movement of the suspension as brake pressures are modulated. At the end of an ABS stop, ABS is turned off when the vehicle is slowed to a speed of 3-4 mph (5-6 km/h). user Monday, June 04, 2012 10:04:48 AM

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There may be a slight brake pedal drop anytime that the ABS is deactivated, such as at the end of the stop when the vehicle speed is less than 3 mph (5 km/h) or during an ABS stop where ABS is no longer required. These conditions exist when a vehicle is being stopped on a road surface with patches of ice, loose gravel, or sand on it. Also, stopping a vehicle on a bumpy road surface activates ABS because of the wheel hop caused by the bumps. TIRE NOISE AND MARKS

Although the ABS system prevents complete wheel lockup, some wheel slip is desired in order to achieve optimum braking performance. Wheel slip is defined as follows: 0 percent slip means the wheel is rolling freely and 100 percent slip means the wheel is fully locked. During brake pressure modulation, wheel slip is allowed to reach up to 25-30 percent. This means that the wheel rolling velocity is 25-30 percent less than that of a free rolling wheel at a given vehicle speed. This slip may result in some tire chirping, depending on the road surface. This sound should not be interpreted as total wheel lockup. Complete wheel lockup normally leaves black tire marks on dry pavement. The ABS will not leave dark black tire marks since the wheel never reaches a fully locked condition. However, tire marks may be noticeable as light patched marks. START-UP AND DRIVE-OFF CYCLES

When the ignition is turned on, a popping sound and a slight brake pedal movement may be noticed. The ABS warning lamp will also be on for up to 5 seconds after the ignition is turned on. When the vehicle is first driven off, a humming may be heard or felt by the driver at approximately 12-25 mph (20-40 km/h). All of these conditions are a normal function of ABS as the system is performing a diagnosis check. PREMATURE ABS CYCLING

Symptoms of premature ABS cycling include: clicking sounds from the solenoid valves; pump/motor running; and pulsations in the brake pedal. Premature ABS cycling can occur at any braking rate of the vehicle and on any type of road surface. Neither the red BRAKE indicator lamp, nor the amber ABS indicator lamp, illuminate and no faults are stored in the ABM. Premature ABS cycling is a condition that needs to be correctly assessed when diagnosing problems with the antilock brake system. It may be necessary to use a scan tool to detect and verify premature ABS cycling. Check the following common causes when diagnosing premature ABS cycling: damaged wheel bearings (causing tone wheel issues); damaged wheel speed sensor mounting bosses; damaged teeth on the sensor tone wheel; and loose wheel speed sensor mounting screws. After diagnosing the defective component, repair or replace it as required. When the component repair or replacement is completed, test drive the vehicle to verify that premature ABS cycling has been corrected. ALL-SPEED TRACTION CONTROL

Traction control systems sense impending wheel spin based on a model of the rate of change of wheel speed user Monday, June 04, 2012 10:04:48 AM

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under normal traction conditions. The All-Speed Traction Control uses signals from the same wheel speed sensors as ABS to determine when to apply the brakes to one or more wheels and when to reduce engine torque output using the electronic throttle control (ETC) to prevent wheel slip during acceleration. Throttle control makes the vehicle less reliant on brake application alone to maintain traction, increasing the operating speed range and more closely modulates speed, resulting in smoother operation. With All-Speed Traction Control reducing engine torque as well as applying the brakes, it is possible to achieve almost seamless torque application at the wheels. If the wheel slip is severe enough to require throttle intervention, All-Speed Traction Control will reduce engine torque and sometimes upshift the transmission to avoid the condition. In milliseconds, All-Speed Traction Control interrogates the engine control system to determine the current torque output, determines how much the torque output the current conditions will allow, and signals this requirement to the engine control system, which reduces the torque by partially closing the throttle. With execution of the torque reduction, the brake system reduces brake pressure to make the transition smooth, while maintaining forward progress. By reducing engine power, braking effectiveness is maintained and the system can operate throughout the normal vehicle speed range. That is why the system is identified as providing "all-speed" traction control. The traction control system is enabled at each ignition cycle. It may be turned off by depressing the ESP OFF switch button. The ESP/TCS function indicator lamp illuminates immediately upon depressing the button. Pressing this button again or turning off and restarting the vehicle will enable the traction control system. ELECTRONIC STABILITY PROGRAM

To determine whether the car is responding properly to cornering commands, ESP® uses steering wheel angle, yaw (turning) rate and lateral acceleration sensors (combined into Dynamics Sensor). Using signals from these sensors, in addition to individual wheel speed sensor signals, the system determines appropriate brake and throttle actions. Once initiated, ESP® operates much like All-Speed Traction Control, except that the goal is directional stability. If the vehicle yaw response, or rate of turning, is inconsistent with the steering angle and vehicle speed indications, the ESP® system applies the brakes and, if necessary closes the throttle, to restore control. This occurs whether the vehicle is turning too rapidly (oversteering) or not rapidly enough (understeering). ELECTRONIC ROLL MITIGATION

Typically when a vehicle makes a sudden turn, the outside tires provide the majority of cornering force. In order for the vehicle to make a turn, a significant amount of grip must exist at the tire contact patch. The body tilt that occurs during this event increases the weight on the outside tires. These conditions, plus the lateral acceleration of the vehicle, combined with the center of gravity position in the vehicle can cause the two inside wheels to lift in the turn and the vehicle rolls over the outside tires. ERM uses the principle that a slipping tire creates less cornering force than one that has full grip by applying enough brake pressure to intentionally make the outside tires slip close to the point of lockup. This reduces the cornering force of the outside tires and increases the turning radius. This straighter path reduces the amount of lateral acceleration and transfers some of the weight back to the inside tires, thus preventing a rollover. HILL START ASSIST

Hill Start Assist (HSA) will maintain the level of brake pressure the driver applied for a short period of time after the driver takes his foot off of the brake pedal. If the driver does not apply the throttle during this short user Monday, June 04, 2012 10:04:48 AM

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period of time the system will release brake pressure and the vehicle may roll down the hill. The system will release brake pressure in proportion to the amount of throttle applied as the vehicle starts to move in the intended direction of travel. TRAILER SWAY CONTROL

Programmed into the ESP, Trailer Sway Control will be activated once critical amplitude and frequency of oscillation of the vehicle-trailer system is reached. TSC builds up pressure to decelerate the vehicle-trailer system to below the critical speed. Depending on the oscillation conditions, TSC software can build up an additional asymmetric pressure to counter the trailer oscillation. The ESP function lamp will flash when TSC is activated. HYDRAULIC BRAKE ASSIST

Brake Assist is programmed into the ESP® system. During a panic stop, a pressure sensor determines when the driver is doing so by measuring the brake pedal pressure application rate. A high rate of pedal pressure application causes the ESP® system to apply maximum available pressure to the brakes and the vehicle stops as quickly as available traction will allow. ELECTRONIC VARIABLE BRAKE PROPORTIONING

Upon entry into EVBP the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off. In order to decrease the rear brake pressure, the outlet valve for the rear brake circuit is pulsed. This allows fluid to enter the low pressure accumulator (LPA) in the hydraulic control unit (HCU) resulting in a drop in fluid pressure to the rear brakes. In order to increase the rear brake pressure, the outlet valve is switched off and the inlet valve is pulsed. This increases the pressure to the rear brakes. This back-andforth process will continue until the required slip difference is obtained. At the end of EVBP braking (brakes released) the fluid in the LPA drains back to the master cylinder by switching on the Electronic Shuttle Valve. The EVBP will remain functional during many ABS fault modes. If both the red BRAKE and amber ABS warning indicators are illuminated, the EVBP may not be functioning.

CAUTION CAUTION The antilock brake system uses an electronic control module known as the Antilock Brake Module (ABM). This module is designed to withstand normal current draws associated with vehicle operation. Care must be taken to avoid overloading the circuits. CAUTION: In testing for open or short circuits, do not ground or apply voltage to any of the circuits unless instructed to do so for a diagnostic procedure. CAUTION: These circuits should only be tested using a high impedance multi-meter or the designated scan tool as described in this service information . Power should never be removed or applied to any control module with the user Monday, June 04, 2012 10:04:48 AM

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ignition in the ON position. Before removing or connecting battery cables, fuses, or connectors, always turn the ignition to the OFF position. CAUTION: The ABM 47-way connector should never be connected or disconnected with the ignition switch in the ON position. CAUTION: This vehicle utilizes active wheel speed sensors. Do not apply voltage to wheel speed sensors at any time. CAUTION: Use only factory wiring harnesses. Do not cut or splice wiring to the brake circuits. The addition of aftermarket electrical equipment (car phone, radar detector, citizen band radio, trailer lighting, trailer brakes, etc.) on a vehicle equipped with antilock brakes may affect the function of the antilock brake system. CAUTION: When performing any service procedure on a vehicle equipped with ABS, do not apply a 12-volt power source to the ground circuit of the pump motor in the HCU. Doing this will damage the pump motor and will require replacement of the entire HCU. CAUTION: An attempt to remove or disconnect certain system components may result in improper system operation. Only those components with approved removal and installation procedures in this service information should be serviced. CAUTION: If welding work is to be performed on the vehicle using an electric arc welder, the ABM connector should be disconnected during the welding operation. CAUTION: Many components of the ABS are not serviceable and must be replaced as an assembly. Do not disassemble any component which is not designed to be serviced. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surface, wash off with water immediately. CAUTION: Only the recommended jacking or hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle.

DIAGNOSIS AND TESTING INSPECTION AND ROAD TEST user Monday, June 04, 2012 10:04:48 AM

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1. Visually inspect the ABS for damaged or disconnected components and connectors. 2. Verify the brake lamps are operational. If they are not, repair them prior to continuing.

Fig. 3: Locating Data Link Connector Courtesy of CHRYSLER LLC 3. Connect a scan tool to the Data Link Connector located under the instrument panel to the left of the steering column (1). If the scan tool does not power-up, check the power and ground supplies to the connector. 4. Turn the ignition key to the ON position. 5. Using the scan tool, read and record any Diagnostic Trouble Codes (DTCs). If any DTCs are present, refer to the appropriate diagnostic service information. If no problems are observed, it will be necessary to road test the vehicle. Many ABS conditions judged to be a problem by the driver may be normal operating conditions. To become familiarized with the normal operating characteristics of this antilock brake system. See Operation . Before road testing a brake complaint vehicle, note whether the red BRAKE warning indicator lamp, amber ABS warning indicator lamp, or both are turned on. If it is the red BRAKE warning indicator, there is a brake hydraulic problem that must be corrected before driving the vehicle. See Diagnosis and Testing . If the amber ABS warning indicator is on, road test the vehicle as described below. While only the amber ABS warning indicator is on, the ABS is not functional. The ability to stop the car using the base brake system should not be affected. 6. Turn the key to the OFF position and then back to the ON position. Note whether the amber ABS warning user Monday, June 04, 2012 10:04:48 AM

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indicator lamp continues to stay on. 7. If the amber ABS warning indicator lamp stays on, shift into gear and drive the car to a speed of approximately 25 km/h (15 mph) to complete the ABS Start-Up and Drive-Off Cycles. See Operation . If at this time the amber ABS warning indicator lamp stays on, refer to the appropriate diagnostic service information. 8. If the amber ABS warning indicator lamp goes out at any time, drive the vehicle a short distance. Accelerate the vehicle to a speed of at least 64 km/h (40 mph). Bring the vehicle to a complete stop, braking hard enough to cause the ABS to cycle. Repeat this action several times. Using the scan tool, read and record any Diagnostic Trouble Codes (DTCs). If any DTCs are present, refer to the appropriate diagnostic service information.

STANDARD PROCEDURE ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE:

During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar® DOT 3 brake fluid as required.

BLEEDING

When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them.

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Fig. 4: Bleed Hose Set Up Courtesy of CHRYSLER LLC WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE:

Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system.

4. Bleed the base brake system. See Standard Procedure 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder fluid reservoir to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy.

SPECIFICATIONS BRAKE FASTENER TORQUE BRAKE FASTENER TORQUE DESCRIPTION ABS ABM Mounting Screws (To HCU) ABS ICU Mounting Bolt (To Bracket)

N.m 2 11

Ft. Lbs. 8

In. Lbs. 17 97

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ABS ICU Mounting Pins ABS ICU Mounting Bracket Screws (To Frame) ABS ICU Mounting Bracket Screw And Nut (To Body) - Right-Hand-Drive ABS Wheel Speed Sensor Head Mounting Bolt - Front ABS Wheel Speed Sensor Head Mounting Bolt - Rear ABS Wheel Speed Sensor Routing Bracket Screws Front ABS Wheel Speed Sensor Routing Bracket Screws Rear Brake Tube Nuts Brake Hose Bracket Bolt Brake Hose Caliper Banjo Bolt Brake Shield Mounting Screws Disc Brake Caliper Adapter Mounting Bolts - Front Disc Brake Caliper Adapter Mounting Bolts - Rear Disc Brake Caliper Guide Pin Bolts - Front Disc Brake Caliper Guide Pin Bolts - Rear Disc Brake Caliper Bleeder Screw Dynamics (ESP) Sensor Mounting Nuts Master Cylinder Mounting Nuts Pedal Bracket Upper Mounting Nuts Power Brake Booster Mounting Nuts Parking Brake Cable Mounting Screws to Hand Lever Front Parking Brake Cable Routing Clamp Screws/Nuts Parking Brake Cable Routing Loop Mounting Nuts Parking Brake Lever Mounting Nuts - Foot Lever System Parking Brake Lever Mounting Nuts - Hand Lever System Wheel Mounting (Lug) Nuts

11 23

8 17

97 203

23

17

203

12 6

9 4.5

106 55

20

15

177

20

15

177

17 18 26 8 169 100 35 35 10 9 25 28 28

12.5 13 19 6 125 74 26 26 7 6.5 19 21 21

150 160 230 71 88 80 225 250 250

28

21

250

6 6

4.5 4.5

55 55

28

21

250

20

15

177

135

100

-

ELECTRICAL SENSOR, DYNAMICS Description DESCRIPTION

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Fig. 5: Dynamics Sensor Location Courtesy of CHRYSLER LLC The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Removal REMOVAL

1. Disconnect and isolate the battery negative cable from the battery post.

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Fig. 6: Lower Instrument Panel Silencer Courtesy of CHRYSLER LLC 2. Remove the lower instrument panel trim on each side of console below instrument panel.

Fig. 7: Dynamics Sensor Courtesy of CHRYSLER LLC 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). user Monday, June 04, 2012 10:04:48 AM

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5. Remove the dynamics sensor (1). Installation INSTALLATION

Fig. 8: Dynamics Sensor Courtesy of CHRYSLER LLC 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 N.m (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1).

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Fig. 9: Lower Instrument Panel Silencer Courtesy of CHRYSLER LLC 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. Refer to Electrical - Engine Systems/Battery System - Standard Procedure 6. Perform the Verification Test and clear any faults. See Standard Procedure SENSOR, STEERING WHEEL ANGLE Description DESCRIPTION

Fig. 10: Steering Control Module Courtesy of CHRYSLER LLC The steering angle sensor is an integral part of the clockspring (3) mounted on the steering column. Refer to Restraints/CLOCKSPRING - Description SENSOR, WHEEL SPEED, FRONT Description DESCRIPTION

The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder.

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Fig. 11: Front Wheel Speed Sensor Courtesy of CHRYSLER LLC A front wheel speed sensor (2) is attached to a mounting boss on each front knuckle (3). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Operation OPERATION

The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Removal REMOVAL

NOTE:

Before proceeding. Refer to Brakes - Warning . See Caution .

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Fig. 12: Front Wheel Speed Sensor Wiring Connector Courtesy of CHRYSLER LLC 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure

Fig. 13: Front Wheel Speed Sensor Mounting To Body Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:48 AM

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4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6).

Fig. 14: Wheel Speed Sensor Routing & Brake Flex Hose Bracket Courtesy of CHRYSLER LLC 7. Remove the screw (2) securing the wheel speed sensor routing bracket (3) to the brake flex hose bracket (4). 8. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5).

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Fig. 15: Front Wheel Speed Sensor Courtesy of CHRYSLER LLC 9. Remove the mounting screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle and remove the sensor from the vehicle. Installation INSTALLATION

CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly.

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Fig. 16: Front Wheel Speed Sensor Courtesy of CHRYSLER LLC 1. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 N.m (106 in. lbs.).

Fig. 17: Wheel Speed Sensor Routing & Brake Flex Hose Bracket Courtesy of CHRYSLER LLC 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 3. Position the wheel speed sensor routing bracket (3) on the brake flex hose bracket (4) and install the mounting screw (2). Tighten the mounting screw to 20 N.m (15 ft. lbs.).

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Fig. 18: Front Wheel Speed Sensor Mounting To Body Courtesy of CHRYSLER LLC 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 20 N.m (15 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole.

Fig. 19: Front Wheel Speed Sensor Wiring Connector Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:48 AM

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7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See Standard Procedure SENSOR, WHEEL SPEED, REAR Description DESCRIPTION

The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder.

Fig. 20: Hub And Bearing Courtesy of CHRYSLER LLC The rear wheel speed sensor (2) head is mounted to the rear hub and bearing (1). The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. WSS air gaps are not adjustable. Operation OPERATION

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The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Removal REMOVAL

1. Access and remove the rear brake rotor. Refer to Brakes/Hydraulic/Mechanical/ROTOR, Brake Removal

Fig. 21: Hub And Bearing Courtesy of CHRYSLER LLC CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 2. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1).

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Fig. 22: Brake Tube Routing Bracket Courtesy of CHRYSLER LLC 3. Remove the wheel speed sensor routing clip (4) from the brake tube routing bracket (1). 4. Remove the wheel speed sensor cable from the routing clips (3) above the trailing arm.

Fig. 23: Hub And Bearing Courtesy of CHRYSLER LLC 5. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. user Monday, June 04, 2012 10:04:48 AM

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Fig. 24: Wheel Speed Sensor Routing Clamp Courtesy of CHRYSLER LLC 6. Remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3).

Fig. 25: Brake Flex Hose And Tube Bracket Courtesy of CHRYSLER LLC 7. Remove the screw (2) securing the wheel speed sensor routing clamp (1) to the trailing link.

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Fig. 26: Wheel Speed Sensor Wiring Connector Courtesy of CHRYSLER LLC 8. Disconnect the vehicle wiring harness (3) from the wheel speed sensor connector (2) on the body (1). 9. Disengage the wheel speed sensor connector from the routing clip fastened to the body using a screwdriver. Pull the connector forward off the routing clip. Or, if a NEW routing clip is available, remove the routing clip from the body with the connector attached. 10. Remove the wheel speed sensor from the vehicle. Installation INSTALLATION

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Fig. 27: Wheel Speed Sensor Wiring Connector Courtesy of CHRYSLER LLC 1. Slide the wheel speed sensor wiring connector (2) onto the routing clip mounted on the body until it locks into place or if a NEW routing clip is attached to the connector, push it into the mounting holes on the body. 2. Connect the vehicle wiring harness (3) to the wheel speed sensor connector (2).

Fig. 28: Wheel Speed Sensor Routing Clamp Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:48 AM

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3. Attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 N.m (15 ft. lbs.).

Fig. 29: Brake Flex Hose And Tube Bracket Courtesy of CHRYSLER LLC 4. Attach the wheel speed sensor routing clamp (1) to the trailing link using the mounting screw (2). Tighten the mounting screw to 20 N.m (15 ft. lbs.).

Fig. 30: Hub And Bearing Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:48 AM

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5. Apply bearing grease (supplied with part) to sensor head shaft and O-ring. CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 6. Pass the wheel speed sensor head through the hole in the brake shield, then push it into the mounting hole in hub and bearing (3) and align the mounting screw hole. 7. Install a NEW mounting screw (2). Tighten the mounting screw to 6 N.m (55 in. lbs.).

Fig. 31: Brake Tube Routing Bracket Courtesy of CHRYSLER LLC 8. Install the wheel speed sensor routing clip (4) in the brake tube routing bracket (1). 9. Install the wheel speed sensor cable into the routing clips (3) above the trailing arm. 10. Install brake rotor as well as all components necessary to access it. Refer to Brakes/Hydraulic/Mechanical/ROTOR, Brake - Installation 11. Perform the ABS Verification Test and clear any faults. Refer to DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure SWITCH, ELECTRONIC STABILITY PROGRAM (ESP) Description DESCRIPTION

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Fig. 32: Accessory Switch Bank Module Courtesy of CHRYSLER LLC The ESP Off Switch (2) is part of the accessory switch bank module located in the center bezel (2) on the instrument panel above the radio. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP® back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP® off, it does not completely turn the system off. The ESP® system reduces torque management to a lesser amount, but ESP® function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Removal REMOVAL

NOTE:

The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately.

1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Removal . 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Installation user Monday, June 04, 2012 10:04:48 AM

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INSTALLATION

NOTE:

The ESP Off switch is serviced as part of the accessory switch bank.

NOTE:

There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options.

1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Install the center bezel onto the instrument panel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Installation . 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. See Standard Procedure 6. Verify proper operation of all components controlled by the switch bank.

HYDRAULIC/MECHANICAL HYDRAULIC CONTROL UNIT (HCU) Description DESCRIPTION

The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during TCS and ESP events and to empty the low pressure accumulators during ABS events. NOTE:

The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA).

For more information. See Description ) Removal REMOVAL

NOTE:

The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA).

To remove the HCU, the ICU must be removed and disassembled. See Removal ). See Disassembly) user Monday, June 04, 2012 10:04:48 AM

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Installation INSTALLATION

To install the HCU, assemble and install the ICU. See Assembly ). See Installation ) INTEGRATED CONTROL UNIT (ICU) Description DESCRIPTION

Fig. 33: Integrated Control Unit Courtesy of CHRYSLER LLC 1 - ANTILOCK BRAKE MODULE (ABM) 2 - HYDRAULIC CONTROL UNIT (HCU) 3 - PUMP/MOTOR The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU).

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Fig. 34: Locating Integrated Control Unit (ICU) Courtesy of CHRYSLER LLC The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower.

Fig. 35: Integrated Control Unit Mounting - RHD Courtesy of CHRYSLER LLC On Right-Hand-Drive vehicles, the ICU (1) is located in the engine compartment, mounted to the left side body frame rail and strut tower. The ABS with ESP® and All-Speed Traction Control ICU consists of the following components: the ABM, 8 user Monday, June 04, 2012 10:04:48 AM

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(build/decay) solenoid valves, two traction control solenoid valves, two electronic shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. NOTE:

The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA).

The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. The ABM can be serviced without removing the entire assembly from the vehicle. For additional information on the ABM. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Anti-Lock Brake System - Description . For additional information on the HCU. See Description ). Operation OPERATION

For operation of the ICU, refer to the individual components of the ICU. z

z

ANTILOCK BRAKE MODULE (ABM). Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Anti-Lock Brake System - Description HYDRAULIC CONTROL UNIT (HCU)

Removal LEFT-HAND-DRIVE

NOTE:

Before proceeding. Refer to Brakes - Warning . See Caution .

NOTE:

If servicing the ABM only. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Anti-Lock Brake System Removal

1. Disconnect and isolate battery negative cable from battery post.

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Fig. 36: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 2. Using a brake pedal holding tool as shown in illustration, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover.

Fig. 37: Cowl Top Screen Courtesy of CHRYSLER LLC 4. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). user Monday, June 04, 2012 10:04:48 AM

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5. Remove the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Removal

Fig. 38: Cowl Screen Courtesy of CHRYSLER LLC 6. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3).

Fig. 39: Wheelhouse Brace Courtesy of CHRYSLER LLC 7. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 8. Remove the wheelhouse brace (2). user Monday, June 04, 2012 10:04:48 AM

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9. Remove two screws, then remove the fresh air plenum. 10. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel.

Fig. 40: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC 11. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 12. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7).

Fig. 41: ABM Connector Release Tabs Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:48 AM

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NOTE:

Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs.

Fig. 42: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR 13. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1).

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Fig. 43: Locating Integrated Control Unit (ICU) Courtesy of CHRYSLER LLC 14. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 15. Lift the ICU and mounting bracket (1) off the mounting screws (2). 16. Move the brake tubes around as necessary without bending them and remove the ICU with bracket. NOTE:

The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA).

17. To separate the ABM from the HCU. See Disassembly) . RIGHT-HAND-DRIVE

NOTE:

Before proceeding. Refer to Brakes - Warning . See Caution .

NOTE:

If servicing the ABM only. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Anti-Lock Brake System Removal

1. Disconnect and isolate battery negative cable from battery post.

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Fig. 44: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 2. Using a brake pedal holding tool as shown in illustration, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover.

Fig. 45: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC 4. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the Hydraulic Control Unit (HCU) (7). user Monday, June 04, 2012 10:04:48 AM

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5. Remove the remaining brake tubes (2, 3, 5, 6) at the HCU (7).

Fig. 46: ABM Connector Release Tabs Courtesy of CHRYSLER LLC NOTE:

Use illustration in the following step to release the Antilock Brake Module (ABM) harness connector cover. It shows the location of the release tabs.

Fig. 47: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR 6. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight user Monday, June 04, 2012 10:04:48 AM

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outward (2). The connector can then be pulled straight outward off the ABM (1).

Fig. 48: Integrated Control Unit Mounting - RHD Courtesy of CHRYSLER LLC 7. Loosen, but do not remove, the mounting nut (2) and screw (3) attaching the Integrated Control Unit (ICU) (1) mounting bracket to the body. 8. Lift the ICU and mounting bracket (1) off the mounting stud and screw. NOTE:

The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA).

9. To separate the ABM from the HCU. See Disassembly ). Disassembly DISASSEMBLY

NOTE:

The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA).

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Fig. 49: ICU Mounting Pins Courtesy of CHRYSLER LLC 1. If necessary, remove the mounting pins from the ICU.

Fig. 50: ABM Mounting Screws - With Traction Control Courtesy of CHRYSLER LLC 1 - MOUNTING SCREWS 2 - ABM 2. Remove the four screws (1) attaching the ABM (2) to the HCU.

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Fig. 51: Identifying ABM, HCU, & Solenoid Valve Stem Courtesy of CHRYSLER LLC 1 - ABM 2 - HCU 3 - SOLENOID VALVE STEM 3. Separate the ABM (1) from the HCU (2). Assembly ASSEMBLY

1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant.

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Fig. 52: Solenoid Valve Seal Courtesy of CHRYSLER LLC 1 - SEAL 2 - SOLENOID VALVE STEM 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris;do not reuse solenoid valve stem seals.

Fig. 53: Internal Pump Connector O-Ring Courtesy of CHRYSLER LLC

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1 - O-RING 2 - O-RING MOUNTING GROOVE 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2).

Fig. 54: Identifying ABM, HCU, & Solenoid Valve Stem Courtesy of CHRYSLER LLC 1 - ABM 2 - HCU 3 - SOLENOID VALVE STEM 4. Align components and install the ABM (1) on the HCU (2).

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Fig. 55: ABM Mounting Screws - With Traction Control Courtesy of CHRYSLER LLC 1 - MOUNTING SCREWS 2 - ABM 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.).

Fig. 56: ICU Mounting Pins Courtesy of CHRYSLER LLC 6. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 N.m (97 in. lbs.). user Monday, June 04, 2012 10:04:48 AM

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7. Install the ICU in the vehicle. See Installation ) Installation LEFT-HAND-DRIVE

Fig. 57: Locating Integrated Control Unit (ICU) Courtesy of CHRYSLER LLC 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 N.m (17 ft. lbs.).

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Fig. 58: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.

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Fig. 59: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC CAUTION: The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks. z z z z z z

(1) Master Cylinder Secondary (2) Front Left (3) Front Right (4) Master Cylinder Primary (5) Rear Left (6) Rear Right

Fig. 60: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC 4. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.). 6. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 7. Position the fresh air plenum and install the two mounting screws.

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Fig. 61: Wheelhouse Brace Courtesy of CHRYSLER LLC 8. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Fig. 62: Cowl Screen Courtesy of CHRYSLER LLC 9. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 10. Install the wiper arms. Refer to Electrical - Wipers/Washers/Wipers/Washers/ARM, Wiper Installation

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Fig. 63: Cowl Top Screen Courtesy of CHRYSLER LLC 11. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 12. Install the engine appearance cover.

Fig. 64: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 13. Remove the brake pedal holding tool. 14. Connect the battery negative cable to the battery post. It is important that this be performed properly. Refer to Electrical - Engine Systems/Battery System - Standard Procedure

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Fig. 65: Bleed Hose Set Up Courtesy of CHRYSLER LLC 15. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See Standard Procedure c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. Refer to DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure RIGHT-HAND-DRIVE

Fig. 66: Integrated Control Unit Mounting - RHD Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:04:49 AM

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1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Install the ICU with bracket (1) into the engine compartment. Place the mounting bracket for the ICU (1) over the mounting stud and screw (3) and hang the assembly in place. Tighten the mounting nut (2) and mounting screw (3) to 23 N.m (17 ft. lbs.).

Fig. 67: Wiring Harness Connector At ABM Courtesy of CHRYSLER LLC 1 - ABM (PART OF ICU) 2 - WIRING HARNESS CONNECTOR CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place.

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Fig. 68: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC CAUTION: The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks. z z z z z z

(1) Master Cylinder Secondary (2) Front Left (3) Front Right (4) Master Cylinder Primary (5) Rear Left (6) Rear Right

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Fig. 69: Identifying Brake Tubes At Hydraulic Control Unit Courtesy of CHRYSLER LLC 4. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 N.m (150 in. lbs.).

Fig. 70: BRAKE PEDAL HOLDING TOOL Courtesy of CHRYSLER LLC 6. Remove the brake pedal holding tool. 7. Install the engine appearance cover. 8. Connect the battery negative cable to the battery post. It is important that this be performed properly. Refer to Electrical - Engine Systems/Battery System - Standard Procedure

Fig. 71: Bleed Hose Set Up Courtesy of CHRYSLER LLC 9. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See user Monday, June 04, 2012 10:04:49 AM

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Standard Procedure c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. Refer to DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

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2009 BRAKES ABS - Electrical Diagnostics - Journey

DIAGNOSTIC CODE INDEX DIAGNOSTIC CODE INDEX DTC Description C100A LEFT FRONT WHEEL SPEED SENSOR CIRCUIT C1011 LEFT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE C1014 LEFT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE C1015 RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT C101C RIGHT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE C101F RIGHT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE C1020 LEFT REAR WHEEL SPEED SENSOR CIRCUIT C1027 LEFT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE C102A LEFT REAR WHEEL SPEED COMPARATIVE PERFORMANCE C102B RIGHT REAR WHEEL SPEED SENSOR CIRCUIT C102C RIGHT REAR WHEEL SPEED SENSOR CIRCUIT PERFORMANCE C1032 RIGHT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE C1035 RIGHT REAR WHEEL SPEED COMPARATIVE PERFORMANCE C1041 LEFT FRONT TONE WHEEL PERFORMANCE C1042 RIGHT FRONT TONE WHEEL PERFORMANCE C1043 LEFT REAR TONE WHEEL PERFORMANCE C1044 RIGHT REAR TONE WHEEL PERFORMANCE C1046 LEFT FRONT WHEEL PRESSURE PHASE MONITORING C1047 RIGHT FRONT WHEEL PRESSURE PHASE MONITORING C1048 LEFT REAR WHEEL PRESSURE PHASE MONITORING C1049 RIGHT REAR WHEEL PRESSURE PHASE MONITORING C1073 ABS PUMP MOTOR CONTROL CIRCUIT C1078 TIRE REVOLUTIONS RANGE PERFORMANCE C107C BRAKE PEDAL SWITCH 1/2 STUCK C107D BRAKE PEDAL SWITCH 1/2 CORRELATION C1090 ABS BRAKE LAMP CONTROL CIRCUIT LOW C1091 ABS BRAKE LAMP CONTROL CIRCUIT HIGH C1210 G SENSOR INPUT CIRCUIT PERFORMANCE C1219 STEERING ANGLE SENSOR ERRATIC PERFORMANCE C121A STEERING ANGLE SENSOR NOT INITIALIZED C121C TORQUE REQUEST SIGNAL DENIED C121D BRAKE PRESSURE SENSOR CIRCUIT C121E BRAKE PRESSURE SENSOR COMPARATIVE PERFORMANCE user Monday, June 04, 2012 10:12:31 10:12:21 AM

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C1231 C1232 C1234 C1238 C1239 C123A C123B C123C C123F C1240 C1243 C2100 C2101 C2111 C2114 C2115 C2116 C2202 C2205 C2206 U0100 U0101 U0125 U0126 U0141 U0401 U0402 U0429 U1003 U1004 U1104 U140E U1501 U1502 U1503

DRIVE TEST: STEERING ANGLE SENSOR DRIVE TEST: PRESSURE SENSOR DRIVE TEST: SENSOR CLUSTER INSTALLATION DRIVE TEST: UNSUCCESSFUL EMISSIONS ROLLS TEST ACTIVE ESP SYSTEM SENSORS CALIBRATION ESP SYSTEM CONTROL TOO LONG DYNAMICS SENSOR MOUNTING/INSTALLATION PERFORMANCE STEERING ANGLE SENSOR COMPARATIVE PERFORMANCE STEERING ANGLE SENSOR OVERTRAVEL PERFORMANCE G SENSOR NOT INITIALIZED BATTERY VOLTAGE LOW BATTERY VOLTAGE HIGH ANTI-LOCK BRAKE MODULE INTERNAL DYNAMICS SENSOR SUPPLY VOLTAGE LOW DYNAMICS SENSOR SUPPLY VOLTAGE HIGH ABS PUMP MOTOR SUPPLY LOW VOLTAGE ORIGINAL VIN MISMATCH/MISSING STEERING ANGLE SENSOR INTERNAL VEHICLE CONFIGURATION MISMATCH LOST COMMUNICATION WITH ECM/PCM LOST COMMUNICATION WITH TCM LOST COMMUNICATION WITH DYNAMICS SENSOR LOST COMMUNICATION WITH STEERING ANGLE SENSOR LOST COMMUNICATION WITH FRONT CONTROL MODULE (TIPM) IMPLAUSIBLE DATA RECEIVED FROM ECM/PCM IMPLAUSIBLE DATA RECEIVED FROM TCM IMPLAUSIBLE DATA RECEIVED FROM SCM ESP CAN C BUS PERFORMANCE CAN C BUS TRANSMIT PERFORMANCE CAN C BUS CRC PERFORMANCE IMPLAUSIBLE VEHICLE CONFIGURATION DATA RECEIVED IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM PCM IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM TCM IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM TIPM

DIAGNOSIS AND TESTING C100A-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT

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Fig. 1: Left Front Wheel Speed Sensor Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: When the Left Front Wheel Speed Sensor circuit fails the diagnostic test. Possible Causes

CONNECTOR/TERMINAL DAMAGE (B9) LEFT FRONT WSS SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND OR OPEN (B8) LEFT FRONT WSS SIGNAL CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B8) LEFT FRONT WSS SIGNAL CIRCUIT AND (B9) LEFT FRONT WSS SUPPLY CIRCUIT SHORTED TOGETHER LEFT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C100A LEFT FRONT WHEEL SPEED SENSOR CIRCUIT NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: C100A LEFT FRONT WHEEL SPEED SENSOR CIRCUIT? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

1. Turn the ignition off. user Monday, June 04, 2012 10:12:22 AM

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2. Inspect the Anti-Lock Brake Module harness connector, Left Front WSS, and Left Front WSS harness connector. Is the Left Front WSS or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B9) LEFT FRONT WSS SUPPLY CIRCUIT VOLTAGE z

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Fig. 2: Checking Left Front Wheel Speed Sensor Supply Circuit Voltage Courtesy of CHRYSLER LLC 1. Disconnect the Left Front WSS harness connector. 2. Turn the ignition on. 3. Measure the voltage between the (B9) Left Front WSS Supply circuit and ground. Is the voltage above 10 volts? Yes z

Go to step 6

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Go to step 4 4. CHECK (B9) LEFT FRONT WSS SUPPLY CIRCUIT SHORT TO GROUND z

Fig. 3: Checking Left Front Wheel Speed Sensor Supply Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Disconnect the Anti-Lock Brake Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (B9) Left Front WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Repair the (B9) Left Front WSS Supply circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 5 5. CHECK (B9) LEFT FRONT WSS SUPPLY CIRCUIT OPEN z

Fig. 4: Checking Left Front Wheel Speed Sensor Supply Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B9) Left Front WSS Supply circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (B9) Left Front WSS Supply circuit. Does the test light illuminate brightly Yes z

Go to step 6

z

Repair the (B9) Left Front WSS Supply circuit for an open.

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Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK (B8) LEFT FRONT WSS SIGNAL CIRCUIT SHORT TO VOLTAGE z

Fig. 5: Checking Left Front Wheel Speed Sensor Signal Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Measure the voltage between the (B8) Left Front WSS Signal circuit and ground. Is the voltage above 1 volt? Yes z z

Repair the (B8) Left Front WSS Signal circuit for a short to voltage. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK (B8) LEFT FRONT WSS SIGNAL CIRCUIT SHORT TO GROUND z

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Fig. 6: Checking Left Front Wheel Speed Sensor Signal Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. If not done previously, disconnect the Anti-Lock Brake Module harness connector. 3. Using a 12-volt test light connected to 12-volts, probe the (B8) Left Front WSS Signal circuit. Does the test light illuminate brightly? Yes z z

Repair the (B8) Left Front WSS Signal circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 8 8. CHECK (B8) LEFT FRONT WSS SIGNAL CIRCUIT OPEN z

Fig. 7: Checking Left Front Wheel Speed Sensor Signal Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B8) Left Front WSS Signal circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (B8) Left Front WSS Signal circuit. Does the test light illuminate brightly? user Monday, June 04, 2012 10:12:22 AM

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Yes z

Go to step 9

No Repair the (B8) Left Front WSS Signal circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 9. CHECK (B8) LEFT FRONT WSS SIGNAL CIRCUIT AND (B9) LEFT FRONT WSS SUPPLY CIRCUIT SHORT TOGETHER z

Fig. 8: Checking Left Front Wheel Speed Sensor Signal Circuit & Left Front Wheel Speed Sensor Supply Circuit Short Together Courtesy of CHRYSLER LLC 1. Remove all jumper wires. 2. Measure the resistance between the (B8) Left Front WSS Signal circuit and the (B9) Left Front WSS Supply circuit. Is the resistance above 5.0 Ohms? user Monday, June 04, 2012 10:12:22 AM

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Yes z

Go to step 10

No Repair the (B8) Left Front WSS Signal circuit and the (B9) Left Front WSS Supply circuit for a short together. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. LEFT FRONT WHEEL SPEED SENSOR 1. Replace the Left Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Make sure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. Did DTC C100A LEFT FRONT WHEEL SPEED SENSOR CIRCUIT reset? Yes

z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

C1011-LEFT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

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z

Set Condition: When the Left Front Wheel Speed Sensor (WSS) Signal is intermittently missing while vehicle speed is above 40 km/h (25 mph) or erratic wheel speed signal during acceleration or sensed wheel speed is different from other wheels.

Possible Causes LEFT FRONT WSS LOOSE - B8, B9 CIRCUITS/CONNECTOR/TERMINAL DAMAGE LEFT FRONT TONE WHEEL DAMAGE LEFT FRONT WHEEL/ BEARING DAMAGE IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES LEFT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1011-LEFT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

NOTE:

If DTC C100A Left Front Wheel Speed Sensor Circuit is present it must be repaired before continuing.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Start the engine. CAUTION: Ensure brake capability is available before road testing.

6. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

7. With the scan tool, read DTCs. Does the scan tool display: C1011-LEFT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE active? user Monday, June 04, 2012 10:12:22 AM

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Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Front WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Refer to the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Front Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Left Front Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

No user Monday, June 04, 2012 10:12:22 AM

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Go to step 4 4. CHECK LEFT FRONT WSS LOOSENESS, INSPECT B8, B9 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Left Front WSS, and Left Front WSS harness connector 2. Inspect the Left Front WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B8) Left Front WSS Signal and (B9) Left Front WSS Supply circuits between the Left Front WSS and Anti-Lock Brake Module for damage. Is the Left Front WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK LEFT FRONT WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Left Front Wheel Speed Sensor 2. Inspect the Left Front Wheel Speed Sensor face for damage. z

Is the Left Front Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 6 6. CHECK LEFT FRONT TONE WHEEL/BEARING FOR DAMAGE 1. Inspect the Left Front Tone Wheel/Bearing for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

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Is the Left Front Tone Wheel/Bearing damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK LEFT FRONT WHEEL BEARING FOR DAMAGE 1. Inspect the Left Front wheel bearing for excessive runout or clearance. Refer to Front Suspension/Front/HUB AND BEARING - Diagnosis and Testing z

Is the Left Front Wheel Bearing Damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. LEFT FRONT WHEEL SPEED SENSOR 1. Replace the Left Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C1011-LEFT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock

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Brake (ABS) - Standard Procedure. No z

Test Complete.

C1014-LEFT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Left Front Wheel Speed Sensor (WSS) Signal reading is different from the readings received from the other WSS's at a vehicle speed above 40 km/h (25 mph). The Anti-Lock Brake Module compares WSS readings from side-to-side on an axle and front-to-rear.

Possible Causes LEFT FRONT WSS LOOSE - B8, B9 CIRCUITS/CONNECTOR/TERMINAL DAMAGE IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES LEFT FRONT TONE WHEEL/BEARING DAMAGE LEFT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1014-LEFT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

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4. With the scan tool, read DTCs. Does the scan tool display: C1014-LEFT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Front WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Front Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Left Front Tire improperly inflated or mismatched tires on vehicle? user Monday, June 04, 2012 10:12:22 AM

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Yes z z

Repair as necessary Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK LEFT FRONT WSS LOOSENESS, INSPECT B8, B9 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Left Front WSS, and Left Front WSS harness connector. 2. Inspect the Left Front WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B8) Left Front WSS Signal and (B9) Left Front WSS Supply circuits between the Left Front WSS and Anti-Lock Brake Module for damage. Is the Left Front WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK LEFT FRONT WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Left Front Wheel Speed Sensor 2. Inspect the Left Front Wheel Speed Sensor face for damage. z

Is the Left Front Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No user Monday, June 04, 2012 10:12:22 AM

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Go to step 6 6. CHECK LEFT FRONT TONE WHEEL/BEARING FOR DAMAGE 1. Inspect the Left Front Tone Wheel/Bearing for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Left Front Tone Wheel/Bearing damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. LEFT FRONT WHEEL SPEED SENSOR 1. Replace the Left Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C1014-LEFT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE reset? Yes

z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

C1015-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT

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Fig. 9: Left Front Wheel Speed Sensor Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: If the Right Front Wheel Speed Sensor circuit fails the diagnostic test.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B6) RIGHT FRONT WSS SIGNAL CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B6) RIGHT FRONT WSS SIGNAL CIRCUIT SHORTED TO THE (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT RIGHT FRONT WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR DTC C1015-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: C1015-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

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1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector, Right Front WSS, and Right Front WSS harness connector. Is the Right Front WSS or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT VOLTAGE z

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Fig. 10: Checking Right Front Wheel Speed Sensor 12 Volt Supply Circuit Voltage Courtesy of CHRYSLER LLC 1. Disconnect the Right Front WSS harness connector. 2. Turn the ignition on. 3. Measure the voltage of the (B7) Right Front WSS 12 Volt Supply circuit. Is the voltage above 10.0 volts? Yes z

Go to step 6

No Go to step 4 4. CHECK (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO GROUND z

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Fig. 11: Checking Right Front Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Right Front WSS harness connector. Disconnect the Anti-Lock Brake Module harness connector. Using a 12-volt test light connected to 12-volts, probe the (B7) Right Front WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Repair the (B7) Right Front WSS Supply circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE,

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Antilock Brake (ABS) - Standard Procedure. No Go to step 5 5. CHECK (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT FOR AN OPEN z

Fig. 12: Checking Right Front Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B7) Right Front WSS Supply circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (B7) Right Front WSS Supply circuit. Does the test light illuminate brightly? user Monday, June 04, 2012 10:12:22 AM

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Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Repair the (B7) Right Front WSS Supply circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK (B6) RIGHT FRONT WSS SIGNAL CIRCUIT SHORT TO GROUND z

Fig. 13: Checking Right Front Wheel Speed Sensor Signal Circuit Short To Ground user Monday, June 04, 2012 10:12:22 AM

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Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. If not done previously, disconnect the Anti-Lock Brake Module harness connector. 3. Using a 12-volt test light connected to 12-volts, probe the (B6) Right Front WSS Signal circuit. Does the test light illuminate brightly? Yes z z

Repair the (B6) Right Front WSS Signal circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK (B6) RIGHT FRONT WSS SIGNAL CIRCUIT OPEN z

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Fig. 14: Checking Right Front Wheel Speed Sensor Signal Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B6) Right Front WSS Signal circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (B6) Right Front WSS Signal circuit. Does the test light illuminate brightly? Yes z

Go to step 8

No user Monday, June 04, 2012 10:12:22 AM

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Repair the (B6) Right Front WSS Signal circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 8. CHECK (B6) RIGHT FRONT WSS SIGNAL CIRCUIT FOR AN SHORT TO VOLTAGE z

Fig. 15: Checking Right Front Wheel Speed Sensor Signal Circuit For An Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Remove all jumper wires. 3. Measure the voltage between the (B6) Right Front WSS Signal circuit and ground. Is the voltage above 1 volt? user Monday, June 04, 2012 10:12:22 AM

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Yes z z

Repair the (B6) Right Front WSS Signal circuit for a short to voltage. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. CHECK (B6) RIGHT FRONT WSS SIGNAL CIRCUIT AND (B7) RIGHT FRONT WSS 12 VOLT SUPPLY CIRCUIT SHORTED TOGETHER z

Fig. 16: Checking Right Front Wheel Speed Sensor Signal Circuit & Right Front Wheel Speed Sensor 12 Volt Supply Circuit Shorted Together Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between the (B6) Right Front WSS Signal circuit and the (B7) Right Front WSS Supply circuit. user Monday, June 04, 2012 10:12:22 AM

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Is the resistance above 5.0 Ohms? Yes z

Go to step 10

No Repair the (B6) Right Front WSS Signal circuit and the (B7) Right Front WSS Supply circuit for a short together. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. RIGHT FRONT WHEEL SPEED SENSOR 1. Replace the Right Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure z

CAUTION: Make sure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. Did DTC C1015-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT reset? Yes

z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

C101C-RIGHT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: When the Right Front Wheel Speed Sensor (WSS) Signal is intermittently missing while vehicle speed is above 40 km/h (25 mph) or erratic wheel speed signal during acceleration or sensed wheel speed is different from other wheels.

Possible Causes RIGHT FRONT WSS LOOSE - B6, B7 CIRCUITS/CONNECTOR/TERMINAL DAMAGE RIGHT FRONT TONE WHEEL DAMAGE RIGHT FRONT WHEEL/BEARING DAMAGE IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES RIGHT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C101C-RIGHT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

NOTE:

If DTC C1015-Right Front Wheel Speed Sensor Circuit is present it must be repaired before continuing.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read DTCs. Does the scan tool display: C101C-RIGHT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE active? Yes user Monday, June 04, 2012 10:12:22 AM

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z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Right Front WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Front Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Right Front Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK RIGHT FRONT WSS LOOSENESS, INSPECT B6, B7 CIRCUITS/TERMINALS FOR z

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DAMAGE NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Right Front WSS, and Right Front WSS harness connector 2. Inspect the Right Front WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B6) Right Front WSS Signal and (B7) Right Front WSS Supply circuits between the Right Front WSS and Anti-Lock Brake Module for damage. Is the Right Front WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK RIGHT FRONT WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Right Front Wheel Speed Sensor 2. Inspect the Right Front Wheel Speed Sensor face for damage. z

Is the Right Front Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 6 6. CHECK RIGHT FRONT TONE WHEEL/BEARING FOR DAMAGE 1. Inspect the Right Front Tone Wheel/Bearing for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Right Front Tone Wheel/Bearing damaged? user Monday, June 04, 2012 10:12:22 AM

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Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK RIGHT FRONT WHEEL BEARING FOR DAMAGE 1. Inspect the Right Front wheel bearing for excessive runout or clearance. z

NOTE:

Refer to the appropriate service information, if necessary, for procedures or specifications. Refer to Front Suspension/Front/HUB AND BEARING - Diagnosis and Testing .

Is the Right Front Wheel Bearing Damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. RIGHT FRONT WHEEL SPEED SENSOR 1. Replace the Right Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C101C-RIGHT FRONT WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE reset? Yes z

Replace the Anti-Lock Brakes Module in accordance with the Service Information.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C101F-RIGHT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Right Front Wheel Speed Sensor (WSS) reading is different from the readings received from the other sensors at a vehicle speed above 40 km/h (25 mph). The Anti-Lock Brake Module compares WSS readings from side-to-side on an axle and front-to-rear.

Possible Causes RIGHT FRONT WSS LOOSE B6, B7 CIRCUITS/CONNECTOR/TERMINAL DAMAGE IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES RIGHT FRONT TONE WHEEL/BEARING DAMAGE RIGHT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C101F-RIGHT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

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4. With the scan tool, read DTCs. Does the scan tool display: C101F-RIGHT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Right Front WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Refer to the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Front Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Right Front Tire improperly inflated or mismatched tires on vehicle? user Monday, June 04, 2012 10:12:22 AM

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Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK RIGHT FRONT WSS LOOSENESS, INSPECT B6, B7 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Right Front WSS, and Right Front WSS harness connector. 2. Inspect the Right Front WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B6) Right Front WSS Signal and (B7) Right Front WSS Supply circuits between the Right Front WSS and Anti-Lock Brake Module for damage. Is the Right Front WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK RIGHT FRONT WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Right Front Wheel Speed Sensor 2. Inspect the Right Front Wheel Speed Sensor face for damage. z

Is the Right Front Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No user Monday, June 04, 2012 10:12:22 AM

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Go to step 6 6. CHECK RIGHT FRONT TONE WHEEL/BEARING FOR DAMAGE 1. Inspect the Right Front Tone Wheel/Bearing for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Right Front Tone Wheel/Bearing damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. RIGHT FRONT WHEEL SPEED SENSOR 1. Replace the Right Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C101F-RIGHT FRONT WHEEL SPEED COMPARATIVE PERFORMANCE reset? Yes

z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

C1020-LEFT REAR WHEEL SPEED SENSOR CIRCUIT

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Fig. 17: Left Front Wheel Speed Sensor Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: If the Left Rear Wheel Speed Sensor circuit fails the diagnostic test.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B3) LEFT REAR WSS SIGNAL CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B3) LEFT REAR WSS SIGNAL CIRCUIT SHORTED TO THE (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT LEFT REAR WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR DTC C1020 LEFT REAR WHEEL SPEED SENSOR CIRCUIT NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: C1020-LEFT REAR WHEEL SPEED SENSOR CIRCUIT? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

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1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector, Left Rear WSS, and Left Rear WSS harness connector. Is the Left Rear WSS or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT VOLTAGE z

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Fig. 18: Checking Left Rear Wheel Speed Sensor 12 Volt Supply Circuit Voltage Courtesy of CHRYSLER LLC 1. Disconnect the Left Rear WSS harness connector. 2. Turn the ignition on. 3. Measure the voltage of the (B4) Left Rear WSS 12 Volt Supply circuit. Is the voltage above 10.0 volts? Yes z

Go to step 6

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No Go to step 4 4. CHECK (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO GROUND z

Fig. 19: Checking Left Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Left Rear WSS harness connector. Disconnect the Anti-Lock Brake Module harness connector. Using a 12-volt test light connected to 12 volts, probe the (B4) Left Rear WSS Supply circuit.

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Does the test light illuminate brightly? Yes z z

Repair the (B4) Left Rear WSS Supply circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR AN OPEN z

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Fig. 20: Checking Left Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B4) Left Rear WSS Supply circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B4) Left Rear WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Repair the (B4) Left Rear WSS Supply circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK (B3) LEFT REAR WSS SIGNAL CIRCUIT FOR A SHORT TO GROUND z

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Fig. 21: Checking Left Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. If not done previously, disconnect the Anti-Lock Brake Module harness connector. 3. Using a 12-volt test light connected to 12 volts, probe the (B3) Left Rear WSS Signal circuit. Does the test light illuminate brightly? Yes z z

Repair the (B3) Left Rear WSS Signal circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE,

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Antilock Brake (ABS) - Standard Procedure. No Go to step 7 7. CHECK (B3) LEFT REAR WSS SIGNAL CIRCUIT FOR AN OPEN z

Fig. 22: Checking Left Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B3) Left Rear WSS Signal circuit in the Anti-Lock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B3) Left Rear WSS Signal circuit. user Monday, June 04, 2012 10:12:22 AM

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Does the test light illuminate brightly? Yes z

Go to step 8

No Repair the (B3) Left Rear WSS Signal circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 8. CHECK (B3) LEFT REAR WSS SIGNAL CIRCUIT SHORT TO VOLTAGE z

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Fig. 23: Checking Left Rear Wheel Speed Sensor Signal Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Remove all jumper wires. 3. Measure the voltage between the (B3) Left Rear WSS Signal circuit and ground. Is the voltage above 1 volt? Yes z z

Repair the (B3) Left Rear WSS Signal circuit for a short to voltage. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. CHECK (B3) LEFT REAR WSS SIGNAL CIRCUIT AND (B4) LEFT REAR WSS 12 VOLT SUPPLY CIRCUIT SHORTED TOGETHER z

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Fig. 24: Checking Left Rear Wheel Speed Sensor Signal Circuit & Left Rear Wheel Speed Sensor 12 Volt Supply Circuit Shorted Together Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between the (B3) Left Rear WSS Signal circuit and the (B4) Left Rear WSS Supply circuit. Is the resistance above 5.0 Ohms? Yes user Monday, June 04, 2012 10:12:22 AM

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z

Go to step 10

No Repair the (B3) Left Rear WSS Signal circuit and the (B4) Left Rear WSS Supply circuit for a short together. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. LEFT REAR WHEEL SPEED SENSOR 1. Replace the Left Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Make sure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. Did DTC C1020-LEFT REAR WHEEL SPEED SENSOR CIRCUIT reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1027-LEFT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition:

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When the Left Rear Wheel Speed Sensor (WSS) Signal is intermittently missing while vehicle speed is above 40 km/h (25 mph) or erratic wheel speed signal during acceleration or sensed wheel speed is different from other wheels. Possible Causes LEFT REAR WSS LOOSE - B3, B4 CIRCUITS/CONNECTOR/TERMINAL DAMAGE LEFT REAR TONE WHEEL DAMAGE LEFT REAR WHEEL BEARING DAMAGE AXLE SHAFT FASTENER HARDWARE IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES LEFT REAR WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1027-LEFT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read DTCs. Does the scan tool display: C1027-LEFT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS z

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1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Refer to the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Rear Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Left Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes user Monday, June 04, 2012 10:12:22 AM

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z

Repair as necessary.

No Go to step 5 5. CHECK LEFT REAR WSS LOOSENESS, INSPECT B3, B4 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Left Rear WSS, and Left Rear WSS harness connector 2. Inspect the Left Rear WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B3) Left Rear WSS Signal and (B4) Left Rear WSS Supply circuits between the Left Rear WSS and Anti-Lock Brake Module for damage. Is the Left Rear WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 6 6. CHECK LEFT REAR WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Left Rear Wheel Speed Sensor 2. Inspect the Left Rear Wheel Speed Sensor face for damage. z

Is the Left Rear Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK LEFT REAR TONE WHEEL FOR DAMAGE 1. Inspect the Left Rear Tone Wheel for damage, missing teeth, cracks, corrosion or looseness. z

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NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Left Rear Tone Wheel damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. CHECK LEFT REAR WHEEL BEARING FOR DAMAGE 1. Inspect the Left Rear wheel bearing for excessive runout or clearance. z

NOTE:

Refer to the appropriate service information, if necessary, for procedures or specifications. Refer to Front Suspension/Front/HUB AND BEARING - Diagnosis and Testing

Is the Left Rear Wheel Bearing Damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. LEFT REAR WHEEL SPEED SENSOR 1. Replace the Left Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C1027-LEFT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE reset? user Monday, June 04, 2012 10:12:22 AM

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Yes

z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

C102A-LEFT REAR WHEEL SPEED COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Left Rear Wheel Speed Sensor (WSS) reading is different from the readings received from the other sensors at a vehicle speed above 40 km/h (25 mph). The Anti-Lock Brake Module compares WSS readings from side-to-side on an axle and front-to-rear.

Possible Causes LEFT REAR WSS LOOSE - B3, B4 CIRCUITS/CONNECTOR/TERMINAL DAMAGE IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES LEFT REAR TONE WHEEL DAMAGE AXLE SHAFT FASTENER HARDWARE LEFT REAR WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C102A-LEFT REAR WHEEL SPEED COMPARATIVE PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

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3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read DTCs. Does the scan tool display: C102A-LEFT REAR WHEEL SPEED COMPARATIVE PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Rear Tire pressure. z

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3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. Is the Left Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes z

Repair as necessary.

No Go to step 5 5. CHECK LEFT REAR WSS LOOSENESS, INSPECT B3, B4 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Left Rear WSS, and Left Rear WSS harness connector. 2. Inspect the Left Rear WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B3) Left Rear WSS Signal and (B4) Left Rear WSS Supply circuits between the Left Rear WSS and Anti-Lock Brake Module for damage. Is the Left Rear WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock

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Brake (ABS) - Standard Procedure. No Go to step 6 6. CHECK LEFT REAR WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Left Rear Wheel Speed Sensor 2. Inspect the Left Rear Wheel Speed Sensor face for damage. z

Is the Left Rear Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK LEFT REAR TONE WHEEL FOR DAMAGE 1. Inspect the Left Rear Tone Wheel for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Left Rear Tone Wheel damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. LEFT REAR WHEEL SPEED SENSOR 1. Replace the Left Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to

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be met. 4. With the scan tool, read ABS DTCs. Did DTC C102A-LEFT REAR WHEEL SPEED COMPARATIVE PERFORMANCE reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C102B-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT

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Fig. 25: Left Front Wheel Speed Sensor Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: If the Right Rear Wheel Speed Sensor circuit fails the diagnostic test.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORTED TO (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT RIGHT REAR WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR DTC C102B-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: C102B-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

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1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector, Right Rear WSS, and Right Rear WSS harness connector. Is the Right Rear WSS or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT VOLTAGE z

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Fig. 26: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit Voltage Courtesy of CHRYSLER LLC 1. Disconnect the Right Rear WSS harness connector. 2. Turn the ignition on. 3. Measure the voltage of the (B2) Right Rear WSS 12 Volt Supply circuit. Is the voltage above 10.0 volts? Yes z

Go to step 6

z

Go to step 4

No

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4. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO GROUND

Fig. 27: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Right Rear WSS harness connector. Disconnect the Anti-Lock Brake Module harness connector. Using a 12-volt test light connected to 12 volts, probe the (B2) Right Rear WSS Supply circuit. Does the test light illuminate brightly?

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Yes z z

Repair the (B2) Right Rear WSS Supply circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR AN OPEN z

Fig. 28: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground user Monday, June 04, 2012 10:12:23 AM

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Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B2) Right Rear WSS Supply circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B2) Right Rear WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Repair the (B2) Right Rear WSS Supply circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR A SHORT TO GROUND z

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Fig. 29: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. If not done previously, disconnect the Anti-Lock Brake Module harness connector. 3. Using a 12-volt test light connected to 12 volts, probe the (B1) Right Rear WSS Signal circuit. Does the test light illuminate brightly? Yes user Monday, June 04, 2012 10:12:23 AM

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z z

Repair the (B1) Right Rear WSS Signal circuit for a short to ground. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR AN OPEN z

Fig. 30: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:23 AM

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1. Connect a jumper wire between ground and the (B1) Right Rear WSS Signal circuit in the AntiLock Brakes Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B1) Right Rear WSS Signal circuit. Does the test light illuminate brightly? Yes z

Go to step 8

No Repair the (B1) Right Rear WSS Signal circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 8. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORT TO VOLTAGE z

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Fig. 31: Checking Right Rear Wheel Speed Sensor Signal Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Remove all jumper wires. 3. Measure the voltage between the (B1) Right Rear WSS Signal circuit and ground. Is the voltage above 1 volt? Yes z

Repair the (B1) Right Rear WSS Signal circuit for a short to voltage.

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z

Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR A SHORT TO (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT z

Fig. 32: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Right Rear Wheel Speed Sensor 12 Volt Supply Circuit Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:23 AM

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1. Turn the ignition off. 2. Measure the resistance between the (B1) Right Rear WSS Signal circuit and the (B2) Right Rear WSS Supply circuit. Is the resistance above 5.0 Ohms? Yes z

Go to step 10

No Repair the (B1) Right Rear WSS Signal circuit and the (B2) Right Rear WSS Supply circuit for a short together. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. RIGHT REAR WHEEL SPEED SENSOR 1. Replace the Right Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure z

CAUTION: Make sure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. Did DTC C102B-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C102C-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT PERFORMANCE user Monday, June 04, 2012 10:12:23 AM

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Fig. 33: Right Rear Wheel Speed Sensor 12 Volt Supply Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

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z

Set Condition: If the Right Rear Wheel Speed Sensor circuit fails the diagnostic test.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORTED TO (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT RIGHT REAR WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C102C-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT PERFORMANCE NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: C102C-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT PERFORMANCE? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

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1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector, Right Rear WSS, and Right Rear WSS harness connector. Is the Right Rear WSS or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT VOLTAGE z

Fig. 34: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit Voltage user Monday, June 04, 2012 10:12:23 AM

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Courtesy of CHRYSLER LLC 1. Disconnect the Right Rear WSS harness connector. 2. Turn the ignition on. 3. Measure the voltage of the (B2) Right Rear WSS 12 Volt Supply circuit. Is the voltage above 10.0 volts? Yes z

Go to step 6

No Go to step 4 4. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO GROUND z

Fig. 35: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground user Monday, June 04, 2012 10:12:23 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Right Rear WSS harness connector. Disconnect the Anti-Lock Brake Module harness connector. Using a 12-volt test light connected to 12 volts, probe the (B2) Right Rear WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Repair the (B2) Right Rear WSS Supply circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT FOR AN OPEN z

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Fig. 36: Checking Right Rear Wheel Speed Sensor 12 Volt Supply Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B2) Right Rear WSS Supply circuit in the AntiLock Brake Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B2) Right Rear WSS Supply circuit. Does the test light illuminate brightly? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Repair the (B2) Right Rear WSS Supply circuit for an open.

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Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR A SHORT TO GROUND z

Fig. 37: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Using a 12-volt test light connected to 12 volts, probe the (B1) Right Rear WSS Signal circuit. Does the test light illuminate brightly? Yes z z

Repair the (B1) Right Rear WSS Signal circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock

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Brake (ABS) - Standard Procedure. No Go to step 7 7. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR AN OPEN z

Fig. 38: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Connect a jumper wire between ground and the (B1) Right Rear WSS Signal circuit in the AntiLock Brake Module harness connector. 2. Using a 12-volt test light connected to 12 volts, probe the (B1) Right Rear WSS Signal circuit. Does the test light illuminate brightly? user Monday, June 04, 2012 10:12:23 AM

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Yes z

Go to step 8

No Repair the (B1) Right Rear WSS Signal circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 8. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT SHORT TO VOLTAGE z

Fig. 39: Checking Right Rear Wheel Speed Sensor Signal Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. user Monday, June 04, 2012 10:12:23 AM

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2. Remove all jumper wires. 3. Measure the voltage between the (B1) Right Rear WSS Signal circuit and ground. Is the voltage above one volt? Yes z z

Repair the (B1) Right Rear WSS Signal circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. CHECK (B1) RIGHT REAR WSS SIGNAL CIRCUIT FOR A SHORT TO (B2) RIGHT REAR WSS 12 VOLT SUPPLY CIRCUIT z

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Fig. 40: Checking Right Rear Wheel Speed Sensor Signal Circuit For A Short To Right Rear Wheel Speed Sensor 12 Volt Supply Circuit Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between the (B1) Right Rear WSS Signal circuit and the (B2) Right Rear WSS Supply circuit. Is the resistance above 5.0 ohms? Yes z

Go to step 10

No user Monday, June 04, 2012 10:12:23 AM

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Repair the (B1) Right Rear WSS Signal circuit and the (B2) Right Rear WSS Supply circuit for a short together. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. RIGHT REAR WHEEL SPEED SENSOR 1. Replace the Right Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 25 mph (40 km/h). NOTE:

Vehicle must be driven above 25 mph (40 km/h) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. Did DTC C102C-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT PERFORMANCE reset? Yes

z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test complete.

z

No

C1032-RIGHT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Right Rear Wheel Speed Sensor (WSS) Signal is intermittently missing while vehicle speed is above 40 km/h (25 mph) or erratic wheel speed signal during acceleration or sensed wheel speed is different from other wheels.

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Possible Causes RIGHT REAR WSS LOOSE - B1, B2 CIRCUITS/CONNECTOR/TERMINAL DAMAGE RIGHT REAR TONE WHEEL DAMAGE RIGHT REAR WHEEL BEARING DAMAGE AXLE SHAFT FASTENER HARDWARE IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES RIGHT REAR WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1032-RIGHT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read DTCs. Does the scan tool display: C1032-RIGHT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

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NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Right Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Rear Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Right Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes z

Repair as necessary.

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Go to step 5 5. CHECK RIGHT REAR WSS LOOSENESS, INSPECT B1, B2 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

1. Inspect the Anti-Lock Brake Module harness connector, Right Rear WSS, and Right Rear WSS harness connector. 2. Inspect the Right Rear WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B1) Right Rear WSS Signal and (B2) Right Rear WSS Supply circuits between the Right Rear WSS and Anti-Lock Brake Module for damage. Is the Right Rear WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 6 6. CHECK RIGHT REAR WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Right Rear Wheel Speed Sensor. 2. Inspect the Right Rear Wheel Speed Sensor face for damage. z

Is the Right Rear Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK RIGHT REAR TONE WHEEL FOR DAMAGE 1. Inspect the Right Rear Tone Wheel for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

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Is the Right Rear Tone Wheel damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. CHECK RIGHT REAR WHEEL BEARING FOR DAMAGE 1. Inspect the Right Rear wheel bearing for excessive runout or clearance. z

NOTE:

Refer to the appropriate service information, if necessary, for procedures or specifications. Refer to Front Suspension/Front/HUB AND BEARING - Diagnosis and Testing

Is the Right Rear Wheel Bearing Damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. RIGHT REAR WHEEL SPEED SENSOR 1. Replace the Right Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. Did DTC C1032-RIGHT REAR WHEEL SPEED SENSOR SIGNAL ERRATIC PERFORMANCE reset? Yes user Monday, June 04, 2012 10:12:23 AM

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z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1035-RIGHT REAR WHEEL SPEED COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Right Rear Wheel Speed Sensor (WSS) reading is different from the readings received from the other sensors at a vehicle speed above 40 km/h (25 mph). The Anti-Lock Brake Module compares WSS readings from side-to-side on an axle and front-to-rear.

Possible Causes RIGHT REAR WSS LOOSE - B1, B2 CIRCUITS/CONNECTOR/TERMINAL DAMAGE IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES RIGHT REAR TONE WHEEL/BEARING DAMAGE AXLE SHAFT FASTENER HARDWARE RIGHT REAR WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1035-RIGHT REAR WHEEL SPEED COMPARATIVE PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, record and erase DTCs. CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). user Monday, June 04, 2012 10:12:23 AM

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NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read DTCs. Does the scan tool display: C1035-RIGHT REAR WHEEL SPEED COMPARATIVE PERFORMANCE active? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Right Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Rear Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

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Is the Right Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes z

Repair as necessary.

No Go to step 5 5. CHECK RIGHT REAR WSS LOOSENESS, INSPECT B1, B2 CIRCUITS/TERMINALS FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals

1. Inspect the Anti-Lock Brake Module harness connector, Right Rear WSS, and Right Rear WSS harness connector 2. Inspect the Right Rear WSS for looseness, excessive corrosion and not properly fastened. 3. Inspect the (B1) Right Rear WSS Signal and (B2) Right Rear WSS Supply circuits between the Right Rear WSS and Anti-Lock Brake Module for damage. Is the Right Rear WSS loose or any of the wiring/connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 6 6. CHECK RIGHT REAR WHEEL SPEED SENSOR FOR DAMAGE 1. Remove the Right Rear Wheel Speed Sensor. 2. Inspect the Right Rear Wheel Speed Sensor face for damage. z

Is the Right Rear Wheel Speed Sensor damaged? Yes z z

Replace sensor and hub assembly. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK RIGHT REAR TONE WHEEL/BEARING FOR DAMAGE 1. Inspect the Right Rear Tone Wheel/Bearing for damage, missing teeth, cracks, corrosion or looseness. z

NOTE:

The Tone Wheel teeth should be perfectly square, not bent, or nicked.

Is the Right Rear Tone Wheel/Bearing damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. RIGHT REAR WHEEL SPEED SENSOR 1. Replace the Right Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Road test the vehicle over 40 km/h (25 mph). z

NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be met.

4. With the scan tool, read ABS DTCs. user Monday, June 04, 2012 10:12:23 AM

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Did DTC C1035-RIGHT REAR WHEEL SPEED COMPARATIVE PERFORMANCE reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1041-LEFT FRONT TONE WHEEL PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects periodic drops of a WSS signal.

Possible Causes LEFT FRONT TONE WHEEL/ BEARING DAMAGE IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES DIRTY TONE WHEEL/SENSOR Diagnostic Test

1. CHECK FOR A DTC C1041-LEFT FRONT TONE WHEEL PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid. If DTC C100A Left Front Wheel Speed Sensor Circuit is present it must be repaired before continuing.

1. Turn the ignition on. 2. With the scan tool, read DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch off then on. user Monday, June 04, 2012 10:12:23 AM

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CAUTION: Ensure brake capability is available before road testing. 6. Test drive the vehicle in a straight line to 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

7. With the scan tool, read DTCs. Does the scan tool display: C1041-LEFT FRONT TONE WHEEL PERFORMANCE? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Front WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Front Tire pressure. 3. Check and adjust all other tire pressures. z

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4. Inspect for mismatched tires on vehicle. Is the Left Front Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK THE LEFT FRONT TONE WHEEL/BEARING FOR DAMAGE z

NOTE:

Check the tone wheel teeth for missing teeth, cracks, or looseness. Teeth should be perfectly square, not bent, or nicked.

1. Check the Left Front Tone Wheel/Bearing for damage. 2. Check the Left Front Tone Wheel for dirt. Was the tone wheel dirty? Yes z z

Clean tone wheel and sensor. Clear codes and retest. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the Left Front Tone Wheel/Bearing in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1042-RIGHT FRONT TONE WHEEL PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition:

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When the Anti-Lock Brake Module detects periodic drops of a WSS signal. Possible Causes RIGHT FRONT TONE WHEEL/BEARING DAMAGE IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES DIRTY TONE WHEEL/SENSOR Diagnostic Test

1. CHECK FOR A DTC C1042-RIGHT FRONT TONE WHEEL PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid. If DTC C1015 Right Front Wheel Speed Sensor Circuit is present it must be repaired before continuing.

1. Turn the ignition on. 2. With the scan tool, read DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch off then on. CAUTION: Ensure brake capability is available before road testing.

6. Test drive the vehicle in a straight line to 25 mph (40 km/h). NOTE:

Vehicle must be driven above 25 mph (40 km/h) for set conditions to be meet.

7. With the scan tool, read DTCs. Does the scan tool display: C1042-RIGHT FRONT TONE WHEEL PERFORMANCE? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. z

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2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 25 mph (40 km/h). Is the Right Front WSS speed showing 0 mph (0 km/h) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER RIGHT FRONT TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Front Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Right Front Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK THE RIGHT FRONT TONE WHEEL/BEARING FOR DAMAGE z

NOTE:

Check the tone wheel teeth for missing teeth, cracks, or looseness. Teeth should be perfectly square, not bent, or nicked.

1. Check the Right Front Tone Wheel/Bearing for damage. 2. Check the Right Front Tone Wheel for dirt. user Monday, June 04, 2012 10:12:23 AM

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Was the tone wheel dirty? Yes z z

Clean tone wheel and sensor. Clear codes and retest. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the Right Front Tone Wheel/Bearing in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1043-LEFT REAR TONE WHEEL PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects periodic drops of a WSS signal.

Possible Causes LEFT REAR TONE WHEEL/BEARING DAMAGE IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES AXLE SHAFT FASTENER HARDWARE DIRTY TONE WHEEL/SENSOR Diagnostic Test

1. CHECK FOR A DTC C1043-LEFT REAR TONE WHEEL PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch off then on. user Monday, June 04, 2012 10:12:23 AM

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CAUTION: Ensure brake capability is available before road testing.

6. Test drive the vehicle in a straight line to 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

7. With the scan tool, read DTCs. Does the scan tool display: C1043-LEFT REAR TONE WHEEL PERFORMANCE? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Left Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHECK FOR IMPROPER LEFT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Left Rear Tire pressure. z

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3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. Is the Left Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes z

Repair as necessary.

No Go to step 5 5. CHECK THE LEFT REAR TONE WHEEL FOR DAMAGE z

NOTE:

Check the tone wheel teeth for missing teeth, cracks, or looseness. Teeth should be perfectly square, not bent, or nicked.

1. Check the Left Rear Tone Wheel for damage. 2. Check the Left Rear Tone Wheel for dirt. Was the tone wheel dirty? Yes z z

Clean tone wheel and sensor. Clear codes and retest. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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z z

Replace the Left Rear Tone Wheel in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1044-RIGHT REAR TONE WHEEL PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects periodic drops of a WSS signal.

Possible Causes RIGHT REAR TONE WHEEL/BEARING DAMAGE IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES AXLE SHAFT FASTENER HARDWARE DIRTY TONE WHEEL/SENSOR Diagnostic Test

1. CHECK FOR A DTC C1044-RIGHT REAR TONE WHEEL PERFORMANCE NOTE: 1. 2. 3. 4. 5.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, read DTCs. Record DTC and Freeze Frame information. With the scan tool, erase DTCs. Cycle the ignition switch off then on. CAUTION: Ensure brake capability is available before road testing.

6. Test drive the vehicle in a straight line to 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

7. With the scan tool, read DTCs. user Monday, June 04, 2012 10:12:23 AM

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Does the scan tool display: C1044-RIGHT REAR TONE WHEEL PERFORMANCE? Yes z

Go to step 3

No Go to step 2 2. CHECK WHEEL SPEED SENSOR SIGNALS 1. Turn the ignition on. 2. With the scan tool, monitor and graph ALL the WSS speeds and compare graph while an assistant drives the vehicle. z

NOTE:

If graph shows periodic dropouts pay close attention to the tone wheel.

3. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Is the Right Rear WSS speed showing 0 km/h (0 mph) or not matching other wheels or showing erratic behavior? Yes z

Go to step 3

No Refer to the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure 3. CHECK FOR IMPROPER RIGHT REAR TIRE PRESSURE/MISMATCHED TIRES 1. Turn the ignition off. 2. Check and adjust the Right Rear Tire pressure. 3. Check and adjust all other tire pressures. 4. Inspect for mismatched tires on vehicle. z

Is the Right Rear Tire improperly inflated or mismatched tires on vehicle? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

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No Go to step 4 4. CHECK AXLE SHAFT FASTENER HARDWARE FOR LOOSENESS 1. Inspect the axle shaft fastener for looseness, and not properly fastened. Tighten fastener to proper specification as required. z

Was the Axle Shaft fastener loose? Yes z

Repair as necessary.

No Go to step 5 5. CHECK THE RIGHT REAR TONE WHEEL FOR DAMAGE z

NOTE:

Check the tone wheel teeth for missing teeth, cracks, or looseness. Teeth should be perfectly square, not bent, or nicked.

1. Check the Right Rear Tone Wheel for damage. 2. Check the Right Rear Tone Wheel for dirt. Was the tone wheel dirty? Yes z z

Clean tone wheel and sensor. Clear codes and retest. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

No z z

Replace the Right Rear Tone Wheel in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

C1046-LEFT FRONT WHEEL PRESSURE PHASE MONITORING

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Fig. 41: Rear Wheel Speed Sensor Signal/Supply Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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During active ABS control. z

Set Condition: If the Anti-Lock Brake Module detects a pressure reduction phase and the following pressure hold phase is too long.

Possible Causes LEFT FRONT TONE WHEEL/BEARING DAMAGED WHEEL SPEED SIGNALS SWAPPED LEFT FRONT WSS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. COMPARE WHEEL SPEED SENSOR SIGNALS WARNING: Ensure brake capability is available before road testing.

1. With the scan tool, monitor ALL the WSS speeds while an assistant drives the vehicle. 2. Slowly accelerate as straight as possible from a stop to 25 mph (40 km/h). Does the Left Front WSS speed differ from the other WSS speeds by 5 mph (8 km/h) or show NO speed? Yes z

Go to step 3

No Go to step 2 2. CHECKING INSIDE WHEEL SPEED 1. Slowly accelerate as straight as possible from a stop to 25 mph (40 km/h) and perform a 90 degree turn while monitoring if inside wheel is slower than outside. z

Was the inside wheel slower than outside? Yes z

Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 3 3. INSPECT TONE WHEEL/BEARING 1. Turn the ignition off. 2. Visually inspect the tone wheel and bearing for damage. 3. Check the tone wheel teeth for missing teeth, cracks, and looseness. The teeth must be perfectly square, not bent, or nicked. Check the wheel bearing for worn/looseness. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK WHEEL SPEED SENSOR WIRING 1. Check the Anti-Lock Brake Module and Wheel Speed Sensors harness connectors for incorrectly wired connectors. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. LEFT FRONT WHEEL SPEED SENSOR 1. Replace the Left Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 25 mph (40 km/h). user Monday, June 04, 2012 10:12:23 AM

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NOTE:

Vehicle must be driven above 25 mph (40 km/h) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. NOTE:

The Anti-Lock Brake Module must sense ALL 4 wheels at 7.5 mph (12 km/h) before it will extinguish the ABS indicators.

Did DTC C1046 LEFT FRONT WHEEL PRESSURE PHASE MONITORING reset? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test complete.

C1047-RIGHT FRONT WHEEL PRESSURE PHASE MONITORING

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Fig. 42: Rear Wheel Speed Sensor Signal/Supply Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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During active ABS control. z

Set Condition: If the Anti-Lock Brakes Module detects a pressure reduction phase and the following pressure hold phase is too long.

Possible Causes RIGHT FRONT TONE WHEEL DAMAGED WHEEL SPEED SIGNALS SWAPPED RIGHT FRONT WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. COMPARE WHEEL SPEED SENSOR SIGNALS WARNING: Ensure brake capability is available before road testing.

1. With the scan tool, monitor ALL the WSS speeds while an assistant drives the vehicle. 2. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Does the Right Front WSS speed differ from the other WSS speeds by 8 km/h (5 mph) or show NO speed? Yes z

Go to step 3

No Go to step 2 2. CHECKING INSIDE WHEEL SPEED 1. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph) and perform a 90 degree turn while monitoring if inside wheel is slower than outside. z

Was the inside wheel slower than outside? Yes z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

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Go to step 3 3. INSPECT TONE WHEEL/BEARING 1. Turn the ignition off. 2. Visually inspect the tone wheel and bearing for damage. z Check the tone wheel teeth for missing teeth, cracks, and looseness. The teeth must be perfectly square, not bent, or nicked. Check the wheel bearing for worn/looseness. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK WHEEL SPEED SENSOR WIRING 1. Check the Anti-Lock Brakes Module and Wheel Speed Sensors harness connectors for incorrectly wired connectors. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. RIGHT FRONT WHEEL SPEED SENSOR 1. Replace the Right Front Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). user Monday, June 04, 2012 10:12:23 AM

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NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. NOTE:

The Anti-Lock Brake Module must sense ALL 4 wheels at 12 km/h (7.5 mph) before it will extinguish the ABS indicators.

Did DTC C1047 RIGHT FRONT WHEEL PRESSURE PHASE MONITORING reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1048-LEFT REAR WHEEL PRESSURE PHASE MONITORING

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Fig. 43: Rear Wheel Speed Sensor Signal/Supply Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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During active ABS control. z

Set Condition: If the Anti-Lock Brakes Module detects a pressure reduction phase and the following pressure hold phase is too long.

Possible Causes LEFT REAR TONE WHEEL/WHEEL BEARING WHEEL SPEED SIGNALS SWAPPED LEFT REAR WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. COMPARE WHEEL SPEED SENSOR SIGNALS WARNING: Ensure brake capability is available before road testing.

1. With the scan tool, monitor ALL the WSS speeds while an assistant drives the vehicle. 2. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Does the Left Rear WSS speed differ from the other WSS speeds by 8 km/h (5 mph) or show NO speed? Yes z

Go to step 3

No Go to step 2 2. CHECKING INSIDE WHEEL SPEED 1. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph) and perform a 90 degree turn while monitoring if inside wheel is slower than outside. z

Was the inside wheel slower than outside? Yes z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 3 3. INSPECT TONE WHEEL/BEARING 1. Turn the ignition off. 2. Visually inspect the tone wheel and bearing for damage. z Check the tone wheel teeth for missing teeth, cracks, and looseness. The teeth must be perfectly square, not bent, or nicked. Check the wheel bearing for worn/looseness. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK WHEEL SPEED SENSOR WIRING 1. Check the Anti-Lock Brakes Module and Wheel Speed Sensors harness connectors for incorrectly wired connectors. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. LEFT REAR WHEEL SPEED SENSOR 1. Replace the Left Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). user Monday, June 04, 2012 10:12:23 AM

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NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. NOTE:

The Anti-Lock Brake Module must sense ALL 4 wheels at 12 km/h (7.5 mph) before it will extinguish the ABS indicators.

Did DTC C1048 LEFT REAR WHEEL PRESSURE PHASE MONITORING reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1049-RIGHT REAR WHEEL PRESSURE PHASE MONITORING

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Fig. 44: Rear Wheel Speed Sensor Signal/Supply Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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During active ABS control. z

Set Condition: When the Anti-Lock Brakes Module detects a pressure reduction phase and the following pressure hold phase is too long.

Possible Causes RIGHT REAR TONE WHEEL DAMAGED WHEEL SPEED SIGNALS SWAPPED RIGHT REAR WSS ANTI-LOCK BRAKES MODULE Diagnostic Test

1. COMPARE WHEEL SPEED SENSOR SIGNALS WARNING: Ensure brake capability is available before road testing.

1. With the scan tool, monitor ALL the WSS speeds while an assistant drives the vehicle. 2. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph). Does the Right Rear WSS speed from the other WSS speeds by 8 km/h (5 mph) or show NO speed? Yes z

Go to step 3

No Go to step 2 2. CHECKING INSIDE WHEEL SPEED 1. Slowly accelerate as straight as possible from a stop to 40 km/h (25 mph) and perform a 90 degree turn while monitoring if inside wheel is slower than outside. z

Was the inside wheel slower than outside? Yes z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 3 3. INSPECT TONE WHEEL/BEARING 1. Turn the ignition off. 2. Visually inspect the tone wheel and bearing for damage. z Check the tone wheel teeth for missing teeth, cracks, and looseness. The teeth must be perfectly square, not bent, or nicked. Check the wheel bearing for worn/looseness. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK WHEEL SPEED SENSOR WIRING 1. Check the Anti-Lock Brakes Module and Wheel Speed Sensors harness connectors for incorrectly wired connectors. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. RIGHT REAR WHEEL SPEED SENSOR 1. Replace the Right Rear Wheel Speed Sensor in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

CAUTION: Ensure brake capability is available before road testing.

3. Road test the vehicle over 40 km/h (25 mph). user Monday, June 04, 2012 10:12:24 AM

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NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

4. With the scan tool, read ABS DTCs. NOTE:

The Anti-Lock Brake Module must sense ALL 4 wheels at 12 km/h (7.5 mph) before it will extinguish the ABS indicators.

Did DTC C1049 RIGHT REAR WHEEL PRESSURE PHASE MONITORING reset? Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test Complete.

C1073-ABS PUMP MOTOR CONTROL CIRCUIT

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Fig. 45: Fused B+ Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:24 AM

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z

When Monitored: With the ignition on.

z

Set Condition: The ABM detects low pump motor feedback voltage with actuation of the pump motor relay. Possible Causes

BLOWN PUMP FUSE HIGH RESISTANCE IN B+ CIRCUITS HIGH RESISTANCE IN GROUND CIRCUITS INTEGRATED CONTROL UNIT Diagnostic Test

1. CHECK FOR A DTC C1073-ABS PUMP MOTOR CONTROL CIRCUIT NOTE:

1. 2. 3. 4.

This DTC must be active for the results of this test to be valid. If present, diagnose and repair DTC C2116-ABS PUMP MOTOR SUPPLY LOW VOLTAGE before diagnosing this DTC.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. Road test the vehicle over 40 km/h (25 mph). NOTE:

Vehicle must be driven above 40 km/h (25 mph) for set conditions to be meet.

5. With the scan tool, read DTCs. NOTE:

The Anti-Lock Brake Module must sense ALL 4 wheels at 12 km/h (7.5 mph) before it will extinguish the ABS indicators.

Does the scan tool display: C1073-ABS PUMP MOTOR CONTROL CIRCUIT? Yes z

Go to step 2

z

Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based

No

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Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE ABS PUMP MOTOR FUSED B+ FOR AN OPEN 1. Turn the ignition off. 2. Remove and visually inspect the ABS Pump Motor B+ fuse. Is the ABS Pump Motor B+ fuse open? Yes z

Go to step 3

No Go to step 5 3. CHECK THE (A107) FUSED B(+) FOR A SHORT TO GROUND z

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Fig. 46: Checking Fused B(+) For A Short To Ground Courtesy of CHRYSLER LLC 1. Disconnect the Anti-Lock Brake Module harness connector. 2. Using a 12-volt test light connected to 12-volts, probe the (A107) Fused B+ circuit. Does the test light illuminate brightly? Yes z z

Repair the (A107) Fused B(+) circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 4 4. CHECK THE (A107) FUSED B(+) CIRCUIT 1. Visually inspect the (A107) Fused B(+) circuit in the wiring harness. 2. Look for any signs of intermittent short to ground. z

Is the wiring harness OK? Yes z

Go to step 5

No Repair the (A107) Fused B(+) circuit for a short to ground. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. CHECK THE VOLTAGE ON THE (A107) FUSED B(+) CIRCUIT z

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Fig. 47: Checking Voltage On Fused B(+) Circuit Courtesy of CHRYSLER LLC 1. Disconnect the Anti-Lock Brake Module harness connector. 2. Measure the voltage of the (A107) Fused B(+) circuit in the Anti-Lock Brake Module harness connector. Is the voltage above 10 volts? Yes user Monday, June 04, 2012 10:12:24 AM

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z

Go to step 6

No Repair the (A107) Fused B(+) circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK THE (Z924) GROUND CIRCUIT FOR AN OPEN z

Fig. 48: Checking Ground Circuit For An Open Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:24 AM

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1. Measure the resistance of the (Z924) Ground circuit between the Anti-Lock Brake Module harness connector and ground Is the resistance below 5.0 ohms? Yes z z

Replace the ICU per service information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the high resistance in the affected circuit. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1078-TIRE REVOLUTIONS RANGE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuous.

z

Set Condition: Programmed value for tire size is not within acceptable range.

Possible Causes INCORRECT VALUE PROGRAMMED INTO TOTALLY INTEGRATED POWER MODULE Diagnostic Test

1. INCORRECT VALUE PROGRAMMED INTO TIPM TIRE SIZE P225/70R 16 ALL SEASON 225/65R 17 BSW TOURING 225/65R 16 BSW THREE SEASON

BODY STYLE

ENGINE SIZE

SALES CODE

TIRE CIRCUMFERENCE (MM PER REV)

JC

ALL

TRD

2206

JC

ALL

TRF

2220

JC

ALL

TUJ

2130

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P225/65R 17 BSW A/S JC TOURING 225/55R 19 BSW JC THREE SEASON P225//55R 19 BSW AS JC TOURING

ALL

TVK

2230

ALL

TWC

2250

ALL

TWV

2270

1. Verify the correct tire/wheel information is programmed in the TIPM. Is the correct value programmed in the TIPM according to the chart? Yes z z

Test complete. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

No z z

Program the correct Tire/Wheel information in the TIPM. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

C107C-BRAKE PEDAL SWITCH 1/2 STUCK For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . Diagnostic Test

1. POWERTRAIN CONTROL MODULE (PCM) or ENGINE CONTROL MODULE (ECM) DTCS PRESENT 1. With the scan tool, read ECM/PCM Brake DTCs. Are there any ECM/PCM Brake DTCs present? Yes z

Perform the appropriate diagnostic procedure. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing for gas engine applications or DTCBased Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing for diesel engine applications.

No z

Using the schematics as a guide, check the ECM/PCM terminals for corrosion, damage, or terminal push out. Pay particular attention to all power and ground circuits.

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z

Perform the appropriate VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure for gas engine applications or DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure for diesel engine applications.

C107D-BRAKE PEDAL SWITCH 1/2 CORRELATION For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . Diagnostic Test

1. POWERTRAIN CONTROL MODULE (PCM) or ENGINE CONTROL MODULE (ECM) DTCS PRESENT 1. With the scan tool, read ECM/PCM Brake DTCs. Are there any ECM/PCM Brake DTCs present? Yes z

Perform the appropriate diagnostic procedure. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing for gas engine applications or DTCBased Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing for diesel engine applications.

No z

z

Using the schematics as a guide, check the ECM/PCM terminals for corrosion, damage, or terminal push out. Pay particular attention to all power and ground circuits. Perform the appropriate VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure for gas engine applications or DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure for diesel engine applications.

C1090-ABS BRAKE LAMP CONTROL CIRCUIT LOW

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Fig. 49: Stop Lamp Relay Override Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:24 AM

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z

When Monitored: With the ignition on.

z

Set Condition: When monitoring the Stop Lamp Relay Override Signal circuit the module detects a short to ground.

Possible Causes (B221) STOP LAMP RELAY OVERRIDE SIGNAL OPEN OR SHORTED TO GROUND BLOWEN FUSE BRAKE LAMP RELAY ANTI-LOCK BRAKE MODULE (ABM) Diagnostic Test

1. CHECK FOR DTC C1090-ABS BRAKE LAMP CONTROL CIRCUIT LOW NOTE: 1. 2. 3. 4. 5.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Start the engine. Apply pressure to the brake pedal firmly with at least 80 bar (1160 psi.). With the scan tool, read the DTCs. Does the scan tool display: C1090-ABS BRAKE LAMP CONTROL CIRCUIT LOW? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out or corroded terminals.

1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector and the Brake Lamp Relay harness connector. user Monday, June 04, 2012 10:12:24 AM

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Is the Anti-Lock Brake Module or any of the connectors/terminals damaged? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B221) STOP LAMP RELAY OVERRIDE SIGNAL SHORTED TO GROUND z

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Fig. 50: Checking Stop Lamp Relay Override Signal Shorted To Ground Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Anti-Lock Brake Module Turn the key on. Using a 12-volt test light connected to ground, probe the (B221) Stop Lamp Relay Override Signal circuit at the Anti-Lock Brake Module harness connector. Does the test light illuminate? Yes z z

Replace the Anti-Lock Brake Module in accordance with the service information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK (A108) FUSED B+ z

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Fig. 51: Checking Brake Lamp Relay Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Brake Lamp Relay. Turn the key on. Using a 12-volt test light connected to ground, probe the (A108) Fused B+ circuit at the Brake Lamp Relay harness connector. Does the test light illuminate brightly? Yes

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z

Go to step 5

No Check for open fuse, if OK repair open or short to ground in the (A108) Fused B+ circuit. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. BRAKE LAMP RELAY z

Fig. 52: Measuring Resistance Of Stop Lamp Relay Override Signal Circuit user Monday, June 04, 2012 10:12:24 AM

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Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance of the (B221) Stop Lamp Relay Override Signal Circuit between the Brake Lamp Relay and the Anti-Lock Brake Module. Is the resistance below 5 Ohms? Yes z z

Replace the Brake Lamp Relay in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair open in the (B221) Brake Lamp Inhibit Relay Control circuit. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1091-ABS BRAKE LAMP CONTROL CIRCUIT HIGH

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Fig. 53: Stop Lamp Relay Override Signal Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:24 AM

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z

When Monitored: With the ignition on.

z

When Set: When monitoring the Stop Lamp Relay Override Signal circuit the module detects a short to B+.

Possible Causes (B221) STOP LAMP RELAY OVERRIDE SIGNAL SHORTED TO VOLTAGE BRAKE LAMP RELAY ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC C1091-ABS BRAKE LAMP CONTROL CIRCUIT HIGH NOTE: 1. 2. 3. 4. 5.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Start the engine. Apply brake pedal firmly with at least 80 bar (1160 psi.). With the scan tool, read DTCs. Does the scan tool display: C1091-ABS BRAKE LAMP CONTROL CIRCUIT HIGH? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK CONNECTOR/TERMINAL FOR DAMAGE z

NOTE:

Check all terminals for broken, bent, pushed out, or corroded terminals.

1. Turn the ignition off. 2. Inspect the Anti-Lock Brake Module harness connector and the Brake Lamp Relay harness connector. Is the Anti-Lock Brake Module or any of the connectors/terminals damaged? user Monday, June 04, 2012 10:12:24 AM

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Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK (B221) STOP LAMP RELAY OVERRIDE SIGNAL SHORTED TO VOLTAGE z

Fig. 54: Checking Stop Lamp Relay Override Signal Shorted To Voltage user Monday, June 04, 2012 10:12:24 AM

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Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Turn the ignition off. Disconnect the Anti-Lock Brake Module. Disconnect the Brake Lamp Relay. Turn the ignition on. Using a 12-volt test light connected to ground, probe the (B221) Stop Lamp Relay Override Signal circuit at the Brake Lamp Relay harness connector. Does the test light illuminate brightly? Yes z z

Repair the short to voltage in the (B221) Stop Lamp Relay Override Signal circuit. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. BRAKE LAMP RELAY z

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Fig. 55: Measuring Resistance Across Relay Between Stop Lamp Relay Override Signal Circuit Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance across the relay between the (B221) Stop Lamp Relay Override Signal circuit and the (A103) Fused B+ circuit. Is the resistance 75 ± 5 Ohms? Yes z

Replace the Anti-Lock Brake Module in accordance with the service information.

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z

Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the Brake Lamp Relay in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1210-G SENSOR INPUT CIRCUIT PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously, with ignition on, until vehicle speed exceeds 20 km/h (12.4 mph) for the first time, but not if the sensor voltage is out of range. Or, during diagnostic mode. Or, if the monitoring was inhibited by a corresponding diagnostics command.

z

Set Condition: If the measured acceleration signal is higher than 0.8 g for longer than the specified detection time. Possible Causes

DYNAMICS SENSOR INSTALLATION DYNAMICS SENSOR Diagnostic Test

1. CHECK FOR A DTC C1210-G SENSOR INPUT CIRCUIT PERFORMANCE NOTE: 1. 2. 3. 4. 5. 6.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, read and record DTCs. With the scan tool, read and record information. With the scan tool, erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read and record DTCs. Does the scan tool display: C1210-G SENSOR INPUT CIRCUIT PERFORMANCE?

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Yes z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1219-STEERING ANGLE SENSOR ERRATIC PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuous monitoring.

z

Set Condition: If the Anti-Lock Brake Module detects that the calculated steering wheel angle and the actual steering angle disagree. Possible Causes

VEHICLE DAMAGE STEERING COLUMN / INTERMEDIATE SHAFT DAMAGE STEERING ANGLE SENSOR LOOSE CLOCKSPRING (SAS) Diagnostic Test

1. PERFORM TEST DRIVE AND VERIFY DTC IS STILL ACTIVE NOTE:

If present, diagnose and repair DTC C123F-STEERING ANGLE SENSOR COMPARATIVE PERFORMANCE before diagnosing this DTC.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. Perform ECU initialization with drive test. Perform the ABS VERIFICATION TEST. See DTCBased Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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WARNING: To avoid possible serious or fatal injury, check brake capability is available before road testing. 5. Test drive the vehicle by driving straight at a velocity between 10 and 25 km/hr (6 and 15 mph.) for 1 minute. 6. Park the vehicle. 7. Turn the steering wheel from stop to stop. 8. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK STEERING ANGLE SENSOR OUTPUT 1. Start the engine. 2. Center the steering wheel. 3. With the scan tool, read the Steering Angle Sensor Position. z

Is the Steering Angle Sensor Position within ±15°? Yes z

Go to step 3

No Go to step 4 3. INSPECT VEHICLE, STEERING COLUMN, AND INTERMEDIATE SHAFT FOR DAMAGE z

NOTE:

If possible, check vehicle repair history for collision damage. ABS module must be reinitializes after repair.

1. Turn the ignition off. 2. Inspect the vehicle for damage causing tracking problems. user Monday, June 04, 2012 10:12:24 AM

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3. Inspect the steering column and intermediate shaft for damage. Were any problems found? Yes z z

Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK CLOCKSPRING (SAS) INSTALLATION z

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component 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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE:

Proper Clockspring (SAS) installation is crucial for proper operation.

1. Verify that the Clockspring (SAS) is properly installed. Is the Steering Angle Sensor properly installed? Yes z

z

Replace the Clockspring (SAS) in accordance with the Service Information and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C121A-STEERING ANGLE SENSOR NOT INITIALIZED user Monday, June 04, 2012 10:12:24 AM

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Fig. 56: Fused Ignition Switch Output Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on. z

Set Condition: When the Anti-Lock Brake Module detects a low voltage at the Steering Angle Sensor or Steering Angle Sensor failure.

Possible Causes TERMINAL/CONNECTOR/WIRING HARNESS DAMAGE (F943) FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN (Z926) GROUND CIRCUIT OPEN CLOCKSPRING (SAS) Diagnostic Test

1. CHECK FOR A DTC C121A-STEERING ANGLE SENSOR NOT INITIALIZED NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 10 and 25 km/hr (6 and 15 m.p.h.) for 1 minute. 6. With the scan tool, read and record DTCs. Does the scan tool display: C121A-STEERING ANGLE SENSOR NOT INITIALIZED? Yes z

Go to step 2

No Perform the ABS-NTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE TERMINALS/CONNECTORS/WIRING HARNESS FOR DAMAGE z

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. user Monday, June 04, 2012 10:12:24 AM

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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 SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE:

Proper Clockspring (SAS) installation is crucial for proper operation.

1. Check the Clockspring (SAS) installation. 2. Check all related wiring for bruised, chafed, pierced, or partially broken wires. 3. Check all related connectors for broken, bent, pushed out, or corroded terminals. Were any problems found? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE VOLTAGE ON THE (F943) FUSED IGNITION SWITCH OUTPUT CIRCUIT z

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Fig. 57: Checking Voltage On Fused Ignition Switch Output Circuit Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Clockspring C3 (SAS) harness connector. Turn the ignition on. Measure the voltage of the (F943) Fused Ignition Switch Output circuit. Is the voltage above 10 volts? Yes

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z

Go to step 4

No Repair the (F943) Fused Ignition Switch Output circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 4. CHECK THE RESISTANCE OF THE (Z926) GROUND CIRCUIT z

Fig. 58: Checking Resistance Of Ground Circuit Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:24 AM

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1. Turn the ignition off. 2. Measure the resistance between the (Z926) Ground circuit and ground. Is the resistance below 5.0 Ohms? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the (Z926) Ground circuit for an open. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C121C-TORQUE REQUEST SIGNAL DENIED For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the engine running.

z

Set Condition: When the Powertrain Control Module indicates, for an extended period of time, that engine management relevant for Automatic Yaw Control/Traction Control System control can not be accomplished. Possible Causes

ANTI-LOCK BRAKE MODULE POWERTRAIN CONTROL MODULE Diagnostic Test

1. CHECK FOR A DTC C121C-TORQUE REQUEST SIGNAL DENIED NOTE:

This DTC must be active for the results of this test to be valid and this DTC may set while driving under severe load conditions.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the user Monday, June 04, 2012 10:12:24 AM

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4. 5. 6. 7.

DTC was set. With the scan tool, erase DTCs. Cycle the ignition switch from off to on. Start Engine. With the scan tool, read and record DTCs and monitor ESP Torque Request status. Does the scan tool display: C121C-TORQUE REQUEST SIGNAL DENIED? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE POWERTRAIN DTCS 1. With the scan tool, read and record Powertrain DTCs. z

Were any Powertrain related DTCs found? Yes z

Repair the Powertrain Diagnostics. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing .

No Go to step 3 3. ESP TORQUE REQUEST SIGNAL 1. Engine started. 2. With the scan tool, read the Allow ESP Torque Request status bit. z

Was the Allow ESP Torque Request showing NOT set? Yes z z

Replace the Powertrain Module in accordance with the Service Information. Perform POWERTRAIN VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

No z

Replace the Anti-Lock Brake Module in accordance with the Service Information.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C121D-BRAKE PRESSURE SENSOR CIRCUIT For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module indicates that the Brake Pressure Sensor Signal is out of range.

Possible Causes AIR IN BRAKE SYSTEM/WORN MECHANICAL COMPONENTS ECU INTERNAL FAILURE HCU INTERNAL FAILURE Diagnostic Test

1. CHECK FOR A DTC C121D-BRAKE PRESSURE SENSOR CIRCUIT NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Start the engine. 6. Slowly depress and release the brake pedal. 7. With the scan tool, read and record DTCs. Does the scan tool display: C121D-BRAKE PRESSURE SENSOR CIRCUIT? Yes z

Go to step 2

z

Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based

No

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Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. HCU/ECU ISOLATION 1. Turn the ignition off. 2. Separate the ECU from the HCU. 3. With the scan tool, monitor brake pressure. Does the scan tool display brake pressure above 218 bar (3162 psi)? Yes z z

Replace the HCU in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the ECU in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C121E-BRAKE PRESSURE SENSOR COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module indicates that the Brake Pressure Sensor Signal is out of range. Possible Causes

ECU INTERNAL FAILURE HCU INTERNAL FAILURE Diagnostic Test

1. CHECK FOR A DTC C121E-BRAKE PRESSURE SENSOR COMPARATIVE PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record the DTCs. user Monday, June 04, 2012 10:12:24 AM

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3. With the scan tool, read and record the Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the DTCs. 5. Start the engine. 6. Slowly press and release the brake pedal. 7. With the scan tool, read and record the DTCs. Does the scan tool display: C121E-BRAKE PRESSURE SENSOR COMPARATIVE PERFORMANCE? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. HCU/ECU ISOLATION 1. Turn the ignition off. 2. Separate the ECU from the HCU. 3. Turn the ignition on. 4. With the scan tool, monitor the brake pressure. z

Does the scan tool display brake pressure above 218 bar (3162 psi)? Yes z z

Replace the HCU in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the ECU in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1231-DRIVE TEST: STEERING ANGLE SENSOR For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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During the Drive Test. z

Set Condition: If the Anti-Lock Brakes Module detects implausible Steering Angle Sensor data. Possible Causes

CLOCKSPRING INSTALLATION CLOCKSPRING (SAS) ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR A DTC C1231 DRIVE TEST: STEERING ANGLE SENSOR NOTE:

This DTC must be active for the results of this test to be valid.

NOTE:

If any of the following DTCs are present they must be repaired before continuing. z z

DTC C1219-STEERING ANGLE SENSOR ERRATIC PERFORMANCE DTC C121A-STEERING ANGLE SENSOR NOT INITIALIZED

1. 2. 3. 4.

Turn the ignition on. With the scan tool, read and record DTCs. With the scan tool, read and record Freeze Frame information. Perform ECU initialization with drive test. Perform the ABS VERIFICATION TEST. See DTCBased Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure 5. NOTE: The drive test requires a 90° turn. 6. Start the engine. 7. With the scan tool, read and record DTCs. Does the scan tool display: C1231 DRIVE TEST: STEERING ANGLE SENSOR? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. VERIFY THAT THE STEERING ANGLE SENSOR IS ACTIVE ON THE BUS z

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1. With the scan tool, select ECU View. 2. Verify that the Steering Angle Sensor is active on the bus. Is the Steering Angle Sensor active on the bus? Yes z

Go to step 3

No Perform the appropriate diagnostic procedure. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Diagnosis and Testing . 3. CHECK STEERING ANGLE 1. Turn steering wheel so wheels point in a straight ahead position. 2. With scan tool check steering angle. z

Is the Steering Angle reading within 15°? Yes z

Go to step 4

No Go to step 5 4. CHECK STEERING ANGLE CHANGE 1. Turn steering wheel so wheels point in a straight ahead position. 2. With scan tool check steering angle. 3. Rotate steering wheel to the right and the degrees will decrease and rotating steering wheel to the left the degrees will increase. z

Did the steering angle change accordingly? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Replace the Clockspring (SAS) in accordance with the Service Information and clear offsets by initializing ECU with wheels pointing straight ahead.

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Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. CHECK CLOCKSPRING INSTALLATION z

WARNING: To avoid possible serious or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component 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 precautions could result in accidental airbag deployment. NOTE:

Proper Clockspring (SAS) installation is crucial for proper operation.

1. Turn the ignition off. 2. Verify that the Clockspring (SAS) is properly installed. Refer to Restraints/CLOCKSPRING Installation . Is the Clockspring (SAS) properly installed? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1232-DRIVE TEST: PRESSURE SENSOR For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: During the Drive Test.

z

Set Condition:

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If the Pressure Sensor fails to activate. Possible Causes HYDRAULIC / BRAKE SYSTEM COMPONENT INSTALLATION INTEGRATED CONTROL UNIT PRESSURE SENSOR (HYDRAULIC CONTROL UNIT) Diagnostic Test

1. CHECK FOR A DTC C1232 DRIVE TEST: PRESSURE SENSOR NOTE:

This DTC must be active for the results of this test to be valid.

1. 2. 3. 4.

Turn the ignition on. With the scan tool, read and record DTCs. With the scan tool, read and record Freeze Frame information. Perform ECU initialization with drive test. Perform the ABS VERIFICATION TEST. See DTCBased Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. Start the engine and apply the brake firmly. 6. With the scan tool, read and record DTCs. Does the scan tool display: C1232 DRIVE TEST: PRESSURE SENSOR? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK HYDRAULIC SYSTEM AND BRAKE SYSTEM COMPONENT INSTALLATION AND FUNCTION 1. Verify that the Anti-Lock Brakes Module and Hydraulic Control Unit are properly installed. 2. Verify that the hydraulic system is properly filled and bled. 3. Verify that the brake system components are installed and functioning properly. z

Were any problems found? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE,

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Antilock Brake (ABS) - Standard Procedure. No z

z

Clean contacts in HCU first if problem reoccurs replace the Integrated Control Unit in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1234-DRIVE TEST: SENSOR CLUSTER INSTALLATION For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: During the Drive Test.

z

Set Condition: If the Anti-Lock Brakes Module detects implausible Dynamics Sensor data. Possible Causes

DYNAMICS SENSOR INSTALLATION DYNAMICS SENSOR ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR A DTC C1234 DRIVE TEST: SENSOR CLUSTER INSTALLATION NOTE:

This DTC must be active for the results of this test to be valid.

1. 2. 3. 4.

Turn the ignition on. With the scan tool, read and record DTCs. With the scan tool, read and record Freeze Frame information. Perform ECU initialization with drive test. Perform the ABS VERIFICATION TEST. See DTCBased Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. NOTE: The drive test requires a 90° turn. 6. Start the engine. 7. With the scan tool, read and record DTCs. Does the scan tool display: C1234 DRIVE TEST: SENSOR CLUSTER INSTALLATION? Yes

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z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE DYNAMICS SENSOR INSTALLATION z

NOTE:

Dynamics Sensor installation and mounting bolt torque is crucial for proper operation.

1. Turn the ignition off. 2. Check the Dynamics Sensor for damaged, modified, and bent mounting brackets. 3. Check the Dynamics Sensor mounting bolts for a loose or over tightened condition. Were any problems found? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1238-DRIVE TEST: UNSUCCESSFUL For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: During the Drive Test.

z

Set Condition: If the Anti-Lock Brakes Module detects a fault with the Steering Angle Sensor, the Pressure Sensor, or the Dynamics Sensor. Possible Causes

STEERING ANGLE SENSOR user Monday, June 04, 2012 10:12:24 AM

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PRESSURE SENSOR DYNAMICS SENSOR ANTI-LOCK BRAKES MODULE Diagnostic Test

1. DIAGNOSE AND REPAIR ALL DTCs Repair z

Diagnose and repair all DTCs.

C1239-EMISSIONS ROLLS TEST ACTIVE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . Theory of Operation

The functional effects are that the output signal for all wheel speeds mimic the wheel with the highest wheel speed. This DTC sets when the Emissions Rolls Test is active. Close out the Emissions Rolls Test though the TIPM. C123A-ESP SYSTEM SENSORS CALIBRATION

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Fig. 59: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Once per ignition cycle.

z

Set Condition: If the calculated checksum does not match the stored checksum. Possible Causes

ANTI-LOCK BRAKES MODULE Diagnostic Test

1. INITIALIZE ANTI-LOCK BRAKES MODULE 1. Initialize ECU refer to ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure Does this DTC reset? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure

No z

Test complete.

C123B-ESP SYSTEM CONTROL TOO LONG For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module indicates ESP control lasting longer the 10 seconds.

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Possible Causes HYDRAULIC/BRAKE ISSUE DYNAMICS SENSOR INTEGRATED CONTROL MODULE STEERING ANGLE SENSOR WHEEL ALIGNMENT Diagnostic Test

1. CHECK FOR A DTC C123B-ESP SYSTEM CONTROL TOO LONG NOTE:

If other DTCs are set they must be repaired before continuing. To help in the service of the ESP System, it is recommend speaking to the customer to find out what type of environment they were driving in when the ESP concern took place, heavy rain, snow or ice. This should be considered normal operation and no repair is necessary. This DTC may set while driving under excessive driving conditions.

1. Turn the ignition on. 2. Perform ECU initialization with drive test. Refer to Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. NOTE:

Drive test must be performed correctly for ECU to initialize.

3. Cycle the ignition switch from off to on. Did the ECU initialization/drive test pass? Yes z

Go to step 2

No Refer to associated drive test diagnostic procedure. z Refer to the DTC list. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) Diagnosis and Testing 2. CHECK STEERING ANGLE SIGNAL 1. Turn steering wheel so wheels point in a straight ahead position. 2. With scan tool read Steering Angle Sensor Signal. z

Is the Steering Angle reading within ±6 degrees? Yes user Monday, June 04, 2012 10:12:24 AM

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z

Go to step 4

No Go to step 3 3. CHECK STEERING ANGLE INSTALLATION AND WHEEL ALIGNMENT z

NOTE: 1. 2. 3. 4.

Proper Steering Angle Sensor installation is crucial for proper operation.

Turn the ignition off. Inspect the vehicle for damage causing tracking problems or steering wheel misalignment. Inspect the steering column and intermediate shaft for damage. Verify that the Steering Angle Sensor is properly installed. Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Replace the Steering Angle Sensor in accordance with the Service Information. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 4. CHECK HYDRAULIC SYSTEM AND BRAKE SYSTEM COMPONENT INSTALLATION AND FUNCTION 1. Verify that the Anti-Lock Brakes Module and Hydraulic Control Unit are properly installed. 2. Verify that the hydraulic system is properly filled and bled. 3. Verify that the brake system components are installed and functioning properly. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 5 5. REPLACE THE INTEGRATED CONTROL MODULE AND VERIFY IF THE DTC IS STILL ACTIVE 1. Replace the Integrated Control Module in accordance with the Service Information. 2. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. Connect all previously disconnected components and connectors. 4. Turn the ignition on. 5. With the scan tool, erase ABS DTCs. 6. Cycle the ignition switch. z

WARNING: Ensure brake capability is available before road testing.

7. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 10 and 20 km/h (6 and 12 mph). 8. Park the vehicle. 9. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test complete.

C123C-DYNAMICS SENSOR MOUNTING/INSTALLATION PERFORMANCE

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Fig. 60: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module indicates the Dynamics Sensor values are invalid.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE IMPROPERLY INSTALLED SENSOR CLUSTER (G94) DYNAMICS SENSOR GROUND CIRCUIT OPEN DYNAMICS SENSOR Diagnostic Test

1. CHECK FOR A DTC C123C-SENSOR CLUSTER MOUNTING/INSTALLATION PERFORMANCE NOTE:

The Sensor Cluster is the same as the Dynamics Sensor.

NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch from off to on. 6. With the scan tool, read and record DTCs. Does the scan tool display: C123C-SENSOR CLUSTER MOUNTING/INSTALLATION PERFORMANCE? Yes z

Go to step 2

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Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Turn ignition off. 2. Visually inspect the related wiring harness. Look for any bruised, chafed, pierced, or partially broken wires. 3. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE DYNAMICS SENSOR INSTALLATION z

NOTE:

Dynamics Sensor installation and mounting bolt torque is crucial for proper operation.

1. Check the Dynamics Sensor for damaged, modified or bent mounting bracket. 2. Check the Dynamics Sensor mounting bolts for loose or over tightened mounting bolts. Were any problems found? Yes z z

Repair as needed. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK THE RESISTANCE BETWEEN THE (G94) DYNAMICS SENSOR GROUND CIRCUIT AND GROUND z

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Fig. 61: Checking Resistance Between Dynamics Sensor Ground Circuit & Ground Courtesy of CHRYSLER LLC 1. Disconnect the Dynamics Sensor harness connector. 2. Measure the resistance between the (G94) Dynamics Sensor Ground circuit and ground. Is the resistance below 5.0 ohm? Yes user Monday, June 04, 2012 10:12:25 AM

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z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the (G94) Dynamics Sensor Ground circuit for an open circuit. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C123F-STEERING ANGLE SENSOR COMPARATIVE PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With ignition on, but not if a checksum failure of the stored offset values is detected. Or, a CAN time-out failure is detected. Or, a failure is detected by the Steering Angle Sensor.

z

Set Condition: If the Anti-Lock Brakes Module detects that either the calculated steering wheel angle offset or the steering wheel angle signal measured output is out of range. Possible Causes

VEHICLE DAMAGE STEERING COLUMN / INTERMEDIATE SHAFT DAMAGE STEERING WHEEL ALIGNMENT STEERING ANGLE SENSOR LOOSE CLOCKSPRING (SAS) IMPROPERLY INSTALLED (WRONG MOUNTING POSITION) CLOCKSPRING (SAS) ANTI-LOCK BRAKE MODULE Diagnostic Test

1. PERFORM TEST DRIVE AND VERIFY DTC IS STILL ACTIVE NOTE:

If present, diagnose and repair DTC C1219-STEERING ANGLE SENSOR ERRATIC PERFORMANCE, C121A-STEERING ANGLE SENSOR NOT INITIALIZED, or C1240-STEERING ANGLE SENSOR OVERTRAVEL PERFORMANCE before diagnosing this DTC.

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1. Turn the ignition on. 2. With the scan tool, erase ABS DTCs. 3. Cycle the ignition switch. WARNING: To avoid possible serious or fatal injury, check brake capability is available before road testing. 4. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 10 and 25 km/hr (6 and 15 m.p.h.). 5. Park the vehicle. 6. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK STEERING ANGLE SENSOR OUTPUT 1. Start the engine. 2. Turn the steering wheel so wheels point in a straight ahead position. 3. With the scan tool, read the Steering Angle Sensor position. z

Is the Steering Angle Sensor Position within 15° degrees? Yes z

Go to step 5

No Go to step 3 3. INSPECT VEHICLE, STEERING COLUMN, AND INTERMEDIATE SHAFT FOR DAMAGE z

NOTE:

If possible, check vehicle repair history for collision damage.

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3. Inspect the steering column and intermediate shaft for damage. Were any problems found? Yes z z

Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK CLOCKSPRING (SAS) INSTALLATION z

WARNING: To avoid possible serious or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component 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 precautions could result in accidental airbag deployment. NOTE:

Proper Clockspring (SAS) installation is crucial for proper operation.

1. Verify that the Clockspring (SAS) is properly installed. Is the Clockspring (SAS) properly installed? Yes z

Go to step 5

No Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. RE-INITIALIZE THE ESP MODULE 1. Perform ECU initialization with drive test to clear offsets. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. z

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Is DTC C123F STEERING ANGLE SENSOR COMPARATIVE PERFORMANCE still active? Yes z

Go to step 6

No Sensor was probably loose or calibrated with wheels not centered to vehicle. Test complete. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK STEERING ANGLE SENSOR OUTPUT WHILE ROTATING THE STEERING WHEEL 1. With the scan tool, read the Steering Angle Sensor position while rotating the steering wheel to the right and then to the left. The Steering Angle position should decrease when rotating the steering wheel to the right and increase when rotating the steering wheel to the left. z

Did the steering angle change accordingly? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

z

Replace the Clockspring (SAS) in accordance with the Service Information and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1240-STEERING ANGLE SENSOR OVERTRAVEL PERFORMANCE For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With ignition on, but not if a CAN time out failure is detected. Or, if a fault is detected by the Steering Angle Sensor.

z

Set Condition: If the Anti-Lock Brakes Module detects that the absolute value of the measured steering wheel angle is

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greater than 720 degrees. Possible Causes VEHICLE DAMAGE STEERING COLUMN / INTERMEDIATE SHAFT DAMAGE STEERING WHEEL ALIGNMENT STEERING ANGLE SENSOR LOOSE CLOCKSPRING IMPROPERLY INSTALLED (WRONG MOUNTING POSITION) CLOCKSPRING (SAS) Diagnostic Test

1. PERFORM TEST DRIVE AND VERIFY DTC IS STILL ACTIVE 1. Turn the ignition on. 2. With the scan tool, erase ABS DTCs. 3. Cycle the ignition switch. 4. Turn steering wheel from lock to lock. 5. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z

Go to step 2

No Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK STEERING ANGLE SENSOR OUTPUT 1. Start the engine. 2. Center the steering wheel. 3. With the scan tool, read the Steering Angle Sensor Position. z

Is the Steering Angle Sensor Position within 15" ? Yes z

Go to step 4

z

Go to step 3

No

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3. INSPECT VEHICLE, STEERING COLUMN, AND INTERMEDIATE SHAFT FOR DAMAGE NOTE: 1. 2. 3. 4. 5.

If possible, check vehicle repair history for collision damage.

Turn the ignition off. Inspect the vehicle for damage causing tracking problems or steering wheel misalignment. Inspect the steering column and intermediate shaft for damage. Center the steering wheel. With the scan tool, read the Steering Angle Sensor Position. Is the Steering Angle Sensor Position within 15" ? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK STEERING ANGLE CHANGE 1. Turn steering wheel so wheels point in a straight ahead position. 2. With scan tool check steering angle if reading travels to 720 degrees while rotating wheel from lock to lock. z

NOTE:

Sensor damage can occur if wheel is turned over 720 degrees.

3. Rotate steering wheel to the right and the degrees will decrease and rotate steering wheel to the left and the degrees will increase. Did the steering angle change accordingly and display less than 720 degrees from lock to lock? Yes z

Go to step 5

No z

z

Replace the Clockspring (SAS) in accordance with the Service Information and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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5. CHECK CLOCKSPRING INSTALLATION WARNING: To avoid possible or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component 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 precautions could result in accidental airbag deployment. NOTE:

Proper Clockspring (SAS) installation is crucial for proper operation.

1. Verify that the Clockspring is properly installed in accordance with the service information. Is the Clockspring properly installed? Yes z

z

Replace the Clockspring (SAS) and clear offsets by initializing ECU with wheels pointing straight ahead, in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair as necessary and clear offsets by initializing ECU with wheels pointing straight ahead. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C1243-G SENSOR NOT INITIALIZED For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Once after ignition on.

z

Set Condition: If the stored zero point calibration value of the longitudinal acceleration sensor is invalid. Possible Causes

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DYNAMICS SENSOR NOT CALIBRATED DYNAMICS SENSOR ANTI-LOCK BRAKES MODULE Diagnostic Test

1. PERFORM ECU INITIALIZATION 1. Turn the ignition on. 2. With the scan tool, erase ABS DTCs. 3. Cycle the ignition switch. WARNING: To avoid possible serious or fatal injury, check brake capability is available before road testing. 4. Perform ECU initialization with drive test refer to ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. NOTE:

The ECU Initialization process must include driving the vehicle into a 90° turn.

5. Park the vehicle. z Go to step 2 2. VERIFY IF DTC IS STILL ACTIVE 1. Cycle the ignition switch. WARNING: To avoid possible serious or fatal injury, check brake capability is available before road testing. 2. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 10 and 25 km/h (6 and 15 mph). 3. Park the vehicle. 4. With the scan tool, read ABS DTCs. Does this DTC reset? Yes NOTE:

z

Vehicles without a Dynamics Sensor replace Anti-Lock Brake Module.

Replace the Dynamics Sensor or Anti-Lock Brake Module in accordance with the Service Information.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2100-BATTERY VOLTAGE LOW

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Fig. 62: Fused B+ Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:25 AM

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z

When Monitored: With the ignition on.

z

Set Condition: If the Anti-Lock Brakes Module detects system voltage is below 7.5 volts. Possible Causes

ECM OR PCM DTCs PRESENT VEHICLE BATTERY/CHARGING SYSTEM ANTI-LOCK BRAKES MODULE Diagnostic Test

1. DTCS IN THE PCM NOTE: 1. 2. 3. 4. 5. 6. 7.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, read and record DTCs from the PCM. With the scan tool, read and record Freeze Frame information. With the scan tool, erase DTCs. Start the engine. With the scan tool, read and record DTCs. With the scan tool read DTCs from the PCM. Are any charging system codes present? Yes z z

Repair the charging system DTC in the PCM. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 2 2. CHARGING SYSTEM FAILURE 1. Start the engine. 2. Connect voltmeter to vehicle battery. z

Is the vehicle battery voltage under 8.2 volts? user Monday, June 04, 2012 10:12:25 AM

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No z

Go to step 3

Yes Repair the charging system per service information. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 3. CHARGING POWER SUPPLY VOLTAGE 1. With a scan tool read Power Supply Voltage. z

Is Power Supply Voltage under 8.2 volts? No z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2101-BATTERY VOLTAGE HIGH

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Fig. 63: Fused B+ Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:25 AM

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z

When Monitored: With the ignition on.

z

Set Condition: If the Anti-Lock Brakes Module detects system voltage is above 17 volts. Possible Causes

ECM/PCM DTCs PRESENT VEHICLE BATTERY / CHARGING SYSTEM ANTI-LOCK BRAKES MODULE Diagnostic Test

NOTE: 1. 2. 3. 4. 5. 6. 7.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, read and record DTCs from the ECM/PCM. With the scan tool, read and record Freeze Frame information. With the scan tool, erase DTC's. Start the engine. With the scan tool, read and record DTCs. With the scan tool read DTCs from the PCM. Are any charging system codes present? Yes

z

Repair the charging system DTC in the ECM/PCM. Perform the POWERTRAIN VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

z

Go to step 1

z

No

1. CHARGING SYSTEM FAILURE 1. Start the engine. 2. Connect voltmeter to vehicle battery. Is the vehicle battery voltage over 16.8 volts? user Monday, June 04, 2012 10:12:25 AM

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No z

Go to step 2

Yes Repair the charging system per service information. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHARGING POWER SUPPLY VOLTAGE 1. With a scan tool read Power Supply Voltage. z

Is Power Supply Voltage over 16.8 volts? No z

Perform ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

Yes z z

Replace the Anti-Lock Brakes Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2111-ANTI-LOCK BRAKE MODULE INTERNAL

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Fig. 64: Fused B+ Circuit Shorted To Ground, Voltage Or Open Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:25 AM

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z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects an internal fault, the DTC is set.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE FUSED B+ CIRCUIT(S) SHORTED TO GROUND, VOLTAGE, OR OPEN GROUND CIRCUIT(S) OPEN ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR A DTC C2111-ANTI-LOCK BRAKE MODULE INTERNAL NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch from off to on. 6. With the scan tool, read and record DTCs Does the scan tool display: C2111-ANTI-LOCK BRAKE MODULE INTERNAL? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Turn the ignition off. 2. Visually inspect the related wiring harness. Look for any bruised, chafed, pierced, or partially broken wires. 3. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or z

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corroded terminals. Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. FUSED B+ CIRCUIT(S) OPEN OR HIGH RESISTANCE z

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Fig. 65: Checking Anti-Lock Brake Module Harness Connector Courtesy of CHRYSLER LLC 1. Disconnect the Anti-Lock Brake Module harness connector. 2. Using a 12-volt test light connected to ground, check the (A111) Fused B+ circuit. NOTE:

The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

Is the test light illuminated and bright? user Monday, June 04, 2012 10:12:25 AM

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Yes z

Go to step 4

No Repair the Fused B+ circuit(s) for an open circuit or high resistance. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 4. GROUND CIRCUIT OPEN OR HIGH RESISTANCE z

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Fig. 66: Checking Ground Circuit Open Or High Resistance Courtesy of CHRYSLER LLC 1. Using a 12-volt test light connected to 12-volts, check the (Z924) Ground circuits. NOTE:

The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

Is the test light illuminated and bright? user Monday, June 04, 2012 10:12:25 AM

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Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the Ground circuit(s) for an open circuit or high resistance. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2114-DYNAMICS SENSOR SUPPLY VOLTAGE LOW

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Fig. 67: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: If the Dynamics Sensor status changes from initialized to not initialized due to low voltage on the (G4) Dynamics Sensor Supply circuit.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (G4) DYNAMICS SENSOR SUPPLY CIRCUIT HIGH RESISTANCE (G94) DYNAMICS SENSOR GROUND CIRCUIT HIGH RESISTANCE DYNAMICS SENSOR ANTI-LOCK BRAKES MODULE Diagnostic Test

1. CHECK FOR A DTC C2114-DYNAMICS SENSOR SUPPLY VOLTAGE LOW NOTE:

The Sensor Cluster is the same as the Dynamics sensor.

NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record the DTCs. 3. With the scan tool, read and record the Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the DTCs. 5. Start the engine. NOTE:

Attempt to operate the vehicle under conditions similar to which the DTC was set. It may be necessary to test drive the vehicle within the DTC monitoring and set conditions, in order for this DTC to set.

6. With the scan tool, read and record the DTCs. Does the scan tool display: C2114-DYNAMICS SENSOR SUPPLY VOLTAGE LOW? user Monday, June 04, 2012 10:12:25 AM

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Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Check the Dynamics Sensor installation and torque of the mounting bolts. 2. Visually inspect the related wiring harness. Look for any bruised, chafed, pierced or partially broken wires. 3. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out or corroded terminals. z

Were any problems found? Yes z z

Repair as necessary. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE VOLTAGE ON THE (G4) DYNAMICS SENSOR SUPPLY CIRCUIT z

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Fig. 68: Checking Voltage On Dynamics Sensor Supply Circuit Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Dynamics Sensor harness connector. Turn the ignition on. Measure the voltage across the (G4) Dynamics Sensor Supply Circuit and the (G94) Dynamics Sensor Ground Circuit. Is the voltage above 10 volts? Yes

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z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK (G4) DYNAMICS SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE z

Fig. 69: Checking Dynamics Sensor Supply Circuit For High Resistance Courtesy of CHRYSLER LLC 1. Turn the ignition off. user Monday, June 04, 2012 10:12:25 AM

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2. Disconnect the Anti-Lock Brakes Module harness connector. 3. Measure the resistance of the (G4) Dynamics Sensor Supply circuit between the Dynamics Sensor harness connector and the Anti-Lock Brake Module harness connector. Is the resistance below 5.0 Ohms? Yes z

Go to step 5

No Repair the (G4) Dynamics Sensor Supply circuit for high resistance. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. CHECK (G94) DYNAMICS SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE z

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Fig. 70: Checking Dynamics Sensor Ground Circuit For High Resistance Courtesy of CHRYSLER LLC 1. Measure the resistance of the (G94) Dynamics Sensor Ground circuit between the Dynamics Sensor harness connector and the Anti-Lock Brake Module harness connector. Is the resistance below 5.0 Ohms? Yes z

Replace the Anti-Lock Brake Module in accordance with the Service Information.

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z

Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the (G94) Dynamics Sensor Ground circuit for high resistance. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2115-DYNAMICS SENSOR SUPPLY VOLTAGE HIGH

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Fig. 71: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module indicates the operating voltage is out of specified range.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE CHARGING SYSTEM (G4) SENSOR CLUSTER SUPPLY CIRCUIT SHORTED TO GROUND OR VOLTAGE (G94) SENSOR CLUSTER GROUND CIRCUIT SHORTED TO VOLTAGE OR OPEN SENSOR CLUSTER ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR A DTC C2115-SENSOR CLUSTER SUPPLY VOLTAGE HIGH NOTE:

The Sensor Cluster is the same as the Dynamics sensor.

NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition from off to on. 6. With the scan tool, read and record DTCs. Does the scan tool display: C2115-SENSOR CLUSTER SUPPLY VOLTAGE HIGH? Yes z

Go to step 2

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Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Turn ignition off. 2. Check all related wiring for bruised, chafed, pierced, or partially broken wires. 3. Check all related connectors for broken, bent, pushed out, or corroded terminals. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE VOLTAGE ON THE (G4) SENSOR CLUSTER SUPPLY CIRCUIT z

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Fig. 72: Checking Voltage On Sensor Cluster Supply Circuit Courtesy of CHRYSLER LLC WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. 2. 3. 4.

Disconnect the Sensor Cluster harness connector. Start the engine. Raise engine speed above 1800 RPM. Measure the voltage of the (G4) Sensor Cluster Supply Circuit. Is the voltage above 17 volts?

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Yes z

Go to step 4

No Go to step 7 4. CHECK THE VOLTAGE ON THE FUSED B(+) CIRCUITS z

Fig. 73: Checking Voltage On Fused B(+) Circuits Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:25 AM

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WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. 2. 3. 4. 5.

Turn the ignition off. Disconnect the Anti-Lock Brake Module harness connector. Start the engine. Raise engine speed above 1800 RPM. Measure the voltage of the (A107) and the (A200) Fused B(+) circuits. Is the voltage above 17 volts? Yes z z

Refer to appropriate Service Information for Charging System testing and repair. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. (G4) SENSOR CLUSTER SUPPLY CIRCUIT SHORT TO GROUND z

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Fig. 74: Checking Sensor Cluster Supply Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between ground and the (G4) Sensor Cluster Supply circuit. Is the resistance below 5.0 ohms? Yes z z

Repair the (G4) Sensor Cluster Supply circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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Go to step 6 6. (G4) SENSOR CLUSTER SUPPLY CIRCUIT SHORT TO VOLTAGE z

Fig. 75: Checking Voltage On Sensor Cluster Supply Circuit Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Measure the voltage of the (G4) Sensor Cluster Supply circuit. Is there any voltage present? Yes z

Repair the (G4) Sensor Cluster Supply circuit for a short to voltage.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. SENSOR CLUSTER z

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Fig. 76: Checking Resistance Between Dynamics Sensor Ground Circuit & Ground Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. If necessary, disconnect the Sensor Cluster harness connector. If necessary, connect the Anti-Lock Brake Module harness connector. Measure the resistance between the (G94) Sensor Cluster Ground Circuit at the Sensor Cluster harness connector and ground. Is the resistance below 5.0 ohms? Yes z z

Replace the Sensor Cluster in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. (G94) SENSOR CLUSTER GROUND CIRCUIT SHORT TO VOLTAGE z

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Fig. 77: Checking Sensor Cluster Ground Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Measure the voltage of the (G94) Sensor Cluster Ground circuit. Is there any voltage present? Yes z z

Repair the (G94) Sensor Cluster Ground circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 9 9. (G94) SENSOR CLUSTER GROUND CIRCUIT OPEN z

Fig. 78: Checking Sensor Cluster Ground Circuit Open Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance of the (G94) Sensor Cluster Ground circuit user Monday, June 04, 2012 10:12:25 AM

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Is the resistance below 5.0 ohms? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the (G94) Sensor Cluster Ground circuit for an open. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2116-ABS PUMP MOTOR SUPPLY LOW VOLTAGE

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Fig. 79: ABS Pump Motor Fuse & Fused B(+) Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:25 AM

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z

When Monitored: With the ignition on and the ABS pump motor deactivated.

z

Set Condition: When the Anti-Lock Brake Module indicates the ABS Pump Motor supply voltage is below 6.0 volts, the circuit fails the diagnostic test.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE ABS PUMP MOTOR FUSE OPEN (A107) FUSED B(+) CIRCUIT SHORTED TO GROUND OR OPEN (Z924) GROUND CIRCUIT(S) OPEN OR HIGH RESISTANCE ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR A DTC C2116-ABS PUMP MOTOR SUPPLY LOW VOLTAGE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. CAUTION: Make sure braking capability is available before road testing.

5. Drive the vehicle over 40 Km/h (25 mph). 6. Park the vehicle and cycle the ignition switch from off to on. 7. With the scan tool, read and record DTCs Does the scan tool display: C2116-ABS PUMP MOTOR SUPPLY LOW VOLTAGE? Yes z

Go to step 2

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Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK ABS PUMP OPERATION WITH SCAN TOOL 1. Cycle ignition switch off to on. 2. With the scan tool, actuate the ABS Pump Motor. z

Did the ABS Pump Motor operate? Yes z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE ABS PUMP MOTOR FUSE FOR AN OPEN 1. Turn the ignition off. 2. Remove and inspect the ABS Pump Motor fuse. z

Is the ABS Pump Motor fuse open? Yes z

Go to step 4

No Go to step 5 4. CHECK THE (A107) FUSED B(+) FOR A SHORT TO GROUND 1. Turn the ignition off. 2. Check the (A107) Fused B(+) circuit in the wiring harness for a short to ground. z

Is the (A107) Fused B(+) circuit in the wiring harness OK? Yes z

Go to step 5

No z z

Repair the (A107) Fused B(+) circuit as necessary. Replace the fuse. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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5. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS NOTE:

Check all related wiring for bruised, chafed, pierced, or partially broken wires. Check all related connectors for broken, bent, pushed out, or corroded terminals.

1. Inspect the Anti-Lock Brake Module harness connector and (A107) Fused B(+) circuit in the wiring harness. Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 6 6. (A107) FUSED B(+) CIRCUIT OPEN z

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Fig. 80: Checking Anti-Lock Brake Module Harness Connector Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Disconnect the Anti-Lock Brake Module harness connector. 3. Using a 12-volt test light connected to ground, check the (A107) Fused B(+) circuit in the AntiLock Brake Module harness connector. NOTE:

The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

Is the test light illuminated and bright? user Monday, June 04, 2012 10:12:25 AM

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Yes z

Go to step 7

No Repair the (A107) Fused B(+) circuit for an open circuit or high resistance. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 7. GROUND CIRCUIT(S) OPEN OR HIGH RESISTANCE z

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Fig. 81: Checking Ground Circuit Open Or High Resistance Courtesy of CHRYSLER LLC 1. Using a 12-volt test light connected to 12-volts, check the (Z924) Ground circuits. NOTE:

The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

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Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the Ground circuit(s) for an open circuit or high resistance. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2202-ORIGINAL VIN MISMATCH/MISSING For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: At power up, VIN is read off the CAN bus.

z

Set Condition: The VIN stored in the ABM does not match the VIN read off of the CAN bus.

Possible Causes ABM MOVED FROM DIFFERENT VEHICLE WRONG VIN PROGRAMMED INTO VEHICLE Diagnostic Test

1. CHECK FOR A DTC C2202-ORIGINAL VIN MISMATCH/MISSING NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. Perform ECU initialization with drive test. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. Start the engine. 6. With the scan tool, read and record DTCs. Does the scan tool display: C2202-ORIGINAL VIN MISMATCH/MISSING? user Monday, June 04, 2012 10:12:25 AM

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Yes z

Go to step 2

No ABM has learned new VIN. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. WRONG VIN PROGRAMMED INTO VEHICLE z

Is the VIN stored in the ABM and PCM the same? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Reprogram the VIN per service information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2204-DYNAMICS SENSOR INTERNAL For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously, with ignition on, until vehicle speed exceeds 12.4 mph (20 km/h) for the first time, but not if the sensor voltage is out of range.

z

Set Condition: If the Anti-Lock Brake Module detects that the Yaw or Lateral Sensor signal is out of range. Possible Causes

DYNAMICS SENSOR INSTALLATION DYNAMICS SENSOR Diagnostic Test

1. VERIFY DTC IS ACTIVE user Monday, June 04, 2012 10:12:25 AM

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NOTE:

If present, diagnose and repair DTC C123C-DYNAMICS SENSOR MOUNTING/INSTALLATION PERFORMANCE before diagnosing this DTC.

1. Turn the ignition on. 2. With the scan tool, read and record the ABS DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the ABS DTCs. 5. Cycle the ignition switch. WARNING: Make sure brake capability is available before road testing.

NOTE:

Attempt to operate the vehicle under conditions similar to which the DTC was set. It may be necessary to test drive the vehicle within the DTC monitoring and set conditions in order for this DTC to set.

6. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 6 and 12 mph (10 and 20 km/h). 7. Park the vehicle. 8. With the scan tool, read the ABS DTCs. Does this DTC reset? Yes z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2205-STEERING ANGLE SENSOR INTERNAL For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With ignition on, but not if supply voltage faults are detected.

z

Set Condition:

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If the Anti-Lock Brake Module detects that the Steering Angle Sensor sends an internal failure message. Possible Causes CLOCKSPRING (SAS) Diagnostic Test

1. CHECK FOR A DTC C2205-STEERING ANGLE SENSOR INTERNAL NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. WARNING: Ensure brake capability is available before road testing.

5. Start the vehicle and turn the wheel from lock to lock. 6. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 10 and 25 km/h (6 and 15 mph). 7. Park the vehicle. 8. With the scan tool, read and record DTCs. Does the scan tool display: C2205-STEERING ANGLE SENSOR INTERNAL? Yes z z

Replace the Clockspring (SAS) in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Perform the ABS-INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

C2206-VEHICLE CONFIGURATION MISMATCH For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . user Monday, June 04, 2012 10:12:25 AM

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z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects the signal from the gateway module relevant for vehicle characteristic is missing for a period greater than the specified fault duration.

Possible Causes VEHICLE CONFIGURATION MISMATCH Diagnostic Test

1. CHECK FOR A DTC C2206-VEHICLE CONFIGURATION MISMATCH NOTE:

This DTC must be active for the results of this test to be valid. Diagnose and repair any communication DTCs in the Front Control Module (FCM) before continuing with this test.

NOTE:

Diagnose and repair any system under voltage or over voltage DTCs before continuing with this test.

1. Turn the ignition on. 2. With the scan tool, read the DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the DTCs. 5. Cycle the ignition switch off then on. 6. With the scan tool, read the DTCs. Does the scan tool display: C2206-VEHICLE CONFIGURATION MISMATCH? Yes z

With the scan tool select FCM under ECU selection then Misc Functions and Restore Vehicle Configuration.

No z

Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0100-LOST COMMUNICATION WITH ECM/PCM user Monday, June 04, 2012 10:12:26 AM

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For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on. Battery voltage between 10 and 16 volts. IOD fuse installed. TIPM is configured correctly.

z

Set Condition: Bus messages not received from the Engine Control Module/Powertrain Control Module (ECM/PCM) for approximately 2 to 5 seconds.

Possible Causes (D64) CAN C BUS (-) CIRCUIT SHORTED TO VOLTAGE (D65) CAN C BUS (+) CIRCUIT SHORTED TO GROUND DTCS RELATED TO BATTERY VOLTAGE, IGNITION, OR VIN MESSAGES TIPM NOT CONFIGURED CORRECTLY ECM/PCM POWER AND GROUND ECM/PCM MODULE THAT SET THIS DTC Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

Ensure the IOD fuse is installed and battery voltage is between 10 and 16 volts before proceeding.

1. With the scan tool, read active DTCs. Is this DTC active? Yes z

Perform the appropriate diagnostic procedure. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Diagnosis and Testing .

No z

Perform the appropriate Stored Lost Communication test procedure. Refer to Non-DTC

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Diagnostics/Communication - Diagnosis and Testing . U0101-LOST COMMUNICATION WITH TCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on. Battery voltage between 10 and 16 volts. IOD fuse installed. TIPM is configured correctly.

z

Set Condition: Bus messages not received from the Transmission Control Module (TCM) for approximately 2 to 5 seconds.

Possible Causes (D64) CAN C BUS (-) CIRCUIT SHORTED TO VOLTAGE (D65) CAN C BUS (+) CIRCUIT SHORTED TO GROUND DTCS RELATED TO BATTERY VOLTAGE, IGNITION, OR VIN MESSAGES TIPM NOT CONFIGURED CORRECTLY TCM POWER AND GROUND TCM ANTI-LOCK BRAKE MODULE Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

Ensure the IOD fuse is installed and battery voltage is between 10 and 16 volts before proceeding.

1. With the scan tool, read active DTCs. Is this DTC active? Yes z

Go to step 2

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No Refer to the Stored Lost Communication test procedure. Refer to Non-DTC Diagnostics/Communication - Diagnosis and Testing . 2. CHECK FOR ANY OF THE FOLLOWING ACTIVE DTCS 1. With the scan tool, read all active DTCs from all modules. z

NOTE:

Check for TIPM configuration, CAN C hardware electrical, VIN Missing/Mismatch, battery or ignition related DTCs.

Does the scan tool display any active DTCs to the conditions listed above? Yes z

Diagnose and repair the DTC. Check the Index for a complete list of the symptoms.

No Go to step 3 3. VERIFY THAT THE TCM IS ACTIVE ON THE BUS 1. Turn the ignition on. 2. With the scan tool, select Network Diagnostics. 3. Verify that the TCM is active on the bus. z

Is the TCM active on the bus? Yes z

Go to step 4

No Refer to the No Response test procedure. Refer to Non-DTC Diagnostics/Communication Diagnosis and Testing . 4. CHECK FOR ADDITIONAL COMMUNICATION RELATED DTCS 1. With the scan tool, select Network Diagnostics. z

Is there more than one module with active DTCs "Logged Against" the TCM? Yes z

z

Replace/update the Transmission Control Module in accordance with the service information. Perform the TRANSMISSION VERIFICATION TEST. Refer to DTC-Based

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Diagnostics/MODULE, Transmission Control (TCM) - Standard Procedure . No Go to step 5 5. CLEAR DTC IN MODULE SETTING FAULT 1. With the scan tool, select the module setting the DTC against the TCM. 2. Clear active DTCs. z

Is this DTC still active? Yes z z

Replace/update the module that set this DTC in accordance with the service information. Perform the appropriate VERIFICATION TEST.

No Go to step 6 6. CYCLE IGNITION 1. Cycle the ignition from RUN to OFF three times ending with the key in the RUN position. z

Does this DTC become active? Yes z

Go to step 7

No The condition is not present at this time. Using the SYSTEM WIRING DIAGRAMS as a guide, inspect the wiring for chafed, pierced, pinched, and partially broken wires and the wiring harness connectors for broken, bent, pushed out, and corroded terminals. z Perform the appropriate VERIFICATION TEST. 7. CHECK FOR ADDITIONAL LOST COMMUNICATION FAULTS 1. With the scan tool, select Network Diagnostics. z

Does the TIPM and other CAN C BUS modules show Lost Communication with the remaining CAN C BUS modules? Yes z

Go to step 8

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No Replace/update the module that set this DTC in accordance with the service information. z Perform the appropriate VERIFICATION TEST. 8. (D64) CAN C BUS (-) CIRCUIT SHORTED TO VOLTAGE 1. Measure the voltage between the (D64) CAN C Bus (-) circuit and ground. z

Is the voltage above 5 volts? Yes z z

Repair the (D64) CAN C Bus (-) circuit for a short to voltage. Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .

No Go to step 9 9. (D65) CAN C BUS (+) CIRCUIT SHORTED TO GROUND 1. Turn the ignition off. 2. Measure the resistance between ground and the (D65) CAN C Bus (+) circuit. z

Is the resistance below 10K Ohms? Yes z z

Repair the (D65) CAN C Bus (+) circuit for a short to ground. Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .

No z z

Replace the Anti-Lock Brake Module in accordance with the service information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0125-LOST COMMUNICATION WITH DYNAMICS SENSOR

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Fig. 82: Dynamics Sensor Data Link Voltage Low Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: If the Anti-Lock Brake Module fails to receive bus messages from the Dynamics Sensor.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (G4) DYNAMICS SENSOR SUPPLY CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (G94) DYNAMICS SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE, GROUND, OR OPEN (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT SHORTED TO GROUND, SHORTED TO VOLTAGE, OR OPEN (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT SHORTED TO GROUND, SHORTED TO VOLTAGE, OR OPEN DYNAMICS SENSOR ANTI-LOCK BRAKE MODULE Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

If present, diagnose and repair DTC C2114-DYNAMICS SENSOR SUPPLY VOLTAGE LOW or DTC C2115-DYNAMICS SENSOR SUPPLY VOLTAGE HIGH before proceeding.

1. Turn the ignition on. 2. With the scan tool, read and record the ABS DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the ABS DTCs. 5. Start the engine. NOTE:

Attempt to operate the vehicle under conditions similar to which the DTC was set. It may be necessary to test drive the vehicle within the DTC monitoring and set conditions in order for this DTC to set.

6. With the scan tool, read the ABS DTCs. user Monday, June 04, 2012 10:12:26 AM

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Does this DTC reset? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. INSPECT RELATED WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Visually inspect the related wiring harness. Look for any pinched, chafed, pierced, and partially broken wires. 2. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, and corroded terminals. z

Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE VOLTAGE ON THE (G4) DYNAMICS SENSOR SUPPLY CIRCUIT z

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Fig. 83: Checking Voltage On Dynamics Sensor Supply Circuit Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Dynamics Sensor harness connector. Turn the ignition on. Measure the voltage across (G4) Dynamics Sensor Supply Circuit and (G94) Dynamics Sensor Ground Circuit. Is the voltage above 10 volts? Yes

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z

Go to step 10

No Go to step 4 4. (G4) DYNAMICS SENSOR SUPPLY CIRCUIT SHORT TO GROUND z

Fig. 84: Checking Dynamics Sensor Supply Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Disconnect the Anti-Lock Brake Module harness connector. user Monday, June 04, 2012 10:12:26 AM

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3. Measure the resistance between ground and the (G4) Dynamics Sensor Supply circuit. Is the resistance below 5.0 Ohms? Yes z z

Repair the (G4) Dynamics Sensor Supply circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. (G4) DYNAMICS SENSOR SUPPLY CIRCUIT SHORT TO VOLTAGE z

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Fig. 85: Checking Dynamics Sensor Supply Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Measure the voltage of the (G4) Dynamics Sensor Supply circuit. Is there any voltage present? Yes z z

Repair the (G4) Dynamics Sensor Supply circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 6 6. (G4) DYNAMICS SENSOR SUPPLY CIRCUIT OPEN z

Fig. 86: Checking Dynamics Sensor Supply Circuit For High Resistance Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance of the (G4) Dynamics Sensor Supply circuit. Is the resistance below 5.0 Ohms? Yes user Monday, June 04, 2012 10:12:26 AM

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z

Go to step 7

No Repair the (G4) Dynamics Sensor Supply circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 7. CHECK THE RESISTANCE BETWEEN THE (G94) DYNAMICS SENSOR GROUND CIRCUIT AND GROUND z

Fig. 87: Checking Resistance Between Dynamics Sensor Ground Circuit & Ground Courtesy of CHRYSLER LLC 1. Disconnect the Dynamics Sensor harness connector. user Monday, June 04, 2012 10:12:26 AM

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2. Measure the resistance between the (G94) Dynamics Sensor Ground Circuit and Ground. Is the resistance below 5.0 Ohms? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. (G94) DYNAMICS SENSOR GROUND CIRCUIT SHORT TO VOLTAGE z

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Fig. 88: Checking Dynamics Sensor Ground Circuit Short To Voltage Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Anti-Lock Brake Module harness connector. Turn the ignition on. Measure the voltage of the (G94) Dynamics Sensor Ground circuit. Is there any voltage present? Yes z

Repair the (G94) Dynamics Sensor Ground circuit for a short to voltage.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 9 9. (G94) DYNAMICS SENSOR GROUND CIRCUIT OPEN z

Fig. 89: Checking Dynamics Sensor Ground Circuit For High Resistance Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:26 AM

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1. Turn the ignition off. 2. Measure the resistance of the (G94) Dynamics Sensor Return circuit between the Dynamics Sensor and the Anti-Lock Brake Module. Is the resistance below 5.0 Ohms? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Repair the (G94) Dynamics Sensor Ground circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 10. CHECK THE DATA LINK OUTPUT z

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Fig. 90: Checking Data Link Output Courtesy of CHRYSLER LLC 1. Measure the voltage of the Data Links Circuits the (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT will measure a minimum of 3 volts and the (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT will measure a minimum of 2 volts Is the voltage within specifications? Yes z z

Replace the Dynamic Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock

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Brake (ABS) - Standard Procedure. No Go to step 11 11. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

Fig. 91: Checking Dynamics Sensor High Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC 1. Disconnect the Anti-Lock Brakes Module harness connector. user Monday, June 04, 2012 10:12:26 AM

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2. Disconnect the Dynamics Sensor harness connector. 3. Turn the ignition on. 4. Measure the voltage of the (D465) Dynamics Sensor High Data Link circuit. Is there any voltage present? Yes z z

Repair the (D465) Dynamics Sensor High Data Link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 12 12. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR A SHORT TO GROUND z

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Fig. 92: Checking Dynamics Sensor High Data Link Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance of the (D465) Dynamics Sensor High Data Link circuit between ground and the Dynamics Sensor harness connector. Is the resistance below 5.0 Ohms? Yes z

Repair the (D465) Dynamics Sensor High Data Link circuit for a short to ground.

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z

Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 13 13. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR AN OPEN z

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Fig. 93: Checking Dynamics Sensor High Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D465) Dynamics Sensor High Data Link circuit between the Dynamics Sensor harness connector and the Anti-Lock Brakes Module harness connector. Is the resistance below 5.0 Ohms? Yes z

Go to step 14

No Repair the (D465) Dynamics Sensor High Data Link circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 14. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

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Fig. 94: Checking Dynamics Sensor Low Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. 2. Measure the voltage of the (D464) Dynamics Sensor Low Data Link circuit. Is there any voltage present? Yes z z

Repair the (D464) Dynamics Sensor Low Data Link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 15 15. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO GROUND z

Fig. 95: Checking Dynamics Sensor Low Data Link Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance of the (D464) Dynamics Sensor Low Data Link circuit between ground and the Dynamics Sensor harness connector. user Monday, June 04, 2012 10:12:26 AM

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Is the resistance below 5.0 Ohms? Yes z z

Repair the (D464) Dynamics Sensor Low Data Link circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 16 16. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR AN OPEN z

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Fig. 96: Checking Dynamics Sensor Low Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D464) Dynamics Sensor Low Data Link circuit between the Dynamics Sensor harness connector and the Anti-Lock Brake Module harness connector. Is the resistance below 5.0 Ohms? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock

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Brake (ABS) - Standard Procedure. No z z

Repair the (D464) Dynamics Sensor Low Data Link circuit for an open. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0126-LOST COMMUNICATION WITH STEERING ANGLE SENSOR

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Fig. 97: Fused Ignition Switch Output Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored:

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With the ignition on z Battery voltage between 10 and 16 volts z Ignition Off Draw (IOD) fuse installed Set Condition: z

z

If the Anti-Lock Brake Module fails to receive bus messages from the Steering Angle Sensor for approximately 100 ms. Possible Causes DTCs RELATED TO BATTERY VOLTAGE, IGNITION, OR VIN MESSAGES CAN C BUS CIRCUITS OPEN OR SHORTED STEERING ANGLE SENSOR POWER AND GROUND CLOCKSPRING (SAS) Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

Make sure the IOD fuse is installed and battery voltage is between 10 and 16 volts before proceeding.

1. Turn the ignition on. 2. With the scan tool, read and record ABS DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase ABS DTCs. 5. Cycle the ignition switch. 6. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK FOR ANY OF THE FOLLOWING ACTIVE DTCs z

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1. With the scan tool, read all active DTCs from all CAN C Bus modules. NOTE:

Check for CAN C hardware electrical, VIN Missing/Mismatch, battery or ignition related DTCs.

Does the scan tool display any active DTCs related to the conditions listed above? Yes z

Diagnose and repair the DTC(s). Refer to DIAGNOSTIC CODE INDEX.

No Go to step 3 3. CHECK THE VOLTAGE ON THE (F943) FUSED IGNITION SWITCH OUTPUT CIRCUIT z

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Fig. 98: Checking Clockspring Circuit Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Turn the ignition off. Disconnect the Clockspring C3 (SAS) harness connector. Turn the ignition on. Measure the voltage of the (F943) Fused Ignition Switch Output circuit. Is the voltage above 10 volts?

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Yes z

Go to step 4

No Repair the (F943) Fused Ignition Switch Output circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 4. CHECK THE RESISTANCE OF THE (Z926) GROUND CIRCUIT z

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Fig. 99: Checking Clockspring Circuit Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between the (Z926) Ground circuit and ground. Is the resistance below 5.0 Ohms? Yes z

Go to step 5

No Repair the (Z926) Ground circuit for an open. z Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 5. VERIFY THAT THE STEERING ANGLE SENSOR IS ACTIVE ON THE BUS 1. With the scan tool, select ECU View. 2. Verify that the Steering Angle Sensor is active on the bus. z

Is the Steering Angle Sensor active on the bus? Yes z z

Replace the Clockspring (SAS) in accordance with the service information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Refer to Non-DTC Diagnostics/Communication - Diagnosis and Testing and perform the Stored Lost Communication DTC diagnostic procedure.

U0141-LOST COMMUNICATION WITH FRONT CONTROL MODULE (TIPM) For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

z

When Monitored: z With the ignition on z Battery voltage between 10 and 16 volts z IOD fuse installed z TIPM is configured correctly Set Condition:

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Bus messages not received from the TIPM for approximately 2 to 5 seconds. Possible Causes DTCS RELATED TO BATTERY VOLTAGE, IGNITION, OR VIN MESSAGES TIPM NOT CONFIGURED CORRECTLY TOTALLY INTEGRATED POWER MODULE TOTALLY INTEGRATED POWER MODULE POWER AND GROUND ANTI-LOCK BRAKE MODULE Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

Verify the IOD fuse is installed and battery voltage is between 10 and 16 volts before proceeding.

1. With the scan tool, read active DTCs. Is this DTC active? Yes z

Go to step 2

No Perform the appropriate Stored Lost Communication test procedure. Refer to Non-DTC Diagnostics/Communication - Diagnosis and Testing . 2. CHECK FOR ANY OF THE FOLLOWING ACTIVE DTCS 1. With the scan tool, read all active DTCs from all modules. z

NOTE:

Check for TIPM configuration, CAN B or C hardware electrical, VIN Missing/Mismatch, battery or ignition related DTCs.

Does the scan tool display any active DTCs to the conditions listed above? Yes z

Perform the appropriate diagnostic procedure. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Diagnosis and Testing .

No z

Go to step 3

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3. VERIFY THAT THE TIPM IS ACTIVE ON THE BUS 1. Turn the ignition on. 2. With the scan tool, select Network Diagnostics. 3. Verify that the TIPM is active on the bus. Is the TIPM active on the bus? Yes z

Go to step 4

No For No Response diagnostic procedures. Refer to Non-DTC Diagnostics/Communication Diagnosis and Testing . 4. CHECK FOR ADDITIONAL COMMUNICATION RELATED DTCS 1. With the scan tool, select Network Diagnostics. z

Is there more than one module with active DTCs Logged Against the TIPM? Yes z

z

Replace/update the Totally Integrated Power Module in accordance with the service information. Perform BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .

No z z

Replace the Anti-Lock Brake Module in accordance with the service information Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0401-IMPLAUSIBLE DATA RECEIVED FROM ECM/PCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on, one valid CAN message received at least once, and no U0002-CAN C Bus Off Performance DTC present.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Powertrain Control

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Module (PCM) or Engine Control Module (ECM). Possible Causes ABM CAN BUS DTCS ENGINE DTCS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR DTC U0401-IMPLAUSIBLE DATA RECEIVED FROM ECM/PCM NOTE: 1. 2. 3. 4.

This DTC must be active for the results of this test to be valid.

Turn the ignition on. With the scan tool, record and erase DTCs. Cycle the ignition switch from off to on. With the scan tool, read DTCs. Does the scan tool display: U0401-IMPLAUSIBLE DATA RECEIVED FROM ECM/PCM? Yes z

Go to step 2

No Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK IF TIPM CAN BUS DTCS ARE PRESENT 1. With the scan tool, read TIPM DTCs. z

Are there any TIPM CAN BUS DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing and perform the appropriate diagnostic procedures.

No Go to step 3 3. POWERTRAIN CONTROL MODULE (PCM) or ENGINE CONTROL MODULE (ECM) DTCS ARE PRESENT 1. With the scan tool, read PCM or ECM DTCs. z

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Are there any PCM or ECM DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing for diesel engine applications or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing for gas engine applications and perform the appropriate diagnostic procedure.

No z

z

Using the schematics as a guide, check the Anti-Lock Brake Module pins, terminals, and connectors for corrosion, damage, or terminal push out. Pay particular attention to all power and ground circuits. If no problems are found, replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0402-IMPLAUSIBLE DATA RECEIVED FROM TCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on, one valid CAN message received at least once, and no U0002-CAN C Bus Off Performance DTC present.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Transmission Control Module (TCM). Possible Causes

TIPM CAN BUS DTCS TRANSMISSION DTCS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK IF TIPM CAN BUS DTCS ARE PRESENT 1. With the scan tool, read TIPM DTCs. Are there any TIPM CAN BUS DTCs present? Yes user Monday, June 04, 2012 10:12:26 AM

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z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing .

No Go to step 2 2. CHECK IF TRANSMISSION DTCS ARE PRESENT 1. With the scan tool, read Transmission DTCs. z

Are there any Transmission DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Transmission Control (TCM) - Diagnosis and Testing .

No z

z

Using the schematics as a guide, check the Anti-Lock Brake Module pins, terminals, and connectors for corrosion, damage, or terminal push out. Pay particular attention to all power and ground circuits. If no problems are found, replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U0429-IMPLAUSIBLE DATA RECEIVED FROM SCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on, one valid CAN message received at least once, and no U0002-CAN C Bus Off Performance DTC present.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Clockspring (steering angle sensor or SAS) for approximately 200 mSec. Possible Causes

CLOCKSPRING (SAS) ANTI-LOCK BRAKE MODULE Diagnostic Test user Monday, June 04, 2012 10:12:26 AM

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1. CHECK IF STEERING ANGLE SENSOR DTCS ARE PRESENT 1. With the scan tool, read Steering Angle Sensor DTCs. Are there any Steering Angle Sensor DTCs present? Yes z

Perform the appropriate diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Diagnosis and Testing.

No z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U1003-ESP CAN C BUS PERFORMANCE

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Fig. 100: Dynamics Sensor Data Link Voltage Low Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: If the Anti-Lock Brake Module detects too many CAN Bus off events on the Dynamics Sensor Data Link circuits.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT SHORTED TO GROUND, VOLTAGE, OR OPEN (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT SHORTED TO GROUND, VOLTAGE, OR OPEN DYNAMICS SENSOR ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK FOR A DTC U1003-ESP CAN C BUS PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

NOTE:

If present, diagnose and repair DTC U0125-LOST COMMUNICATION WITH DYNAMICS SENSOR before diagnosing this DTC.

1. Turn the ignition on. 2. With the scan tool, read and record the DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase the DTCs. 5. Start the engine. NOTE:

Attempt to operate the vehicle under conditions similar to which the DTC was set. It may be necessary to test drive the vehicle within the DTC monitoring and set conditions in order for this DTC to set.

6. With the scan tool, read and record the DTCs user Monday, June 04, 2012 10:12:26 AM

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Does the scan tool display: U1003-ESP CAN C BUS PERFORMANCE? Yes z

Go to step 2

No Perform ABS INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS z

NOTE:

The Sensor Cluster is the same as the Dynamics sensor.

1. Check the Dynamics Sensor installation and torque of the mounting bolts. 2. Visually inspect the related wiring harness. Look for any bruised, chafed, pierced, or partially broken wires. 3. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

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Fig. 101: Checking Dynamics Sensor High Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Turn the ignition off. Disconnect the Anti-Lock Brake Module harness connector. Disconnect the Dynamics Sensor harness connector. Turn the ignition on. Measure the voltage of the (D465) Dynamics Sensor High Data Link circuit. Is there any voltage present? Yes

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z z

Repair the (D465) Dynamics Sensor High Data link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR A SHORT TO GROUND z

Fig. 102: Checking Dynamics Sensor High Data Link Circuit For A Short To Ground Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:26 AM

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1. 2. 3. 4.

Turn the ignition off. Disconnect the Anti-Lock Brake Module harness connector. Disconnect the Dynamics Sensor harness connector. Measure the resistance between ground and the (D465) Dynamics Sensor High Data Link circuit. Is the resistance below 5.0 Ohms? Yes z z

Repair the (D465) Dynamics Sensor High Data link circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR AN OPEN z

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Fig. 103: Checking Dynamics Sensor High Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D465) Dynamics Sensor High Data Link circuit. Is the resistance below 5.0 Ohms? Yes user Monday, June 04, 2012 10:12:26 AM

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z

Go to step 6

No Repair the (D465) Dynamics Sensor High Data link circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

Fig. 104: Checking Dynamics Sensor Low Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC 1. Turn the ignition on. user Monday, June 04, 2012 10:12:26 AM

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2. Measure the voltage of the (D464) Dynamics Sensor Low Data Link circuit. Is there any voltage present? Yes z z

Repair the (D464) Dynamics Sensor Low Data link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO GROUND z

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Fig. 105: Checking Dynamics Sensor Low Data Link Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between ground and the (D464) Dynamics Sensor Low Data Link circuit. Is the resistance below 5.0 Ohms? Yes z z

Repair the (D464) Dynamics Sensor Low Data link circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

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No Go to step 8 8. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR AN OPEN z

Fig. 106: Checking Dynamics Sensor Low Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D464) Dynamics Sensor Low Data link circuit. Is the resistance below 5.0 Ohms? user Monday, June 04, 2012 10:12:26 AM

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Yes z

Go to step 9

No Repair the (D464) Dynamics Sensor Low Data link circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 9. REPLACE DYNAMICS SENSOR & VERIFY IF DTC IS STILL ACTIVE 1. Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) Standard Procedure 2. Test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 6 and 15 mph (10 and 25 km/h). 3. Park the vehicle. With the scan tool, read ABS DTCs. z

Does this DTC reset? Yes z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

Test complete.

U1004-CAN C BUS TRANSMIT PERFORMANCE

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Fig. 107: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects invalid CAN message from the Dynamics Sensor.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT SHORTED TO GROUND, VOLTAGE, OR OPEN (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT SHORTED TO GROUND, VOLTAGE, OR OPEN DYNAMICS SENSOR Diagnostic Test

1. CHECK FOR A DTC U1004-CAN C BUS TRANSMIT PERFORMANCE NOTE:

This DTC must be active for the results of this test to be valid.

1. Turn the ignition on. 2. With the scan tool, read and record DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase DTCs. 5. Cycle the ignition switch from off to on. 6. With the scan tool, read and record DTCs Does the scan tool display: U1004-CAN C BUS TRANSMIT PERFORMANCE? Yes z

Go to step 2

z

Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based

No

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Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK THE WIRING HARNESS, TERMINALS, AND CONNECTORS 1. Check the Dynamic Sensor installation and torque of the mounting bolts. 2. Visually inspect the related wiring harness. Look for any bruised, chafed, pierced, or partially broken wires. 3. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. Were any problems found? Yes z z

Repair as necessary. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 3 3. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

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Fig. 108: Checking Dynamics Sensor High Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Turn the ignition off. Disconnect the Dynamics Sensor harness connector. Disconnect the Anti-Lock Brake Module harness connector. Turn the ignition on. Measure the voltage of the (D465) Dynamics Sensor High Data Link circuit. Is there any voltage present? Yes

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z z

Repair the (D465) Dynamics Sensor High Data Link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 4 4. (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT SHORT TO GROUND z

Fig. 109: Checking Dynamics Sensor High Data Link Circuit Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between ground and the (D465) Dynamics Sensor High Data Link circuit. user Monday, June 04, 2012 10:12:27 AM

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Is the resistance below 5.0 ohms? Yes z z

Repair the (D465) Dynamics Sensor High Data Link circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 5 5. CHECK THE (D465) DYNAMICS SENSOR HIGH DATA LINK CIRCUIT FOR AN OPEN z

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Fig. 110: Checking Dynamics Sensor High Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D465) Dynamics Sensor High Data Link circuit. Is the resistance below 5.0 ohms? Yes z

Go to step 6

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No Repair the (D465) Dynamics Sensor High Data Link circuit for an open. z Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 6. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO VOLTAGE z

Fig. 111: Checking Dynamics Sensor Low Data Link Circuit For A Short To Voltage Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:12:27 AM

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1. Turn the ignition on. 2. Measure the voltage of the (D464) Dynamics Sensor Low Data Link circuit. Is there any voltage present? Yes z z

Repair the (D464) Dynamics Sensor Low Data Link circuit for a short to voltage. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 7 7. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR A SHORT TO GROUND z

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Fig. 112: Checking Dynamics Sensor Low Data Link Circuit For A Short To Ground Courtesy of CHRYSLER LLC 1. Turn the ignition off. 2. Measure the resistance between ground and the (D464) Dynamics Sensor Low Data Link circuit. Is the resistance below 5.0 ohms? Yes user Monday, June 04, 2012 10:12:27 AM

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z z

Repair the (D464) Dynamics Sensor Low Data Link circuit for a short to ground. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No Go to step 8 8. CHECK THE (D464) DYNAMICS SENSOR LOW DATA LINK CIRCUIT FOR AN OPEN z

Fig. 113: Checking Dynamics Sensor Low Data Link Circuit For An Open Courtesy of CHRYSLER LLC 1. Measure the resistance of the (D464) Dynamics Sensor Low Data Link circuit. user Monday, June 04, 2012 10:12:27 AM

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Is the resistance below 5.0 ohms? Yes z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z z

Repair the (D464) Dynamics Sensor High Data Link circuit for an open. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U1104-CAN C BUS CRC PERFORMANCE

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Fig. 114: Dynamics Sensor Supply/Ground Circuit Schematic Courtesy of CHRYSLER LLC For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: With the ignition on.

z

Set Condition: If the Anti-Lock Brake Module detects an invalid CAN message from the Dynamics Sensor. Possible Causes

DYNAMICS SENSOR Diagnostic Test

1. VERIFY DTC IS ACTIVE 1. Turn the ignition on. 2. With the scan tool, read and record ABS DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase ABS DTCs. 5. Cycle the ignition switch. 6. With the scan tool, read ABS DTCs. Does this DTC reset? Yes z z

Replace the Dynamics Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

No z

z

The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U140E-IMPLAUSIBLE VEHICLE CONFIGURATION DATA RECEIVED user Monday, June 04, 2012 10:12:27 AM

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For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Once per ignition cycle, but not during cranking. Or, if low supply voltage faults are detected.

z

Set Condition: If the Anti-Lock Brake Module either fails to receive vehicle configuration data from the Engine Control Module (ECM), Powertrain Control Module (PCM), Totally Integrated Power Module (TIPM), or the configuration data it receives from the ECM, PCM, and TIPM is invalid.

Possible Causes WIRING HARNESS, TERMINAL, CONNECTOR DAMAGE DTCS RELATED TO BATTERY VOLTAGE, IGNITION, OR VIN MESSAGES CAN C BUS CIRCUITS OPEN OR SHORTED ECM OR PCM DTCs PRESENT ECM OR PCM NOT PROGRAMMED OR PROGRAMMED WITH INCORRECT VIN TIPM NOT PROGRAMMED OR PROGRAMMED WITH INCORRECT INFORMATION ECM OR PCM TOTALLY INTEGRATED POWER MODULE (TIPM) ANTI-LOCK BRAKE MODULE Diagnostic Test

1. VERIFY DTC IS ACTIVE NOTE:

This DTC must be active for the results of this test to be valid. If DTC C2206-VEHICLE CONFIGURATION MISMATCH is present it must be repaired before continuing.

1. Turn the ignition on. 2. With the scan tool, read and record ABS DTCs. 3. With the scan tool, read and record Environmental Data to help identify the conditions in which the DTC was set. 4. With the scan tool, erase ABS DTCs. 5. Cycle the ignition switch. 6. With the scan tool, read ABS DTCs. Does this DTC reset? Yes user Monday, June 04, 2012 10:12:27 AM

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z

Go to step 2

No The condition that caused the symptom is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires. z Perform the ABS-INTERMITTENT CONDITION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure. 2. CHECK FOR ANY OF THE FOLLOWING ACTIVE DTCs 1. With the scan tool, read all active DTCs from all CAN C Bus modules. z

NOTE:

Check for CAN C hardware electrical, VIN Missing/Mismatch, battery or ignition related DTCs.

Does the scan tool display any active DTCs related to the conditions listed above? Yes z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing and perform the appropriate diagnostic procedure.

No Go to step 3 3. VERIFY CORRECT TIPM CONFIGURATION 1. With the scan tool, verify that the TIPM part number is correct for the vehicle and programmed correctly by selecting TIPM from ECU view then Misc Functions and Restore Vehicle Configuration z

Is the correct TIPM installed in the vehicle? No z z

Replace and program the TIPM in accordance with the Service Information. Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .

Yes Go to step 4 4. CHECK IF ECM OR PCM DTCs ARE PRESENT 1. With the scan tool, read ECM or PCM DTCs. z

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Are any DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing for diesel engine applications or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing for gas engine applications and perform the appropriate diagnostic procedure.

No Go to step 5 5. VERIFY CORRECT ECM OR PCM IS INSTALLED IN THE VEHICLE 1. With the scan tool, verify that the ECM or PCM part number is correct for the vehicle. z

Is the correct ECM or PCM installed in the vehicle? No z z

Replace and program the ECM or PCM in accordance with the Service Information. Perform appropriate VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

Yes Go to step 6 6. VERIFY ECM OR PCM IS PROGRAMMED WITH CORRECT VIN 1. With the scan tool, verify that the ECM or PCM is programmed with the correct VIN. z

Is the ECM or PCM programmed with the correct VIN? No z z

Using the scan tool, perform ECM/PCM Replaced to update the VIN in the ECM/PCM. Perform appropriate VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

Yes Go to step 7 7. CHECK FOR ADDITIONAL COMMUNICATION RELATED DTCs 1. With the scan tool, select Network View and select Advanced. z

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Is there more than one module with active DTCs Logged Against the ECM or PCM? Yes z z

Replace/update the ECM or PCM in accordance with the service information. Perform appropriate VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

No z

z

Using the schematics as a guide, check the Anti-Lock Brake Module pins, terminals, and connectors for corrosion, damage, and terminal push out. Pay particular attention to all Communication circuits. If no problems are found, replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U1501-IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM PCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Powertrain Control Module (PCM) Engine Control Module (ECM). Possible Causes

TIPM CAN BUS DTCS ENGINE DTCS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK IF TIPM CAN BUS DTCs ARE PRESENT 1. With the scan tool, read TIPM DTCs. Are there any TIPM CAN BUS DTCs present? Yes user Monday, June 04, 2012 10:12:27 AM

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z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing and perform the appropriate diagnostic procedure.

No Go to step 2 2. POWERTRAIN CONTROL MODULE (PCM) or ENGINE CONTROL MODULE (ECM) DTCS ARE PRESENT 1. With the scan tool, read PCM or ECM DTCs. z

Are there any PCM or ECM DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing for diesel engine applications or DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing for gas engine applications and perform the appropriate diagnostic procedure.

No z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform the ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U1502-IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM TCM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Transmission Control Module (TCM). Possible Causes

TIPM CAN BUS DTCS TRANSMISSION DTCS ANTI-LOCK BRAKE MODULE Diagnostic Test user Monday, June 04, 2012 10:12:27 AM

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1. CHECK IF TIPM CAN BUS DTCS ARE PRESENT 1. With the scan tool, read TIPM DTCs. Are there any TIPM CAN BUS DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing .

No Go to step 2 2. CHECK IF TRANSMISSION DTCS ARE PRESENT 1. With the scan tool, read Transmission DTCs. z

Are there any Transmission DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Transmission Control (TCM) - Diagnosis and Testing .

No z

z

Using the schematics as a guide, check the Anti-Lock Brake Module pins, terminals, and connectors for corrosion, damage, or terminal push out. Pay particular attention to all power and ground circuits. If no problems are found, replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

U1503-IMPLAUSIBLE MESSAGE DATA LENGTH RECEIVED FROM TIPM For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . z

When Monitored: Continuously with the ignition on.

z

Set Condition: When the Anti-Lock Brake Module detects an incorrect CAN message from the Totally Integrated Power Module (TIPM).

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Possible Causes TIPM CAN BUS DTCS ANTI-LOCK BRAKE MODULE Diagnostic Test

1. CHECK IF TIPM CAN BUS DTCs ARE PRESENT 1. With the scan tool, read TIPM DTCs. Are there any TIPM CAN BUS DTCs present? Yes z

Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) Diagnosis and Testing .

No z z

Replace the Anti-Lock Brake Module in accordance with the Service Information. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

STANDARD PROCEDURE ABS INTERMITTENT CONDITION TEST For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS . Diagnostic Test

1. PERFORM ABS INTERMITTENT CONDITION TEST NOTE:

If the conditions that set the DTC are not present at this time, the following list may help in identifying an intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury.

1. Refer to any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Environmental Data information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. user Monday, June 04, 2012 10:12:27 AM

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4. Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Wiggle the wires while checking for shorts and open circuits. 6. Perform a voltage drop test on the related circuits between the suspected faulty component and the Anti-Lock Brake Module. 7. Inspect and clean all PCM, ABS, engine, and chassis grounds that are related to the most current DTC. 8. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 9. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 10. Use the scan tool to perform a System Test if one applies to the failing component. 11. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes

z

Perform the necessary repairs. Perform ABS VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Standard Procedure.

z

Test Complete.

z

No

ABS VERIFICATION TEST Diagnostic Test

1. Perform ABS Verification Test WARNING: Ensure braking capability is available before road testing.

NOTE:

If the ABM (Anti-Lock Brake Module), SAS (Steering Angle Sensor), Dynamics Sensor was replaced, or if any mounting problems with SAS or Dynamics Sensor, ABM must be initialized using the scan tool. If not initialized, the ABS indicator will flash continuously with no DTCs. To initialize the ABM and clear offsets have wheels pointing straight ahead and follow the directions on the scan tool. The drive test requires a 90? turn. If the Dynamics Sensor was replaced, test drive the vehicle by turning the vehicle left or right in a curving manner at a velocity between 6

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and 15 mph (10 and 25 km/h). 1. 2. 3. 4.

Turn the ignition off. Connect all previously disconnected components and connectors. Ensure all accessories are turned off and the battery is fully charged. Ensure that the ignition is on, with the scan tool, erase all Diagnostic Trouble Codes from All modules. Start the engine and allow it to run for two minutes and fully operate the system that was malfunctioning. 5. Turn the ignition off and wait five seconds. Turn the ignition on and using the scan tool, read DTCs from all modules. 6. If any Diagnostic Trouble Codes are present, return to DTC list and perform the appropriate diagnostic procedure. NOTE:

For Sensor Signal and Pump Motor faults, the ABM must sense all 4 wheels at 7.5 mph (12 km/h) before it will extinguish the ABS indicator.

7. If there are no DTCs present after turning ignition on, road test the vehicle for at least five minutes. Perform several anti-lock braking stops. 8. Again, with the scan tool read DTCs. If any DTCs are present, refer to DIAGNOSTIC CODE INDEX for the diagnostic test procedure and perform the appropriate diagnostic procedure. 9. If there are no Diagnostic Trouble Codes (DTCs) present, and the customer's concern can no longer be duplicated, the repair is complete. Are any DTCs present or is the original concern still present? Yes z

Repair is not complete, perform the appropriate diagnostic procedure. See DTC-Based Diagnostics/MODULE, Antilock Brake (ABS) - Diagnosis and Testing.

No z

Repair is complete.

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2009 DRIVELINE/AXLES Differential and Driveline - Journey

HALF SHAFT, FRONT DESCRIPTION DESCRIPTION

This vehicle is equipped with either an equal length halfshaft system, consisting of short halfshafts on both sides with an intermediate drive shaft on the right side, or an unequal length halfshaft system consisting of short left and long right halfshafts. The halfshafts consist of a fixed constant velocity (CV) joint at the outboard end connected by a solid shaft to a plunging CV joint on the inboard end. The inner (CV) joint has a splined connection into the transmission, or onto the intermediate drive shaft, and is retained with a snap ring. The outer joint has a spline connection to the wheel hub and is retained with a steel lock nut. All the halfshaft assemblies use the same type of inner and outer joints. The inner joint is a tripod joint that allows for the changes in halfshaft length through the jounce and rebound travel of the front suspension. The outer joint is a Rzeppa joint that allows articulation during front suspension travel and steering. Both tripod joints and Rzeppa joints are true constant velocity (CV) joint assemblies. The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs. DIAGNOSIS AND TESTING HALFSHAFT VEHICLE INSPECTION

1. Check for grease in the vicinity of the inboard tripod joint and outboard CV joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. NOISE OR VIBRATION IN TURNS

A clicking noise or a vibration in turns could be caused by one of the following conditions: z

z

Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. Noise may also be caused by another component of the vehicle coming in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION

This noise may be a result of one of the following conditions: user Monday, June 04, 2012 4:45:36 4:45:31 PM

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z z z

A torn seal boot on the inner or outer joint of the half shaft assembly. A loose or missing clamp on the inner or outer joint of the half shaft assembly. A damaged or worn half shaft CV joint.

SHUDDER OR VIBRATION DURING ACCELERATION

This problem could be a result of: z z z

A worn or damaged half shaft inner tripod joint. A sticking tripod joint spider assembly (inner tripod joint only). Improper wheel alignment. Refer to Front Suspension/Wheel Alignment - Standard Procedure

VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of: z z z

Foreign material (mud, etc.) packed on the backside of the wheel(s). Out of balance tires or wheels. Refer to Tires and Wheels - Standard Procedure Improper tire or wheel runout. Refer to Tires and Wheels - Diagnosis and Testing

REMOVAL WITHOUT INTERMEDIATE SHAFT

NOTE:

Never grasp the halfshaft assembly by the inner or outer boots doing so may damage to the boot.

NOTE:

The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs.

NOTE:

Some halfshafts use a tuned rubber damper weight. When replacing a halfshaft assembly, be sure the replacement halfshaft has a damper weight.

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Fig. 1: Removing/Installing Halfshaft Nut Courtesy of CHRYSLER LLC 1. Raise vehicle. 2. Remove the wheel and tire assembly from the vehicle. Refer to Tires and Wheels - Removal 3. Apply the service brakes to keep hub from turning, then loosen the halfshaft nut (2). NOTE:

Do not re-use the hub nut. The hub nut is a single-use type. A new hub nut is required for reassembly.

4. Remove the nut (2) from the halfshaft (1) and discard it.

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Fig. 2: Front Brake Mounting Courtesy of CHRYSLER LLC 5. Remove the two bolts (4) that secure the front disc brake caliper (5) and adapter (6) to the steering knuckle (3).

Fig. 3: Properly Supported Disc Brake Caliper - Typical Courtesy of CHRYSLER LLC 6. Remove the disc brake caliper assembly (3) from the steering knuckle (1). Caliper assembly is removed by first rotating top of caliper assembly away from steering knuckle and then removing bottom of assembly out from under machined abutment on steering knuckle. NOTE:

Do not allow the brake caliper assembly to hang by the brake flex hose (2).

7. Support disc brake caliper assembly by using a wire hanger (4) and suspend it from the strut assembly (5). user Monday, June 04, 2012 4:45:31 PM

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Fig. 4: Strut To Steering Knuckle Attaching Bolts Courtesy of CHRYSLER LLC 8. Remove the brake rotor from the hub and bearing assembly. 9. Remove the steering knuckle-to-strut attachment bolts (2) from the steering knuckle (3). 10. Pull the steering knuckle from the strut clevis bracket (1).

Fig. 5: Outer C/V Joint On Interconnecting Shaft Courtesy of CHRYSLER LLC NOTE:

Due to tight tolerances, the outer C/V joint might have to be forced apart from the bearing hub. To avoid damaging the axle half shaft threads during removal, install the hub nut (4) so that approximately half the threads are engaged on the shaft, and use a soft faced hammer (1) to tap the shaft (2) out of the hub.

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NOTE:

Care must be taken not to separate the inner C/V joint during this operation. Do not allow halfshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of halfshaft must be supported.

11. Pull steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the joint out of the hub bearing.

Fig. 6: Disengaging Inner Tripod Joint From Transaxle Courtesy of CHRYSLER LLC NOTE:

Transaxle fluid might leak when the half shaft is removed from the transaxle.

12. If equipped, remove the engine belly pan. 13. Support the outer end of the halfshaft assembly. Insert a pry bar (3) between inner tripod joint (1) and transaxle case (2). Pry against inner tripod joint, until tripod joint retaining snap-ring is disengaged from transaxle side gear.

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Fig. 7: View Of Manual Right Side Axle - 2.0L Gas Courtesy of CHRYSLER LLC 14. Pull the steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the halfshaft (1) out of the transmission. 15. Remove the half shaft. WITH INTERMEDIATE SHAFT

NOTE:

Never grasp the halfshaft assembly by the inner or outer boots. This can cause damage to the boot, which will allow contaminants to enter the C/V joint.

NOTE:

The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs.

NOTE:

Some halfshafts use a tuned rubber damper weight to cancel vibration. When replacing a halfshaft assembly, be sure the replacement halfshaft has a damper.

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Fig. 8: Removing/Installing Halfshaft Nut Courtesy of CHRYSLER LLC 1. Raise vehicle. 2. Remove the wheel and tire assembly from the vehicle. Refer to Tires and Wheels - Removal 3. Apply the service brakes to keep hub from turning, then loosen the halfshaft nut (2). NOTE:

Do not re-use the hub nut. The hub nut is a single-use type. A new hub nut is required for reassembly.

4. Remove the nut (2) from the halfshaft (1) and discard it.

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Fig. 9: Front Brake Mounting Courtesy of CHRYSLER LLC 5. Remove the two bolts (4) that secure the front disc brake caliper (5) and adapter (6) to the steering knuckle (3).

Fig. 10: Properly Supported Disc Brake Caliper - Typical Courtesy of CHRYSLER LLC 6. Remove the disc brake caliper assembly (3) from the steering knuckle (1). Caliper assembly is removed by first rotating top of caliper assembly away from steering knuckle and then removing bottom of assembly out from under machined abutment on steering knuckle. NOTE:

Do not allow the brake caliper assembly to hang by the brake flex hose (2).

7. Support disc brake caliper assembly by using a wire hanger (4) and suspend it from the strut assembly (5).

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Fig. 11: Strut To Steering Knuckle Attaching Bolts Courtesy of CHRYSLER LLC 8. Remove the brake rotor from the hub and bearing assembly. 9. Remove the steering knuckle-to-strut attachment bolts (2) from the steering knuckle (3). 10. Pull the steering knuckle from the strut clevis bracket (1).

Fig. 12: Outer C/V Joint On Interconnecting Shaft Courtesy of CHRYSLER LLC NOTE:

Due to tight tolerances, the outer C/V joint might have to be forced apart from the bearing hub. To avoid damaging the axle half shaft threads

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during removal, install the hub nut (4) so that approximately half the threads are engaged on the shaft, and use a soft faced hammer (1) to tap the shaft (2) out of the hub. NOTE:

Care must be taken not to separate the inner C/V joint during this operation. Do not allow halfshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of halfshaft must be supported.

11. Pull steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the joint out of the hub bearing.

Fig. 13: Right Halfshaft From Intermediate Shaft Courtesy of CHRYSLER LLC NOTE:

Transaxle fluid might leak when the half shaft is removed from the transaxle.

12. If equipped, remove the engine belly pan. 13. Support the outer end of the halfshaft assembly. Insert a pry bar (2) between inner tripod joint (1) and the intermediate shaft (3), or the transaxle case if removing the left half shaft. Pry against inner tripod joint, until tripod joint retaining snap-ring is disengaged from the intermediate shaft or transaxle side gear.

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Fig. 14: Outer C/V Joint Of Half Shaft Assembly Courtesy of CHRYSLER LLC NOTE:

3.5L Shown in illustration, all others equipped with an intermediate shaft are similar.

14. Pull the steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the halfshaft (1 or 2) out of the transmission. 15. Remove the half shaft. INSTALLATION WITHOUT INTERMEDIATE SHAFT

NOTE:

The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs.

NOTE:

Some halfshafts use a tuned rubber damper weight. When replacing a halfshaft assembly, be sure the replacement halfshaft has the same damper weight as the original.

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Fig. 15: View Of Manual Right Side Axle - 2.0L Gas Courtesy of CHRYSLER LLC 1. Thoroughly clean spline and oil seal sealing surface on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding halfshaft assembly (1) by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand. Be sure to engage splines prior to applying force. NOTE:

Attempt to remove tripod joint by hand to verify that the snap ring is fully engaged. If snap ring is fully engaged, tripod joint will not be removable from transmission by hand.

3. Forcefully push the tripod joint into the transaxle side gear, until snap-ring is fully engaged.

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Fig. 16: Outer CV Joint Inspection Courtesy of CHRYSLER LLC 4. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint (1) will be installed into steering knuckle. 5. Ensure that front of outer CV joint (2) which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly.

Fig. 17: Correctly Installed Eccentric Attaching Bolt Courtesy of CHRYSLER LLC 6. Slide half shaft back into front hub and bearing assembly. user Monday, June 04, 2012 4:45:31 PM

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CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle. CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket. 7. Install steering knuckle (1) into clevis bracket (4). Install the strut damper to steering knuckle attaching bolts (3 and 3). Tighten both bolts to 88 N.m (65 ft. lbs.) plus an additional 1/4 turn.

Fig. 18: Front Brake Mounting Courtesy of CHRYSLER LLC 8. Install brake disc (1) onto hub and bearing assembly (2). 9. Install front disc brake caliper (5) and adapter (6) to the steering knuckle (3). Caliper is installed by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment. 10. Install the two bolts (4) that secure the front disc brake caliper and adapter to the steering knuckle. Tighten the bolts to 169 N.m (125 ft. lbs.).

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Fig. 19: View Of Hub Nut & Axle Shaft Courtesy of CHRYSLER LLC NOTE:

Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.

11. Clean all foreign matter from the threads of the outer CV joint. Install the half shaft to hub/bearing assembly nut (1) onto halfshaft (2). 12. With the brakes applied to keep hub from turning, tighten the hub nut to 160 N.m (118 ft. lbs.). 13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N.m (100 ft. lbs.). 14. Lower vehicle. 15. Check for correct fluid level in transaxle assembly. Refer to Transmission and Transfer Case/Manual Automatic - Getrag MPS6/FLUID - Standard Procedure 16. If equipped, install the engine belly pan. WITH INTERMEDIATE SHAFT

NOTE:

The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs.

NOTE:

Some halfshafts use a tuned rubber damper weight. When replacing a halfshaft assembly, be sure the replacement halfshaft has the same damper weight as the original.

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NOTE:

3.5L Shown in illustration, all others equipped with an intermediate shaft are similar.

NOTE:

Care must be taken not to separate the inner C/V joint during this operation. Do not allow halfshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of halfshaft must be supported.

Fig. 20: Outer C/V Joint Of Half Shaft Assembly Courtesy of CHRYSLER LLC 1. Thoroughly clean spline and oil seal sealing surface on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding half shaft assembly (1) or (2) by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear (left side) or the intermediate shaft (right side) as far as possible by hand. Be sure to engage splines prior to applying force. NOTE:

Attempt to remove tripod joint by hand to verify that the snap ring is fully engaged. If snap ring is fully engaged, tripod joint will not be removable from transmission by hand.

3. Forcefully push the tripod joint into the transaxle side gear, until snap-ring is fully engaged.

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Fig. 21: Outer CV Joint Inspection Courtesy of CHRYSLER LLC 4. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint (1) will be installed into steering knuckle. 5. Ensure that front of outer CV joint (2) which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly.

Fig. 22: Strut To Steering Knuckle Attaching Bolts Courtesy of CHRYSLER LLC 6. Install the steering knuckle(3) to the strut clevis bracket (1). 7. Install the steering knuckle-to-strut attachment bolts and nuts (2). While holding the bolts in place, tighten user Monday, June 04, 2012 4:45:32 PM

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the nuts to 140 N.m (103 ft. lbs.)

Fig. 23: Front Brake Mounting Courtesy of CHRYSLER LLC 8. Install brake disc (1) onto hub and bearing assembly (2). 9. Install front disc brake caliper (5) and adapter (6) to the steering knuckle (3). Caliper is installed by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment. 10. Install the two bolts (4) that secure the front disc brake caliper and adapter to the steering knuckle. Tighten the bolts to 169 N.m (125 ft. lbs.).

Fig. 24: View Of Hub Nut & Axle Shaft user Monday, June 04, 2012 4:45:32 PM

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Courtesy of CHRYSLER LLC NOTE:

Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.

11. Clean all foreign matter from the threads of the outer CV joint. Install the half shaft to hub/bearing assembly nut (1) onto halfshaft (2). 12. With the brakes applied to keep hub from turning, tighten the hub nut to 160 N.m (118 ft. lbs.). 13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N.m (100 ft. lbs.). 14. Lower vehicle. 15. Check for correct fluid level in transaxle assembly. Refer to Transmission and Transfer Case/Manual Automatic - Getrag MPS6/FLUID - Standard Procedure 16. If equipped, install the engine belly pan. SPECIFICATIONS SPECIFICATIONS

TORQUE SPECIFICATIONS DESCRIPTION Bolts, Caliper Adapter to Knuckle Nut, Hub Nuts, Front Wheel Lug Nut, Tie Rod End to Knuckle Nut, Strut Clevis to Knuckle Bolts, Heat shield Bolts, Strut Damper to Steering Knuckle Bolts, Disc Brake Caliper Adapter 10 mm Bolts, Intermediate Bearing to block

N.m

Ft. Lbs.

In. Lbs.

169

125

-

160 135

118 100

-

75

55

-

88 +90°

65 +90°

-

14

-

124

88

65

-

169

125

-

54

39

-

BOOT, DRIVE SHAFT, OUTER Removal REMOVAL

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Fig. 25: Outer C/V Joint Seal Boot Clamps Courtesy of CHRYSLER LLC 1 - SMALL CLAMP 2 - SEALING BOOT 3 - OUTER CV JOINT HOUSING 4 - LARGE CLAMP 5 - INTERCONNECTING SHAFT 1. Remove halfshaft assembly requiring boot replacement from vehicle. See Removal 2. Remove large boot clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp (1) that retains outer CV joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer CV joint and interconnecting shaft.

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Fig. 26: Outer C/V Joint Removal from Interconnecting Shaft Courtesy of CHRYSLER LLC 1 - SOFT HAMMER (TAP INNER RACE ONLY) 2 - WEAR SLEEVE 3 - CIRCLIP (OUTER END OF SHAFT) 4. Remove outer CV joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer (1) , sharply hit the end of the CV joint housing to dislodge housing from internal circlip (3) on interconnecting shaft. Then slide outer CV joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer.

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Fig. 27: Circlip Removal from Interconnecting Shaft Courtesy of CHRYSLER LLC 1 - SNAP RING PLIERS 2 - INTERCONNECTING SHAFT 3 - CIRCLIP NOTE:

Always use a new circlip.

5. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV joint sealing boot. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Installation INSTALLATION

Fig. 28: Sealing Boot Installation on Interconnecting Shaft Courtesy of CHRYSLER LLC 1 - SEALING BOOT 2 - RAISED BEAD IN THIS AREA OF SEALING BOOT 3 - GROOVE 4 - INTERCONNECTING SHAFT user Monday, June 04, 2012 4:45:32 PM

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1. Slide new sealing boot clamp (2) onto interconnecting shaft (4). Slide the outer CV joint assembly sealing boot (1) onto the interconnecting shaft (4). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft.

Fig. 29: Outer C/V Joint On Interconnecting Shaft Courtesy of CHRYSLER LLC 1 - SOFT FACED HAMMER 2 - STUB AXLE 3 - OUTER C/V JOINT 4 - HUB NUT NOTE:

Always use a new circlip.

2. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start outer CV joint onto interconnecting shaft. 3. Install outer CV joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4) installed) until outer CV joint (3) is fully seated on interconnecting shaft.

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Fig. 30: Outer CV Joint Correctly Installed on Interconnecting Shaft Courtesy of CHRYSLER LLC 1 - INTERCONNECTING SHAFT 2 - CROSS 3 - OUTER C/V JOINT ASSEMBLY 4. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV joint assembly (3) is seated against circlip on interconnecting shaft (1).

Fig. 31: Crimping Tool Installed on Sealing Boot Clamp Courtesy of CHRYSLER LLC 1 - CRIMPING TOOL C-4975A 2 - INTERCONNECTING SHAFT user Monday, June 04, 2012 4:45:32 PM

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3 - CLAMP 4 - SEALING BOOT 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot (4) . 6. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft (2) using crimper, Crimping Tool C-4975A and the following procedure. Place Crimping Tool C-4975A (1) over bridge of clamp (3).

Fig. 32: Sealing Boot Retaining Clamp Installed Courtesy of CHRYSLER LLC 1 - CLAMP 2 - JAWS OF CRIMPING TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT 8. Tighten nut on Crimping Tool C-4975A until jaws on tool (2) are closed completely together, face to face.

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Fig. 33: Crimping Tool Installed on Sealing Boot Clamp Courtesy of CHRYSLER LLC 1 - CLAMP 2 - TRIPOD JOINT HOUSING 3 - CRIMPING TOOL C-4975A 4 - SEALING BOOT CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 9. Position outer CV joint sealing boot (4) into its retaining groove on outer CV joint housing. Install sealing boot to outer CV joint retaining clamp (1) evenly on sealing boot. 10. Clamp sealing boot onto outer CV joint housing using Crimping Tool C-4975A (3) and the following procedure. Place Crimping Tool C-4975A over bridge of clamp (1).

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Fig. 34: Sealing Boot Retaining Clamp Installed Courtesy of CHRYSLER LLC 1 - CLAMP 2 - TRIPOD HOUSING 3 - CRIMPING TOOL C-4975A 4 - JAWS OF CRIMPING TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT 11. Tighten nut on Crimping Tool C-4975A until jaws on tool are closed completely together (4) , face to face. 12. Install the halfshaft requiring boot replacement back on the vehicle. See Installation

HALF SHAFT, REAR DESCRIPTION DESCRIPTION

The inner joints of both half shaft assemblies are tripod joints. The outer joints of both assemblies are Rzeppa Joints. The tripod joints are true constant velocity (CV) joint assemblies, which allow for the changes in half shaft length through the jounce and rebound travel of the rear suspension. user Monday, June 04, 2012 4:45:32 PM

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The inner tripod joint of both half shafts is splined into the rear differential assembly and retained by a snap ring. The outer CV joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut. DIAGNOSIS AND TESTING HALFSHAFT VEHICLE INSPECTION

1. Check for grease in the vicinity of the inboard tripod joint and outboard CV joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. NOISE OR VIBRATION IN TURNS

A clicking noise or a vibration in turns could be caused by one of the following conditions: z

z

Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. Noise may also be caused by another component of the vehicle coming in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION

This noise may be a result of one of the following conditions: z z z

A torn seal boot on the inner or outer joint of the half shaft assembly. A loose or missing clamp on the inner or outer joint of the half shaft assembly. A damaged or worn half shaft CV joint.

SHUDDER OR VIBRATION DURING ACCELERATION

This problem could be a result of: z z z

A worn or damaged half shaft inner tripod joint. A sticking tripod joint spider assembly (inner tripod joint only). Improper wheel alignment. Refer to Front Suspension/Wheel Alignment - Standard Procedure

VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of: z z z

Foreign material (mud, etc.) packed on the backside of the wheel(s). Out of balance tires or wheels. Refer to Tires and Wheels - Standard Procedure Improper tire or wheel runout. Refer to Tires and Wheels - Diagnosis and Testing

REMOVAL user Monday, June 04, 2012 4:45:32 PM

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REMOVAL

Fig. 35: Removing/Installing Halfshaft Nut Courtesy of CHRYSLER LLC NOTE:

Rear suspension and drivetrain design require this procedure to be performed on a "drive-on" hoist, as the front and rear suspension needs to be compressed to ride height to facilitate rear halfshaft removal.

1. Place vehicle on drive-on hoist in Park. 2. Remove rear wheel center cap. 3. Remove hub nut.

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Fig. 36: Support Module With Jack Courtesy of CHRYSLER LLC 1 - DRIVELINE MODULE 2 - TRANSMISSION JACK 4. 5. 6. 7. 8.

Raise vehicle on hoist. Remove exhaust system center hanger (at propeller shaft bearing/support). Disconnect exhaust system at rear-most hanger and lower. Lower exhaust system at least 254 mm (10 in.). Support system with suitable wire or rope. Support driveline module (1) with transmission jack (or equivalent) (2).

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Fig. 37: Seal Protector Courtesy of CHRYSLER LLC 1 - HALFSHAFT 2 - SEAL PROTECTOR NOTE:

Never grasp the halfshaft assembly by the inner or outer boots doing so may damage to the boot.

9. Using suitable screwdriver, partially dislodge halfshaft (side being removed) from differential. Install Seal Protector 9099 (2) to protect seal upon disassembly.

Fig. 38: Module Mounting Bolts Courtesy of CHRYSLER LLC 1 - BOLT (2) 2 - DRIVELINE MODULE 10. Remove two rear driveline module-to-crossmember bolts .

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Fig. 39: Module Mounting Bolt Courtesy of CHRYSLER LLC 1 - BOLT 2 - DRIVELINE MODULE 11. Remove the remaining driveline module-to-crossmember bolt (1) . 12. Lower driveline module assembly just enough to facilitate removal of shaft from differential. Make sure Seal Protector 9099 engages seal. 13. Remove halfshaft from hub/bearing assembly. INSTALLATION INSTALLATION

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Fig. 40: Seal Protector Courtesy of CHRYSLER LLC 1 - HALFSHAFT 2 - SEAL PROTECTOR 1. Install halfshaft to hub/bearing assembly. Install hub nut and washer but do not tighten at this time. 2. Using Seal Protector 9099 (2) , install halfshaft (1) to differential assembly. Clean tool and seal area to prevent debris intrusion.

Fig. 41: Module Mounting Bolt Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:45:32 PM

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1 - BOLT 2 - DRIVELINE MODULE 3. Raise driveline module into position. Install module mounting bolt (1) .

Fig. 42: Module Mounting Bolts Courtesy of CHRYSLER LLC 1 - BOLT (2) 2 - DRIVELINE MODULE 4. 5. 6. 7. 8.

Install remaining two module mounting bolts (2) . Torque module-to-cradle bolts to 102 N.m (75 ft. lbs.) Torque the halfshaft/hub nut to 160 N.m (118 ft.lbs.). Install wheel center cap. Check and adjust differential fluid level. See STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE

SPECIFICATIONS SPECIFICATIONS

DESCRIPTION Bolt, Propeller Shaft-toDriveline Module Bolt/Nut, Driveline Module-to-Cradle Nut, Hub

N.m

Ft. Lbs.

In. Lbs.

55

40

-

102

75

-

160

118

-

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Nuts, Rear Wheel Lug

135

100

-

SPECIAL TOOLS SPECIAL TOOLS

Fig. 43: Protector, 9099 Courtesy of CHRYSLER LLC

INTERMEDIATE SHAFT, GAS REMOVAL 2.4L

1. Remove the right half shaft. See Removal .

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Fig. 44: Intermediate Shaft - 2.4L Courtesy of CHRYSLER LLC 2. Remove the three intermediate shaft bolts (1). 3. Remove the intermediate shaft (2). 2.7L

1. Remove the right half shaft. See Removal .

Fig. 45: Identifying Intermediate Shaft, Heat Shield & Bolts Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:45:32 PM

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2. 3. 4. 5.

Remove the heat shield bolts (2). Remove the heat shield (3). Remove the intermediate shaft bolts (1) and (5). Remove the intermediate shaft (4).

3.5L

1. Remove the right half shaft. See Removal .

Fig. 46: 3.5L Right Half Shaft Components Courtesy of CHRYSLER LLC 2. 3. 4. 5.

Remove the intermediate shaft bolts (1). Remove the heat shield bolts (2). Remove the heat shield (3). Remove the intermediate shaft (4).

INSTALLATION 2.4L

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Fig. 47: Intermediate Shaft - 2.4L Courtesy of CHRYSLER LLC 1. Install the intermediate shaft (2). 2. Install the three intermediate shaft bolts (1). 3. Install the right half shaft. See Removal . 2.7L

Fig. 48: Identifying Intermediate Shaft, Heat Shield & Bolts Courtesy of CHRYSLER LLC 1. Install the intermediate shaft (4). 2. Install the intermediate shaft bolts (1) and (5). Tighten bolt (1) to 38 Nm (28 ft. lb.) and bolts (5) to 23 user Monday, June 04, 2012 4:45:32 PM

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Nm (17 ft. lb.). 3. Install the heat shield (3). 4. Install the heat shield bolts (2). 5. Install the right half shaft. See Installation . 3.5L

Fig. 49: 3.5L Right Half Shaft Components Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Install the intermediate shaft (4). Install the intermediate shaft bolts (1) and tighten to 38 Nm (28 ft. lb.). Install the heat shield (3). Install the heat shield bolts (2) and tighten to 10 Nm (7 ft. lb). Install the right half shaft. See Installation .

INTERMEDIATE SHAFT, DIESEL REMOVAL 2.0L DIESEL

1. Remove the right half shaft. See Removal .

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Fig. 50: 2.0L Diesel Right Half Shaft Components Courtesy of CHRYSLER LLC 2. Remove the two intermediate shaft bolts (1). 3. Remove the intermediate shaft (2).

Fig. 51: Intermediate Shaft Bracket & Bolts Courtesy of CHRYSLER LLC 4. If necessary, remove the intermediate shaft bracket bolts (1) and the intermediate shaft bracket (2). INSTALLATION user Monday, June 04, 2012 4:45:32 PM

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2.0L DIESEL

Fig. 52: Intermediate Shaft Bracket & Bolts Courtesy of CHRYSLER LLC 1. If the intermediate shaft bracket was removed, install the intermediate shaft bracket (2), and the intermediate shaft bracket bolts (1). Tighten the bolts to 23 Nm (17 in. lbs.).

Fig. 53: 2.0L Diesel Right Half Shaft Components Courtesy of CHRYSLER LLC 2. Install the intermediate shaft (2). 3. Install the two intermediate shaft bolts (1). Tighten the bolts to 38 Nm (28 in. lbs.). user Monday, June 04, 2012 4:45:32 PM

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4. Install the right axle half shaft. See Installation .

PROPELLER SHAFT DESCRIPTION DESCRIPTION

WARNING: Due to propeller shaft imbalance concerns, the propeller shaft can only be serviced as an assembly. AWD models utilize a "three-piece" propeller shaft to transmit torque to the rear driveline module assembly. This three-piece design consists of: z z z z

Front center and rear shaft segments Plunging front CV joint. Center support bearings Rubber coupler at driveline module flange

The front shaft segment utilizes a plunging CV joint at the power transfer unit connection. The center and rear shaft segments utilize a support bearing/bracket assembly. The rear shaft segment uses a rubber coupler at the driveline module flange. OPERATION OPERATION

The propeller shaft is used to transmit torque from the transaxle power transfer unit (PTU) to the rear driveline module of AWD equipped models. The propeller shaft front segment utilizes a plunging CV joint at the PTU flange. The joint is flexible, allowing for torsional movement of the powertrain. The propeller shaft center and rear segments utilize a support bearing/bracket, which support this three-piece assembly and isolates driveline vibrations from the body. The rubber coupler at the driveline module flange dampens out propeller shaft torsional vibrations, as the driveline module it connects to is fastened to the rear suspension crossmember. REMOVAL REMOVAL

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Fig. 54: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC CAUTION: Propeller shaft removal is a two-man operation. Never allow propeller shaft to hang from the center bearing, or while only connected to power transfer unit (PTU) or rear driveline module flanges. A helper is required. If a propshaft section is hung unsupported, damage may occur to the joint, boot, and/or center bearing from over-angulation. This may result in driveline vibrations. NOTE:

1. 2. 3. 4.

Rubber coupler is part of the propeller shaft assembly. Removing coupler from propeller shaft will result in vibration/balance issues.

Make sure transaxle is in neutral (N). Raise vehicle on hoist. Apply alignment index marks (4) on the rear axle flange (5) and rubber coupler (1). Remove three rear propeller shaft rubber coupler to rear axle input flange retaining bolts (3).

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Fig. 55: Center Bracket/Heat Shield Courtesy of CHRYSLER LLC 5. Remove the bolts (3) from the center support heat shield (2). 6. Remove the heat shield (2). 7. Remove the center support mounting bolts (1).

Fig. 56: Removing / Installing Propeller Shaft Courtesy of CHRYSLER LLC 8. Remove the bolts (2) at the PTU 9. Remove the propeller shaft (3). INSTALLATION user Monday, June 04, 2012 4:45:32 PM

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INSTALLATION

Fig. 57: Removing / Installing Propeller Shaft Courtesy of CHRYSLER LLC CAUTION: Propeller shaft installation. Never allow propeller shaft to hang while connected to Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation. This may result in vibration/balance issues. A helper may be needed. 1. Make sure transaxle is in Neutral (N) position. 2. Raise vehicle on hoist. 3. Obtain a helper if needed and lift propeller shaft assembly into position. Install propeller shaft to PTU with mounting bolts and tighten to 30 N.m (22 ft. lbs.).

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2009 Dodge Journey SE 2009 DRIVELINE/AXLES Differential and Driveline - Journey

Fig. 58: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 4. Align marks (4) on propeller shaft rubber coupler (1) to rear axle input flange (5). 5. Install three rear propeller shaft to rear axle retaining bolts (3) and tighten to 58 N.m (43 ft. lbs.).

Fig. 59: Center Bracket/Heat Shield Courtesy of CHRYSLER LLC 6. Raise the center support into position and install mounting bolts (1), tighten bolts to 41 N.m (30 lbs.ft.). 7. Install heat shield (2) and retaining nuts tighten to 21 N.m (15 ft. lbs.). 8. Lower vehicle. user Monday, June 04, 2012 4:45:32 PM

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REAR DRIVELINE MODULE OPERATION OPERATION

The primary benefits of All Wheel Drive are: z z

Superior straight line acceleration, and cornering on all surfaces Better traction and handling under adverse conditions, resulting in improved hill climbing ability and safer driving.

The electronically controlled clutch (ECC) controls torque transfer to the rear differential assembly. ECU (Inside vehicle) uses throttle position, wheel speeds and steering angle (if equipped) to control clutch. DIAGNOSIS AND TESTING REAR DRIVELINE MODULE NOISE

Different sources can be the cause of noise that the rear driveline module assembly is suspected of making. Refer to the following causes for noise diagnosis. DRIVELINE MODULE ASSEMBLY NOISE

The most important part of driveline module service is properly identifying the cause of failures and noise complaints. The cause of most driveline module failures is relatively easy to identify. The cause of driveline module noise is more difficult to identify. If vehicle noise becomes intolerable, an effort should be made to isolate the noise. Many noises that are reported as coming from the driveline module may actually originate at other sources. For example: z z z z z z z z

Tires Road surfaces Wheel bearings Engine Transmission Exhaust Propeller shaft (vibration) Vehicle body (drumming)

Driveline module noises are normally divided into two categories: gear noise or bearing noise. A thorough and careful inspection should be completed to determine the actual source of the noise before replacing the driveline module. user Monday, June 04, 2012 4:45:32 PM

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The rubber mounting bushings help to dampen-out driveline module noise when properly installed. Inspect to confirm that no metal contact exists between the driveline module case and the body or suspension cradle. The complete isolation of noise to one area requires expertise and experience. Identifying certain types of vehicle noise baffles even the most capable technicians. Often such practices as: z z z

Increase tire inflation pressure to eliminate tire noise. Listen for noise at varying speeds with different driveline load conditions Swerving the vehicle from left to right to detect wheel bearing noise.

All driveline module assemblies produce noise to a certain extent. Slight carrier noise that is noticeable only at certain speeds or isolated situations should be considered normal. Carrier noise tends to peak at a variety of vehicle speeds. Noise is NOT ALWAYS an indication of a problem within the carrier. TIRE NOISE

Tire noise is often mistaken for driveline module noise. Tires that are unbalanced, worn unevenly or are worn in a saw-tooth manner are usually noisy. They often produce a noise that appears to originate in the driveline module. Tire noise changes with different road surfaces, but driveline module noise does not. Inflate all four tires with approximately 20 psi (138 kPa) more than the recommended inflation pressure (for test purposes only). This will alter noise caused by tires, but will not affect noise caused by the differential. Rear axle noise usually ceases when coasting at speeds less than 30 mph (48 km/h); however, tire noise continues, but at a lower frequency, as the speed is reduced. After test has been completed lower tire pressure back to recommended pressure. GEAR NOISE (DRIVE PINION AND RING GEAR)

Abnormal gear noise is rare and is usually caused by scoring on the ring gear and drive pinion. Scoring is the result of insufficient or incorrect lubricant in the carrier housing. Abnormal gear noise can be easily recognized. It produces a cycling tone that will be very pronounced within a given speed range. The noise can occur during one or more of the following drive conditions: z z z z

Drive Road load Float Coast

Abnormal gear noise usually tends to peak within a narrow vehicle speed range or ranges. It is usually more pronounced between 30 to 40 mph (48 to 64 km/h) and 50 to 60 mph (80 to 96 km/h). When objectionable gear noise occurs, note the driving conditions and the speed range. BEARING NOISE (DRIVE PINION AND DIFFERENTIAL)

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Defective bearings produce a rough growl that is constant in pitch and varies with the speed of vehicle. Being aware of this will enable a technician to separate bearing noise from gear noise. Drive pinion bearing noise that results from defective or damaged bearings can usually be identified by its constant, rough sound. Drive pinion front bearing is usually more pronounced during a coast condition. Drive pinion rear bearing noise is more pronounced during a drive condition. The drive pinion bearings are rotating at a higher rate of speed than either the differential side bearings or the axle shaft bearing. Differential side bearing noise will usually produce a constant, rough sound. The sound is much lower in frequency than the noise caused by drive pinion bearings. Bearing noise can best be detected by road testing the vehicle on a smooth road (black top). However, it is easy to mistake tire noise for bearing noise. If a doubt exists, the tire treads should be examined for irregularities that often causes a noise that resembles bearing noise. ENGINE AND TRANSMISSION NOISE

Sometimes noise that appears to be in the driveline module assembly is actually caused by the engine or the transmission. To identify the true source of the noise, note the approximate vehicle speed and/or RPM when the noise is most noticeable. Stop the vehicle next to a flat brick or cement wall (this will help reflect the sound). Place the transaxle in NEUTRAL . Accelerate the engine slowly up through the engine speed that matches the vehicle speed noted when the noise occurred. If the same noise is produced, it usually indicates that the noise is being caused by the engine or transaxle. REAR DRIVELINE MODULE OPERATION

Driveline module operation requires relatively straight-forward diagnosis. Refer to the following chart: CONDITION No AWD in forward or reverse directions, propeller shaft turning No AWD in forward or reverse directions, propeller shaft not turning Vibration at all speeds, continuous torque transfer

POSSIBLE CAUSES 1. Check ECC 2. Rear differential failure

CORRECTION 1. Review ECC diagnostic information 2. Replace the rear differential assembly

1. Power transfer unit failure.

1. Replace power transfer unit components as necessary

1. Mis-matched tires, worn tires on front axle.

1. Replace worn or incorrect (mismatched) tires with same make and size

REMOVAL REMOVAL

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2009 Dodge Journey SE 2009 DRIVELINE/AXLES Differential and Driveline - Journey

Fig. 60: Support Module With Jack Courtesy of CHRYSLER LLC 1 - DRIVELINE MODULE 2 - TRANSMISSION JACK NOTE:

Rear suspension and drivetrain design require this procedure to be performed on a "drive-on" hoist, as the front and rear suspension needs to be compressed to ride height to facilitate rear halfshaft removal.

1. 2. 3. 4.

Make sure transaxle is in Neutral (N) position. Raise vehicle on hoist. Remove exhaust system center hanger (at propeller shaft bearing/support). Disconnect exhaust system at rear-most hanger and lower at least 254 mm (10 in.). Support system with suitable wire or rope. 5. Drain differential lubricant to prevent fluid spillage upon removal. See STANDARD PROCEDURE DIFFERENTIAL ASSEMBLY FLUID CHANGE. 6. Support driveline module (1) with transmission jack (2) (or equivalent).

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Fig. 61: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 7. Apply alignment index marks (4) on the rear axle flange (5) and rubber coupler (1). 8. Remove three rear propeller shaft rubber coupler to rear axle input flange retaining bolts (3).

Fig. 62: ECC Electrical Connector Courtesy of CHRYSLER LLC 9. Unplug ECC electrical connector.

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Fig. 63: Seal Protector Courtesy of CHRYSLER LLC 1 - HALFSHAFT 2 - SEAL PROTECTOR 10. Using suitable screwdriver, partially dislodge halfshafts (1) from differential. Install Seal Protector 9099 (2) to protect seal upon disassembly. Clean tool and seal area to prevent debris intrusion.

Fig. 64: RDA To Crossmember Bolts Courtesy of CHRYSLER LLC 11. Remove the RDA - to - crossmember mounting bolts (1). user Monday, June 04, 2012 4:45:32 PM

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Fig. 65: Rear RDA Module-To-Crossmember Bolt Courtesy of CHRYSLER LLC 12. Remove the rear RDA module-to-crossmember bolt (2).

Fig. 66: Secure Propeller Shaft to Exhaust Courtesy of CHRYSLER LLC 1 - PROPELLER SHAFT 2 - EXHAUST SYSTEM 3 - STRAP 13. Lower driveline module assembly just enough to facilitate removal of halfshafts from differential. Make sure Seal Protector 9099 engages seal. user Monday, June 04, 2012 4:45:32 PM

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14. Disconnect propeller shaft (1) from driveline module and secure to exhaust system (2) or support with jack stand. CAUTION: Do not allow the propeller shaft to hang from the vehicle unsupported. Damage may occur to the joint, boot, and center bearing from over-angulation. 15. Remove driveline module assembly. INSTALLATION INSTALLATION

Fig. 67: Seal Protector Courtesy of CHRYSLER LLC 1 - HALFSHAFT 2 - SEAL PROTECTOR 1. Install driveline module to transmission jack. Secure module to jack. 2. Using Seal Protector 9099 (2), load halfshafts to differential, one side at a time. Clean tool and seal area to prevent debris intrusion.

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Fig. 68: Support Module With Jack Courtesy of CHRYSLER LLC 1 - DRIVELINE MODULE 2 - TRANSMISSION JACK 3. Raise driveline module (1) into position.

Fig. 69: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 4. Align marks (4) on propeller shaft rubber coupler (1) to rear axle input flange (5). 5. Install three rear propeller shaft to rear axle retaining bolts (3) but do not tighten at this time. user Monday, June 04, 2012 4:45:32 PM

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Fig. 70: RDA To Crossmember Bolts Courtesy of CHRYSLER LLC 6. Install the RDA - to - crossmember mounting bolts (1) and tighten to 102 N.m (75 ft. lbs.).

Fig. 71: Rear RDA Module-To-Crossmember Bolt Courtesy of CHRYSLER LLC 7. 8. 9. 10.

Install the rear RDA - to - crossmember mounting bolt (2) to 102 N.m (75 ft. lbs.) Tighten propeller shaft-to-driveline module bolts to 58 N.m (43 ft.lbs.). Raise exhaust system into position and install hanger/brackets. Fill differential with 0.7L (0.74 Quarts) of Mopar® Gear and Axle Lubricant (75W-90). See STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE.

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SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS DESCRIPTION Bolt, Driveline Moduleto-Body Bolt, Overrunning Clutch Housing-to-Differential Nut, Input Flange Plug, Differential Drain/Fill Bolt, Module to Cradle Bolts, Propeller Shaft-toDriveline Module

N.m

Ft. Lbs.

In. Lbs.

54

40

-

60

44

-

135

100

-

35

26

-

102

75

-

54

40

-

SPECIAL TOOLS SPECIAL TOOLS

Fig. 72: Flange Wrench, C-3281 Courtesy of CHRYSLER LLC

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Fig. 73: Installer 8493 Courtesy of CHRYSLER LLC

Fig. 74: Installer 9231A Courtesy of CHRYSLER LLC

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Fig. 75: Protector, 9099 Courtesy of CHRYSLER LLC

Fig. 76: Universal Handle C-4171 Courtesy of CHRYSLER LLC CASE ASSEMBLY, DIFFERENTIAL Description DESCRIPTION

The differential gear system divides the torque between the axle shafts. It allows the axle shafts to rotate at different speeds when turning corners. user Monday, June 04, 2012 4:45:32 PM

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Each differential side gear is splined to an axle shaft. The pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft. The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts. Operation OPERATION

Fig. 77: Differential Operation-Straight Ahead Driving Courtesy of CHRYSLER LLC 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE In operation, power flow occurs as follows: z z z z

The pinion gear (2) rotates the ring gear The ring gear (bolted to the differential case) rotates the case The differential pinion gears (mounted on the pinion mate shaft in the case) rotate the side gears The side gears (splined to the axle shafts) rotate the shafts

During straight-ahead driving, the differential pinion gears do not rotate on the pinion mate shaft. This occurs user Monday, June 04, 2012 4:45:32 PM

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because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it.

Fig. 78: Pinion Gears Courtesy of CHRYSLER LLC 1 - PINION GEARS ROTATE ON PINION SHAFT When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns. To accomplish this, the differential allows the axle shafts to turn at unequal speeds. In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed. FLUID, DIFFERENTIAL Standard Procedure STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE

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Fig. 79: Differential Assembly Fluid Change Courtesy of CHRYSLER LLC The drain plug (2) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (3) for the differential assembly is located on the left side of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. 1. 2. 3. 4. 5. 6. 7.

Raise the vehicle on a hoist. Position a drain pan under the differential drain plug. Remove the drain plug and allow the fluid to drain into the pan. Install the drain plug and torque to 35 N.m (26 ft. lbs.). Re-position the drain pan under the differential fill plug. Remove the differential fill plug. Using a suction gun or equivalent, fill the differential assembly with 0.7 L (0.74 Quarts) of Mopar® Gear and Axle Lubricant (75W-90). 8. Install the fill plug and torque to 35 N.m (26 ft. lbs.). SEAL, INPUT FLANGE Removal REMOVAL

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Fig. 80: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC NOTE: 1. 2. 3. 4.

Rubber coupler is part of the propeller shaft assembly. Removing coupler from propeller shaft will result in vibration/balance issues.

Raise vehicle on hoist. Apply alignment index marks (4) on the rear axle flange (5) and rubber coupler (1). Remove three rear propeller shaft rubber coupler to rear axle input flange retaining bolts (3). Slide propeller shaft (2) back off rear axle input flange (5) and move out of the way as needed.

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Fig. 81: Pinion Flange Nut Removal/Installation Courtesy of CHRYSLER LLC 5. Using tool C-3281 (1), loosen input flange nut.

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Fig. 82: Input Flange Nut Removal/Installation Courtesy of CHRYSLER LLC 1 - NUT 6. Remove input flange nut (1), and discard.

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Fig. 83: Input Flange Washer Courtesy of CHRYSLER LLC 1 - WASHER 7. Remove input flange washer (1).

Fig. 84: Suitable Puller & Input Flange Courtesy of CHRYSLER LLC 8. Using suitable puller (2), remove input flange (1).

Fig. 85: Input Flange Seal Removal/Installation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:45:32 PM

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1 - SEAL 2 - SCREWDRIVER 9. Using suitable screwdriver (2), remove input flange seal from overrunning clutch housing. Installation INSTALLATION

Fig. 86: Clutch Case Courtesy of CHRYSLER LLC 1. Using tool 9231A (1), install input flange seal to overrunning clutch case (2).

Fig. 87: Input Flange Shaft Seal user Monday, June 04, 2012 4:45:32 PM

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Courtesy of CHRYSLER LLC 2. Install input flange shaft seal (1), on shaft threads at midway point of threads (2).

Fig. 88: Input Flange Removal/Installation Courtesy of CHRYSLER LLC 1 - INPUT FLANGE 3. Install input flange (1).

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Fig. 89: Input Flange Washer Courtesy of CHRYSLER LLC 1 - WASHER 4. Install flange washer (1).

Fig. 90: Input Flange Nut Removal/Installation Courtesy of CHRYSLER LLC 1 - NUT 5. Install new flange nut (1).

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Fig. 91: Pinion Flange Nut Removal/Installation Courtesy of CHRYSLER LLC 6. Using tool C-3281 (2), torque flange nut to 135 N.m (100 ft. lbs.).

Fig. 92: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 7. Align marks (4) on propeller shaft rubber coupler (1) to rear axle input flange (5). 8. Install three rear propeller shaft to rear axle retaining bolts (3) and tighten to 58 N.m (43 ft. lbs.). 9. Lower vehicle. SEAL, OUTPUT FLANGE Removal REMOVAL

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2009 Dodge Journey SE 2009 DRIVELINE/AXLES Differential and Driveline - Journey

Fig. 93: Axle Seal Removal Courtesy of CHRYSLER LLC 1 - SEAL 2 - SCREWDRIVER 1. Raise vehicle on hoist. 2. Remove rear driveline module. See Removal 3. Use suitable screwdriver (2) to remove output seal (1). Installation INSTALLATION

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Fig. 94: Axle Seal Installation Courtesy of CHRYSLER LLC 1 - HANDLE C-4171 2 - INSTALLER 8493 1. Install output flange seal to differential housing using handle C- 4171A (1) and installer 8493 (2). 2. Install rear driveline module. See Installation 3. Check differential assembly fluid level and adjust as required. See STANDARD PROCEDURE DIFFERENTIAL ASSEMBLY FLUID CHANGE

ELECTRONICALLY CONTROLLED CLUTCH REMOVAL REMOVAL

NOTE:

Rubber coupler is part of the propeller shaft assembly. Removing coupler from propeller shaft will result in vibration/balance issues.

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2009 Dodge Journey SE 2009 DRIVELINE/AXLES Differential and Driveline - Journey

Fig. 95: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Make sure transaxle is in neutral (N). Raise vehicle on hoist. Apply alignment index marks (4) on the rear axle flange (5) and rubber coupler (1). Remove three rear propeller shaft rubber coupler to rear axle input flange retaining bolts (3). Slide propeller shaft (2) back off rear axle input flange (5) and move out of the way as needed.

Fig. 96: Electrical Connector At ECC Courtesy of CHRYSLER LLC 6. Unplug the electrical connector at the ECC. 7. Remove the mounting bolts at the ECC. 8. Remove the ECC. user Monday, June 04, 2012 4:45:32 PM

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INSTALLATION INSTALLATION

Fig. 97: Electrical Connector At ECC Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Make sure transaxle is in Neutral (N) position. Raise vehicle on hoist. Install the ECC. Install the mounting bolts at the ECC and tighten to 60 N.m (44 ft. lbs.). Connect the electrical connector at the ECC.

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Fig. 98: Removing /Installing Propeller Shaft Courtesy of CHRYSLER LLC 6. Align marks (4) on propeller shaft rubber coupler (1) to rear axle input flange (5). 7. Install three rear propeller shaft to rear axle retaining bolts (3) and tighten to 58 N.m (43 ft. lbs.). 8. Lower vehicle.

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

2009 ELECTRICAL Battery System - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Battery Components Courtesy of CHRYSLER LLC This vehicle is equipped with a single 12-volt battery. All of the components of the battery system are located in the front of the vehicle, just ahead of the left front wheel and tire assembly. The battery system for this vehicle contains the following components: z

z

z z

Battery (4) - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle. Positive (2) and Negative (1) Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to the vehicle electrical system. Battery Hold-down (5) - The battery hold-down hardware secures the battery in the battery tray. Battery Tray (6) - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery hold-down hardware.

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

Fig. 2: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. For battery system maintenance schedules. Refer to Vehicle Quick Reference/Maintenance Schedules Description . For the proper jump starting procedures, Refer to the vehicle Owner's Manual.

OPERATION OPERATION The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and storing electrical energy. This electrical energy is required to operate the engine starting system, as well as to operate many of the other vehicle accessory systems for limited durations while the engine and/or the charging system are not operating. The battery system is also designed to provide a reserve of electrical energy to supplement the charging system for short durations while the engine is running and the electrical current demands of the vehicle exceed the output of the charging system. In addition to delivering, and storing electrical energy for the vehicle, the battery system serves as a capacitor and voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or transient voltages caused by the switching of any of the electrical components or circuits in the vehicle.

DIAGNOSIS AND TESTING user Monday, June 04, 2012 5:03:17 PM

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

BATTERY SYSTEM The battery, starting, and charging systems in the vehicle operate with one another and must be tested as a complete system. In order for the engine to start and the battery to maintain its charge properly, all of the components that are used in these systems must perform within specifications. It is important that the battery, starting, and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal battery discharge, overcharging or early battery failure must be diagnosed and corrected before a battery is replaced and before a vehicle is returned to service. The service information for these systems has been separated within this service information to make it easier to locate the specific information you are seeking. However, when attempting to diagnose any of these systems, it is important that you keep their interdependency in mind. The diagnostic procedures used for the battery, starting, and charging systems include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, a volt/ohmmeter, a battery charger, a carbon pile rheostat (load tester) and a 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to Electrical - Engine Systems/Charging - Diagnosis and Testing for the proper charging system on-board diagnostic test procedures. MICRO 420 BATTERY TESTER (GASOLINE ENGINES)

The Micro 420 automotive battery tester is designed to help diagnose the cause of a defective battery. Follow the instruction service information supplied with the tester to properly diagnose a vehicle. If the instruction service information is not available. See Standard Procedure which includes the directions for using the Micro 420 battery tester. OTC ONE STEP BATTERY ANALYZER AND CHARGER (DIESEL ENGINES)

The OTC One Step Battery Analyzer and Charger is designed to help diagnose the cause of a defective battery. Follow the instruction service information supplied with the tester to properly diagnose a vehicle. BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS WEAK 1. The electrical system 1. See Standard Procedure for the OR DEAD WHEN ATTEMPTING ignition-off draw is appropriate test procedures. Repair the TO START THE ENGINE. excessive. excessive ignition-off draw, as required. 2. The charging system is 2. Determine if the charging system is inoperative. performing to specifications. Refer to Electrical - Engine Systems/Charging Diagnosis and Testing for the appropriate charging system diagnosis and testing procedures. Repair the inoperative charging system, as required. 3. The battery is 3. Determine the battery state-of-charge discharged. using the appropriate battery tester. user Monday, June 04, 2012 5:03:17 PM

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

THE BATTERY STATE OF CHARGE CANNOT BE MAINTAINED.

Charge the inoperative battery, as required. 4. The battery terminal 4. See Diagnosis and Testing for the connections are loose or appropriate battery cable diagnosis and corroded. testing procedures. Clean and tighten the battery terminal connections, as required. 5. The battery has an 5. See Specifications for the proper incorrect size or rating for battery size and rating. Replace an this vehicle. incorrect battery, as required. 6. The battery is 6. Test the battery using the appropriate inoperative. battery tester. Replace the inoperative battery, as required. 7. The starting system is 7. Determine if the starting system is inoperative. performing to specifications. Refer to Electrical - Engine Systems/Starting Diagnosis and Testing for the appropriate starting system diagnosis and testing procedures. Repair the inoperative starting system, as required. 8. The battery is 8. Inspect the battery for loose terminal physically damaged. posts or a cracked and leaking case. Replace the damaged battery, as required. 1. The battery has an 1. See Specifications for the proper incorrect size or rating for battery size and rating. Replace an this vehicle. incorrect battery, as required. 2. The battery terminal 2. See Diagnosis and Testing for the connections are loose or appropriate battery cable diagnosis and corroded. testing procedures. Clean and tighten the battery terminal connections, as required. 3. The electrical system 3. See Standard Procedure for the ignition-off draw is appropriate test procedures. Repair the excessive. excessive ignition-off draw, as required. 4. The battery is 4. Test the battery using the appropriate inoperative. battery tester. Replace the inoperative battery, as required. 5. The starting system is 5. Determine if the starting system is inoperative. performing to specifications. Refer to Electrical - Engine Systems/Starting Diagnosis and Testing for the appropriate starting system diagnosis and testing procedures. Repair the inoperative starting system, as required. 6. The charging system is 6. Determine if the charging system is inoperative. performing to specifications. Refer to Electrical - Engine Systems/Charging Diagnosis and Testing for the

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

THE BATTERY WILL NOT ACCEPT A CHARGE.

appropriate charging system diagnosis and testing procedures. Repair the inoperative charging system, as required. 7. Electrical loads exceed 7. Inspect the vehicle for aftermarket the output of the charging electrical equipment which might cause system. excessive electrical loads. 8. Slow driving or 8. Advise the vehicle operator, as prolonged idling with required. high-amperage draw loads in use. 1. The battery is 1. Test the battery using the appropriate inoperative. battery tester. Replace the inoperative battery, as required.

STANDARD PROCEDURE BATTERY RECONNECTION NOTE:

This reconnection procedure is to be performed anytime the battery has been disconnected.

1. Connect the negative battery cable remote terminal to the remote battery post and tighten the nut. CAUTION: Once the battery has been connected, review and perform the following information as applicable. ELECTRONIC STABILITY PROGRAM (ESP)

If the vehicle is equipped with ESP, once the battery is reconnected, the Steering Angle Sensor (SAS) in the clockspring needs to be calibrated. The SAS requires calibration anytime the battery or an ABS (ESP) component has been disconnected for any length of time. If the SAS is not calibrated following battery reconnection, the ESP/BAS indicator lamp is illuminated following five ignition cycles indicating the need for calibration. To calibrate, perform the following: 1. Start the engine. 2. Center the steering wheel. 3. Turn the steering wheel all the way to the left until the internal stop in the steering gear is met, then turn the wheel all the way to the right until the opposite internal stop in the steering gear is met. 4. Center the steering wheel. 5. Stop the engine.

CLEANING user Monday, June 04, 2012 5:03:17 PM

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

CLEANING The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in this service information and the Owner's Manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service.

Fig. 3: Cleaning Battery Cable Terminal Clamps Using Terminal Cleaning Tool Courtesy of CHRYSLER LLC 1. Clean the battery cable terminal clamps (2) of all corrosion. Remove any corrosion using a wire brush (1) or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution. 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.

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

Fig. 4: Cleaning Outside Of Battery Case Courtesy of CHRYSLER LLC 3. If the removed battery is to be reinstalled, clean the outside of the battery case (3) and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush (1) to remove any acid film. 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. See 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. Clean the battery thermal guard with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film.

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

Fig. 5: Cleaning Battery Terminal Post Using Terminal Cleaner Courtesy of CHRYSLER LLC 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.

INSPECTION INSPECTION The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this service information and the owner's manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. 1. Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or deformed terminal clamp. 2. Inspect the battery tray and battery hold-down 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 (if equipped). Replace any battery thermal guard that has been damaged. 5. Inspect the battery built-in test indicator sight glass (if equipped) for an indication of the battery condition. If the battery is discharged, charge as required. Refer to Standard Procedure for detailed instructions. user Monday, June 04, 2012 5:03:17 PM

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SPECIFICATIONS BATTERY The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below. NOTE:

z

z

z

z

z

Vehicles equipped with a diesel engine utilize a unique battery. The specifications for this battery may differ from the standards shown in this information. Refer to the battery manufacturer for detailed specifications.

Group Size - The outside dimensions and terminal placement of the battery conform to standards established by the Battery Council International (BCI). Each battery is assigned a BCI Group Size number to help identify a correctly-sized replacement. Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (in amperes) the battery can deliver for thirty seconds at -18° C (0° F). Terminal voltage must not fall below 7.2 volts during or after the thirty second discharge period. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the battery fully-charged at 26.7° C (80° F). This rating estimates how long the battery might last after a charging system failure, under minimum electrical load. Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can deliver steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating is also sometimes identified as the twenty-hour discharge rating. Load Test Amperage - The Load Test Amperage rating specifies the current (in amperes) that a battery should be tested at with the battery load test equipment. This value should always be 50 percent of the CCA. For example: if the CCA for this battery is 700 amps, the Load Test Amperage is 50 percent of that or 350 amps.

BCI Group Size Classification 34 86

BATTERY CLASSIFICATIONS AND RATINGS Cold Cranking Reserve Ampere Amperage Capacity Hours 700 120 Minutes 66 525 150 Minutes 75

Load Test Amperage 350 265

TORQUE TORQUE SPECIFICATIONS DESCRIPTION Battery Terminal Clamp

N.m

Ft. Lbs.

In. Lbs.

5

-

45

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Pinch-Bolt Hex Nut Negative Battery Cable Remote Terminal Nut Positive Battery Cable Remote Terminal Nut Battery Hold Down Bolt Starter Solenoid B(+) Terminal Stud Nut Battery Negative Cable Ground Eyelet Terminal To Engine Block Bolt Totally Integrated Power Module B(+) Terminal Stud Nut Battery Tray Support Bolt Battery Tray Bolt

16.5

-

145

16.5

-

145

16

-

142

13

-

115

16.5

-

145

10

-

90

16

-

142

16

-

142

SPECIAL TOOLS SPECIAL TOOLS

Fig. 6: Micro 420 Battery Tester - PSE p/n 165-EXP-1020KIT Courtesy of CHRYSLER LLC

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BATTERY DESCRIPTION DESCRIPTION

There are two different batteries available for this vehicle. Vehicles equipped with a diesel engine utilize a spiral cell battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery. This additional power is required by a diesel engine during cold cranking. Vehicles equipped with a gasoline engine utilize a conventional battery. Refer to the following information for detailed differences and descriptions of these two batteries. SPIRAL CELL BATTERY - DIESEL ENGINE

Fig. 7: Spiral Plate Battery - Typical Courtesy of CHRYSLER LLC WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery damage may result. By tightly winding layers of spiral grids and acid-permeated vitreous separators into cells, the battery has more power and service life than conventional batteries of the same size. The spiral cell battery is completely, permanently sealed. Through gas recombination, hydrogen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte, eliminating the need to add distilled water. Therefore, these batteries have non-removable battery vent caps. The acid inside a spiral cell battery is bound within the vitreous separators, ending the threat of acid leaks. This user Monday, June 04, 2012 5:03:17 PM

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feature allows the battery to be installed in any position anywhere in the vehicle. Spiral cell technology is the process by which the cells holding the active material in the battery are wound tightly in coils instead of hanging flat, like conventional batteries. This design has a lower internal resistance and also increases the active material surface area. Due to the maintanance-free design, distilled water cannot be added to this battery. Therefore, if more than 14.4 volts are used during the spiral cell battery charging process, water vapor can be exhausted through the pressure-sensitive battery vents and lost for good. This can permanently damage the spiral cell battery. CONVENTIONAL BATTERY - GASOLINE ENGINE

Low-maintenance conventional batteries are used on vehicles equipped with a gasoline engine, these batteries have non-removable battery cell caps. Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates. Conventional batteries are made up of six individual cells that are connected in series. Each cell contains positive charged cell groups made of lead oxide, and negatively charged cell groups made of sponge lead. The cells are submerged in a sulfuric acid and water solution called electrolyte. The battery is used to store electrical energy potential in a chemical form. When an electrical load is applied to the battery terminals, an electrochemical reaction occurs within the battery. This reaction causes the battery to discharge electrical current. OPERATION OPERATION

The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals. As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the battery discharging process is reversed. Charging the battery gradually changes the sulfated lead plates back into sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the difference in the electron charges deposited on the plates, and the voltage potential of the battery cells. For a battery to remain useful, it must be able to produce high-amperage current over an extended period. A battery must also be able to accept a charge, so that its voltage potential may be restored. The battery is vented to release excess hydrogen gas that is created when the battery is being charged or user Monday, June 04, 2012 5:03:17 PM

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discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may arc internally and explode. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level becomes low. DIAGNOSIS AND TESTING BATTERY

The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed. See Cleaning for the proper battery cleaning procedures. See Inspection for the proper battery inspection procedures. Refer to Standard Procedure for the proper battery charging procedures. MICRO 420 BATTERY TESTER (GASOLINE ENGINES)

The Micro 420 automotive battery tester is designed to help diagnose the cause of a defective battery. Follow the instruction service information supplied with the tester to properly diagnose a vehicle. If the instruction service information is not available refer toStandard Procedure , which includes the directions for using the Micro 420 battery tester. OTC ONE STEP BATTERY ANALYZER AND CHARGER (DIESEL ENGINES)

The OTC One Step Battery Analyzer and Charger is designed to help diagnose the cause of a defective battery. Follow the instruction information supplied with the tester to properly diagnose a vehicle. WARNING: If the battery shows signs of freezing, leaking or loose posts, do not test, assist-boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result. WARNING: Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result. WARNING: The battery contains sulfuric acid, which is poisonous and caustic. Avoid contact with the skin, eyes, or clothing. In the event of contact, flush with water and call a physician immediately. Keep out of the reach of children. WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery damage may result. A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fullycharged battery must be tested to determine its cranking capacity. A battery that is fully-charged, but fails the OTC One Step Battery Analyzer and Charger or other load test, is faulty and must be replaced. user Monday, June 04, 2012 5:03:17 PM

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NOTE:

Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedure for the proper battery charging procedures.

STANDARD PROCEDURE SPIRAL CELL BATTERY CHARGING

WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery damage may result. Vehicles equipped with a diesel engine utilize a unique spiral cell battery. This battery has a maximum charging voltage that must not be exceeded in order to restore the battery to its full potential, failure to use the following spiral cell battery charging procedure could result in damage to the battery or personal injury. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: z

z z

OTC One Step Battery Analyzer and Charger special tool number OT-3641 or equivalent tester indicates battery is OK. Open-circuit voltage of the battery is 12.65 volts or above. Battery passes Load Test multiple times. WARNING: If the battery shows signs of freezing, leaking, loose posts or low electrolyte level, do not test, assist-boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result. WARNING: Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result. WARNING: The battery contains sulfuric acid, which is poisonous and caustic. Avoid contact with the skin, eyes, or clothing. In the event of contact, flush with water and call a physician immediately. Keep out of the reach of children. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Charge the battery directly at the battery terminals. Do not exceed 14.4 volts while charging a battery. CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result.

After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. If the battery passes a load test, return the battery to service. If the battery fails a load test, it is faulty user Monday, June 04, 2012 5:03:17 PM

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and must be replaced. Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. See Cleaning for the proper battery system cleaning procedures. See Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED SPIRAL CELL BATTERY

WARNING: Never exceed 14.4 volts when charging a spiral cell battery. Personal injury and/or battery damage may result. The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

Fig. 8: Voltmeter Courtesy of CHRYSLER LLC 1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. Refer to Battery Removal and Installation for access instructions. If the reading is below ten volts, the battery charging current will be low. It could take several hours before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers. 2. Disconnect and isolate the battery negative cable. Connect the OTC One Step Battery Analyzer and Charger special tool number OT-3641 or equivalent. NOTE:

Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.

3. Battery chargers vary in the amount of voltage and current they provide. The amount of time required for user Monday, June 04, 2012 5:03:17 PM

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a battery to accept measurable charging current at various voltages is shown in SPIRAL CELL BATTERY CHARGE RATE TABLE . If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. SPIRAL CELL BATTERY CHARGE RATE TABLE Voltage 14.4 volts maximum 13.0 to 14 volts 12.9 volts or less

Minutes up to 10 minutes up to 20 minutes up to 30 minutes

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors: z

z

z

z

Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. 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 eight amperes will require a shorter charging time. State-Of-Charge - A completely discharged battery 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 battery charges, the specific gravity of the electrolyte will gradually rise.

The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity. SPIRAL CELL BATTERY CHARGE TIME TABLE Charging Amperage Open Circuit Voltage 12.25 to 12.49 12.00 to 12.24 10.00 to 11.99 Below 10.00

5 Amps 8 Amps Hours Charging @ 21° C (70° F) 6 hours 3 hours 10 hours 5 hours 14 hours 7 hours 18 hours 9 hours

CONVENTIONAL BATTERY CHARGING

CAUTION: Vehicles equipped with a diesel engine utilize a unique spiral cell battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the spiral cell battery charging procedure could result in damage to the battery or user Monday, June 04, 2012 5:03:17 PM

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personal injury. See Standard Procedure for the appropriate procedure. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: z z z

Micro 420 battery tester indicates battery is OK. Open-circuit voltage of the battery is 12.65 volts or above. Battery passes Load Test multiple times. WARNING: If the battery shows signs of freezing, leaking, loose posts, do not test, assist-boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result. WARNING: Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result. WARNING: The battery contains sulfuric acid, which is poisonous and caustic. Avoid contact with the skin, eyes, or clothing. In the event of contact, flush with water and call a physician immediately. Keep out of the reach of children. WARNING: If the battery is equipped with removable cell caps, be certain that each of the cell caps is in place and tight before the battery is returned to service. Personal injury and/or vehicle damage may result from loose or missing cell caps. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result. CAUTION: Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery may result from overcharging. CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result.

After the battery has been charged to an open-circuit voltage reading of 12.4 volts or greater, retest the battery with the Micro 420 tester or perform a load test to determine the battery cranking capacity. See Standard Procedure for the proper battery test procedures. If the battery passes a load test, return the battery to service. If the battery fails a load test, it is faulty and must be replaced. user Monday, June 04, 2012 5:03:17 PM

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Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. See Cleaning for the proper battery system cleaning procedures. See Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

Fig. 9: Identifying Battery Load Tester Courtesy of CHRYSLER LLC 1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers. 2. Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry. 3. Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the CONVENTIONAL BATTERY CHARGE RATE TABLE . If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. CONVENTIONAL BATTERY CHARGE RATE TABLE Voltage

Minutes

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16.0 volts maximum 14.0 to 15.9 volts 13.9 volts or less

up to 10 min. up to 20 min. up to 30 min.

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors: z

z

z

z

Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. 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 charging time. State-Of-Charge - A completely discharged battery 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 battery charges, the specific gravity of the electrolyte will gradually rise.

The Conventional Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity. CONVENTIONAL BATTERY CHARGING TIME TABLE Charging Amperage 5 Amps 10 Amps 20 Amps Open Circuit Voltage Hours Charging @ 21° C (70° F) 12.25 to 12.49 6 hours 3 hours 1.5 hours 12.00 to 12.24 10 hours 5 hours 2.5 hours 10.00 to 11.99 14 hours 7 hours 3.5 hours Below 10.00 18 hours 9 hours 4.5 hours USING MICRO 420 BATTERY TESTER (GASOLINE ENGINES)

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Fig. 10: Identifying Micro Battery Tester Courtesy of CHRYSLER LLC NOTE:

The Micro 420 battery tester should only be used to test vehicles equipped with gasoline engines. If the vehicle being tested has a diesel engine the OTC, One Step Battery Analyzer and Charger (OTC) special tool number OT-3641 or equivalent should be used to test the battery.

Always use the Micro 420 instruction manual that was supplied with the tester as a reference. If the instruction manual is not available the following procedure can be used: WARNING: Always wear appropriate eye protection and use extreme caution when working with batteries. Failure to do so may result in serious or fatal injury. BATTERY TESTING

1. If testing the battery out of vehicle, clean the battery terminals with a wire brush before testing. If the battery is equipped with side post terminals, install and tighten the supplied lead terminal stud adapters. Do not use steel bolts. Failure to properly install the stud adapters or using stud adapters that are dirty or worn-out may result in false test readings. 2. If testing the battery in the vehicle, make certain all of the vehicle accessory loads are off, including the ignition. 3. Connect the tester to the battery, the red clamp to the positive (+) terminal and the black clamp to the negative (-) terminal. user Monday, June 04, 2012 5:03:17 PM

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NOTE:

Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test. Failure to disconnect may result in false battery test readings.

4. Using the ARROW key select in or out of vehicle testing and press ENTER to make a selection. 5. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery rating for your area (see menu). The tester then runs its self programmed test of the battery and display the results. Refer to the BATTERY TEST RESULTS chart. CAUTION: If replacing the battery is the result of the test, this may mean a poor connection between the vehicle cables and battery exists. After disconnecting the vehicle battery cables from the battery, retest the battery using the out of vehicle test before replacing. 6. While viewing the battery test result, press the CODE button and the tester, prompts you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character, then press ENTER to select and move to the next digit. Press the ENTER button to view the service code. Pressing the CODE button a second time returns you to the test results. BATTERY TEST RESULTS GOOD BATTERY GOOD - RECHARGE CHARGE AND RETEST REPLACE BATTERY BAD-CELL REPLACE

Return to service. Fully charge battery and return to service. Fully charge battery and retest battery. Replace the battery and retest complete the system. Replace the battery and retest complete the system.

OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. Before proceeding with this test, completely charge the battery, refer to the appropriate battery charging procedure.

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

Fig. 11: Voltmeter Courtesy of CHRYSLER LLC 1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize. 2. Disconnect and isolate both battery cables, negative cable first. 3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage. See the OPEN-CIRCUIT VOLTAGE chart. This voltage reading will indicate the battery state-of-charge, but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking capacity. OPEN CIRCUIT VOLTAGE TABLE Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.0 volts 25% 12.2 volts 50% 12.4 volts 75% 12.6 volts or more 100% IGNITION-OFF DRAW TEST

The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately 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 Totally Integrated Power Module (TIPM). This will reduce battery discharging. Excessive IOD can be caused by: z z z z z

Electrical items left on. Faulty or improperly adjusted switches. Faulty or shorted electronic modules and components. 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 replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been user Monday, June 04, 2012 5:03:17 PM

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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 illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. 2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Totally Integrated Power Module (TIPM), one at a time until the amperage reading becomes very low, or nonexistent. Refer to SYSTEM WIRING DIAGRAMS for complete TIPM 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 Electrical Engine Systems/Charging - Diagnosis and Testing 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-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. REMOVAL REMOVAL user Monday, June 04, 2012 5:03:17 PM

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WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing.

Fig. 12: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC 1. Disconnect and isolate the negative battery cable remote terminal from the remote battery post.

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Fig. 13: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 2. Remove the left front wheel and tire assembly. Refer to Tires and Wheels - Removal . NOTE:

Gasoline battery shown in illustration, diesel battery similar.

Fig. 14: Push-Puns & Splash Shield Courtesy of CHRYSLER LLC 3. Remove the push pins (1) and remove the left front wheelhouse splash shield (2). Refer to Body/Exterior/SHIELD, Splash - Removal .

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Fig. 15: Battery, Bracket & Nut Courtesy of CHRYSLER LLC 4. Loosen the nut (1) and position the battery hold down bracket out of the way (3).

Fig. 16: Battery And Pinch Clamp Bolts Courtesy of CHRYSLER LLC 5. Loosen the pinch clamp bolts and position aside the battery cable clamps from the battery. user Monday, June 04, 2012 5:03:17 PM

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Fig. 17: Battery Courtesy of CHRYSLER LLC 6. Remove the battery (1) from the battery tray (2). INSTALLATION INSTALLATION

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing.

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Fig. 18: Battery Courtesy of CHRYSLER LLC 1. Install the battery (1) into the battery tray (2).

Fig. 19: Battery And Pinch Clamp Bolts Courtesy of CHRYSLER LLC 2. Install the battery terminal pinch clamps (1, 2) onto the battery posts. Tighten the pinch clamp nut to 17.5 N.m (13 in. lbs.)

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Fig. 20: Battery, Bracket & Nut Courtesy of CHRYSLER LLC 3. Position back the battery hold down bracket (3) and install the bracket nut (1). Tighten the pinch clamp nut to 55 N.m (40 ft. lbs.)

Fig. 21: Push-Puns & Splash Shield Courtesy of CHRYSLER LLC 4. Install the left front wheelhouse splash shield (2) and push pins (1). Refer to Body/Exterior/SHIELD, Splash - Installation . user Monday, June 04, 2012 5:03:17 PM

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Fig. 22: TIRE AND WHEEL MOUNTING Courtesy of CHRYSLER LLC 5. Install the left front wheel and tire assembly. Refer to Tires and Wheels - Removal .

Fig. 23: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC 6. Install the negative battery cable remote terminal onto the remote battery post. Tighten the nut to 28 N.m (9.5 in. lbs.) user Monday, June 04, 2012 5:03:17 PM

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CABLES, BATTERY DESCRIPTION DESCRIPTION

The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then soldered. The battery positive cable wires feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a smaller female battery terminal clamp. There are two separate battery cable harnesses used on this vehicle. The battery harness includes both the battery positive and negative cables to the remote battery connection and may include portions of the wiring circuits for other components on some vehicles. The starter harness includes both the battery positive and negative cables from the remote battery connection down to the starter and engine ground location. These two harnesses are sold as separate assemblies. OPERATION OPERATION

The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal 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 opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block. DIAGNOSIS AND TESTING BATTERY CABLES

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. user Monday, June 04, 2012 5:03:17 PM

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When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST

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: z

z z

z z

The battery is fully-charged and load tested. Refer to Standard Procedure for the proper battery charging and load test procedures. Fully engage the parking brake. If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can be found in the Junction Block located in the left front engine compartment area. See the layout label affixed to the underside of the Junction Block cover for ASD relay identification and location.

Fig. 24: Connecting Voltmeter Leads To Battery Negative Terminal Courtesy of CHRYSLER LLC 1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post.

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Fig. 25: Connecting Voltmeter Leads To Battery Positive Terminal Courtesy of CHRYSLER LLC 2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post.

Fig. 26: Connecting Voltmeter To Terminal Clamp And Stud Courtesy of CHRYSLER LLC 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid B(+) terminal stud (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection 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.

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Fig. 27: Connecting Voltmeter To Battery And Engine Block Courtesy of CHRYSLER LLC 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. REMOVAL REMOVAL BATTERY HARNESS

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current.

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Fig. 28: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. 1. Disconnect and isolate the negative battery cable (2) remote terminal from the remote battery post (1).

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Fig. 29: Battery And Pinch Clamp Bolts Courtesy of CHRYSLER LLC 2. Raise vehicle on hoist. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 3. Remove the battery and set aside. See Removal . 4. On diesel engine equipped vehicles, disconnect the in-line connector to the instrument panel harness (2)

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Fig. 30: View Of Battery Harness & Attachments - Diesel Shown, Gasoline Similar Courtesy of CHRYSLER LLC NOTE:

Diesel battery harness shown in illustration, gasoline battery harness similar.

5. Lower the vehicle. 6. Remove the negative battery cable remote terminal nut (8) from the remote negative battery post. Remove the battery harness negative cable (7) from the remote negative battery post. 7. Remove the cover (1) from the remote positive battery terminal (2). Remove the starter harness positive cable retaining nut (4) and remove the cable (3) from the remote positive battery post. 8. Remove the remote positive battery terminal (2) from mounting bracket on the left strut tower (15) by lifting straight up. 9. On diesel engine equipped vehicles: z Disconnect the glow plug module connector (14) z Disconnect the cabin heater relay connectors (11 and 13) z Disconnect the in-line connector to the instrument panel harness (12)

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Fig. 31: Retaining Nut And Battery Harness Cable Courtesy of CHRYSLER LLC 10. Remove the retaining nut (1) and remove the battery harness cable (2) from the TIPM stud.

Fig. 32: Mounting Clips And TIPM Housing Courtesy of CHRYSLER LLC 11. Depress the four mounting clips (2) to disengage and remove the TIPM housing (1) from its mounting bracket, position aside to allow access to the battery harness. 12. One at a time, trace any remaining battery harness retaining push pins, fasteners and routing clips until the harness is free from the vehicle. 13. Remove the battery harness from the vehicle. STARTER HARNESS

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Fig. 33: Identifying Starter Harness Negative Cable Retaining Nut & Cable Courtesy of CHRYSLER LLC 1. Remove the negative battery cable remote terminal nut (5) from the remote negative battery post (1). Remove and isolate the battery harness negative cable (4) on something other than the remote negative battery post (1). 2. Remove the starter harness negative cable retaining nut (3) and remove the cable (2) from the remote negative battery post (1).

Fig. 34: Identifying Positive Cable Retaining Nut & Cable user Monday, June 04, 2012 5:03:17 PM

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Courtesy of CHRYSLER LLC 3. Remove the cover (1) from the remote positive battery terminal. Remove the starter harness positive cable retaining nut (4) and remove the cable (3) from the remote positive battery post (2).

Fig. 35: Identifying Starter & Cables Courtesy of CHRYSLER LLC 4. Raise vehicle on hoist. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 5. Remove the starter harness negative cable retaining bolt (4) and remove the cable (5) from the engine block. 6. Remove the starter harness positive cable retaining nut (6) and remove the cable (2) from the starter positive battery post. 7. One at a time, trace any remaining starter harness retaining pushpins, fasteners and routing clips until the harness is free from the vehicle. 8. Remove the starter harness (3) from the engine compartment. INSTALLATION INSTALLATION BATTERY HARNESS

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Fig. 36: Mounting Clips And TIPM Housing Courtesy of CHRYSLER LLC 1. Position the battery harness into the vehicle. 2. One at a time, install the battery harness retaining pushpins, fasteners and routing clips until the harness is installed exactly where it was in the vehicle. 3. Position the battery harness cable (2) onto the TIPM stud (3). Install the retaining nut (1) and tighten to 10 N.m (90 in. lbs.) 4. Install the TIPM on the bracket posts, push down until you hear a click.

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Fig. 37: View Of Battery Harness & Attachments - Diesel Shown, Gasoline Similar Courtesy of CHRYSLER LLC NOTE:

Diesel battery harness shown in illustration, gasoline battery harness similar.

5. On diesel engine equipped vehicles: z Connect the glow plug module connector (14) z Connect the cabin heater relay connectors (11 and 13) z Connect the in-line connector to the instrument panel harness (12) 6. Install the remote positive battery terminal (2) onto the mounting bracket on the left strut tower (15) by pushing straight down until fully engaged. 7. Remove the cover (1) from the remote positive battery terminal (2). Position the starter harness positive cable (3) onto the remote positive battery post. Install the retaining nut (4) and tighten to 16.5 N.m (145 in. lbs.) Install the cover (1) onto the remote positive battery terminal (2).

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Fig. 38: Battery And Pinch Clamp Bolts Courtesy of CHRYSLER LLC 8. Raise vehicle on hoist. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 9. Install the battery. See Installation .

Fig. 39: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:03:17 PM

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10. Lower the vehicle. 11. Install the negative battery cable remote terminal (2) onto the remote battery post (1). Install the nut (3) and tighten to 16.5 N.m (145 in. lbs.) STARTER HARNESS

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing.

Fig. 40: Identifying Starter Harness Negative Cable Retaining Nut & Cable Courtesy of CHRYSLER LLC 1. Remove and isolate the battery harness negative cable (4) on something other than the remote negative battery post (1). 2. Position the starter harness into the vehicle. 3. One at a time, install the starter harness retaining pushpins, fasteners and routing clips until the harness is installed exactly where it was in the vehicle. 4. Position the starter harness negative cable (2) onto the remote negative battery post (1). Install the retaining nut (3) and tighten to 16.5 N.m (145 in. lbs.) user Monday, June 04, 2012 5:03:17 PM

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Fig. 41: Identifying Positive Cable Retaining Nut & Cable Courtesy of CHRYSLER LLC

Fig. 42: Identifying Starter & Cables Courtesy of CHRYSLER LLC Remove the cover (1) from the remote positive battery terminal (2). Position the starter harness positive cable (3) onto the remote positive battery post. Install the retaining nut (4) and tighten to 16.5 N.m (145 user Monday, June 04, 2012 5:03:17 PM

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in. lbs.) Install the cover (1) onto the remote positive battery terminal (2). 5. Raise vehicle on hoist. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 6. Position the starter harness positive cable (2) onto the starter positive battery post. Install the retaining nut (6) and tighten to 13 N.m (115 in. lbs.) 7. Position the starter harness negative cable (5) onto the engine block. Install the retaining bolt (4) and tighten to 16.5 N.m (145 in. lbs.)

Fig. 43: Identifying Starter Harness Negative Cable Retaining Nut & Cable Courtesy of CHRYSLER LLC 8. Lower the vehicle. 9. Position the negative battery harness cable remote terminal (4) onto the remote battery post (1). Install the nut (5) and tighten to 16.5 N.m (145 in. lbs.)

TRAY, BATTERY DESCRIPTION DESCRIPTION

The battery is placed and secured in a stamped steel battery tray. The battery tray is located in the left front side of the vehicle, just ahead of the left front wheel and tire assembly. The battery tray is secured to the left front frame rail with four bolts. REMOVAL REMOVAL user Monday, June 04, 2012 5:03:17 PM

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2009 Dodge Journey SE 2009 ELECTRICAL Battery System - Journey

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current.

Fig. 44: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. 1. Disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Remove the battery. See Removal .

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Fig. 45: View Of Battery Tray & Fasteners Courtesy of CHRYSLER LLC 3. Remove the four bolts (2) securing the battery tray (3) to the left front frame rail (1). 4. Remove the battery tray from the vehicle. INSTALLATION INSTALLATION

WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing.

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Fig. 46: View Of Battery Tray & Fasteners Courtesy of CHRYSLER LLC 1. Position the battery tray (3) onto the left front frame rail (1). 2. Install the bolts (2) securing the battery tray (3) to the frame rail (1). Tighten the bolts to 16 N.m (142 in. lbs.)

Fig. 47: Identifying Battery Cables & Terminals Courtesy of CHRYSLER LLC user Monday, June 04, 2012 5:03:18 PM

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3. Install the battery. See Installation . 4. Install the negative battery cable remote terminal onto the remote battery post. Tighten the nut to 16.5 N.m (145 in. lbs.)

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2009 Dodge Journey SE 2009 ELECTRICAL Charging - Service Information - Journey

2009 ELECTRICAL Charging - Service Information - Journey

DESCRIPTION DESCRIPTION The charging system consists of: z z z z z z z

z z

Generator Decoupler Pulley (2.4L and Diesel Only) Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM) Ignition switch (refer to IGNITION CONTROL - SERVICE INFORMATION for information) Battery (refer to BATTERY SYSTEM for information) Inlet Air Temperature (calculated battery temperature) (If equipped) Voltmeter (refer to INSTRUMENT CLUSTER - SERVICE INFORMATION for information if equipped) Wiring harness and connections (refer to SYSTEM WIRING DIAGRAMS for information) Accessory drive belt (refer toCOOLING for more information)

OPERATION OPERATION

Fig. 1: Charging System Operation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:58:16 4:58:11 PM

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2009 Dodge Journey SE 2009 ELECTRICAL Charging - Service Information - Journey

1 - Generator Field Circuit 2 - Powertrain Control Module (PCM) 3 - Battery Sense Input 4 - Gateway (Totally Integrated Power Module, Integrated Power Module) 5 - Battery

6 - Generator 7 - Resistor (Gasoline Engines Only) 8 - Generator Case Ground 9 - B+ Circuit (Generator Output) 10 - B+ Sense Circuit

The charging system is turned on and off with the Powertrain Control Module (PCM) (2) and ignition switch with engine running. The field circuit will not be energized until engine is running and ignition switch is on. This voltage is connected through the PCM (2) and supplied to the generator field circuit (1) at the back of the generator (6). The generator (6) is internally grounded through the generator case ground (8). The generator (6) regulates the field using Pin 1 of the field connector (High side driver). The generator (6) is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement. The PCM (2) receives a voltage input from the generator (6) via the B+ sense circuit (10) and also a battery sense input (3) from the Gateway (Totally Integrated Power Module, Integrated Power Module) (4), it then compares the voltages to the desired voltage programed in the Electronic Voltage Regulator (EVR) software and if there is a difference it sends a signal to the generator EVR circuit to increase or decrease output. It uses Pulse Width Modulation (PWM) to send signals to the generator circuitry to control the amount of output from the generator. The amount of DC current produced by the generator is controlled by the EVR circuitry contained within the PCM (2). All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges. The lamp is located on the instrument panel. Refer to INSTRUMENT CLUSTER SERVICE INFORMATION for additional information. Voltage is monitored at B+ sense circuit (10) to insure the cable is connected. If the B+ circuit (generator output) (9) cable is loose anywhere in the circuit the B+ sense circuit (10) will show high voltage. This condition causes the PCM (2) to shut down the generator field circuit (1). Because of this feature, pin 2 of the field connector is internally connected to the B+ circuit (9). The diesel generator is internally regulated. The generator and PCM communicate for diagnostics, etc. If the generator regulator becomes disconnected from the PCM it will operate, but in a default mode.

DIAGNOSIS AND TESTING ON-BOARD DIAGNOSTIC SYSTEM The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit user Monday, June 04, 2012 4:58:12 PM

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monitored by the OBD system. Some circuits are checked continuously and some are checked only under certain conditions. If the OBD system senses that a monitored circuit is bad, it will put a DTC into electronic memory. The DTC will stay in electronic memory as long as the circuit continues to be bad. The PCM is programmed to clear the memory after 40 good trips if the problem does not occur again. DIAGNOSTIC TROUBLE CODES

A DTC description can be read using the scan tool. Refer to the appropriate Powertrain Diagnostic article for information. A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set. ERASING DIAGNOSTIC TROUBLE CODES

The scan tool must be used to erase a DTC. The following procedures may be used to diagnose the charging system if: z z z

the check gauges lamp or battery lamp is illuminated with the engine running the voltmeter (if equipped) does not register properly an undercharged or overcharged battery condition occurs.

Remember that an undercharged battery is often caused by: z z

z

accessories being left on with the engine not running a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test. Refer to Electrical/Battery System/BATTERY - Standard Procedure loose generator belt.

INSPECTION

The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions. Refer to Diagnostic Trouble Codes in; Powertrain Diagnostic service information for more DTC information. This will include a complete list of DTC's including DTC's for the charging system. To perform a complete test of the charging system, refer to the appropriate Powertrain Diagnostic Procedures service information and the scan tool. Perform the following inspections before attaching the scan tool. user Monday, June 04, 2012 4:58:12 PM

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1. Inspect the battery condition. Refer to Electrical/Battery System - Diagnosis and Testing for procedures. 2. Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required. 3. Inspect all fuses in the fuseblock for tightness in receptacles. They should be properly installed and tight. Repair or replace as required. 4. Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to Specifications. Also refer to GENERATOR Removal/Installation procedures. . 5. Inspect generator drive belt condition and tension. Tighten or replace belt as required. 6. Inspect decoupler pulley (if equipped). Ensure decoupler pulley is driving the alternator rotor. 7. Inspect automatic belt tensioner (if equipped). Refer to BELT, SERPENTINE for more information. 8. Inspect generator electrical connections at generator field, battery output, and ground terminal (if equipped). Also check generator ground wire connection at engine (if equipped). They should all be clean and tight. Repair as required.

SPECIFICATIONS GENERATOR GENERATOR MANUFACTURER BOSCH BOSCH MITSUBISHI ELECTRIC DENSO DENSO

ENGINE

NOMINAL RATING

2.0L Diesel 150A 2.0L Diesel 200A 2.4L 160A 2.7, 3.5L 140A 2.7, 3.5L 160A TEST CONDITIONS 1. Engine RPM : 2500 RPM (ENGINE HOT) 2. Voltage Output : 13.0 - 16.0 V

MINIMUM OUTPUT (AMPS) (@ SPECIFIED TEST CONDITIONS) 100A 150A 110A 90A 110A

TORQUE TORQUE DESCRIPTION Battery Terminal Nut Generator B+ Nut Generator Mounting Bolt 2.4L Generator Mounting Bolt 2.7L

N.m 4.5 10 61 27

Ft. Lbs. 45

In. Lbs. 40 88.5 -

20

-

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Generator Mounting Bolt 3.5L Lower Idler Pulley Bolt 2.4L

42

31

-

50

37

-

GENERATOR DESCRIPTION DESCRIPTION

The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage. OPERATION OPERATION

As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. The Y type stator winding connections deliver the induced AC current to positive and negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: z z z z z z z

Worn, loose or defective bearings Loose or defective drive pulley Incorrect, worn, damaged or misadjusted drive belt Loose mounting bolts Misaligned drive pulley Defective stator or diode Damaged internal fins

REMOVAL 2.0L TURBO DIESEL

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Fig. 2: Generator Cables Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove engine cover. Disconnect and isolate the negative battery cable. Remove accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal . Disconnect battery cable from generator. Disconnect electrical connector from generator.

Fig. 3: Idler Cap Location Courtesy of CHRYSLER LLC 6. Remove cap from idler pulley mounting bolt.

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Fig. 4: Idler Pulley Bolt Location Courtesy of CHRYSLER LLC 7. Remove idler pulley bolt.

Fig. 5: Right Engine Mount Courtesy of CHRYSLER LLC 8. It may be necessary to remove the two engine mounting bolts (2) from the right engine mount (1) and reposition engine in order to remove the lower generator mounting bolt. Reposition ground strap (3) if required. Refer to Engine/Engine Mounting/INSULATOR, Engine Mount - Removal .

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Fig. 6: Generator Lower Mounting Bolt Courtesy of CHRYSLER LLC 9. Remove lower generator mounting bolt.

Fig. 7: Removing/Installing Generator Courtesy of CHRYSLER LLC 10. Remove upper generator mounting bolt. 11. Remove generator. 2.4L

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Fig. 8: Removing/Installing Underbody Air Dam Courtesy of CHRYSLER LLC CAUTION: Disconnect the negative battery cable before removing the battery output wire from generator. Failure to do so can result in injury or damage to electrical system. 1. Disconnect and isolate negative battery cable. 2. Remove underbody air dam. 3. Remove right front wheelhouse splash shield. Refer to Cooling/Accessory Drive/BELT, Serpentine Removal . 4. Remove generator drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .

Fig. 9: Identifying A/C Compressor Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:58:12 PM

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NOTE:

Do not disconnect the A/C lines when relocating the A/C compressor. CAUTION: Support the A/C compressor when relocating. Failure to properly support the A/C compressor can cause damage to the lines and or seals. This can cause a leak in the A/C system.

5. Relocate A/C compressor. Refer to Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C Removal .

Fig. 10: 2.4L Generator Electrical Connector Courtesy of CHRYSLER LLC CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. 6. Unsnap plastic protective cover (1) from B+ mounting stud. 7. Remove B+ terminal mounting nut (2) and B+ terminal (3) from generator. 8. Disconnect field wire electrical connector (4) by pushing on connector tab.

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Fig. 11: Removing/Installing Idler Pulley Courtesy of CHRYSLER LLC 9. Remove bolt and lower idler pulley.

Fig. 12: Removing/Installing Generator Courtesy of CHRYSLER LLC 10. Remove upper mounting bolt (3) from generator (1). 11. Remove lower mounting bolt (2) from generator (1). 12. Remove generator (1) from engine mounting bracket.

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Fig. 13: Identifying Generator Pulley Courtesy of CHRYSLER LLC 13. Rotate generator so that the pulley faces down.

Fig. 14: Removing/Installing Generator Courtesy of CHRYSLER LLC 14. Position generator in order to move past the A/C compressor and out of vehicle. user Monday, June 04, 2012 4:58:12 PM

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2.7L

Fig. 15: Alternator Electrical Connection Courtesy of CHRYSLER LLC CAUTION: Disconnect the negative battery cable before removing the battery output wire from generator. Failure to do so can result in injury or damage to electrical system. 1. Disconnect and isolate negative battery cable. CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. 2. 3. 4. 5.

Remove generator drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal . Unsnap plastic protective cover (1) from B+ mounting stud. Remove B+ terminal mounting nut (2) and B+ terminal (3) at top of generator. Disconnect field wire electrical connector (4) by pushing on connector tab.

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Fig. 16: 2.7L Removing/Installing Generator Courtesy of CHRYSLER LLC 6. Remove upper mounting bolts (3) from generator (1). 7. Remove lower mounting bolt (2) from generator (1). 8. Remove generator (1) from engine mounting bracket. 3.5L

Fig. 17: 3.5L Generator Electrical Connector Courtesy of CHRYSLER LLC CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. user Monday, June 04, 2012 4:58:12 PM

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1. 2. 3. 4. 5.

Disconnect and isolate negative battery cable. Remove generator drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal . Unsnap plastic protective cover (4) from B+ mounting stud. Remove B+ terminal mounting nut (3) and B+ terminal (2) at top of generator. Disconnect field wire electrical connector (1) by pushing on connector tab.

Fig. 18: 3.5L Removing/Installing Generator Courtesy of CHRYSLER LLC 6. Remove short mounting bolt (3) from generator (1). 7. Remove long mounting bolt (2) from generator (1). 8. Remove generator (1) from engine mounting bracket. INSTALLATION 2.0L TURBO DIESEL

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Fig. 19: Generator Bushing Courtesy of CHRYSLER LLC 1. If reinstalling the old generator, install a generator mounting bolt and tap bushing out slightly to ease mounting of generator.

Fig. 20: Removing/Installing Generator Courtesy of CHRYSLER LLC 2. Install generator.

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Fig. 21: Generator Lower Mounting Bolt Courtesy of CHRYSLER LLC 3. Loosely install lower generator mounting bolt. 4. Install upper generator mounting bolt. 5. Tighten generator mounting bolts to 54 N.m (40 ft. lbs.).

Fig. 22: Right Engine Mount Courtesy of CHRYSLER LLC 6. If removed, install two engine mounting bolts (2) to right engine mount (1). Reposition ground strap (3) if required. Refer to Engine/Engine Mounting/BRACKET, Engine Mount - Installation .

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Fig. 23: Idler Pulley Bolt Location Courtesy of CHRYSLER LLC 7. Install idler pulley and tighten bolt. Refer to Cooling/Accessory Drive/PULLEY, Idler - Installation .

Fig. 24: Idler Cap Location Courtesy of CHRYSLER LLC 8. Install idler bolt cap.

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Fig. 25: Generator Cables Courtesy of CHRYSLER LLC 9. 10. 11. 12. 13.

Connect battery cable to generator and tighten nut to 10 N.m (88.5 in. lbs.). Connect electrical connector to generator. Install accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation . Reconnect negative battery cable. Install engine cover.

2.4L

Fig. 26: Removing/Installing Generator user Monday, June 04, 2012 4:58:12 PM

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Courtesy of CHRYSLER LLC 1. Position generator in order to move past the A/C compressor and up toward generator mounting bracket.

Fig. 27: Identifying Generator Pulley Courtesy of CHRYSLER LLC 2. Continue moving generator up towards generator mounting bracket.

Fig. 28: Removing/Installing Generator Courtesy of CHRYSLER LLC 3. Install generator (1) to engine mounting bracket. user Monday, June 04, 2012 4:58:12 PM

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4. Install lower mounting bolt (2) and upper mounting bolt (3) to generator (1). Tighten bolts to 61 N.m (45 ft. lbs.).

Fig. 29: Removing/Installing Idler Pulley Courtesy of CHRYSLER LLC 5. Install lower idler pulley and bolt. Tighten bolt to 50 N.m (37 ft. lbs.).

Fig. 30: 2.4L Generator Electrical Connector Courtesy of CHRYSLER LLC 6. Connect field wire connector (4) into generator. 7. Install B+ terminal (3) and nut (2) to generator mounting stud. Tighten nut to 10 N.m (88.5 in. lbs.) 8. Snap plastic protective cover (1) to B+ terminal. user Monday, June 04, 2012 4:58:12 PM

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Fig. 31: Identifying A/C Compressor Courtesy of CHRYSLER LLC 9. Install A/C compressor. Refer to Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C Installation . CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer toBELT, SERPENTINE . 10. Install drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .

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Fig. 32: Removing/Installing Underbody Air Dam Courtesy of CHRYSLER LLC 11. Install right front wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash - Installation . 12. Install underbody air dam. 13. Connect negative battery cable, tighten nut to 4.5 N.m (40 in. lbs.). 2.7L

Fig. 33: 2.7L Removing/Installing Generator Courtesy of CHRYSLER LLC 1. Install generator (1) to engine mounting bracket. 2. Install lower mounting bolt (2) and upper mounting bolt (3) to generator (1). Tighten bolts to 27 N.m (20 ft. lbs.). user Monday, June 04, 2012 4:58:12 PM

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Fig. 34: Alternator Electrical Connection Courtesy of CHRYSLER LLC 3. Connect field wire connector (4) into generator. 4. Install B+ terminal (3) and nut (2) to generator mounting stud. Tighten nut to 10 N.m (88.5 in. lbs.) 5. Snap plastic protective cover (1) to B+ terminal. CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to BELT, SERPENTINE . 6. Install drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation . 7. Connect negative battery cable, tighten nut to 4.5 N.m (40 in. lbs.). 3.5L

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Fig. 35: 3.5L Removing/Installing Generator Courtesy of CHRYSLER LLC 1. Install generator (1) to engine mounting bracket. 2. Install long mounting bolt (2) and short mounting bolt (3) to generator (1). Tighten bolts to 42 N.m (31 ft. lbs.).

Fig. 36: 3.5L Generator Electrical Connector Courtesy of CHRYSLER LLC 3. 4. 5. 6.

Connect field wire connector (1) into generator. Install B+ terminal (2) and nut (3) to generator mounting stud. Tighten nut to 10 N.m (88.5 in. lbs.) Snap plastic protective cover (4) to B+ terminal. Install drive belt. Refer to BELT, SERPENTINE for belt routing, belt adjustment and bolt tightening procedures.

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7. Connect negative battery cable, tighten nut to 4.5 N.m (40 in. lbs.).

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2009 Dodge Journey SE 2009 ELECTRICAL Fuses & Circuit Breakers - Journey

2009 ELECTRICAL Fuses & Circuit Breakers - Journey

IDENTIFICATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. TOTALLY INTEGRATED POWER MODULE For integrated power module location, see Fig. 1.

Fig. 1: Locating Totally Integrated Power Module Courtesy of CHRYSLER CORP.

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Fig. 2: Identifying Totally Integrated Power Module Components Courtesy of CHRYSLER CORP. Totally Integrated Power Module Fuses FUSE NO. AMPS FUNCTION J1 40A Power Folding Seat J2 30A Transfer Case Module - If Equipped J3 40A Rear Door Module J4 25A Driver Door Node J5 25A Passenger Door Node J6 40A Anti-Lock Brake System (ABS) Pump/Electronic Stability Program (ESP) J7 30A Anti-Lock Brake System (ABS) Valve/Electronic Stability Program (ESP) J8 40A Power Memory Seat - If Equipped J9 40A PZEV Motor/Flex Fuel - If Equipped J10 30A Headlamp Wash Relay - If Equipped/Manual Turning Valve J11 30A Sway Bar - If Equipped/Thatchum Security (BUX)/Power Sliding Door J13 60A Ignition Off Draw (IOD) - Main J14 40A Electric Back Light (EBL) J15 30A Rear Blower - If Equipped J17 40A Starter Solenoid J18 20A NGC (Powertrain Control Module)/Trans Range J19 60A Radiator Fan Motor J20 30A Front Wiper LO/HI J21 20A Front/Rear Washer J22 25A Sunroof Module - If Equipped user Monday, June 04, 2012 4:55:20 PM

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M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

15A 20A 20A 10A 25A 20A 20A 20A 20A 20A

M11

10A

M12 M13

30A 20A

M14 M15

20A 20A

M16

10A

M17 M18 M19 M20

15A 15A 25A 15A

M21 M22 M23 M24 M25 M26 M27 M28 M29 M30 M31 M32 M33

20A 10A 10A 25A 20A 10A 10A 10A 10A 15A 20A 10A 10A

Center High Mounted Stop Light (CHMSL)/Brake Switch Trailer Lighting - If Equipped Front/Rear Axle Trailer Tow - If Equipped Power Inverter - If Equipped Power Outlet #1/Accessory (ACC) Rain Sensor Power Outlet #2 (BATT/ACC SELECT) Front Heated Seats - If Equipped Rear Heated Seats - If Equipped Vanity Lamps/Hands-Free Module (HFM) - If Equipped, Remote Display - If Equipped, Satellite Digital Audio Receiver (SDARS) - If Equipped, Universal Garage Door Opener (UGDO) - If Equipped, Vanity Light, Video Entertainment System (VES) - If Equipped Automatic Temperature Control (ATC) - If Equipped, Underhood Light Radio, Amplifier (AMP) Cabin Compartment Node (IOD-CCN), Siren Module/Multifunction Switch Trailer Tow (BUX) - If Equipped Auto Dim Rear View Mirror - If Equipped, Infrared Sensor - If Equipped, Multifunction Switch, Tire Pressure Monitor (TPM) - If Equipped, Transfer Case Module - If Equipped Occupant Restraint Controller/Occupant Classification Module (ORC/OCM) Left Park/Side Marker/Running/Tail Lights, License Lights Right Park/Side Marker/Running/Tail Lights Auto Shut Down (ASD #1 & #2) Electronic Vehicle Information Center (EVIC) - If Equipped, Interior Lighting, Steering Wheel Switches - If Equipped, Switch Bank Auto Shut Down (ASD #3) Right Horn Left Horn Rear Wiper Fuel Pump, Diesel Lift Pump Power Mirrors Switch, Driver Window Switch Steering Column Lock, Wireless Ignition Node (WIN) NGC (Powertrain Control Module)/Transmission Feed Occupant Classification Module (OCM) Rear Wiper Module, Power Folding Mirror Back-Up Lamps Occupant Restraint Controller (ORC) NGC (Powertrain Control Module) Battery Feed

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M34

10A

M35 M36 M37

10A 20A 10A

M38

25A

Park Assist Module, HVAC Module, Headlamp Washers, Compass Module - If Equipped, Flashlight - If Equipped Heated Mirrors - If Equipped Power Outlet #3 (BATT) Anti-Lock Brake System (ABS), Electronic Stability Program (ESP), Stop Light Switch Lock/Unlock Motors

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2009 Dodge Journey SE 2009 CHRYSLER Journey

2009 CHRYSLER Journey

BUZZERS, RELAYS & TIMERS BUZZERS, RELAYS & TIMERS LOCATION Component Auto Shut Down Relay Blower Motor - Rear Relay Brake Lamp Relay PCM Relay Radiator Fan Control Relay Radiator Fan High Relay Rear Window Defogger Relay Run/Accessory Relay Run Relay Run/Start Relay Secondary Air Pump Relay Secondary Door Unlock Relay Starter Relay Trailer Tow Stop Lamp Left - Relay Trailer Tow Stop Lamp Right - Relay Trailer Tow Stop/Turn Left - Relay Trailer Tow Stop/Turn Right - Relay

Location Totally Integrated power module. See Fig. 42. Totally Integrated power module. See Fig. 42. Left quarterpanel. See Fig. 52. Totally Integrated power module. See Fig. 51. Totally Integrated power module. See Fig. 42. Behind radiator. See Fig. 46. Totally Integrated power module. See Fig. 42. Totally Integrated power module. See Fig. 42. Totally Integrated power module. See Fig. 42. Totally Integrated power module. See Fig. 42. Right side of engine. See Fig. 23. Left front of engine compartment. See Fig. 21. Totally Integrated power module. See Fig. 42. Under left side of rear bumper. See Fig. 39. Under right side of rear bumper. See Fig. 39. Base of left "D" pillar. See Fig. 39. Base of right "D" pillar. See Fig. 39.

CIRCUIT PROTECTION DEVICES CIRCUIT PROTECTION DEVICES LOCATION Component Circuit Breaker 1 Power Seat Circuit Breaker Totally Integrated Power Module

Location Totally Integrated power module. See Fig. 42. Under driver's seat. See Fig. 34. Left rear of engine compartment. See Fig. 20.

CONTROL UNITS CONTROL UNITS LOCATION Component All Wheel Drive Control Module Anti-Lock Brakes Module Driver Door Module

Location Left side of dash. See Fig. 54. Right rear of engine compartment. See Fig. 49. Driver's door. See Fig. 26.

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Front Blower Power (ATC) Module Hands Free Module Heated Seats Module Inverter Module Occupant Restraint Controller Module Powertrain Control Module Rear Blower Module Steering Column Lock Module (VTSA) Steering Control Module Video Screen Module

Right end of HVAC. See Fig. 4. Left end of dash. See Fig. 2. Under driver's seat. See Fig. 34. Under driver's seat. See Fig. 35. Center of dash. See Fig. 1. Left side of engine compartment. See Fig. 18. Right quarterpanel. See Fig. 33. On steering column. See Fig. 2. In steering wheel. See Fig. 5. Center rear of roof. See Fig. 44.

MOTORS MOTORS LOCATION Component Blend Door Actuator - Left Blend Door Actuator - Right Blower Motor - Front Blower Motor - Rear Door Latch - Driver Door Latch - Left Rear Door Latch - Passenger Door Latch - Right Rear Fuel Pump Module Fuel Pump Module C1 (AWD) Fuel Pump Module C2 (AWD) Horizontal Seat Adjuster Motor - Driver Mode Door Actuator Outside Rearview Mirror - Driver Outside Rearview Mirror - Passenger Radiator Cooling Fan Module Recirculation Door Actuator Secondary Air Pump Starter (2.4L) Starter (3.5L) Sunroof Motor Throttle Body (2.4L) Throttle Body (3.5L) Vertical Seat Adjuster Motor - Driver Front Vertical Seat Adjuster Motor - Driver Rear Window Motor - Driver

Location On HVAC unit. See Fig. 1. On front HVAC. See Fig. 3. Right end of HVAC. See Fig. 3. Right quarterpanel. See Fig. 33. Driver's door. See Fig. 26. Left rear door. See Fig. 27. Front passenger's door. Right rear door. Top left side of fuel tank. See Fig. 50. Top left side of fuel tank. See Fig. 37. Top right side of fuel tank. See Fig. 37. Under driver's seat. See Fig. 34. Middle of front HVAC. See Fig. 3. Driver's door. Front passenger's door. See Fig. 48. Behind radiator. See Fig. 46. Right side of HVAC. See Fig. 4. Right side of engine. See Fig. 23. Lower left rear of engine. See Fig. 47. Lower left rear of engine. See Fig. 19. Center front of roof. See Fig. 44. Left rear of engine. See Fig. 14. Top rear of engine. See Fig. 13. Under driver's seat. See Fig. 34. Under driver's seat. See Fig. 34. Driver's door. See Fig. 26.

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Window Motor - Left Rear Window Motor - Passenger Window Motor - Right Rear Windshield Washer Pump Wiper Motor - Front

Left rear door. See Fig. 27. Front passenger's door. Right rear door. Left front of engine compartment. See Fig. 20. Left rear of engine compartment. See Fig. 18.

SENDING UNITS & SENSORS SENDING UNITS & SENSORS LOCATION Component Accelerator Pedal Position Sensor A/C Pressure Transducer Air Flow Sensor Ambient Air Temperature Sensor Brake Fluid Level Sensor Camshaft 1/1 Position Sensor (2.4L) Camshaft 1/1 Position Sensor (3.5L) Camshaft 1/2 Position Sensor (2.4L) Crankshaft Position Sensor (2.4L) Crankshaft Position Sensor (3.5L) Dynamics Sensor Engine Coolant Temperature 1 Sensor Engine Coolant Temperature 2 Sensor Evaporator Temperature Sensor Front Impact Sensor - Left Front Impact Sensor - Right Infrared Sensor Input Speed Sensor (2.4L) Input Speed Sensor (3.5L) Intake Air Temperature/Boost Pressure Sensor Intake Air Temperature Sensor (2.4L) Intake Air Temperature Sensor (3.5L) Intrusion Transceiver Module Knock Sensor (2.4L) Knock Sensor (3.5L) Manifold Absolute Pressure Sensor (2.4L) Manifold Absolute Pressure Sensor (3.5L) Oil Temperature Sensor Output Speed Sensor (2.4L) Output Speed Sensor (3.5L)

Location Left side of dash. See Fig. 54. Right front corner of engine compartment. See Fig. 53. Rear of engine. See Fig. 23. Behind center of front fascia. See Fig. 20. Left rear of engine compartment. See Fig. 18. Left rear of engine. See Fig. 43. Left rear of engine. See Fig. 47. Left rear of engine. See Fig. 40. Rear of engine. See Fig. 14. Right rear of engine. See Fig. 19. Center of dash. See Fig. 16. Rear of engine. See Fig. 13. Left rear of engine. See Fig. 47. On HVAC unit. See Fig. 1. Left front of engine compartment. See Fig. 20. Right front of engine compartment. See Fig. 46. Front of headliner. See Fig. 44. Left side of transmission. See Fig. 14. Top of transmission. See Fig. 17. Left front of engine compartment. See Fig. 21. Left rear of engine. See Fig. 40. Rear of engine. See Fig. 13. Center of overhead rail. See Fig. 12. Left rear of engine. See Fig. 47. Right rear of engine. See Fig. 13. Top left of engine. See Fig. 14. Right rear of engine. See Fig. 13. Left front of engine. See Fig. 43. Left side of transmission. See Fig. 14. Right side of transmission. See Fig. 17.

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Oxygen Sensor 1/1 (2.4L) Oxygen Sensor 1/1 (3.5L) Oxygen Sensor 1/2 (2.4L) Oxygen Sensor 1/2 (3.5L) Oxygen Sensor 2/1 Oxygen Sensor 2/2 Seat Track Position Sensor - Driver Seat Track Position Sensor - Passenger Side Impact Sensor - Left 1 Side Impact Sensor - Left 2 Side Impact Sensor - Left 3 Side Impact Sensor - Right 1 Side Impact Sensor - Right 2 Side Impact Sensor - Right 3 Sun Sensor Transfer Speed Sensor Transmission Range Sensor Washer Fluid Level Sensor - Front Wheel Speed Sensor - Left Front Wheel Speed Sensor - Left Rear Wheel Speed Sensor - Right Front Wheel Speed Sensor - Right Rear

Left rear of engine. See Fig. 40. Right side of engine. See Fig. 13. Right side of transmission. See Fig. 14. Right side of transmission. See Fig. 19. Left side of engine. See Fig. 19. Left side of transmission. See Fig. 19. Under driver's seat. See Fig. 34. Under front passenger's seat. See Fig. 9. Driver's door. See Fig. 26. Left "C" pillar. See Fig. 52. Left quarterpanel. See Fig. 30. Front passenger's door. Right "C" pillar. See Fig. 32. Right quarterpanel. See Fig. 32. Top center of dash. See Fig. 1. Right rear of transmission. See Fig. 17. Left side of transmission. See Fig. 14. Left front of engine compartment. See Fig. 20. Left front wheel hub assembly. See Fig. 18. Left rear wheel hub assembly. Right front wheel hub assembly. See Fig. 49. Right rear wheel hub assembly.

SOLENOIDS & SOLENOID VALVES SOLENOIDS & SOLENOID VALVES LOCATION Component A/C Compressor Clutch (2.4L) A/C Compressor Clutch (3.5L) EGR Valve Assembly Electronically Controlled Clutch Solenoid EVAP/Purge Solenoid Fuel Injector 1 (2.4L) Fuel Injector 1 (3.5L) Fuel Injector 2 (2.4L) Fuel Injector 2 (3.5L) Fuel Injector 3 (2.4L) Fuel Injector 3 (3.5L) Fuel Injector 4 (2.4L) Fuel Injector 4 (3.5L)

Location Lower left front of engine. See Fig. 14. Lower left front of engine. See Fig. 19. Rear of engine. See Fig. 13. Rear differential. See Fig. 37. Left rear corner of engine compartment. See Fig. 18. Top left of engine. See Fig. 43. Top right of engine. See Fig. 13. Top left of engine. See Fig. 43. Top left of engine. See Fig. 13. Top left of engine. See Fig. 43. Top right of engine. See Fig. 13. Top left of engine. See Fig. 43. Top left of engine. See Fig. 13.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

Fuel Injector 5 Fuel Injector 6 Manifold Flow Valve Manifold Tuning Valve Pressure Sensor/Variable Force Solenoid Short Runner Valve Solenoid Transmission Solenoid/TRS Assembly Variable Valve Timing Solenoid - Exhaust Variable Valve Timing Solenoid - Intake

Top right of engine. See Fig. 13. Top left of engine. See Fig. 13. Left rear of engine. See Fig. 14. Right front of engine. See Fig. 19. Left side of transmission. See Fig. 14. Front of engine. See Fig. 13. Left side of transmission. See Fig. 17. Right front of engine. See Fig. 43. Left front of engine. See Fig. 43.

SWITCHES SWITCHES LOCATION Component Clutch Interlock Switch Driver Seat Belt Switch Hood Ajar Switch Horn Switch Oil Pressure Switch (2.4L) Oil Pressure Switch (3.5L) Parking Brake Switch (A/T) Parking Brake Switch (M/T) Stop Lamp Switch Transmission Solenoid/Pressure Switch

Location Left side of dash. See Fig. 54. Base of left "B" pillar. See Fig. 28. Right front of engine compartment. See Fig. 46. Under steering wheel pad. See Fig. 5. Lower left rear of engine. See Fig. 47. Lower left side of engine. See Fig. 41. Under rear of enter console. See Fig. 16. Left kick panel. See Fig. 54. Left side of dash. See Fig. 54. Left side of transmission. See Fig. 14.

MISCELLANEOUS MISCELLANEOUS LOCATION Component Airbag Squib 1 - Driver's Airbag Squib 1 - Passenger Airbag Squib 2 - Driver's Airbag Squib 2 - Passenger Amplifier - Radio Antenna - Navigation Antenna - Radio Blower Motor Resistor - Front Blower Motor Resistor - Rear Data Link Connector Generator (2.4L) Generator (3.5L)

Location Under steering wheel pad. See Fig. 5. Right side of dash. See Fig. 4. Under steering wheel pad. See Fig. 5. Right side of dash. See Fig. 4. Right kick panel. See Fig. 10. Left side of dash. See Fig. 11. Rear of overhead rail. See Fig. 12. Under front blower motor. See Fig. 3. Rear blower motor. See Fig. 33. Left side of dash. See Fig. 45. Left front of engine. See Fig. 14. Top left front of engine. See Fig. 19.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

Horn 1 Ignition Coil 1 (2.4L) Ignition Coil 1 (3.5L) Ignition Coil 2 (2.4L) Ignition Coil 2 (3.5L) Ignition Coil 3 (2.4L) Ignition Coil 3 (3.5L) Ignition Coil 4 (2.4L) Ignition Coil 4 (3.5L) Ignition Coil 5 Ignition Coil 6 Ignition 1 Capacitor (2.4L) Ignition 1 Capacitor (3.5L) Radiator Fan Resistor Rear Cabin Heater Rear Video Camera Remote Jump Post - Negative Seat Back Heater - Driver Seat Back Heater - Passenger Seat Belt Tensioner - Driver Seat Belt Tensioner - Passenger Seat Cushion Heater - Passenger Shift Lever Assembly Side Curtain Airbag - Left Side Curtain Airbag - Right Side Thorax Airbag - Left Side Thorax Airbag - Right Siren

Right front of engine compartment. Top right of engine. See Fig. 43. Top right of engine. See Fig. 13. Top right of engine. See Fig. 43. Top left of engine. See Fig. 13. Top right of engine. See Fig. 43. Top right of engine. See Fig. 13. Top right of engine. See Fig. 43. Top left of engine. See Fig. 13. Top right of engine. See Fig. 13. Top left of engine. See Fig. 13. Left rear of engine. See Fig. 40. Left rear of engine. See Fig. 13. Behind radiator. See Fig. 46. Right quarterpanel. See Fig. 32. Left side of liftgate. See Fig. 38. Left side of engine compartment. See Fig. 19. Driver's seat back. See Fig. 8. Front passenger's seat back. See Fig. 9. Base of left "B" pillar. See Fig. 28. Under front passenger's seat. See Fig. 29. Under passenger seat. See Fig. 9. Under center console. See Fig. 15. Top of left "C" pillar. See Fig. 6. Top of right "C" pillar. See Fig. 7. Left side of driver's seat back. See Fig. 8. Right side of front passenger's seat back. See Fig. 9. Left front of engine compartment. See Fig. 20.

CONNECTORS CONNECTORS LOCATION Component C100 (Black, 8 Pin) C101 (Black, 14 Pin) C105 (6 Pin) C106 (12 Pin) C107 (Black, 1 Pin) C112 (Gray, 40 Pin) C113 (Natural, 57 Pin) C114 (Natural, 57 Pin)

Location Left side of engine compartment. See Fig. 18. Left side of engine compartment. See Fig. 18. Above transmission. See Fig. 17. Above left headlight assembly. See Fig. 21. Above left headlight assembly. See Fig. 20. Left kick panel. See Fig. 54. Left end of dash. See Fig. 54. Left kick panel. See Fig. 2.

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2009 Dodge Journey SE 2009 CHRYSLER Journey

C116 (16 Pin) C117 (Black, 2 Pin) C118 (Dark Gray, 4 Pin) C119 (Dark Gray, 2 Pin) C200 (Natural, 57 Pin) C201 (8 Pin) C202 (White, 2 Pin) C203 (12 Pin) C204 (Early) (8 Pin) C204 (Late) (12 Pin) C205 (Black, 16 Pin) C206 (14 Pin) C207 (Natural, 2 Pin) C208 (Yellow, 2 Pin) C211 (Light Gray, 2 Pin) C300 (Black, 18 Pin) C301 (Black, 12 Pin) C302 (Black, 18 Pin) C303 (Black, 12 Pin) C304 (12 Pin) C305 (14 Pin) C306 (Black, 12 Pin) C307 (Black, 6 Pin) C308 (Natural, 12 Pin) C309 (Black, 8 Pin) C310 (Black, 10 Pin) C312 (Light Gray, 12 Pin) C313 (Yellow, 4 Pin) C314 (Light Gray, 13 Pin) C315 (Yellow, 4 Pin) C316 (Gray, 4 Pin) C317 (Black, 2 Pin) C318 (Black, 3 Pin) C319 (Green, 3 Pin) C320 (Green, 3 Pin)

Left side of engine compartment. See Fig. 22. Left side of engine compartment. See Fig. 22. Left side of engine compartment. See Fig. 22. Left side of engine compartment. See Fig. 22. Left kick panel. See Fig. 45. Base of left "A" pillar. See Fig. 24. Base of left "A" pillar. See Fig. 24. Base of left "A" pillar. See Fig. 24. Base of right "A" pillar. See Fig. 25. Base of right "A" pillar. See Fig. 25. Base of right "A" pillar. See Fig. 25. Base of right "A" pillar. See Fig. 25. Left kick panel. See Fig. 2. Base of right "A" pillar. See Fig. 55. Left kick panel. See Fig. 2. Left kick panel. See Fig. 26. Left kick panel. See Fig. 54. Right kick panel. See Fig. 10. Right kick panel. See Fig. 10. Left "B" pillar. See Fig. 28. Right "B" pillar. See Fig. 29. Under center console. See Fig. 15. Left "D" pillar. See Fig. 30. Left "D" pillar. See Fig. 30. Under front of center console. See Fig. 31. Right "D" pillar. See Fig. 33. Under driver's seat. See Fig. 34. Under driver's seat. See Fig. 34. Under front passenger's seat. See Fig. 9. Under front passenger's seat. See Fig. 9. Top left of fuel tank. See Fig. 37. Left center of liftgate. See Fig. 38. Base of left "D" pillar. See Fig. 39. Base of left "D" pillar. See Fig. 39. Base of right "D" pillar. See Fig. 39.

GROUNDS GROUNDS LOCATION Component G100

Location Left rear of engine. See Fig. 19.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

G102 G103 G104 G105 G200 G201 G203 G204 G300 G301 G302 G303 G304 G305 G306

Left rear of engine compartment. See Fig. 18. Right rear of engine compartment. See Fig. 49. Left rear of engine compartment. See Fig. 18. Right rear of engine compartment. See Fig. 49. Left end of dash. See Fig. 2. Right end of dash. See Fig. 4. Center of dash. See Fig. 1. Left end of dash. See Fig. 2. Right kick panel. See Fig. 10. Under driver's seat. See Fig. 35. Left end of dash. See Fig. 54. Right quarterpanel. See Fig. 32. Under driver's seat. See Fig. 35. Under front passenger's seat. See Fig. 36. Left quarterpanel. See Fig. 30.

SPLICES SPLICES LOCATION Component S100 (2.4L) S100 (3.5L) S101 S102 (2.4L) S102 (3.5L) S103 S104 (2.4L) S104 (3.5L) S105 (2.4L) S105 (3.5L) S106 (2.4L) S106 (3.5L) S107 S108 (2.4L) S108 (3.5L) S109 (2.4L) S109 (3.5L) S110 S111 S113 S114

Location Left rear of engine. See Fig. 47. Left rear of engine. See Fig. 41. Top left side of engine. See Fig. 43. Left rear of engine. See Fig. 40. Rear of engine. See Fig. 13. Rear of engine. See Fig. 43. Rear of engine. See Fig. 43. Rear of engine. See Fig. 13. Left rear of engine. See Fig. 40. Rear of engine. See Fig. 13. Rear of engine. See Fig. 43. Left side of engine. See Fig. 13. Left rear of engine. See Fig. 40. Left rear of engine. See Fig. 47. Rear of engine. See Fig. 13. Rear of engine. See Fig. 43. Left rear of engine. See Fig. 13. Right rear of engine. See Fig. 13. Left rear of engine. See Fig. 13. Left side of engine compartment. See Fig. 18. Left side of engine compartment. See Fig. 22.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

S116 S117 S118 S119 S125 S126 S127 (2.4L) S127 (3.5L) S128 S129 S130 S131 S132 S133 S134 S135 S136 S142 S143 S144 S153 S154 S160 S170 S171 S172 S200 S201 S202 S203 S204 S205 S206 S207 S208 S210 S211 S212 S213 S214 S215

Under TIPM. See Fig. 51. Under TIPM. See Fig. 51. Left side of engine compartment. See Fig. 18. Left side of engine compartment. See Fig. 18. Above transmission. See Fig. 17. Above transmission. See Fig. 17. Above transmission. See Fig. 14. Above transmission. See Fig. 17. Near radiator fan relay. See Fig. 46. Above left headlight assembly. See Fig. 20. Left front of engine compartment. See Fig. 20. Left side headlight harness. See Fig. 20. Left side headlight harness. See Fig. 20. Above right headlight assembly. See Fig. 46. Left side headlight harness. See Fig. 20. Above right headlight assembly. See Fig. 46. Right front of engine compartment. See Fig. 46. Left of transmission. See Fig. 14. Left rear of engine. See Fig. 47. Left rear of engine. See Fig. 47. Left front of engine compartment. See Fig. 21. Headlight & dash harness. Air pump assembly. Near right headlight assembly. See Fig. 46. Front end lighting harness. Front end lighting harness. Left side of dash. See Fig. 2. Right side of dash. See Fig. 3. Right side of dash. See Fig. 4. Instrument cluster. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Right side of dash. See Fig. 4. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Center of dash. See Fig. 1. Center of dash. See Fig. 1. Right side of dash. See Fig. 3.

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

Right side of dash. See Fig. 4. Right side of dash. See Fig. 4. Center of dash. See Fig. 1. Steering wheel jumper. Steering wheel jumper. Steering wheel jumper. Steering wheel jumper. Left side of dash. See Fig. 2. Left side of dash. See Fig. 2. Left quarterpanel. See Fig. 30. Left kick panel. See Fig. 54. Right footwell. See Fig. 10. Left kick panel. See Fig. 54. Left kick panel. See Fig. 54. Body harness. Base of left "C" pillar. See Fig. 28. Left kick panel. See Fig. 54. Right footwell. See Fig. 10. Left kick panel. See Fig. 54. Left kick panel. See Fig. 54. Left quarterpanel. See Fig. 52. Base of right "C" pillar. See Fig. 29. Under front of center console. See Fig. 16. Left kick panel. See Fig. 54. Left kick panel. See Fig. 54. Body harness. Left front of headliner. See Fig. 44. Left front of headliner. See Fig. 44. Left side of headliner. See Fig. 44. Front passenger's door. See Fig. 48. Driver's door. See Fig. 26. Driver's door. See Fig. 26. Driver's door. See Fig. 26. Left rear door. See Fig. 27. Right rear door. See Fig. 27. Left "D" pillar. See Fig. 39. Left "D" pillar. See Fig. 39. Under left rear of vehicle. See Fig. 39. Under left rear of vehicle. See Fig. 39. Right rear of vehicle. See Fig. 39. Right footwell. See Fig. 10.

S219 S221 S230 S231 S232 S233 S240 S241 S300 S301 S302 S303 S304 S305 S306 S307 S308 S309 S310 S311 S312 S313 S316 S317 S320 S322 S323 S324 S327 S328 S329 S330 S332 S333 S338 S339 S340 S341 S342 S350 user Monday, June 04, 2012 4:56:46 PM

Page 10

© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

Right footwell. See Fig. 10. Rear HVAC jumper. Seat jumper. Seat jumper. Seat jumper. Seat jumper. Driver's seat. Driver's seat. Driver's seat.

S380 S388 S389 S390 S391 S392 S393 S394

COMPONENT LOCATION GRAPHICS NOTE:

Figures may show multiple component locations. Refer to appropriate table for proper figure references.

Fig. 1: Center Of Dash Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 2: Left Side Of Dash Courtesy of CHRYSLER LLC

Fig. 3: Right Side Of Dash Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 4: Right Side Of Dash Courtesy of CHRYSLER LLC

Fig. 5: Steering Wheel Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 6: Left "C" Pillar Courtesy of CHRYSLER LLC

Fig. 7: Right "C" Pillar Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 8: Driver's Seat Courtesy of CHRYSLER LLC

Fig. 9: Front Passenger's Seat Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 10: Right Kick Panel Courtesy of CHRYSLER LLC

Fig. 11: Left Side Of Dash Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 12: Overhead Rail Courtesy of CHRYSLER LLC

Fig. 13: Top Of Engine (3.5L) Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 14: Left Side & Rear Of Engine (2.4L) Courtesy of CHRYSLER LLC

Fig. 15: Center Console Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 16: Left Front Floor Courtesy of CHRYSLER LLC

Fig. 17: Transmission (3.5L) Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 18: Left Rear Of Engine Compartment Courtesy of CHRYSLER LLC

Fig. 19: Left Side & Rear Of Engine (3.5L) Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 20: Left Front Of Engine Compartment Courtesy of CHRYSLER LLC

Fig. 21: Left Side Of Engine Compartment Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 22: Left Side Of Engine Compartment Courtesy of CHRYSLER LLC

Fig. 23: Right Side Of Engine (2.4L) Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 24: Left "A" Pillar Courtesy of CHRYSLER LLC

Fig. 25: Right "A" Pillar Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 26: Driver's Door (Front Passenger's Similar) Courtesy of CHRYSLER LLC

Fig. 27: Left Rear Door (Right Rear Similar) Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 28: Left "B" & "C" Pillars Courtesy of CHRYSLER LLC

Fig. 29: Right "B" & "C" Pillars Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 30: Left Quarterpanel Courtesy of CHRYSLER LLC

Fig. 31: Under Center Of Dash Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 32: Right Quarterpanel Courtesy of CHRYSLER LLC

Fig. 33: Right Quarterpanel Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 34: Driver's Seat Courtesy of CHRYSLER LLC

Fig. 35: Floor Under Driver's Seat Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 36: Floor Under Front Passenger's Seat Courtesy of CHRYSLER LLC

Fig. 37: Top Of Fuel Tank (AWD) Courtesy of CHRYSLER LLC

Fig. 38: Liftgate Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:56:46 PM

Page 29

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 39: Rear Of Vehicle Courtesy of CHRYSLER LLC

Fig. 40: Left Side Of Engine (2.4L) Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 41: Left Rear Of Engine (3.5L) Courtesy of CHRYSLER LLC

Fig. 42: Totally Integrated Power Module Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 43: Top Of Engine (2.4L) Courtesy of CHRYSLER LLC

Fig. 44: Roof Courtesy of CHRYSLER LLC

Fig. 45: Lower Left Side Of Dash Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 46: Right Front Of Engine Compartment Courtesy of CHRYSLER LLC

Fig. 47: Left Rear Of Engine (2.4L & 3.5L) Courtesy of CHRYSLER LLC

Fig. 48: Front Passenger's Door (Driver's Similar) Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:56:46 PM

Page 33

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 49: Right Rear Of Engine Compartment Courtesy of CHRYSLER LLC

Fig. 50: Top Of Fuel Tank (Except AWD) Courtesy of CHRYSLER LLC user Monday, June 04, 2012 4:56:46 PM

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 51: Totally Integrated Power Module Courtesy of CHRYSLER LLC

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 52: Left "C" Pillar Courtesy of CHRYSLER LLC

Fig. 53: Right Front Of Engine Compartment user Monday, June 04, 2012 4:56:46 PM

Page 36

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Courtesy of CHRYSLER LLC

Fig. 54: Left Side Of Dash & Kick Panel Courtesy of CHRYSLER LLC

user Monday, June 04, 2012 4:56:46 PM

Page 37

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2009 Dodge Journey SE 2009 CHRYSLER Journey

Fig. 55: Right "A" Pillar Courtesy of CHRYSLER LLC

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2009 ENGINE 2.0L Diesel - Service Information - Journey

DESCRIPTION DESCRIPTION

Fig. 1: Serial Number Courtesy of CHRYSLER LLC This is an 2.0L electronic unit injector turbo diesel engine. The engine serial number is located on the rear flange of the engine block behind the oil filter housing (2).

STANDARD PROCEDURE COMPRESSION TESTING ENGINE CAUTION: Injector retaining bolts must be replaced after performing compression test. 1. 2. 3. 4. 5. 6.

Warm up engine to operating temperature (approximately 80 °C, 176°F). Shut off engine. Remove engine cover. See Removal . Disconnect fuel feed and return lines from the fuel filter. Operate a vacuum pump connected to the return line until no more fuel comes out. Remove injectors. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Removal .

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7. Crank engine several times with the starter to eliminate combustion residues in the cylinders. 8. Insert compression adapter 9889 into injector hole of cylinder to be tested. Install injector retainer bolts and tighten. 9. Test compression pressure by cranking engine with starter for at least 8 revolutions. 10. Carry out test procedure at the remaining cylinders in the same way. 11. Compare pressure readings obtained with the specified pressures. If the pressure reading is below the minimum compression pressure or if the permissible difference between the individual cylinders is exceeded. See Standard Procedure . COMPRESSION SPECIFICATION - 2.0L COMPRESSION SPECIFICATION Minimum Allowable 18 bar (261 psi.) Maximum Allowable 3 bar (44 psi.) Difference Between Cylinders Average Compression 24 - 30 bar (348 - 435 psi) 12. Remove adapter from cylinder head. NOTE:

Injector retaining bolts must be replaced when installing injectors.

13. Install injectors with new bolts. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel Installation . 14. Install engine cover. See Installation . FORM-IN-PLACE GASKETS AND SEALERS NOTE:

All sealants mentioned below are not used on every engine, they are listed as general reference guide. See Service Information for specific sealer usage.

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin of a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use formin-place gaskets and sealers must be free of grease or oil. Clean surfaces with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, assemble the parts within 10 minutes. Numerous types of form-in-place gasket materials are used in the engine area. Mopar® Sealant RTV Silicone Rubber Adhesive, MOPAR® Silicone Rubber RTV, Mopar® ATF-RTV and Mopar® Gasket Maker gasket materials, each have different properties and cannot be used in place of the other. MOPAR® SEALANT RTV SILICONE RUBBER ADHESIVE is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available user Monday, June 04, 2012 10:21:10 AM

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in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® SILICONE RUBBER RTV is used to seal components exposed to engine oil, gear lubricant, and coolant. This material is a specially designed gray silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil, gear lubricant and coolant. Excellent adhesion even on oily surfaces, withstands temperatures to 330° C (626° F). Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® ATF-RTV is a specially designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. It can be used on threaded and machined parts under all temperatures. This material also prevents corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or in a 4 oz. or 6 oz. can with applicator. SEALER APPLICATION

Apply 1 mm (0.040 in.) diameter or less of Mopar® Gasket Maker material to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Tighten the components in place within 15 minutes. Use a locating dowel during assembly to prevent smearing material off the location. Apply Mopar® RTV or ATF-RTV gasket material in a continuous bead approximately 3 mm (0.120 in.) in diameter. For corner sealing and "T-Joint" locations and waffle pad area, a 0.635 mm (0.025 in.) drop is placed in the center of the gasket contact area. Remove uncured sealant with a shop towel. Tighten the components in place while the sealant is still wet to the touch (within 10 minutes). Use a locating dowel during assembly to prevent smearing material off the location. CYLINDER LEAK DOWN TEST 1. Warm engine to operating temperature. WARNING: Do not open cooling system unless coolant temperature is below 90° C (194°F). Risk of injury to skin and eyes as a result of scalding with hot coolant which splashes out. Risk of poisoning from swallowing coolant. Open cap slowly and release pressure. Store coolant in proper containers only. Wear protective gloves, clothing and eye protection. user Monday, June 04, 2012 10:21:10 AM

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NOTE:

2. 3. 4. 5.

Turn cap carefully as far as first detent, release pressure, then unscrew cap.

Open cooling system cap at coolant recover pressure container. Remove engine cover. See Removal . Unscrew oil filler cap. Remove glow plugs. Refer to Electrical - Ignition Control/Ignition Control/PLUG, Glow - Removal . NOTE:

Crank engine at crankshaft in direction of rotation of the engine (clockwise).

6. Position cylinder to be tested to ignition Top Dead Center (TDC). NOTE:

Calibrate cylinder leak down tester and remove check valve in screw-in fitting.

7. Connect cylinder leak down tester and refer to INSPECTING. INSPECTING

NOTE:

If crankshaft rotates, install retaining lock for crankshaft/ring gear.

1. Pressurize cylinder with compressed air and read off pressure loss at cylinder leak tester. If excessive pressure loss exists, refer to DETERMINING PRESSURE LOSS. NOTE:

If the retaining lock is installed, remove it, rotate engine and install lock once again.

2. Carry out test of other cylinders in the firing order of engine. DETERMINING PRESSURE LOSS

If a great pressure loss was detected, listen using a stethoscope around suspected areas, such as the cylinder head gasket through the air suction area, the exhaust system, the oil filler neck, the pre-chamber, the bore wholes of the cylinder effected or neighboring cylinders. Observe the coolant in the expansion tank, looking for traces of bubbles. The possible causes of pressure loss are:

z

If air leak is detected through the prechamber, cylinder bore hole, from a neighboring cylinder or air bubbles in the coolant expansion tank, pressure loss may be caused by the cylinder head gasket. If the air leak occurs in the air suction area, the pressure loss may be caused by the intake valve(s).

z

Air leak through the exhaust system, may be caused by the exhaust valve(s).

z

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z

Air leak through the oil filler neck, may be caused by piston, ring, or cylinder sleeve.

If none of the above evidence supports a failure, the engine may be assembled and run until operating temperature is reached. Reconnect engine leak down tester on a warm engine with a few drops of clean engine oil in the cylinder being tested. Engine oil seals the clearance between the piston and cylinder for a short length of time. If under this condition a smaller pressure loss occurs for a shorter length of time, it is possible that the cause is piston, ring or cylinder sleeve related. ENGINE GASKET SURFACE PREPARATION

Fig. 2: Proper Tool Usage For Surface Preparation Courtesy of CHRYSLER LLC To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces: z z z

Metal scraper (1). High speed power tool with an abrasive pad or paper to clean cylinder block and head (2). High speed power tool with 3M Roloc™ Bristle Disc (white or yellow) (3).

NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces: z z

Solvent or a commercially available gasket remover. Plastic or wood scraper (4).

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REMOVAL ENGINE COVER

Fig. 3: Engine Cover Removal/Installation Courtesy of CHRYSLER LLC 1. Remove engine cover (1) by lifting upwards. ENGINE CAUTION: When removing or disconnecting components, plug all inlet/outlet and fluid lines to prevent residual leakage and contamination.

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Fig. 4: Air Cleaner Housing Courtesy of CHRYSLER LLC 1. Remove air cleaner assembly (2).

Fig. 5: Battery Cable Courtesy of CHRYSLER LLC 2. Disconnect negative battery cable (1).

Fig. 6: Engine Cover Courtesy of CHRYSLER LLC 3. Remove engine cover. See Removal . 4. Remove body ground. user Monday, June 04, 2012 10:21:10 AM

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5. 6. 7. 8.

Disconnect the EGR cooler vacuum line. Disconnect the swirl valve vacuum line. Disconnect the turbocharger vacuum line. Disconnect ECM connector.

Fig. 7: Coolant Reservoir Courtesy of CHRYSLER LLC 9. 10. 11. 12. 13.

Drain cooling system. Refer to Cooling - Standard Procedure . Discharge air conditioning. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure . Remove cooling module assembly. Refer to Cooling/Engine/FAN, Cooling - Removal . Remove coolant recovery reservoir (2). Remove power steering reservoir (3) and reposition.

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Fig. 8: Pressure Line Courtesy of CHRYSLER LLC 14. Remove accessory drive belt (5). 15. Remove power steering line support bracket retaining bolt (2). 16. Remove power steering pump (6) and set aside.

Fig. 9: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 17. Remove accessory drive idler pulley (2). 18. Disconnect electrical connectors at generator. 19. Remove generator.

Fig. 10: A/C Compressor-Refrigerant Lines user Monday, June 04, 2012 10:21:10 AM

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Courtesy of CHRYSLER LLC 20. Disconnect A/C compressor electrical connector (2). 21. Disconnect A/C lines (4) at the compressor. 22. Remove A/C compressor (3).

Fig. 11: Tandem Pump Courtesy of CHRYSLER LLC 23. Disconnect vacuum hose at tandem pump (1). 24. Disconnect heater hoses at engine. 25. Remove air inlet tube from intake manifold.

Fig. 12: Starter Electrical Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:10 AM

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26. Disconnect starter electrical connections (1, 2) and remove starter.

Fig. 13: Hydraulic Line Courtesy of CHRYSLER LLC 27. Remove shift cables (2) from transaxle. 28. Remove shift cable retaining bracket from transaxle. 29. Disconnect hydraulic clutch line (1). NOTE:

When removing tripod joint, DO NOT let spline or snap ring drag across transaxle oil seal lip.

30. Remove left and right axle shafts. Refer to Differential and Driveline/Half Shaft - Removal .

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Fig. 14: Air Inlet Tube Courtesy of CHRYSLER LLC 31. Remove turbocharger inlet and outlet tubes. 32. Remove air tube retaining bolt (1) and remove air inlet tube (2).

Fig. 15: Transmission Crossmember Courtesy of CHRYSLER LLC 33. Remove front transaxle mount through bolt (4). 34. Remove fore/aft member retaining bolts (2,3) and remove fore/aft member (1). user Monday, June 04, 2012 10:21:10 AM

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Fig. 16: Catalytic Converter - Diesel Courtesy of CHRYSLER LLC 35. 36. 37. 38.

Disconnect catalytic converter (1) from exhaust pipe. Loosen catalytic converter clamp (2) and remove catalytic converter (1) and gasket (3) from turbocharger. Remove catalytic converter assembly (1). Remove PTU assembly (if equipped).

Fig. 17: Rear Mount Courtesy of CHRYSLER LLC 39. Remove rear engine mount through bolt (3). user Monday, June 04, 2012 10:21:10 AM

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40. Remove rear engine mount bracket retaining bolts (1) and remove engine mount bracket (2). 41. Remove rear engine mount.

Fig. 18: Engine Cradle Bracket 6973 Courtesy of CHRYSLER LLC 42. Install engine cradle bracket 6973 (2) to engine block.

Fig. 19: Engine Dolly Courtesy of CHRYSLER LLC 43. Lower vehicle and position power train dolly 6135 (2) and engine support cradle 6710A (1) under engine. 44. Position the engine cradle support and dolly with the support posts 6710A (3,5,8,9) underneath the user Monday, June 04, 2012 10:21:10 AM

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engine. 45. Carefully lower the vehicle enough to position the engine above the support posts. 46. Adjust the height of each support post as necessary and tighten the support posts and cradle fasteners.

Fig. 20: Engine Dolly Courtesy of CHRYSLER LLC 47. Carefully lower vehicle enough to seat engine onto support posts. WARNING: Safety straps must be used to secure engine to the dolly fixture.

48. Install, tighten and lock safety straps (6,7) around engine and attach them to the cradle. 49. Lower vehicle so that only the weight of the engine and transmission assembly is on dolly fixture.

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Fig. 21: Right Engine Mount Courtesy of CHRYSLER LLC 50. Remove right mount (1) to engine bracket retaining bolts.

Fig. 22: Left Engine Mount Courtesy of CHRYSLER LLC 51. Remove left mount (3) to transaxle retaining bolts. CAUTION: It may be necessary to adjust the engine and transmission assembly, with the dolly fixture attached, to successfully clear the engine compartment. 52. While watching for obstructions, slowly raise the vehicle until the engine and transmission assembly clear user Monday, June 04, 2012 10:21:10 AM

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the engine compartment. 53. Separate engine and transmission.

INSTALLATION ENGINE COVER

Fig. 23: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 1. Align engine cover (1) with mounting retainers. 2. Firmly press cover onto mounting studs. ENGINE

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Fig. 24: Engine Dolly Courtesy of CHRYSLER LLC WARNING: Safety straps must be used to secure engine to the dolly fixture.

1. Seat engine onto fixture support posts then install safety straps (6,7) around engine, securing it to the cradle. 2. Position the engine and transmission assemblies below vehicle engine compartment. CAUTION: It may be necessary to adjust the engine and transmission assembly, with the dolly fixture attached, to successfully clear the engine compartment. 3. While watching for obstructions, slowly lower the vehicle until the engine and transmission assembly clearly fit the engine compartment.

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Fig. 25: Left Engine Mount Courtesy of CHRYSLER LLC 4. Install left mount bracket (3) to transaxle retaining bolts and tighten to 65 N.m (50 ft. lbs.).

Fig. 26: Right Engine Mount Courtesy of CHRYSLER LLC 5. Install right mount bracket (1) to frame rail retaining bolts and tighten to 65 N.m (50 ft. lbs.).

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Fig. 27: Engine Dolly Courtesy of CHRYSLER LLC 6. 7. 8. 9. 10. 11.

Remove safety straps (6,7) and remove dolly fixture Carefully raise the vehicle enough to clear the cradle and support post. Install catalytic converter loosely with new seal. If equipped, install PTU. Place a suitable jack under transaxle and raise engine/trans assembly. Install exhaust to PTU mount.

Fig. 28: Catalytic Converter - Diesel user Monday, June 04, 2012 10:21:10 AM

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Courtesy of CHRYSLER LLC 12. Install catalytic converter band clamp (2) and tighten. 13. Install power steering hose clamp to exhaust manifold. 14. Install PTU to block support bracket.

Fig. 29: Transmission Crossmember Courtesy of CHRYSLER LLC 15. Install rear mount bracket to cradle. 16. Install front transaxle mount bracket to transaxle. 17. Install fore/aft member (1).

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Fig. 30: Front Mount Through Bolt Courtesy of CHRYSLER LLC 18. 19. 20. 21. 22. 23.

Install front mount through bolt (1) and tighten. Install turbo outlet pipe. Install axle shafts. Refer to Differential and Driveline/Half Shaft - Installation . Install turbo inlet pipe from air cleaner to turbocharger. Install charge air hose from inter cooler to throttle body. Install shift cables.

Fig. 31: Starter Bolts Courtesy of CHRYSLER LLC 24. Position starter and install starter mounting bolts (1). user Monday, June 04, 2012 10:21:10 AM

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Fig. 32: Starter Electrical Courtesy of CHRYSLER LLC 25. 26. 27. 28.

Connect starter electrical connectors. Install vacuum harness and coolant tube. Connect fuel lines near head. Connect vacuum hose to brake booster.

Fig. 33: A/C Compressor-Refrigerant Lines Courtesy of CHRYSLER LLC 29. Install A/C compressor (3) and connect A/C lines (4). 30. Connect engine wiring harness connectors. 31. Install generator and connect electrical connectors. user Monday, June 04, 2012 10:21:10 AM

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32. Install serpentine belt tensioner and install serpentine belt.

Fig. 34: Coolant Reservoir Courtesy of CHRYSLER LLC 33. 34. 35. 36. 37. 38.

Install coolant reservoir (4). Install coolant module, connect cooling fan connectors. Connect upper and lower radiator hoses. Connect charge air hoses to intercooler. Connect A/C lines to condenser and connect electrical connectors. Fill engine with coolant. Refer to Cooling - Standard Procedure .

Fig. 35: Filter In Housing Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:10 AM

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39. Install new oil filter (2) and fill engine with oil.

Fig. 36: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 40. Evacuate the refrigerant system. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure . 41. Charge the refrigerant system. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure . 42. Install engine cover (1). 43. Start engine and check for leaks.

SPECIFICATIONS 2.0L DIESEL ENGINE GENERAL DESCRIPTION

SPECIFICATION Metric

Type Number of Cylinders Firing Order Compression Ratio

Standard In-Line OHV, DOHC 4 1-3-4-2 18.5:1

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Max. Variation Between Cylinders Displacement Bore Stroke

25% 2.0 L 81.0 mm 95.5 mm

CYLINDER BLOCK DESCRIPTION

122 CID 3.188 in 3.759 in.

SPECIFICATION Metric

Material Cylinder Bore Diameter Cylinder Bore Diameter Out-ofRound (Max.) Cylinder Bore Diameter Taper (Max.)

Cast Iron 81.01 mm

3.189 in.

0.10 mm

0.003 in.

0.10 mm

0.003 in.

PISTONS DESCRIPTION Piston Diameter

SPECIFICATION Metric 80.96 mm

PISTON RINGS DESCRIPTION Ring Gap-Top Compression Ring Wear Limit Ring Gap - 2nd Compression Ring Wear Limit Ring Gap - Oil Scraper Wear Limit Ring Side Clearance-Top Compression Wear Limit Ring Side Clearance -2nd Compression Ring Wear Limit Ring Side Clearance - Oil Scraper Wear Limit

Standard

Standard 3.187 in.

SPECIFICATION Metric 0.20 - 0.40 mm 1.0 mm 0.20 - 0.40 mm 1.0 mm 0.20 - 0.50 mm 1.0 mm

Standard 0.007 - 0.015 in. 0.039 in. 0.007 - 0.015 in. 0.039 in. 0.007 - 0.019 in. 0.039 in.

0.06 - 0.09 mm

0.002 - 0.003 in.

0.25 mm

0.009 in.

0.05 - 0.08 mm

0.001 - 0.003 in.

0.25 mm 0.03 - 0.06 mm 0.15 mm

0.009 in. 0.001 - 0.002 in. 0.005 in.

CONNECTING ROD DESCRIPTION Bearing Clearance

SPECIFICATION Metric 0.03 - 0.08 mm

Standard 0.001 - 0.003 in.

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Side Clearance

0.37 mm

0.014 in.

CRANKSHAFT DESCRIPTION Connecting Rod Journal Diameter Main Bearing Journal Diameter End Play Wear Limit Main Bearing Clearance Wear Limit

SPECIFICATION Metric 50.878 - 50.942 mm 53.978 - 54.042 mm 0.07 - 0.17 mm 0.37 mm 0.03 - 0.08 mm 0.17 mm

CAMSHAFT DESCRIPTION End Play - Max

SPECIFICATION Metric 0.15 mm

VALVE GUIDE DESCRIPTION Stem to Guide Clearance - Max

Standard 2.003 - 2.005 in. 2.125 - 2.127 in. 0.002 - 0.006 in. 0.014 in. 0.001 - 0.003 in. 0.006 in.

Standard 0.005 in.

SPECIFICATION Metric 1.3 mm

Standard 0.051 in.

NOTE: Insert new valve into guide. The end of the valve stem must be flush with guide. Use only inlet valve in inlet guide and exhaust valve in exhaust guide. Determine rock. Cylinder head must be renewed if rock exceeds wear limit.

VALVES DESCRIPTION Face Angle - Intake and Exhaust Head Diameter - Intake Head Diameter - Exhaust Valve Length (Overall) Intake Exhaust Valve Stem Diameter Intake Exhaust

SPECIFICATION Metric 45° 29.40 mm 25.50 mm 88.50 mm 88.20 mm 5.980 mm 5.965 mm

VALVE STEM TO GUIDE CLEARANCE DESCRIPTION

Standard 45° 1.157 in. 1.003 in. 3.484 in. 3.472 in. 0.235 in. 0.234 in.

SPECIFICATION Metric

Standard

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Intake Max. Allowable Exhaust Max. Allowable

1.3 mm 1.3 mm

0.051 in. 0.051 in.

OIL PRESSURE DESCRIPTION At Curb Idle Speed* At 2000 RPM Max Oil Pressure

SPECIFICATION Metric 0.55 bar 2.0 bar 7.0 bar

Standard 8 psi 29 psi 101 psi

CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 2000 RPM.

TORQUE DESCRIPTION Accessory Bracket-Bolts Accessory Drive Belt Tensioner-Bolt Bearing Frame-Bolts Cable Retainer-Bolts Camshaft Hub-Bolt Camshaft Position Sensor-Bolt Camshaft Sprocket-Bolt Connecting Rod Cap-Bolts Crankshaft Main Bearing Cap-Bolts Crankshaft Damper-Bolt Crankshaft Position Sensor-Bolt Crankshaft Front Sealing Flange-Bolts Crankshaft Rear Sealing Flange-Bolts Crankshaft Sprocket Cylinder Head-Bolts Cylinder Head Cover-Bolts Engine Support Bracket-Bolts Exhaust Gas Recirculation Valve-Bolts Exhaust Gas Recirculation Valve Tube-Bolts Exhaust Manifold-Nuts Exhaust Manifold Heat Shield-Bolts Flywheel-Bolts Fuel Pump-Bolts Glow Plugs

N.m 45 25 20 10 100 10 25 30 + 90° 65 + 90° 10 + 90° 5 15 15 120 + 90° 10 45 10 20 25 25 60 + 90° 20 10

Ft. Lbs. 33 74 22 + 90° 48 + 90° 89 + 90° Refer to Procedure 33 44 + 90° -

In. Lbs. 221 177 89 89 221 89 + 90° 44 133 133 89 89 177 221 221 177 89

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Injector-Bolts Intake Manifold-Bolts Intake Manifold Flap-Bolts Oil Cooler Connector Bolt Oil Filter Cover Oil Filter Housing-Bolts Oil Pan-Bolts Oil Pan Drain-Plug Oil Pump-Bolts Oil Pump Drive Chain Tensioner-Bolt Oil Pump Pick-up Tube-Bolts Oil Pump Sprocket-Bolt Oil Spray Jet-Bolt Rocker Arm Shaft-Bolts Thermostat Housing-Bolts Timing Belt Covers Timing Belt Tensioner Assembly-Nut Timing Belt Idler Upper Pulley-Bolt Timing Belt Idler Lower Pulley-Nut

3 + 90° +180° 20 10 25 25 15 + 90° 15 30 15 15 15 22 + 90° 25 20 + 90° 15 10 20 + 45° 40 + 90° 20

22 30 + 90° -

27 + 90° +180° 177 89 221 221 133 + 90° 133 133 133 133 195 + 90° 221 177 + 90° 133 89 177 + 45° 177

SPECIAL TOOLS 2.0L DIESEL

Fig. 37: Camshaft Hub Holder 9880 Courtesy of CHRYSLER LLC

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Fig. 38: Camshaft Locking Pins 9882 Courtesy of CHRYSLER LLC

Fig. 39: Cam Seal Installer 9884 Courtesy of CHRYSLER LLC

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Fig. 40: Compression Adapter 9889 Courtesy of CHRYSLER LLC

Fig. 41: Crankshaft Front Oil Seal Installer 9884 Courtesy of CHRYSLER LLC

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Fig. 42: Crankshaft Lock 9883 Courtesy of CHRYSLER LLC

Fig. 43: Crankshaft Lock 10122 Courtesy of CHRYSLER LLC

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Fig. 44: Injector Remover 9887 Courtesy of CHRYSLER LLC

Fig. 45: Rear Main Seal Installer 9888 Courtesy of CHRYSLER LLC

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Fig. 46: Valve Spring Remover Installer 9916 Courtesy of CHRYSLER LLC

CYLINDER HEAD DESCRIPTION DESCRIPTION

The aluminum cylinder head is a two piece design. It consists of the cylinder head and a bearing frame. The cylinder head is a cross flow type design with 4 valves per cylinder. The valves are installed vertically. The bearing frame is used to mount the camshafts and provides mounting of the central power supply connector. It also provides mounting for the injector rocker shaft. REMOVAL REMOVAL

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Fig. 47: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 1. Remove engine cover (1).

Fig. 48: Battery Cable Courtesy of CHRYSLER LLC 2. Disconnect negative battery cable (1).

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Fig. 49: Air Cleaner Housing Courtesy of CHRYSLER LLC 3. Disconnect MAF sensor electrical connector (4). 4. Remove clean air tube (1). 5. Remove air cleaner housing (2).

Fig. 50: Vacuum Solenoid Connectors Courtesy of CHRYSLER LLC 6. Remove electrical connector (1) and set aside. 7. Remove vacuum harness (3) and set aside. 8. Disconnect brake booster vacuum line.

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Fig. 51: Coolant Reservoir Courtesy of CHRYSLER LLC WARNING: Risk of injury to skin and eyes from scalding coolant. Do not open cooling system unless temperature is below 90°c (194°F). Open cap slowly to release pressure. Store coolant in approved container only. Wear protective gloves, clothing and eye wear. 9. Drain coolant. 10. Remove coolant tube from reservoir (1). 11. Remove coolant reservoir (4).

Fig. 52: Fuel Pump-High Pressure Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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12. Disconnect injector harness connector (1) at cylinder head. 13. Remove fuel line retaining bracket.

Fig. 53: Tandem Pump Courtesy of CHRYSLER LLC NOTE:

Place rags below pump to catch fuel spillage.

14. Drain fuel from the injection system prior to removing fuel pump. Refer to Fuel System/Fuel Injection Standard Procedure . 15. Disconnect vacuum line (1) from pump. 16. Disconnect fuel lines (3,4) from pump. 17. Remove fuel pump retaining bolts (2) and remove pump. 18. Disconnect coolant hose near fuel pump. 19. Remove upper radiator hose at cylinder head. 20. Disconnect engine electrical connectors. 21. Remove air inlet hose from throttle body. 22. Raise vehicle. 23. Remove right splash shield. 24. Remove turbo outlet pipe retaining bolt (1) and remove pipe (2). 25. Remove turbo inlet pipe. 26. Remove power steering hose support bracket at exhaust manifold. Refer to Steering/Pump/HOSE, Power Steering - Removal . 27. Remove EGR cooler.

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Fig. 54: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 28. Remove accessory drive belt. 29. Remove balancer (4).

Fig. 55: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 30. Remove right engine mount bracket (5) lower bolt. 31. Lower vehicle.

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Fig. 56: Right Engine Mount Courtesy of CHRYSLER LLC 32. 33. 34. 35.

Support oil pan with a suitable jack. Remove right engine mount through bolt (2). Remove right engine mount bracket (1). Remove right engine mount (3).

Fig. 57: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 36. Remove accessory drive belt tensioner (3). 37. Remove the remaining engine mounting bracket retaining bolts (1). 38. Remove right engine mounting bracket (5). user Monday, June 04, 2012 10:21:11 AM

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39. 40. 41. 42.

Remove harmonic balancer (4). Remove timing belt. See Removal . Remove oil feed pipe from turbo and remove pipe retainers. Remove exhaust manifold.

Fig. 58: Cam Holder Courtesy of CHRYSLER LLC 43. 44. 45. 46. 47.

Remove camshaft sprockets. Remove camshaft sprocket hubs. Remove injector rocker arm shaft. Remove bearing frame. Remove camshafts.

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Fig. 59: Injector Courtesy of CHRYSLER LLC 48. Remove injector retaining bolts (2) and discard.

Fig. 60: Injector Removal Courtesy of CHRYSLER LLC 49. Remove injectors (3) using injector remover 9887 (2) and a slide hammer (1). Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Removal .

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Fig. 61: Cylinder Head Bolt Torque Sequence Courtesy of CHRYSLER LLC NOTE:

Loosen cylinder head bolts in the reverse order of the tightening sequence.

50. Remove cylinder head bolts and discard. 51. Remove cylinder head. WARNING: No fire, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury from skin and eye contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. CLEANING CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block. See Standard Procedure . Be careful not to gouge or scratch the aluminum head sealing surface. Clean all engine oil passages. INSPECTION user Monday, June 04, 2012 10:21:11 AM

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INSPECTION

NOTE:

Cylinder head cannot be resurfaced.

NOTE:

Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers.

Fig. 62: Checking Cylinder Head Flatness Courtesy of CHRYSLER LLC 1 - FEELER GAUGE 2 - STRAIGHT EDGE 1. Cylinder head must be flat within 0.1 mm (0.004 in.) .

Fig. 63: Checking Wear on Valve Guide-Typical Courtesy of CHRYSLER LLC 1 - TOP 2 - MIDDLE 3 - BOTTOM 4 - CUT AWAY VIEW OF VALVE GUIDE user Monday, June 04, 2012 10:21:11 AM

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MEASUREMENT LOCATIONS 2. Inspect camshaft bearing journals for scoring. 3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4. Using a small hole gauge and a micrometer, measure valve guides in 3 places top (1), middle (2), and bottom (3). See Specifications. Replace guides if they are not within specification. 5. Check valve guide height. 6. Prior to installing cylinder head, the cylinder block should be checked for flatness. INSTALLATION INSTALLATION

Fig. 64: Gasket Identification Courtesy of CHRYSLER LLC WARNING: No fire, open flames or smoking. Service vehicles in well ventilated areas. Risk of poisoning from inhaling or swallowing fuel. Risk of injury from skin and eye contact with fuel. Wear protective clothing. NOTE:

Thoroughly clean all mating surfaces with appropriate solvents and blow out bolt holes, to assure that no grease or oil is present during reassembly.

NOTE:

If piston or connecting rods have been replaced, measure piston projection to ensure proper head gasket selection. See Standard Procedure .

NOTE:

Check facing cylinder head contact surface.

1. Remove crankshaft lock 9883. user Monday, June 04, 2012 10:21:11 AM

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2. Rotate crankshaft counterclockwise until all pistons are in the middle of the bore. NOTE:

Ensure that the gasket is correct before installing. Gasket is identified by holes stamped in the gasket (1).

3. Position the cylinder head gasket with writing (2) facing upwards on engine using the dowel pins as guide.

Fig. 65: Cylinder Head Bolt Torque Sequence Courtesy of CHRYSLER LLC 4. Position the cylinder head on the engine and install new cylinder head bolts. a. Tighten cylinder head bolts to 35 N.m (26 ft. lbs.) in the sequence shown in illustration. b. Tighten cylinder head bolts to 60 N.m (44 ft. lbs.) in the sequence shown in illustration. c. Rotate each bolt in the sequence above 90°. d. Rotate each bolt in the sequence above an additional 90°.

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Fig. 66: CAM REMOVAL/INSTALLATION Courtesy of CHRYSLER LLC 5. Install camshafts (1). See Installation , 6. Install camshaft oil seals. See Installation .

Fig. 67: Injectors Courtesy of CHRYSLER LLC CAUTION: When installing unit injectors, new bolts (5) must be used.

NOTE:

When installing used unit injector, new o-rings must be used.

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7. Install unit injectors (4). Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .

Fig. 68: Power Steering Line Support Courtesy of CHRYSLER LLC 8. Install exhaust manifold gasket and manifold. 9. Install oil feed pipe (4) to turbo and install pipe hold down clamp (5). 10. Install exhaust manifold heat shields.

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Fig. 69: Intake Manifold Courtesy of CHRYSLER LLC 11. 12. 13. 14. 15. 16.

Install intake manifold gasket (2) and manifold (1). See Installation . Install EGR assembly (7). Install throttle plate assembly (5). Install exhaust manifold to EGR tube (3). Install coolant hose to EGR cooler assembly. Install timing belt cover.

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Fig. 70: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 17. Install right engine mount bracket (5). 18. Install accessory drive belt tensioner.

Fig. 71: Right Engine Mount Courtesy of CHRYSLER LLC 19. 20. 21. 22.

Install right engine mount (3). Remove jack. Raise vehicle. Install right engine mount lower bolt.

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Fig. 72: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 23. Install balancer (4). 24. Install accessory drive belt.

Fig. 73: Power Steering Line Support Courtesy of CHRYSLER LLC 25. 26. 27. 28. 29.

Install power steering hose support bracket at exhaust manifold (2). Install turbo outlet pipe. Install turbo inlet pipe. Install right splash shield. Lower vehicle.

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30. 31. 32. 33. 34.

Install coolant recovery bottle. Install air inlet hose to throttle body. Connect engine electrical connectors. Install upper radiator hose at cylinder head. Connect coolant hoses near fuel pump.

Fig. 74: Tandem Pump Courtesy of CHRYSLER LLC 35. 36. 37. 38. 39. 40. 41. 42.

Install fuel pump. Refer to Fuel System/Fuel Delivery/PUMP, Tandem Fuel - Installation . Install fuel line retaining bracket. Connect injector harness at cylinder head. Connect brake booster vacuum hose (1). Connect coolant tube at reservoir. Install vacuum harness. Fill with coolant. Install new oil filter and fill with oil.

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Fig. 75: Air Cleaner Housing Courtesy of CHRYSLER LLC 43. Install air cleaner assembly (2).

Fig. 76: Battery Cable Courtesy of CHRYSLER LLC 44. Connect negative battery cable (1). 45. Start engine and check for leaks.

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Fig. 77: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 46. Install engine cover (1). CAMSHAFT, ENGINE Removal REMOVAL

Fig. 78: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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1. Disconnect negative battery cable. 2. Remove engine cover. See Removal . WARNING: No fire, open flames or smoking. Risk of poisoning from inhaling or swallowing fuel. Risk of injury from skin and eye contact with fuel. Wear protective clothing. Store fuel only in suitable and appropriately marked containers.

Fig. 79: Crankshaft Timing Marks Courtesy of CHRYSLER LLC NOTE:

Engine equipped with a balance shaft module use an oval toothed belt, and crankshaft holding tool 10122 must be used

3. Place engine at TDC. 4. Install crankshaft lock 9883 or 10122. 5. Remove timing belt. See Removal .

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Fig. 80: Tandem Pump Courtesy of CHRYSLER LLC 6. Remove tandem pump (refer to tandem pump REMOVAL).

Fig. 81: Cam Holder Courtesy of CHRYSLER LLC 7. Loosen camshaft hub retaining bolt using camshaft sprocket/hub holder 9880 (1). 8. Remove camshaft sprocket retaining bolts using camshaft sprocket/hub holder 9880 (1) and remove sprockets. 9. Remove camshaft hub retaining bolt and remove hubs with puller. 10. Loosen injector adjusting lock nut and back off injector adjuster.

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Fig. 82: Rocker Arm Shaft Bolt Removal/Installation Sequence Courtesy of CHRYSLER LLC 11. Remove rocker arm shaft and bearing frame retaining bolts. 12. Remove rocker arm shaft.

Fig. 83: Cam Bearing Frame Torque Courtesy of CHRYSLER LLC 13. Remove bearing frame. NOTE:

If bearing shells are to be reused, clean them and identify location with a marker.

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Fig. 84: CAM REMOVAL/INSTALLATION Courtesy of CHRYSLER LLC 14. Remove camshafts (1). Installation INSTALLATION

Fig. 85: CAM REMOVAL/INSTALLATION Courtesy of CHRYSLER LLC 1. Install new bearing shells in cylinder head. 2. Lubricate bearings with clean engine oil. 3. Install camshafts with cylinder #1 lobes pointing upwards. user Monday, June 04, 2012 10:21:11 AM

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Fig. 86: Cam Bearing Frame Torque Courtesy of CHRYSLER LLC 4. Apply a bead of RTV to cylinder head. 5. Install bearing frame and tighten bolts as shown in illustration.

Fig. 87: Rocker Arm Shaft Bolt Removal/Installation Sequence Courtesy of CHRYSLER LLC 6. 7. 8. 9. 10.

Install injector rocker arm shaft. Tighten bolts to 20 N.m (15 in. lbs.) in the sequence shown in illustration. Tighten rocker arm shaft bolts an additional 90° as shown in illustration. Install camshaft oil seals using. See Installation . Install camshafts hubs onto camshafts and install bolts.

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11. Install sprockets on camshaft hubs with the toothed segment facing upward. 12. Install retaining bolts finger tight.

Fig. 88: Cam Holder Courtesy of CHRYSLER LLC 13. 14. 15. 16.

Tighten camshaft hub bolts to 100 N.m (74 ft. lbs.) using hub/sprocket holder 9880 (1). Install camshaft locking pins 9882. Install timing belt. See Installation . Perform injector adjustment. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Standard Procedure .

Fig. 89: Tandem Pump Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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17. Install fuel pump. Refer to Fuel System/Fuel Delivery/PUMP, Tandem Fuel - Installation . 18. Install cylinder head cover. See Installation .

Fig. 90: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 19. 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 clothing. CAUTION: When new rocker fingers have been installed, engine must not be started for 30 minutes. The hydraulic compensation elements must settle or the pistons will contact the valves. 20. Start engine and inspect for leaks. 21. Install engine cover (1). See Installation . COVER(S), CYLINDER HEAD Removal REMOVAL

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Fig. 91: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable (1).

Fig. 92: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover. See Removal .

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Fig. 93: Coolant Tube Courtesy of CHRYSLER LLC 3. Remove coolant tube retaining bolts (1) and reposition coolant tubes.

Fig. 94: Removing/Installing Cylinder Head Cover Courtesy of CHRYSLER LLC 4. Remove cylinder head cover retaining bolts and remove cover. Installation INSTALLATION

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Fig. 95: Cylinder Head Cover Installation Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Clean sealing surfaces. Install new cylinder head cover gasket. Install cylinder head cover. Tighten cylinder head cover bolts in the sequence shown in illustration to 10 N.m (89 in. lbs.).

Fig. 96: Coolant Tube Courtesy of CHRYSLER LLC 5. Install coolant tubes retaining bolts (1) and tighten.

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Fig. 97: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 6. Install engine cover.

Fig. 98: Battery Cable Courtesy of CHRYSLER LLC 7. Connect negative battery cable (1). SEAL(S), CAMSHAFT Removal REMOVAL

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Fig. 99: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 1. Remove engine cover (1). 2. Remove upper timing belt cover. See Removal .

Fig. 100: Right Engine Mount Courtesy of CHRYSLER LLC 3. 4. 5. 6.

Support engine and remove right engine mount through bolt (2). Remove right engine mount bracket. Remove timing belt. See Removal . Remove timing belt rear cover.

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7. Remove camshaft sprockets. 8. Remove camshaft hubs.

Fig. 101: Installing Bolt Into Camshaft Courtesy of CHRYSLER LLC 9. Insert a bolt (1) in the camshaft.

Fig. 102: Cam Seal Remover Courtesy of CHRYSLER LLC 10. Screw seal remover 6771 (1) into camshaft seal. user Monday, June 04, 2012 10:21:11 AM

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11. Tighten force screw (2) to remove camshaft oil seals. Installation INSTALLATION

Fig. 103: Cam Seal Courtesy of CHRYSLER LLC 1. Position new cam seal (1) on camshaft (2) as shown in illustration.

Fig. 104: Cam Seal Installer Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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2. Position cam seal installer 9884 (1) over camshaft and insert bolt (2).

Fig. 105: Cam Seal Installation Courtesy of CHRYSLER LLC 3. 4. 5. 6. 7.

Tighten bolt until seal bottoms out. Install timing belt hubs. Install timing belt sprockets. Install timing belt. See Installation . Install lower timing belt cover. See Installation .

Fig. 106: Right Engine Mount Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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8. Install right engine mount bracket. 9. Install damper. 10. Install right engine mount.

Fig. 107: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 11. Install upper timing belt cover. See Installation . 12. Install engine cover (1). SPRING(S), VALVE Removal REMOVAL

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Fig. 108: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable (1).

Fig. 109: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover (1). See Removal . 3. Remove camshafts. See Removal . 4. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank engine. DO NOT rotate engine backward.

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Fig. 110: Compression Adapter 9939 Courtesy of CHRYSLER LLC 5. Remove glow plugs. Refer to Electrical - Ignition Control/Ignition Control/PLUG, Glow - Removal . 6. Install glow plug adapter 9939 (2). 7. Connect air supply (1) to glow plug adapter 9939 (2) and pressurize the cylinder to 5 bar (73 psi.).

Fig. 111: Valve Spring Compressor 9916 Courtesy of CHRYSLER LLC CAUTION: Valve springs and retainers must be kept in order of the cylinder they were removed. user Monday, June 04, 2012 10:21:11 AM

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8. Install valve spring compressor 9916 (1,2,3).

Fig. 112: Exploded View Of Cylinder Head Components Courtesy of CHRYSLER LLC 9. 10. 11. 12. 13.

Compress valve spring. Remove valve keepers. Remove top valve spring retainer and valve spring. Remove valve stem seals. Remove bottom valve spring retainer. NOTE:

Inspect all cylinder head components for wear or damage.

14. Repeat procedure for each cylinder as necessary. Installation INSTALLATION

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Fig. 113: Compression Adapter 9939 Courtesy of CHRYSLER LLC NOTE:

Inspect all valve springs and retainers for wear or damage. Replace as necessary.

1. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank engine or rotate engine counter clockwise. 2. Install glow plug adapter 9939 (2). 3. Connect air supply (1) to #9939 glow plug adaptor and pressurize the cylinder to 5 bar (73 psi).

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Fig. 114: Exploded View Of Cylinder Head Components Courtesy of CHRYSLER LLC 4. 5. 6. 7.

Install lower valve spring retainer. Install valve stem seal. Install valve spring. Install valve spring retainer.

Fig. 115: Valve Spring Installer 9916 Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:11 AM

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8. Install valve spring installer 9916. 9. Compress valve and install valve keepers. NOTE: 10. 11. 12. 13.

Ensure that the valve keepers are seated properly.

Repeat procedure for each cylinder as necessary. Remove special tooling from cylinder head. Position piston of #1 cylinder to ignition TDC. Install camshafts and check basic position. See Installation .

Fig. 116: Battery Cable Courtesy of CHRYSLER LLC 14. Reconnect negative battery cable (1). CAUTION: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. 15. Start the engine and inspect for leaks.

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Fig. 117: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 16. Install engine cover (1). See Installation . VALVES, INTAKE AND EXHAUST Removal REMOVAL

Fig. 118: Battery Cable Courtesy of CHRYSLER LLC

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NOTE:

Valves can not be ground, only lapping is permitted.

1. Disconnect negative battery cable (1).

Fig. 119: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover (1). See Removal . 3. Remove cylinder head. See Removal . CAUTION: Suitably mark the valve and the position in the cylinder head before removal. Failure to do so will result in improperly seated valves and possible engine damage after reassembly.

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Fig. 120: Exploded View Of Cylinder Head Components Courtesy of CHRYSLER LLC 4. 5. 6. 7. 8. 9.

Using a suitable valve spring compressor, compress valve spring. Remove valve keepers. Remove top valve spring retainer and valve spring. Remove valve stem seals. Repeat steps 5 through 9 for each valve as necessary. Remove any burrs with a file prior to pulling valves through the guide. CAUTION: Valves, springs and retainers must be kept in order of the cylinder they were removed.

10. Remove valves. Installation INSTALLATION

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.

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Fig. 121: Exploded View Of Cylinder Head Components Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Install valves in their original position in the cylinder head. Install lower valve spring retainer. Install valve stem seal. Install valve spring. Install valve spring retainer. NOTE:

Ensure that the valve keepers are seated properly.

6. Using a suitable valve spring compressor, compress valve spring and install valve keepers. 7. Repeat steps 3 through 7 for each valve as necessary.

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Fig. 122: Battery Cable Courtesy of CHRYSLER LLC 8. Install cylinder head on engine block. See Installation . 9. Install glow plugs. Refer to Electrical - Ignition Control/Ignition Control/PLUG, Glow - Installation . 10. Connect negative battery cable (1).

Fig. 123: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC WARNING: Us 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. user Monday, June 04, 2012 10:21:11 AM

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11. Start engine and check for leaks. 12. Install engine cover. See Installation .

ENGINE BLOCK STANDARD PROCEDURE REPLACING ENGINE CORE AND OIL GALLERY PLUGS

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug .

Fig. 124: Core Hole Plug Removal Courtesy of CHRYSLER LLC 1 - CYLINDER BLOCK 2 - REMOVE PLUG WITH PLIERS 3 - STRIKE HERE WITH HAMMER 4 - DRIFT PUNCH 5 - CUP PLUG CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer. It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in user Monday, June 04, 2012 10:21:11 AM

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service immediately. MEASURING CYLINDER BORES

Fig. 125: Measuring Cylinder Bores Courtesy of CHRYSLER LLC 1 - MEASURING POINT OF CYLINDER BORE 2 - MEASURING POINT OF CYLINDER BORE 3 - MEASURING POINT OF CYLINDER BORE 1a - UPPER REVERSAL POINT OF #1 PISTON RING 1b - BOTTOM DEAD CENTER OF PISTON 1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING 1A - LONGITUDINAL DIRECTION 1B - TRANSVERSE DIRECTION NOTE:

This must be done with engine completely disassembled.

1. Thoroughly clean all cylinder bores with appropriate cleaning solvent. 2. Measure each cylinder at the three measuring points shown in illustration . 3. Using the three measurement points, measure cylinder in the longitudinal and in the transverse direction . PISTON PROTRUSION

NOTE:

Any time a rod or piston is replaced, the piston protrusion must be checked.

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Fig. 126: Zero Dial Indicator Courtesy of CHRYSLER LLC 1. Position scooter block D-115-2A (4) and a dial indicator flat on the cylinder block (3) head surface and zero the dial indicator.

Fig. 127: Piston Height Courtesy of CHRYSLER LLC 2. Slide Scooter block D-155-2A (4) so that the dial indicator (1) is now on the piston (2). 3. Read measurement and refer to the HEAD GASKET SELECTION table for the correct head gasket. HEAD GASKET SELECTION Piston Protrusion Head Gasket Identification Notches 0.91 - 1.00 mm 0.035 - 0.039 in. 1 user Monday, June 04, 2012 10:21:12 AM

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1.01 - 1.10 mm 0.040 - 0.043 in. 1.11 - 1.20 mm 0.044 - 0.047 in.

2 3

4. Look up piston protrusion measurement in the table to find the correct head gasket. The head gasket is marked round holes (1). CRANKSHAFT Standard Procedure MEASURE CRANKSHAFT AND BLOCK JOURNALS

NOTE:

After bearing damage has occurred, remove all debris which is present in the main oil gallery, connecting rod bores, and in the crankshaft and oil galleries. Include removal of the inserting steel ball of the main oil gallery before cleaning.

1. Remove crankshaft. See Removal . 2. Clean all engine parts thoroughly. CAUTION: After bearing damage has occurred, replace connecting rods which have suffered overheating because of bearing damage. The connecting rod must not have any cross scores and notches. 3. 4. 5. 6. 7. 8.

Inspect connecting rod. If damage is present, inspect crankshaft, replace as necessary. Inspect crankcase. Inspect standard size of crankshaft bearing shells. Inspect crankshaft bearing cap. Mount crankshaft radially. Inspect crankshaft bearing play. NOTE:

Radial mounting of the main bearings of standard size crankshaft is possible by assigning the color-coded bearing shells.

ASSIGN CRANKSHAFT BEARING SHELLS The oil pan rail of the cylinder block is marked with chisel punches indicating which bearing shells are used. 9. Assign crankshaft bearing shells. 10. Mount crankshaft axially. 11. Inspect crankshaft bearing play. Removal user Monday, June 04, 2012 10:21:12 AM

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REMOVAL

Fig. 128: Battery Cable Courtesy of CHRYSLER LLC NOTE:

The engine must be removed from the vehicle to service crankshaft.

1. Disconnect negative battery cable (1).

Fig. 129: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover (1). 3. Remove engine. See Removal . user Monday, June 04, 2012 10:21:12 AM

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4. Remove cylinder head. See Removal . 5. Remove rear crankshaft seal adapter. See Removal .

Fig. 130: Crank And Bearings Courtesy of CHRYSLER LLC 6. Remove front crankshaft seal retainer. NOTE:

Mark piston and rod location prior to removal with paint pen. Do not use a punch.

7. Remove piston and connecting rod assemblies. See Removal . CAUTION: The crankshaft bearing caps are numbered consecutively, beginning with the first crankshaft bearing cap at the front of engine. Attention must be paid to the way crankshaft bearing caps fit. 8. Unbolt crankshaft bearing caps (2). 9. Inspect crankshaft bearing caps (2) and bolts (1) for wear and stretching. 10. Remove crankshaft (5) from engine block. user Monday, June 04, 2012 10:21:12 AM

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Installation INSTALLATION

CAUTION: Oil bearing shells before inserting crankshaft.

CAUTION: Oil thread and head contact surfaces of bolts that retain crankshaft bearing caps; tighten bolts from inside to outside, beginning at fit bearing. Rotate crankshaft to check clearance. NOTE:

The crankshaft bearing caps are numbered consecutively, beginning with the first crankshaft bearing cap at the front of engine. Attention must be paid to the way crankshaft bearing caps fit.

Fig. 131: Crank And Bearings Courtesy of CHRYSLER LLC 1. Install bearing shells into engine block (7). 2. Oil bearing shells. 3. Install upper thrust bearings in block (6). user Monday, June 04, 2012 10:21:12 AM

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4. 5. 6. 7. 8.

Install crankshaft into engine block (5). Install bearing shells (3) into bearing caps (2). Install lower thrust bearings (4). Install crankshaft bearing caps (2). Tighten bolts in two stages. 65 N.m (48 lbs ft), then 90°. Install piston and connecting rod assemblies. See Installation .

Fig. 132: Front Seal Flange RTV Path Courtesy of CHRYSLER LLC 9. Apply RTV to front sealing flange as shown in illustration. 10. Install front crankshaft sealing flange.

Fig. 133: Front Crank Seal Sleeve user Monday, June 04, 2012 10:21:12 AM

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Courtesy of CHRYSLER LLC 11. Install front seal (1) and seal installation guide (2).

Fig. 134: Front Crank Seal Installation Courtesy of CHRYSLER LLC 12. 13. 14. 15. 16. 17. 18.

Install front crankshaft oil seal (1) using installer (2) and bolt (3). Install rear timing belt cover. Install rear crankshaft oil seal. See Installation . Install timing belt cover. See Installation . Install the engine. See Installation . Fill crankcase with the correct engine oil, to the proper level. Fill cooling system with the proper coolant, to the proper level. Refer to Cooling - Standard Procedure .

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Fig. 135: Battery Cable Courtesy of CHRYSLER LLC 19. Connect negative battery cable (1). 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. 20. Start engine and inspect for leaks.

Fig. 136: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:12 AM

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21. Install engine cover (1). See Installation . MODULE, BALANCE SHAFT Description DESCRIPTION

The balance shaft module bolts to the bottom of the engine. The oil pump is an integral part of the balance shaft module and cannot be serviced separately. Operation OPERATION

The balance shaft module is gear driven off the crankshaft. The oil pump is housed in the front portion of the module. The oil pump supplies the engines oil requirements. The balance shaft portion is for NVH reduction. Removal REMOVAL

NOTE:

When Balance Shaft Module (BSM) is removed, a new BSM MUST be installed.

Fig. 137: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 1. Remove oil pan. See Removal . 2. Remove lower timing belt cover (1).

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Fig. 138: Crankshaft Timing Marks Courtesy of CHRYSLER LLC 3. Rotate engine to TDC and insert crankshaft timing lock 9883.

Fig. 139: Balance Shaft Retaining Bolt Torque Sequence Courtesy of CHRYSLER LLC 4. Remove balance shaft retaining bolts. 5. Remove balance shaft. Installation user Monday, June 04, 2012 10:21:12 AM

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INSTALLATION

NOTE:

When installing a new balance shaft module, the oil pick-up and dip stick guide must be removed.

Fig. 140: BSM Timing Marks Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Remove dipstick guide from new BSM and discard. Remove pick-up tube from BSM and discard. Pour 15 ml (0.5 oz.) of oil into oil pump and turn balance shaft gear (2) a minimum of 3 revolutions. Install new pick-up tube and new o-ring. Tighten pick-up tube retaining bolt to 10 N.m (89 in. lbs.). Tighten pick-up tube support bracket to 22 N.m (195 in. lbs.).

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Fig. 141: BSM Timing Lock Courtesy of CHRYSLER LLC 7. Install BSM lock 9991-2 (2). 8. Install 2 new locating sleeves.

Fig. 142: BSM Timing Marks Courtesy of CHRYSLER LLC 9. Loosen intermediate gear (1) retaining bolt 90°. 10. Install BSM with white dot on intermediate gear pointing towards the crankshaft.

Fig. 143: Balance Shaft Retaining Bolt Torque Sequence user Monday, June 04, 2012 10:21:12 AM

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Courtesy of CHRYSLER LLC 11. 12. 13. 14.

Tighten all bolts to 6 N.m (53 in. lbs.) in the sequence shown in illustration. Tighten bolts 1,2,3,4,6,8 to 20 N.m (177 in. lbs.). Tighten bolts 5 and 7 to 15 N.m (133 in. lbs.). Tighten all bolts an additional 90°.

Fig. 144: BSM Timing Marks Courtesy of CHRYSLER LLC 15. Install balance shaft gear (2) and tighten bolts to 20 N.m (177 in. lbs.). 16. Tighten bolts an additional 90°.

Fig. 145: BSM Timing Lock Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:12 AM

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17. Remove BSM timing lock 9991-2 (2).

Fig. 146: Securing Bolt Courtesy of CHRYSLER LLC 18. Secure gear lash adjuster 9991-1 (1) to engine block and install securing bolt (2).

Fig. 147: Gear Lash Adjuster Courtesy of CHRYSLER LLC 19. 20. 21. 22.

Tighten tensioner screw (2) to 2-4 N.m (18-35 in. lbs.). Tighten intermediate gear (3) bolt to 90 N.m (66 ft. lbs.). Loosen tension screw (2). Check for zero backlash between gears.

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23. If backlash is present, loosen intermediate gear (3) bolt 90° and repeat steps 19 through 22. 24. If no backlash was present, tighten intermediate gear an additional 90°. CAUTION: If you have backlash after the intermediate bolt has been tightened the additional 90°, the BSM MUST be replaced.

Fig. 148: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 25. 26. 27. 28. 29.

Install the lower timing belt cover (1). Install the crankshaft damper. Install the oil pan. See Installation . Fill with oil. Start engine and check for leaks.

PUMP, TANDEM VACUUM Description DESCRIPTION

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Fig. 149: Tandem Pump Courtesy of CHRYSLER LLC This pump is a tandem pump design. It contains a fuel pump and a vacuum pump in 1 housing. If either pump fails, the tandem pump assembly must be replaced. Removal REMOVAL

Fig. 150: Fuel Filter Courtesy of CHRYSLER LLC 1. Remove Fuel feed line at filter (2). 2. Remove fuel return line at filter (1). user Monday, June 04, 2012 10:21:12 AM

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3. Connect vacuum pump to line and operate pump until no more fuel comes out.

Fig. 151: Tandem Pump Courtesy of CHRYSLER LLC 4. Remove fuel feed line (4). 5. Remove fuel return line (3). 6. Remove retaining bolts (2) and remove pump. Installation INSTALLATION

Fig. 152: Pump And Gasket Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:12 AM

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1. Place new gasket (3) on pump (1). 2. Align pump drive (2) on pump.

Fig. 153: Fuel Pump Drive Courtesy of CHRYSLER LLC 3. Insert pump drive into slot on camshaft (1).

Fig. 154: Tandem Pump Courtesy of CHRYSLER LLC 4. install pump retaining bolts (2) and tighten. 5. Install fuel feed line (4). 6. Install fuel return line (3). user Monday, June 04, 2012 10:21:12 AM

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ROD, PISTON AND CONNECTING Removal REMOVAL

1. Remove cylinder head. 2. Remove oil pan. NOTE:

It may be necessary to remove the oil pump to gain access to all of the rods.

3. Remove oil pump if necessary. NOTE: 4. 5. 6. 7.

Do not use a punch to mark connecting rods.

Mark connecting rods with paint marker. Remove connecting rod bolts and discard. Push piston and rod assembly out of the engine block. Repeat as needed.

Installation INSTALLATION

1. 2. 3. 4. 5.

Make sure the ring end gaps are properly staggered. Lubricate the piston and rings with clean engine oil. Compress piston rings with a ring compressor. Install upper rod bearing shell in to connecting rod and oil bearing shell. Push piston into cylinder. NOTE:

6. 7. 8. 9. 10. 11. 12. 13.

Be careful when guiding rod into place not to nick the crankshaft journals.

Install lower bearing shell into connecting rod cap. Lubricate lower bearing shell and position rod cap. Install new rod bolts and tighten to 30 N.m + 90° (22 ft. lbs. + 90°). Install oil pan. See Engine/Lubrication/PAN, Oil - Installation . Install cylinder head. See Installation . Replace oil filter and fill with oil. See Installation . Fill cooling system. Refer to Cooling - Standard Procedure . Start engine and check for leaks.

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SEAL, CRANKSHAFT OIL, REAR Removal REMOVAL

Fig. 155: Pressure Plate Courtesy of CHRYSLER LLC 1. Disconnect the negative battery cable. 2. Remove the flywheel. Refer to Clutch/FLYWHEEL - Removal .

Fig. 156: Vibration Damper Dust Cover Courtesy of CHRYSLER LLC 3. I equipped, remove the vibration damper dust cover. user Monday, June 04, 2012 10:21:12 AM

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4. Rotate the crankshaft to align the timing mark (1) with mark (2) to set cylinder No. 1 at Top Dead Center (TDC).

Fig. 157: Oil Pan-Removal Courtesy of CHRYSLER LLC 5. Drain the engine oil. 6. Remove the oil pan bolts. 7. Using a suitable pry bar, remove the oil pan.

Fig. 158: Crankshaft Position Sensor Courtesy of CHRYSLER LLC 8. Disconnect the crankshaft position sensor harness connector (1). 9. Remove the bolt (2) and the Crankshaft Position Sensor (CKP) (3). user Monday, June 04, 2012 10:21:12 AM

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Fig. 159: Rear Crankshaft Seal Assembly Removal Courtesy of CHRYSLER LLC 10. Install the three M6 x 35 bolts into the rear crankshaft seal assembly as illustrated. 11. Alternately screw in bolts 1/2 turn at a time to pull seal assembly off. 12. Wipe excess oil off the crankshaft. Installation INSTALLATION

NOTE:

The rear crankshaft seal comes with and installation sleeve that must not be removed prior to installation.

NOTE:

The sealing flange and sender wheel must not be separated or rotated after removing from package.

NOTE:

The sealing flange and seal are one unit that must be replaced together with the sender wheel only.

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Fig. 160: Rear Main Installer 9888 Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Screw in nut (3) to the edge of the clamping surface (2) of threaded spindle. Clamp rear main seal installer 9888 in a vice on the clamping surface of threaded spindle (2). Press assembly bell housing (4) down so it lies on nut (3). Screw nut (3) onto threaded spindle (1) until inner part of assembly device and assembly are bell housing are level.

Fig. 161: Securing Clip Courtesy of CHRYSLER LLC 5. Remove securing clip (1) from rear crankshaft sealing flange (2). user Monday, June 04, 2012 10:21:12 AM

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Fig. 162: Locating Hole Courtesy of CHRYSLER LLC NOTE:

The sender wheel must not be taken out of the sealing flange or turned.

6. Locating hole (1) on sender wheel (3) must align with marking (2) on rear main seal.

Fig. 163: Sealing Lip Support Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:12 AM

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7. Place seal on clean flat surface with the outer edge facing down. 8. Push sealing lip support ring (1) downward until it lies on flat surface.

Fig. 164: Sender Wheel Alignment Courtesy of CHRYSLER LLC 9. Upper edge of sender wheel and front edge of rear main seal must align.

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Fig. 165: Locating Pin Courtesy of CHRYSLER LLC 10. Place rear main seal with outer edge on rear main seal installer 9888 (1) so that locating pin (2) can be inserted into hole (3). NOTE:

Ensure that the rear main seal lies flat on the installer.

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Fig. 166: Seal and Installer Courtesy of CHRYSLER LLC 11. Push the flange and support ring for the sealing lip (1) against the installer (2) while tightening the three knurled knobs (3) so the locating pin cannot slide out of the sender wheel hole.

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Fig. 167: Attaching Seal to Installer Courtesy of CHRYSLER LLC NOTE:

When installing rear main seal, the sender wheel must remain fixed in assembly tool.

NOTE:

The crankshaft flange must be free from oil and grease.

NOTE:

The engine must be at TDC on the #1 cylinder.

12. Screw nut (3) to the end of the spindle. 13. Press threaded spindle of seal installer (1) until nut (3) lies against assembly bell housing (2). 14. Align flat side of assembly bell housing on sump side of crankcase sealing surface.

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Fig. 168: Secure Installer to Crankshaft Courtesy of CHRYSLER LLC 15. Secure assembly tool (2) to crankshaft using Allen head bolts (3).

Fig. 169: Guide Bolts Courtesy of CHRYSLER LLC 16. To guide sealing flange, screw two M7 x 35 mm bolts (1) into cylinder block.

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Fig. 170: Seal to Crankshaft Alignment Courtesy of CHRYSLER LLC 17. Push assembly bell housing (3) by hand in the direction shown in illustration until sealing lip support ring (2) contacts the crankshaft (1). 18. Push guide pin with black knob (5), into hole in crankshaft. This is done to ensure the sender wheel reaches its final installation position. 19. Hand tighten both hexagon socket head bolts of assembly tool. 20. Screw hexagon nut (4) onto threaded spindle by hand until it lies against assembly bell housing (3).

Fig. 171: Pressing Seal in Place Courtesy of CHRYSLER LLC NOTE:

After nut is tightened, a small air gap must be present between cylinder block and sealing flange.

21. Torque hexagon nut to 35 N.m (26 ft. lbs.). Checking sender wheel installation position

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Fig. 172: Hexagon Nut, Bolts, Cylinder Block And Knurled Screws Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove hexagon nut (5) to the end of the threaded spindle. Remove the two bolts (1) from cylinder block. Loosen the three knurled screws (2). Remove rear main installer 9888. Remove sealing lip support ring.

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Fig. 173: Crankshaft Flange & Sender Wheel Courtesy of CHRYSLER LLC 6. The sender wheel is in the correct position if a gap of 0.5 mm (0.019 in.) exists between the crankshaft flange (1) and the sender wheel (2). Measure the distance -a- between the crankshaft flange and the sender wheel.

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Fig. 174: Measuring Distance Between Crankshaft Flange & Sender Wheel Courtesy of CHRYSLER LLC 7. Set vernier gauge on crankshaft flange. 8. Measure the distance between the crankshaft flange and the sender wheel. 9. If the measurement is too small, press sender wheel further.

Fig. 175: Hexagon Nut, Bolts, Cylinder Block And Knurled Screws Courtesy of CHRYSLER LLC NOTE: a. b. c. d. e. f. g. h.

Re-pressing sender wheel.

Secure assembly rear main installer 9888 to crankshaft flange using Allen head bolts. Hand tighten both hexagon socket head bolts. Push assembly tool by hand to sealing flange. Screw hexagon nut (5) onto threaded spindle by hand until it lies against assembly bell housing (3). Tighten nut to 40 N.m (30 ft. lbs.). Check installation position again. If dimension is too small, repeat steps a through d again and torque to 45 N.m (33 ft. lbs.). Check installation position again.

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Fig. 176: Tighten Rear Main Bolts In Sequence Courtesy of CHRYSLER LLC 10. If dimension is attained, tighten rear sealing flange bolts to 15 N.m (133 in. lbs.) in the sequence shown in illustration.

Fig. 177: Crankshaft Position Sensor Courtesy of CHRYSLER LLC 11. Install crankshaft position sensor (3). Tighten bolt (2) to 5 N.m (44 in. lbs.). 12. Connect the crankshaft position sensor harness connector (1).

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Fig. 178: Applying Engine Sealant RTV Courtesy of CHRYSLER LLC 13. Clean the oil gasket surfaces. 14. Apply a 3 mm bead of engine sealant RTV (1).

Fig. 179: Identifying Oil Pan Bolts Courtesy of CHRYSLER LLC 15. Install oil pan. z Tighten bolts (A) to 15 N.m (133 in. lbs). z Tighten bolts (B) to 45 N.m (33 ft. lbs). z Tighten bolts (C) to 40 N.m (30 ft. lbs).

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Fig. 180: Flywheel Assembly Courtesy of CHRYSLER LLC 16. Install the flywheel. Refer to Clutch/FLYWHEEL - Installation . 17. If equipped, install the vibration damper dust cover. 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. 18. Fill engine with the recommended engine oil. 19. Start engine and inspect for leaks. 20. Connect the negative battery cable.

LUBRICATION DESCRIPTION DESCRIPTION

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly. OPERATION OPERATION

Engine oil is drawn up through the pickup tube and is pressurized by the oil pump and routed through the fullflow filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to user Monday, June 04, 2012 10:21:12 AM

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connecting rod journals. Balance shaft lubrication is provided through an internal oil passage at the #3 bearing location around the BSM mounting bolt. A vertical hole at the number one bulkhead routes pressurized oil through a filter screen and head gasket up to the cylinder head. The oil then divides into three passages; one to the intake cam phaser, one to the exhaust cam phaser and one to the camshafts. The passage to the camshafts divides to feed both of the hollow camshafts at the second cam journal. The rest of cam journals are feed oil through the hollow camshafts. The #1 cam journals are fed oil through the VVT oil passages. Oil passages to the phasers are directed through the OCV (oil control valves) to the #1 journals. The oil then flows through the camshafts then to the cam phasers. Oil returning to the pan from pressurized components supplies lubrication to the valve stems, cam lobes, and tappets. Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars. DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE

Fig. 181: Oil Pressure Sender Courtesy of CHRYSLER LLC 1. Disconnect and remove oil pressure switch (1). See Removal .

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Fig. 182: Oil Pressure Gauge Courtesy of CHRYSLER LLC 2. Install oil pressure gauge (1). 3. Start engine and record oil pressure. Refer to Specifications for correct oil pressure requirements. See Specifications . CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test.

4. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pickup screen or a damaged oil pick-up tube O-ring. 5. Remove oil pan and inspect for debris. See Removal . 6. Remove pressure relief valve and inspect. If damaged replace pressure relief valve. 7. If pressure relief valve is OK, replace balance shaft module assembly. 8. After test is complete, remove test gauge and fitting (1).

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Fig. 183: Oil Pressure Sender Courtesy of CHRYSLER LLC 9. Install oil pressure switch (1) and connector. See Installation . FILTER, ENGINE OIL Removal REMOVAL

Fig. 184: Filter In Housing Courtesy of CHRYSLER LLC 1. Remove oil filter housing cover. 2. Pull filter cartridge (2) out of the filter housing (1) and discard. user Monday, June 04, 2012 10:21:12 AM

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Installation INSTALLATION

Fig. 185: Filter In Housing Courtesy of CHRYSLER LLC 1. Install oil filter cartridge (2) into housing (1).

Fig. 186: Oil Filter Courtesy of CHRYSLER LLC 2. Install new O-ring (2) onto cover (1). 3. Install cover. OIL user Monday, June 04, 2012 10:21:12 AM

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Standard Procedure ENGINE OIL LEVEL CHECK

Fig. 187: Oil Level Indicator Courtesy of CHRYSLER LLC The best time to check engine oil level is after the vehicle has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick and observe oil level. Add oil only when the level is at or below the MIN mark (3). CAUTION: Do not operate engine if the oil level is above the MAX (2) mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. ENGINE OIL AND FILTER CHANGE

WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to Vehicle Quick Reference/Maintenance Schedules - Description . 1. Run engine until achieving normal operating temperature. user Monday, June 04, 2012 10:21:12 AM

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2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13.

Position the vehicle on a level surface and turn engine off. Remove oil fill cap. Raise vehicle on hoist. Place a suitable oil collecting container under oil pan drain plug. Remove oil pan drain plug or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. Remove oil filter. See Removal . Install oil pan drain plug. Tighten drain plug to 28 N.m (20 ft. lbs.). Install new oil filter. See Installation . Lower vehicle and fill crankcase with specified type and amount of engine oil. Refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Specifications and refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Description . Install oil fill cap. Start engine and inspect for leaks. Stop engine and inspect oil level.

OIL FILTER SPECIFICATION

All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar® oil filter or the equivalent. USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. PAN, OIL Removal REMOVAL

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Fig. 188: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable (1). 2. Raise vehicle on hoist. 3. Remove engine compartment lower silencer and accessory drive belt splash shield.

Fig. 189: Oil Pan-Removal Courtesy of CHRYSLER LLC 4. Drain engine oil. NOTE:

It may be necessary to rotate crankshaft to gain access to the rear oil pan bolts.

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5. Remove oil pan fasteners. 6. Remove oil pan by prying off with suitable pry bar. 7. Clean oil pan and engine block sealing surfaces. Installation INSTALLATION

Fig. 190: Oil Pan RTV Path Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7.

Clean oil pan and all sealing surfaces. Apply a 2-3 mm bead of RTV to oil pan as shown in illustration. Position oil pan and install bolts. Hand tighten oil pan bolts. Install oil pan to bell housing bolts and hand tighten. Tighten oil pan bolts to 15 N.m (133 in. lbs.). Tighten oil pan to bell housing bolts to 40 N.m (30 ft. lbs.).

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Fig. 191: Battery Cable Courtesy of CHRYSLER LLC 8. Install accessory drive belt splash shield and engine compartment lower silencer. 9. Lower vehicle. NOTE:

Sealer must cure for a minimum of 30 minutes prior to filling with oil.

10. Refill engine oil. 11. Connect negative battery cable (1). 12. Start engine and check for leaks. SENSOR, OIL PRESSURE Description DESCRIPTION

The oil pressure switch is located on the right front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a single terminal device. Operation OPERATION

The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Removal user Monday, June 04, 2012 10:21:12 AM

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REMOVAL

Fig. 192: Oil Pressure Sender Courtesy of CHRYSLER LLC 1. Disconnect oil pressure sensor electrical connector. 2. Remove oil pressure sensor (1). Installation INSTALLATION

Fig. 193: Oil Pressure Sender Courtesy of CHRYSLER LLC 1. Install oil pressure sensor (1) and tighten to 20 N.m (177 in. lbs.). user Monday, June 04, 2012 10:21:12 AM

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2. Connect oil pressure sensor electrical connector.

VALVE TIMING BELT, TIMING Removal REMOVAL - TIMING BELT

Fig. 194: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable.

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Fig. 195: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover. See Removal . 3. Remove cylinder head cover. NOTE:

When rotating engine to TDC, verify that cylinder #1 is on the compression stroke. The camshaft lobes for cylinder #1 should be pointing upward.

Fig. 196: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 4. Remove lower timing belt cover (1). user Monday, June 04, 2012 10:21:12 AM

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Fig. 197: Crankshaft Timing Marks Courtesy of CHRYSLER LLC NOTE: 5. 6. 7. 8. 9.

Engine equipped with a balance shaft module use an oval toothed belt, and crankshaft holding tool 10122 must be used

Rotate engine to TDC and insert crankshaft lock 10122. Insert camshaft locking pins 9882. Loosen tensioner retaining nut. Rotate tensioner counterclockwise to release tension. Remove timing belt.

Installation TIMING BELT

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Fig. 198: Cam Holder Courtesy of CHRYSLER LLC CAUTION: IT IS ESSENTIAL that the installation procedure is followed exactly. Failure to do so will result in severe engine damage. 1. 2. 3. 4. 5. 6.

Loosen camshaft sprocket bolt using sprocket/hub holder 9880. Start the timing belt around the crankshaft sprocket. Wrap belt around water pump pulley, idler pulley, and tensioner. Position belt over camshaft sprockets. Tighten tensioner until marks are aligned. Tighten tensioner nut to 20 N.m + 45° (177 in. lbs. + 45°).

Fig. 199: Crankshaft Timing Marks user Monday, June 04, 2012 10:21:12 AM

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Courtesy of CHRYSLER LLC 7. Tighten camshaft sprocket bolts using sprocket/hub holder 9880 to 25 N.m (221 in. lbs.). 8. Remove camshaft locking pins 9882. 9. Remove crankshaft lock 10122.

Fig. 200: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 10. 11. 12. 13.

Install lower timing belt cover (1). Install balancer. Install accessory drive belt. Install upper timing belt cover.

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Fig. 201: Engine Cover Courtesy of CHRYSLER LLC 14. Install engine cover. See Installation .

Fig. 202: Battery Cable Courtesy of CHRYSLER LLC 15. Connect negative battery cable (1). 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. COVER(S), ENGINE TIMING, LOWER Removal REMOVAL

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Fig. 203: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove right splash shield. Remove accessory drive belt. Remove crankshaft damper. Remove lower timing belt cover (1).

Installation INSTALLATION

Fig. 204: Lower Timing Belt Cover Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:12 AM

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1. 2. 3. 4. 5.

Position lower timing belt cover. Install lower timing belt cover retaining bolts and tighten. Install crankshaft balancer and tighten to 10 N.m + 90° (89 lbs. in. + 90°). Install accessory drive belt. Install splash shield.

COVER(S), ENGINE TIMING, UPPER Removal REMOVAL

Fig. 205: Timing Belt Cover Courtesy of CHRYSLER LLC 1. Remove upper timing belt cover (1) by releasing clasps and pull upward. Installation INSTALLATION

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Fig. 206: Timing Belt Cover Courtesy of CHRYSLER LLC 1. Position upper timing belt cover (1) in place and snap clasps in place. TENSIONER, ENGINE TIMING Removal REMOVAL

Fig. 207: Battery Cable user Monday, June 04, 2012 10:21:12 AM

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Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable (1).

Fig. 208: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 2. Remove lower timing belt cover (1). 3. Position piston of number #1 cylinder to ignition TDC.

Fig. 209: Crankshaft Timing Marks Courtesy of CHRYSLER LLC 4. Install crankshaft lock 9883.

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Fig. 210: Timing Belt Cover Courtesy of CHRYSLER LLC 5. Remove upper timing belt cover (1). 6. Install camshaft lock pins 9882. 7. Install engine support fixture.

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Fig. 211: Right Engine Mount Courtesy of CHRYSLER LLC 8. Remove right engine mount through bolt (2). 9. Remove frame mount (1) and isolator (3).

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Fig. 212: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 10. Remove right engine mount bracket (5). 11. Raise vehicle on hoist. 12. Remove balancer (4).

Fig. 213: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 13. Remove splash shield. 14. Remove lower timing belt cover (1).

Fig. 214: Timing Belt Tensioner & Retaining Nut Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:13 AM

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15. Remove tensioner retaining nut (2). 16. Remove timing belt tensioner. Installation INSTALLATION

Fig. 215: Installing Tensioner Courtesy of CHRYSLER LLC 1. Position timing belt tensioner so finger (2) is in slot (1) and hand tighten nut.

Fig. 216: Tensioner Adjustment user Monday, June 04, 2012 10:21:13 AM

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Courtesy of CHRYSLER LLC 2. Insert Allen wrench into tensioner (3) and rotate tensioner until indicator (1) is in the middle of the slot.

Fig. 217: Timing Belt Tensioner & Retaining Nut Courtesy of CHRYSLER LLC 3. Tighten nut (2) to 20 N.m + 45° (177 in. lbs. +45°). NOTE:

Tensioner indicator (1) will move out of the slot when nut (2) is tightened. This is normal, do not reposition tensioner.

Fig. 218: Timing Belt Cover Courtesy of CHRYSLER LLC 4. Remove camshaft locking pins 9882. 5. Install upper timing belt cover (1). user Monday, June 04, 2012 10:21:13 AM

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Fig. 219: Crankshaft Timing Marks Courtesy of CHRYSLER LLC 6. Remove crankshaft lock 9883.

Fig. 220: Lower Timing Belt Cover Courtesy of CHRYSLER LLC 7. Install lower timing belt covers (1). 8. Install balancer and tighten to 10 N.m + 90° (89 in. lbs. + 90°).

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Fig. 221: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 9. Install engine mount bracket (5).

Fig. 222: Right Engine Mount Courtesy of CHRYSLER LLC 10. 11. 12. 13.

Install isolator (3). Install engine mount (1). Install engine mount through bolt (2). Remove engine support fixture.

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Fig. 223: Battery Cable Courtesy of CHRYSLER LLC 14. 15. 16. 17.

Install accessory drive belt. Install splash shield. Lower vehicle. Connect negative battery cable (1).

Fig. 224: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 18. Install engine cover (1).

MANIFOLDS user Monday, June 04, 2012 10:21:13 AM

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MANIFOLD, EXHAUST Removal EXHAUST MANIFOLD/TURBOCHARGER

Fig. 225: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect the negative battery cable (1).

Fig. 226: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:13 AM

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2. 3. 4. 5. 6. 7.

Remove the engine cover (1). See Installation Remove the turbo air inlet hose at the air cleaner. Remove the PCV air makeup hose. Remove the air inlet hose at the turbocharger. Remove the oil feed line at the turbocharger. Remove the diesel particulate filter (DPF). Refer to Exhaust System/FILTER, Diesel Particulate Removal 8. Raise and support the vehicle.

Fig. 227: EGR Tube , Exhaust Manifold & EGR Cooler Courtesy of CHRYSLER LLC 9. 10. 11. 12. 13. 14. 15. 16.

Remove the charge air cooler outlet hose from the turbocharger. Remove the charge air cooler outlet hose from the intermediate tube. Remove the EGR tube (3) from the exhaust manifold (2) and the EGR cooler (4). Remove the turbocharger oil return bolts at the turbocharger flange. Remove the exhaust heat shield. Remove the eight nuts from the exhaust manifold (2). Lower the vehicle. Remove the exhaust manifold/turbocharger assembly (2) from the vehicle.

Installation EXHAUST MANIFOLD/TURBOCHARGER

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Fig. 228: EGR Tube , Exhaust Manifold & EGR Cooler Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Install the exhaust manifold gasket. Position the exhaust manifold/turbo assembly (3) in place. Install the eight exhaust manifold nuts. Tighten the nuts to 25 N.m (18 ft. lbs.). Install the turbocharger oil return tube/support (5) at the engine block. Install the exhaust heat shield. Tighten the fasteners to 5 N.m (44 in. lbs.). Install the turbocharger oil return tube bolts at the turbocharger flange. Install the EGR tube (3) to the exhaust manifold (2) and the EGR cooler (4). Tighten the bolts to 20 N.m (15 ft. lbs.). Install the charge air cooler outlet hose to the intermediate tube. Install the charge air cooler outlet hose to the turbocharger. Lower the vehicle. Install the diesel particulate filter (DPF). Refer to Exhaust System/FILTER, Diesel Particulate Installation . Install turbo oil feed line at oil filter housing. Tighten the fitting to 22 N.m (16 ft. lbs.). Install the air inlet tube at the turbocharger. Install the PCV air makeup hose. Install the air inlet tube at the air cleaner.

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Fig. 229: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 16. Install the engine cover by pushing downward. See Installation.

Fig. 230: Battery Cable Courtesy of CHRYSLER LLC 17. Connect the negative battery cable (1). MANIFOLD, INTAKE Description DESCRIPTION

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The intake manifold is one-piece design and is made from aluminum. Removal REMOVAL

Fig. 231: Battery Cable Courtesy of CHRYSLER LLC 1. Disconnect negative battery cable (1).

Fig. 232: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 2. Remove engine cover by pulling upward. user Monday, June 04, 2012 10:21:13 AM

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3. Partially drain cooling system. Refer to Cooling - Standard Procedure .

Fig. 233: EGR Valve Courtesy of CHRYSLER LLC 4. Remove vacuum harness (1).

Fig. 234: Coolant Tube Courtesy of CHRYSLER LLC 5. Remove coolant bypass tube retaining bolts (1) and reposition tube. 6. Remove fuel hose from lift bracket. user Monday, June 04, 2012 10:21:13 AM

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7. Remove upper radiator hose from cylinder head and reposition.

Fig. 235: Intake Manifold Courtesy of CHRYSLER LLC 8. Release air inlet pipe from throttle body. 9. Remove EGR pipe (3).

Fig. 236: Dipstick Support Retaining Bolt Courtesy of CHRYSLER LLC 10. Remove dip stick support bracket retaining bolt (1). 11. Remove left and right engine cover brackets.

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Fig. 237: Intake Manifold Courtesy of CHRYSLER LLC 12. 13. 14. 15.

Disconnect throttle body connectors. Remove throttle body assembly (5). Remove EGR valve (7). Remove electrical connector from intake bracket.

Fig. 238: Intake Manifold Bolt Torque Sequence Courtesy of CHRYSLER LLC 16. Remove intake manifold bolts. 17. Remove intake manifold. user Monday, June 04, 2012 10:21:13 AM

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Cleaning CLEANING

1. Discard gasket(s). 2. Clean all sealing surfaces. Inspection INSPECTION

1. Inspect manifold for cracks or distortion. Replace manifold if necessary. 2. Inspect manifold for gasket surface damage or warpage. Replace manifold if necessary. Installation INSTALLATION

Fig. 239: Intake Manifold Bolt Torque Sequence Courtesy of CHRYSLER LLC 1. Clean gaskets/seals mating surfaces. 2. Install new gasket. 3. Place intake on cylinder head and install retaining bolts. Tighten bolts to 20 N.m (14.7 lbs. ft.) as shown in illustration.

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Fig. 240: Intake Manifold Courtesy of CHRYSLER LLC 4. 5. 6. 7. 8. 9. 10.

Install electrical connector to intake bracket. Install new EGR gasket (8) and EGR valve (7). Install throttle plate assembly (5). Connect throttle body electrical connector. Install right and left engine cover brackets. Install EGR pipe. Install EGR pipe support bracket.

Fig. 241: Dipstick Support Retaining Bolt Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:13 AM

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11. 12. 13. 14.

Install dipstick support retaining bolt (1). Connect air inlet pipe to throttle body. Install upper radiator hose to cylinder head. Install fuel hose retainer to engine lift bracket.

Fig. 242: Coolant Tube Courtesy of CHRYSLER LLC 15. Position coolant tube in place and install fasteners (1).

Fig. 243: EGR Valve Courtesy of CHRYSLER LLC 16. Install vacuum harness (1). user Monday, June 04, 2012 10:21:13 AM

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17. Fill cooling system. 18. Change oil and filter.

Fig. 244: Battery Cable Courtesy of CHRYSLER LLC 19. Connect negative battery cable (1). 20. Start engine and check for leaks.

Fig. 245: Engine Cover-Removal/Installation Courtesy of CHRYSLER LLC 21. Install engine cover (1).

AIR INTAKE SYSTEM user Monday, June 04, 2012 10:21:13 AM

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AIR CLEANER Removal REMOVAL

Fig. 246: Air Filter Element Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Unfasten clasps on front of air cleaner housing. Move cover (1) aside. Remove filter element (2). If necessary, clean the inside of the air cleaner housing.

Installation INSTALLATION

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Fig. 247: Air Filter Element Courtesy of CHRYSLER LLC 1. Install new filter element (2). 2. Replace air cleaner cover (1). 3. Snap clasps in place. BODY, AIR CLEANER Description DESCRIPTION

The air cleaner housing attaches to the inner fender in front of the left side strut tower. An ambient air duct supplies underhood air for the engine. It attaches to the lower air cleaner box. Removal REMOVAL

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Fig. 248: AIR CLEANER HOUSING Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove the hold down screw (3) from the air cleaner housing (2). Disconnect turbocharger inlet hose (1) from air cleaner housing (2). Disconnect mass air flow sensor electrical connector (4). Pull air cleaner housing straight up to remove.

Installation INSTALLATION

Fig. 249: AIR CLEANER HOUSING Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:13 AM

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1. Lower air cleaner housing assembly into engine compartment and align studs at bottom of housing with bracket. Push housing assembly (2) down until fully seated in bracket. 2. Connect turbocharger inlet hose (1) to air cleaner housing (2). 3. Connect mass air flow sensor connector (4). 4. Install hold down screw (3) and tighten.

ENGINE MOUNTING DESCRIPTION DESCRIPTION

The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque controlling mounts. The load-carrying mounts are located on each frame rail. The right and left mounts are hydro-elastic mounts. The two torque controlling mounts are attached to a fore/aft member and the front and rear of the engine. OPERATION OPERATION

The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and vibration. The front and rear mounts absorb torque reaction forces and torsional vibrations. BRACKET, ENGINE MOUNT, RIGHT Removal REMOVAL

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Fig. 250: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove right engine mount. See Removal . Remove accessory drive belt. Remove bracket retaining bolts (1). Remove bracket (5) through bottom rear.

Installation INSTALLATION

Fig. 251: Right Engine Mount Bracket Courtesy of CHRYSLER LLC 1. Position right engine mount bracket (5). 2. Install bracket retaining (1) bolts and tighten to 50 N.m (37 ft. lbs.). 3. Install accessory drive belt.

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Fig. 252: Right Engine Mount Courtesy of CHRYSLER LLC 4. Install mount (3). See Installation . INSULATOR, ENGINE MOUNT, LEFT Removal REMOVAL

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Fig. 253: AIR CLEANER HOUSING Courtesy of CHRYSLER LLC 1. Remove air cleaner assembly (2).

Fig. 254: Battery Cable Courtesy of CHRYSLER LLC 2. Disconnect battery negative cable (1).

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Fig. 255: ECM Bracket Courtesy of CHRYSLER LLC 3. 4. 5. 6.

Disconnect ECM connectors and reposition harness. Disconnect vacuum solenoid vacuum and electrical connectors. Remove ECM mounting bracket retaining bolts (1). Support engine with a suitable jack.

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Fig. 256: Left Engine Mount Courtesy of CHRYSLER LLC 7. 8. 9. 10.

Remove mount through bolt (2). Remove mount bracket (3) from transaxle. Remove mount to frame rail retaining bolts. Remove engine mount (1).

Installation INSTALLATION

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Fig. 257: Left Engine Mount Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Position mount (1) on frame rail. Install mount retaining bolts and tighten to 75 N.m (55 ft. lbs.). Install mount bracket (3) to transaxle and tighten bolts to 61 N.m (45 ft. lbs.). Install mount through bolt (2) and tighten to 100 N.m (74 ft. lbs.). Remove jack.

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Fig. 258: ECM Bracket Courtesy of CHRYSLER LLC 6. Install ECM mounting bracket retaining bolts (1). 7. Connect vacuum solenoid vacuum and electrical connectors. 8. Connect ECM electrical connectors.

Fig. 259: AIR CLEANER HOUSING Courtesy of CHRYSLER LLC 9. Install air cleaner assembly (2). user Monday, June 04, 2012 10:21:13 AM

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INSULATOR, ENGINE MOUNT, RIGHT Removal REMOVAL

Fig. 260: Coolant Reservoir Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove right splash shield. Remove accessory drive belt. Lower vehicle. Support engine with suitable jack. Remove coolant reservoir (1).

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Fig. 261: Right Engine Mount Courtesy of CHRYSLER LLC 6. Remove upper mount bolts. 7. Remove through bolt (2). 8. Remove mount (3). Installation INSTALLATION

Fig. 262: Right Engine Mount Courtesy of CHRYSLER LLC 1. Position mount (3) in place. 2. Install mount retaining bolts and tighten to 75 N.m (55 ft. lbs.). 3. Install mount through bolt (2) and tighten to 88 N.m (65 ft. lbs.).

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Fig. 263: Coolant Reservoir Courtesy of CHRYSLER LLC 4. 5. 6. 7. 8. 9.

Install coolant reservoir (1). Remove jack. Raise vehicle. Install lower mount bracket bolt and tighten to 68 N.m (50 ft. lbs.). Install accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation . Install splash shield.

INSULATOR, ENGINE MOUNT, FRONT Removal REMOVAL

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Fig. 264: Front Mount Through Bolt Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Raise vehicle. Remove fore aft member (3) to mount (4) bolts. Remove mount through bolt (1). Remove fore aft member (3) mounting bolts and remove. Remove front mount (4).

Installation INSTALLATION

Fig. 265: Front Mount Through Bolt Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:21:13 AM

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1. 2. 3. 4.

Position mount (4) and tighten bolts to 47 N.m (35 ft. lbs.). Install fore aft member (3) and tighten bolts to 100 N.m (74 ft. lbs.). Install mount through bolt (1) and tighten to 47 N.m (35 ft. lbs.). Lower vehicle.

INSULATOR, ENGINE MOUNT, REAR Removal REMOVAL

Fig. 266: Rear Mount - A/T Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Remove rear mount retaining bolts (4). Remove rear mount through bolt (1). Remove oxygen sensor connector (2) from mount. Remove rear mount (3).

Installation INSTALLATION

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Fig. 267: Rear Mount - A/T Courtesy of CHRYSLER LLC 1. 2. 3. 4.

Position rear mount (3). Install rear mount retaining bolts (4) and tighten to 50 N.m (37 ft. lbs.). Install rear mount through bolt (1) and tighten to 75 N.m (55 ft. lbs.). Install oxygen sensor connector (2) retainer to mount (3).

TURBOCHARGER SYSTEM COOLER AND HOSES, CHARGE AIR Removal CHARGE AIR COOLER

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Fig. 268: Charge Air Cooler LH Clamp Courtesy of CHRYSLER LLC 1 - CHARGE AIR COOLER 2 - LH CLAMP 3 - TUBING CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum based lubricant on the isolators, as damage to the rubber material can occur. NOTE:

Band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off the exhaust pipe.

1. Raise and support vehicle. 2. Remove belly pan (if equipped). 3. Remove front fascia lower closeout panel. Refer to Frame and Bumpers/Bumpers/FASCIA, Front Lower - Removal . 4. Remove front fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Removal . 5. Remove RH tubing clamp (2) and tubing (1) at charge air cooler (3).

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Fig. 269: Charge Air Cooler RH Clamp Courtesy of CHRYSLER LLC 1 - TUBING 2 - CLAMP 3 - CHARGE AIR COOLER 6. Remove LH tubing clamp (2) and tubing (1) at charge air cooler (3). 7. Remove charge air cooler mounting bolts and charge air cooler (3). Installation CHARGE AIR COOLER

Fig. 270: Charge Air Cooler LH Clamp user Monday, June 04, 2012 10:21:13 AM

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Courtesy of CHRYSLER LLC 1 - CHARGE AIR COOLER 2 - LH CLAMP 3 - TUBING 1. Position charge air cooler (3) and install mounting bolts. Tighten bolts to 35 N.m (25 ft. lbs.). 2. Install LH tubing (3) and clamp (2) at charge air cooler (1). Tighten clamp to 10 N.m (89 in. lbs.).

Fig. 271: Charge Air Cooler RH Clamp Courtesy of CHRYSLER LLC 1 - TUBING 2 - CLAMP 3 - CHARGE AIR COOLER 3. Install RH tubing (1) and clamp (2) at charge air cooler (3). Tighten clamp to 10 N.m (89 in. lbs.). 4. Install front fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Installation . 5. Install front fascia lower closeout panel. Refer to Frame and Bumpers/Bumpers/FASCIA, Front Lower - Installation . 6. Lower vehicle. TURBOCHARGER Removal DIESEL ENGINE

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1. For turbocharger removal, see Removal . Installation DIESEL ENGINE

1. For turbocharger installation, see Installation .

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2009 ENGINE 2.4L Gas - Service Information - Journey

DESCRIPTION DESCRIPTION The 2.4 Liter (148 cu. in.) inline four cylinder engine is a double over head camshaft design with mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the valves in the event of a timing chain failure. The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2.

Fig. 1: Serial Number Courtesy of CHRYSLER LLC The engine serial number (1) is located on the rear of the cylinder block behind the oil pan. The serial number is visible with the oil pan in place. The serial number contains engine build date information.

DIAGNOSIS AND TESTING INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls). user Monday, June 04, 2012 10:44:46 10:44:35 AM

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Refer to MECHANICAL and PERFORMANCE diagnostic charts, for possible causes and corrections of malfunctions. For fuel system diagnosis, see FUEL SYSTEM . Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following: z z

z z z

z

Cylinder Compression Pressure Test: Refer to CYLINDER COMPRESSION PRESSURE TEST. Cylinder Combustion Pressure Leakage Test: Refer to CYLINDER COMBUSTION PRESSURE LEAKAGE TEST. Engine Cylinder Head Gasket Failure Diagnosis: Refer to CYLINDER HEAD GASKET. Intake Manifold Leakage Diagnosis: Refer to INTAKE MANIFOLD LEAKS. Mechanical Valve Tappet Noise Diagnosis: Refer to MECHANICAL VALVE TAPPET NOISE DIAGNOSIS. Engine Oil Leak Inspection: Refer to ENGINE OIL LEAK INSPECTION.

PERFORMANCE CONDITION ENGINE WILL NOT START

POSSIBLE CAUSE 1. Weak battery.

2. Corroded or loose battery connections. 3. Faulty starter. 4. Faulty coil(s) or control unit. 5. Incorrect spark plug gap. 6. Contamination in fuel system. 7. Faulty fuel pump. 8. Incorrect engine timing. ENGINE STALLS OR IDLES

1. Idle speed too low.

CORRECTION 1. Test battery. Charge or replace as necessary. Refer to Electrical Engine Systems/Battery System - Diagnosis and Testing . 2. Clean and tighten battery connections. Apply a coat of light mineral grease to terminals. 3. Test starting system. Check for codes. (Refer to Appropriate Diagnostic Information) 4. Test and replace as needed. (Refer to Appropriate Diagnostic Information) 5. Set gap. Refer to Electrical Ignition Control/Ignition Control - Specifications . 6. Clean system and replace fuel filter. 7. Test fuel pump and replace as needed. (Refer to Appropriate Diagnostic Information) 8. Check for a skipped timing belt/chain. 1. Test minimum air flow. (Refer

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ROUGH 2. Incorrect fuel mixture. 3. Intake manifold leakage. 4. Faulty ignition coil(s).

5. Contamination in Oil Control Valve (OCV). ENGINE LOSS OF POWER

1. Dirty or incorrectly gapped plugs. 2. Contamination in fuel system. 3. Faulty fuel pump. 4. Incorrect valve timing. 5. Leaking cylinder head gasket. 6. Low compression. 7. Burned, warped, or pitted valves. 8. Plugged or restricted exhaust system. 9. Faulty ignition coil(s).

ENGINE MISSES ON ACCELERATION

ENGINE MISSES AT HIGH SPEED

to Appropriate Diagnostic Information) 2. (Refer to Appropriate Diagnostic Information) 3. Inspect intake manifold, manifold gasket, and vacuum hoses. 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 5. Remove OCV and inspect for contamination. Replace OCV if contaminated. 1. Clean plugs and set gap. 2. Clean system and replace fuel filter. 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Correct valve timing. 5. Replace cylinder head gasket. 6. Test compression of each cylinder. 7. Replace valves. 8. Perform exhaust restriction test. Install new parts. Refer to Exhaust System - Diagnosis and Testing , as necessary. 9. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Clean spark plugs and set gap.

1. Dirty or incorrectly gapped spark plugs. 2. Contamination in Fuel System. 2. Clean fuel system and replace fuel filter. 3. Burned, warped, or pitted 3. Replace valves. valves. 4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Dirty or incorrect spark plug 1. Clean spark plugs and set gap. gap. 2. Faulty ignition coil(s). 2. Test and replace as necessary.

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3. Dirty fuel injector(s). 4. Contamination in fuel system.

(Refer to Appropriate Diagnostic Information) 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Clean system and replace fuel filter.

MECHANICAL CONDITION VALVETRAIN NOISE

CONNECTING ROD NOISE

MAIN BEARING NOISE

POSSIBLE CAUSES 1. High or low oil level in crankcase. 2. Thin or diluted oil. 3. Thick oil -

CORRECTION 1. Check and correct engine oil level. 2. Change oil to correct viscosity. 3. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. 4. Low oil pressure. 4. (a) Check and correct engine oil level. (b) Check pressure regulating valve. 5. Worn cam lobe. 5. Install new camshaft. 6. Worn tappet bucket. 6. Install new select fit tappet bucket. 7. Worn valve guides. 7. Replace cylinder head. 8. Excessive runout of valve seats 8. Grind valve seats and replace on valve faces. valves. 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thin or diluted oil. 3. Change oil to correct viscosity. 4. Thick oil 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Connecting rod journal out-of- 6. Replace crankshaft or grind round. surface. 7. Connecting rod out-of-round. 7. Replace connecting rod. 8. Misaligned connecting rods. 8. Replace bent connecting rods. 1. Insufficient oil supply. 1. Check engine oil level.

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2. Low oil pressure. 3. Thin or diluted oil. 4. Thick oil 5. Excessive bearing clearance. 6. Excessive end play.

OIL PRESSURE DROP

7. Crankshaft journal out-ofround or worn. 8. Loose flywheel or torque converter. 1. Low oil level. 2. Faulty oil pressure sending unit. 3. Low oil pressure.

1. Check engine oil level. 2. Install new sending unit.

4. Clogged oil filter. 5. Worn parts in oil pump. 6. Thin or diluted oil. 7. Oil pump relief valve stuck. 8. Excessive bearing clearance. OIL LEAKS

OIL CONSUMPTION OR SPARK PLUGS FOULED

2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Change oil to correct viscosity. 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. 5. Measure bearings for correct clearance. Repair as necessary. 6. Check thrust bearing for wear on flanges. 7. Replace crankshaft or grind journals. 8. Tighten to correct torque.

1. Misaligned or deteriorated gaskets. 2. Loose fastener, broken or porous metal part. 3. Misaligned or deteriorated cup or threaded plug. 1. PCV system malfunction.

3. Check sending unit and main bearing oil clearance. 4. Install new oil filter. 5. Replace balance shaft module. 6. Change oil to correct viscosity. 7. Remove valve and inspect, clean, or replace. 8. Measure bearings for correct clearance. 1. Replace gasket(s). 2. Tighten, repair or replace the part. 3. Replace as necessary.

1. Check system and repair as necessary. Refer to Emissions Control/Evaporative Emissions/VALVE, Positive Crankcase Ventilation (PCV) Diagnosis and Testing . 2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new rings. 3. Carbon in oil ring slots. 3. Install new rings. 4. Rings fitted too tightly in 4. Remove rings and check grooves. grooves. If groove is not proper width,

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replace piston. 5. Replace cylinder head. 6. Replace seal(s).

5. Worn valve guide(s). 6. Valve stem seal(s) worn or damaged. CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: z z z

Exhaust and intake valve leaks (improper seating). Leaks between adjacent cylinders or into water jacket. Any causes for combustion/compression pressure loss. WARNING: Do not remove the pressure cap with the system hot and under pressure because serious burns from coolant can occur.

1. 2. 3. 4. 5. 6. 7.

Check the coolant level and fill as required. DO NOT install the pressure cap. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF. Clean spark plug recesses with compressed air. Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended. 8. Perform the test procedures on each cylinder according to the tester manufacturer's instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the coolant. 9. All gauge pressure indications should be equal, with no more than 25% leakage per cylinder. 10. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder. CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and user Monday, June 04, 2012 10:44:36 AM

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3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. Remove engine cover. Disconnect coil electrical connectors and remove coils. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. Disconnect injector electrical connectors. Install a suitable compression test gauge into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. Repeat the previous step for all remaining cylinders. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. If one or more cylinders have abnormally low compression pressures, repeat the compression test. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.

ENGINE OIL LEAK INSPECTION Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: 1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak. 2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. 3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair as necessary. 4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. 5. If the oil leak source is not positively identified at this time , proceed with the AIR LEAK DETECTION TEST METHOD as follows: z Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on the cover. z Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover. z Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 psi) of test pressure. user Monday, June 04, 2012 10:44:36 AM

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Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service information procedures. z If the leakage occurs at the crankshaft rear oil seal area, refer to INSPECTION FOR REAR SEAL AREA LEAKS. 6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV valve and fresh air hose (make-up air). Proceed to next step. 7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light. z

NOTE:

If oil leakage is observed at the dipstick tube to block location; remove the tube, clean and reseal using Mopar® Stud AND Bearing Mount (press fit tube applications only), and for O-ring style tubes, remove tube and replace the O-ring seal. CAUTION: Do not exceed 20.6 kPa (3 psi).

CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area, remove transmission for further inspection. a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug, bed plate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. 4. If no leaks are detected, pressurize the crankcase as previously described in step 5 under ENGINE OIL LEAK INSPECTION. CAUTION: Do not exceed 20.6 kPa (3 psi). user Monday, June 04, 2012 10:44:36 AM

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5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. 7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as necessary.

STANDARD PROCEDURE REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired. Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special HeliCoil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size. CAUTION: Be sure that the tapped holes maintain the original center line.

Heli-Coil tools and inserts are readily available from automotive parts jobbers. HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.

1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material. 2. Remove negative battery cable. 3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure. 4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket. user Monday, June 04, 2012 10:44:36 AM

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5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). 6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.) 7. Repair engine or components as necessary to prevent this problem from reoccurring. CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. 8. 9. 10. 11. 12. 13.

Install new spark plugs. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Start engine and check for any leaks.

FORM-IN-PLACE GASKETS AND SEALERS NOTE:

All of the sealants mentioned below are not used on every engine, they are listed as general reference guide. See service information for specific sealer usage.

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing surfaces that use formin-place gaskets and sealers must free of grease or oil. Surfaces should be cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts should be assembled in no more than 10 minutes. There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Sealant RTV Silicone Rubber Adhesive, MOPAR® Silicone Rubber RTV Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other. MOPAR® SEALANT RTV SILICONE RUBBER ADHESIVE is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® SILICONE RUBBER RTV is used to seal components exposed to engine oil, gear lubricant, and coolant. This material is a specially designed gray silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil gear lubricant and coolant. Excellent adhesion , even on oily surfaces. Withstands temperatures to 330°C (650°F). Moisture in the air causes the material to cure. This material is user Monday, June 04, 2012 10:44:36 AM

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available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopar® RTV or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. For corner sealing and "T" joint locations and waffle pad area, a mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location. ENGINE GASKET SURFACE PREPARATION

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Fig. 2: PROPER TOOL USAGE FOR SURFACE PREPARATION Courtesy of CHRYSLER LLC To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces: z z z

Metal scraper (1). Abrasive pad or paper to clean cylinder block and head. High speed power tool with an abrasive pad or a wire brush (2,3).

Fig. 3: PROPER TOOL USAGE FOR SURFACE PREPARATION user Monday, June 04, 2012 10:44:36 AM

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Courtesy of CHRYSLER LLC NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces: z z

Solvent or a commercially available gasket remover Plastic or wood scraper (4).

Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or equivalent). CORE/GALLERY PLUGS CYLINDER HEAD CORE PLUGS

Fig. 4: CORE HOLE PLUG REMOVAL Courtesy of CHRYSLER LLC Using a blunt tool (3) such as a drift and a hammer, strike the bottom edge of the cup plug (5). With the cup plug rotated, grasp firmly with pliers or other suitable tool (2) and remove plug (5). CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. Thoroughly clean inside of cup plug hole in cylinder head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount (or equivalent). Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer. user Monday, June 04, 2012 10:44:36 AM

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It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. CYLINDER BLOCK MAIN OIL GALLERY PLUGS

Fig. 5: GALLERY PLUG Courtesy of CHRYSLER LLC CAUTION: Excessive use of brake parts cleaner to clean threads in block could cause #5 main bearing failure. 1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean plug and block. 2. Coat plug threads with Mopar® Thread Sealant (or equivalent). 3. Install plug (2). The plug (2) is correctly installed when it is protruding 1 mm to flush with the block boss face (1). MEASURING BEARING CLEARANCE USING PLASTIGAGE

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Fig. 6: Plastigage Placed in Lower Shell-Typical Courtesy of CHRYSLER LLC Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in Engine - Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE:

Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.

4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

REMOVAL ENGINE COVER

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Fig. 7: Engine Cover Courtesy of CHRYSLER LLC 1. Remove engine cover (1) by pulling upwards. ENGINE ASSEMBLY

Fig. 8: Engine Cover Courtesy of CHRYSLER LLC 1. Remove engine cover (1).

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Fig. 9: Coil Connector Courtesy of CHRYSLER LLC 2. Perform fuel pressure release procedure, then disconnect and remove fuel line (3). Refer to Fuel System/Fuel Delivery - Standard Procedure . 3. Remove make-up air hose (2).

Fig. 10: Air Cleaner Housing Assembly Courtesy of CHRYSLER LLC 4. Remove air cleaner housing assembly (1). See Engine/Air Intake System/BODY, Air Cleaner Removal. user Monday, June 04, 2012 10:44:36 AM

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Fig. 11: BATTERY CABLE Courtesy of CHRYSLER LLC 5. Disconnect negative battery cable (1). 6. Discharge air conditioning system, if equipped. 7. Drain cooling system.

Fig. 12: COOLANT RESERVOIR Courtesy of CHRYSLER LLC 8. Remove coolant reservoir (1). 9. Remove power steering reservoir (2).

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Fig. 13: Power Steering Line Support Courtesy of CHRYSLER LLC 10. Remove power steering line support at engine mount (1). 11. Remove power steering pump and set aside.

Fig. 14: Coolant Adapter Courtesy of CHRYSLER LLC 12. Remove coolant hoses from coolant adapter (3). 13. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).

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Fig. 15: Coil Connector Courtesy of CHRYSLER LLC 14. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness. 15. Remove PCV hose (5) from valve cover. 16. Remove harness from intake (2). 17. Remove throttle body support bracket (1). 18. Remove vacuum lines from throttle body and intake manifold. 19. Disconnect electronic throttle control and manifold flow control valve electrical connectors.

Fig. 16: INTAKE TORQUE SEQUENCE user Monday, June 04, 2012 10:44:36 AM

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Courtesy of CHRYSLER LLC 20. Remove dipstick. 21. Remove intake bolts and remove intake. 22. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, generator, starter, block heater (if equipped), A/C compressor (if equipped), and block ground. 23. Remove accessory drive belt.

Fig. 17: Oil Drain Plug Courtesy of CHRYSLER LLC 24. Raise vehicle. 25. Remove front splash shield. 26. Drain oil (2).

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Fig. 18: Exhaust Manifold Bolts, Heat Shield & Oxygen Sensor Connector Courtesy of CHRYSLER LLC 27. 28. 29. 30.

Remove exhaust pipe to exhaust manifold bolts (1). Disconnect oxygen sensor connector (3). Remove exhaust manifold heat shield (2). Remove exhaust manifold.

Fig. 19: INSPECTION COVER Courtesy of CHRYSLER LLC 31. Remove inspection cover (1) and mark torque converter to flywheel. user Monday, June 04, 2012 10:44:36 AM

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Fig. 20: MODULAR CLUTCH TO FLEX PLATE BOLTS Courtesy of CHRYSLER LLC 32. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1). 33. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1). 34. Remove lower bellhousing bolts (2).

Fig. 21: A/C COMPRESSOR Courtesy of CHRYSLER LLC 35. Remove A/C compressor (1) from engine and set aside. 36. Remove generator and lower idler pulley.

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Fig. 22: CRANKSHAFT POSITION SENSOR Courtesy of CHRYSLER LLC 37. Disconnect CKP sensor (2) electrical connector.

Fig. 23: Right Engine Mount Bracket Retaining Bolts Courtesy of CHRYSLER LLC 38. Remove right engine mount bracket retaining bolts (4). 39. Remove power steering hose hold down (3). 40. Remove retaining nuts (2) and position mount bracket (1) aside.

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Fig. 24: LIFT CHAIN Courtesy of CHRYSLER LLC 41. 42. 43. 44.

Remove intake oil control valve to prevent damage. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front. Hoist engine from vehicle. Separate engine and transmission.

INSTALLATION ENGINE COVER

Fig. 25: Engine Cover user Monday, June 04, 2012 10:44:36 AM

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Courtesy of CHRYSLER LLC 1. Position engine cover (1) over mounting studs. 2. Seat the cover on the rear studs by pushing downwards. 3. Push downward on the front of the cover to seat the front studs. ENGINE ASSEMBLY

Fig. 26: LIFT CHAIN Courtesy of CHRYSLER LLC 1. Connect engine lift chain (1) to engine. 2. Slowly lower engine assembly in to position.

Fig. 27: Right Engine Mount Bracket Retaining Bolts Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:36 AM

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3. Position right mount bracket (1) and install bolts (4). 4. Install retaining nuts (2) and tighten nuts (2) to 30 N.m (22 ft. lbs.). 5. Tighten bolts (4) to 50 N.m (37 ft. lbs.).

Fig. 28: A/C COMPRESSOR Courtesy of CHRYSLER LLC 6. 7. 8. 9.

Install A/C compressor mounting bracket (2). Install A/C compressor (1) and connect lines. Install exhaust manifold and upper lower heat shields (Refer to Manifolds). Install oxygen sensor and connect electrical connector.

Fig. 29: GROUND STRAP Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:36 AM

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10. Install Ground strap (1) near right strut tower. 11. Raise vehicle.

Fig. 30: CRANKSHAFT POSITION SENSOR Courtesy of CHRYSLER LLC 12. Install crankshaft position sensor (CKP) (2). 13. Connect CKP electrical connector (2).

Fig. 31: Exhaust Pipe Bolts Courtesy of CHRYSLER LLC 14. Install manifold to exhaust pipe bolts (1) and tighten bolts. 15. Install generator. user Monday, June 04, 2012 10:44:36 AM

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Fig. 32: MODULAR CLUTCH TO FLEX PLATE BOLTS Courtesy of CHRYSLER LLC 16. Install lower bell housing bolts (2) and tighten. 17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.

Fig. 33: INSPECTION COVER Courtesy of CHRYSLER LLC 18. Install inspection cover (1).

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Fig. 34: OIL FILTER Courtesy of CHRYSLER LLC 19. 20. 21. 22.

Install new oil filter (1). Lower vehicle. Install upper idler pulley. Install power steering pump.

Fig. 35: POWER STEERING LINE SUPPORT Courtesy of CHRYSLER LLC 23. Install power steering line support bracket (1). 24. Install power steering pump. 25. Install accessory drive belt. user Monday, June 04, 2012 10:44:36 AM

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26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater.

Fig. 36: INTAKE TORQUE SEQUENCE Courtesy of CHRYSLER LLC 27. Install intake manifold and tighten bolts to 24 N.m (18 ft. lbs.) as shown in illustration.

Fig. 37: THROTTLE BODY SUPPORT Courtesy of CHRYSLER LLC 28. 29. 30. 31.

Install throttle body support bracket (1). Connect manifold flow control valve and electronic throttle control electrical connectors. Insert wiring harness retainer into intake manifold (2). Install engine oil dip stick.

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Fig. 38: COIL CONNECTOR Courtesy of CHRYSLER LLC 32. 33. 34. 35.

Install PCV hose (5). Install vacuum lines at throttle body and intake manifold. Install intake air tube on throttle body. Connect engine harness electrical connectors.

Fig. 39: COOLANT ADAPTER Courtesy of CHRYSLER LLC 36. Install coolant hoses at coolant adapter (3).

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Fig. 40: Coolant Reservoir Courtesy of CHRYSLER LLC 37. Install coolant reservoir (1) and connect hose.

Fig. 41: COIL CONNECTOR Courtesy of CHRYSLER LLC 38. Connect fuel line to fuel rail (3).

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Fig. 42: BATTERY CABLE Courtesy of CHRYSLER LLC 39. Connect negative battery cable (1).

Fig. 43: Air Cleaner Housing Courtesy of CHRYSLER LLC 40. Install air cleaner housing (1) and connect inlet air hose (Refer to Air Intake System). 41. Fill with coolant. 42. Fill with oil. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution user Monday, June 04, 2012 10:44:36 AM

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will result in serious A/C compressor damage. 43. Evacuate the refrigerant system (refer to appropriate HVAC article). 44. Charge the refrigerant system (refer to appropriate HVAC article).

Fig. 44: Engine Cover Courtesy of CHRYSLER LLC 45. Start engine and check for leaks. 46. Install engine cover (1).

SPECIFICATIONS 2.4L ENGINE GENERAL SPECIFICATIONS DESCRIPTION

SPECIFICATION Metric

Type Number of Cylinders Firing Order Compression Ratio Displacement Bore Stroke Compression Pressure Max. Variation Between Cylinders

Standard In-Line OHV, DOHC 4 1-3-4-2 10.5:1

2.4 Liters 88 mm 97 mm 1172 - 1551 kPa

146.5 cu. in. 3.465 in. 3.819 in. 170 - 225 psi 25%

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CYLINDER BLOCK DESCRIPTION

SPECIFICATION Metric

Material A B C Cylinder Bore Out-of-Round (Max.) Cylinder Bore Diameter Taper (Max.) 1 2 3 Main Bearing Bore Diameter Taper (Max.) PISTONS DESCRIPTION

A B C Clearance to Bore Weight Land Clearance (Diametrical) Piston Length Piston Ring Groove Depth No. 1 Piston Ring Groove Depth No. 2 Piston Ring Groove Depth No. 3

Cast Aluminum Cylinder Bore Diameter 88.000 - 88.010 mm 3.4645 - 3.4649 in. 88.010 - 88.020 mm 3.4649 - 3.4653 in. 88.020 - 88.030 mm 3.4653 - 3.4657 in. 0.020 mm 0.0008 in. 0.028 mm

0.001 in.

Main Bearing Bore Diameter 56.000 - 56.006 mm 56.006 - 56.012 mm 56.012 - 56.018 mm

2.2047 - 2.2049 in. 2.2049 - 2.2051 in. 2.2051 - 2.2054 in.

0.0082 mm

0.0003 in.

SPECIFICATION Metric Standard Piston Diameter 87.995 - 88.015 mm 3.4644 - 3.4652 in. 88.005 - 88.025 mm 3.4648 - 3.4656 in. 88.015 - 88.035 mm 3.4652 - 3.4659 in. (-0.015) - 0.015 mm (-0.0006) - 0.0006 in. 302 - 312 grams 10.65 - 11.00 oz. 0.60 - 0.73 mm 0.0236 - 0.0287 in. 51.5 mm 2.028 in. 3.51 - 3.68 mm 0.1382 - 0.0256 in. 4.05 - 4.25 mm 0.1594 - 0.1673 in. 2.70 - 2.90 mm 0.1063 - 0.1142 in.

PISTON RINGS DESCRIPTION Ring Gap-Top Compression Ring Wear Limit Ring Gap-2nd Compression Ring Wear Limit

Standard

SPECIFICATION Metric 0.15 - 0.30 mm 0.8 mm 0.30 - 0.45 mm 0.8 mm

Standard 0.0059 - 0.0118 in. 0.031 in. 0.0118 - 0.0177 in. 0.031 in.

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Ring Gap-Oil Control Steel Rails Wear Limit Ring Side Clearance-Compression Rings Wear Limit Ring Side Clearance-Oil Ring Pack Ring Width-Top Compression Ring Ring Width-2nd Compression Ring Ring Width-Oil Ring Pack Ring Thickness-Top Compression Ring Ring Thickness-2nd Compression Ring Ring Thickness-Oil Ring Pack

0.20 - 0.70 mm 1.0 mm

0.0079 - 0.0276 in. 0.039 in.

0.03 - 0.07 mm

0.1182 - 0.0028 in.

0.10 mm

0.004 in.

0.06 - 0.15 mm

0.0024 - 0.0059 in.

2.95 - 3.25 mm

0.1161 - 0.1280 in.

3.45 - 3.75 mm

0.1358 - 0.1476 in.

2.30 - 2.60 mm

0.0906 - 0.1024 in.

1.17 - 1.19 mm

0.0461 - 0.0469 in.

1.17 - 1.19 mm

0.0461 - 0.0469 in.

1.88 - 1.95 mm

0.0740 - 0.0768 in.

CONNECTING ROD DESCRIPTION

SPECIFICATION

Bearing Clearance Wear Limit Bore Diameter-Piston Pin Bore Diameter-Crankshaft End Side Clearance Wear Limit Weight-Total (Less Bearing)

Metric 0.032 - 0.060 mm 0.070 mm 20.974 - 20.985 mm 51 - 51.015 mm 0.1 - 0.25 mm 0.27 mm 484 grams

Standard 0.0012 - 0.0023 in. 0.0027 in. 0.8257 - 0.8261 in. 2.0078 - 2.0084 in. 0.0039 - 0.00098 in. 0.0106 in. 17.07 oz.

CRANKSHAFT DESCRIPTION

1 2 3 Rod Journal- Taper (Max)

0 1

SPECIFICATION Metric Connecting Rod Journal Diameter Journal Grade 47.966 - 47.972 mm 47.960 - 47.966 mm 47.954 - 47.960 mm 0.005 mm Main Bearing Journal Diameter Journal Grade 51.985 - 51.988 mm 51.982 - 51.985 mm

Standard

1.8884 - 1.8886 in. 1.8884 - 1.8881 in. 1.8879 - 1.8881 in. 0.0001 in.

2.0466 - 2.0467 in. 2.0465 - 2.0466 in.

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2 3 4 Journal Out-of-Round (Max.) Journal Taper (Max.) End Play Wear Limit Main Bearing Diametrical Clearance Main Bearing Diametrical Clearance (Max)

51.979 - 51.982 mm 51.976 - 51.979 mm 51.973 - 51.976 mm 0.005 mm 0.006 mm 0.05 - 0.25 mm 0.30 mm

2.0464 - 2.0465 in. 2.0462 - 2.0464 in. 2.0461 - 2.0462 in. 0.0001 in. 0.0002 in. 0.0019 - 0.0098 in. 0.0118 in.

0.028 - 0.048 mm

0.0011 - 0.0018 in.

0.058 mm

0.0022 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER DESCRIPTION SPECIFICATION Metric Standard Cam Bearing Bore Front Intake 30.000 - 30.021 mm 1.1810 - 1.1819 in. Front Exhaust 40.000 - 40.024 mm 1.5747 - 1.5756 in. Cam Bearing Bore No. 1-4 24.000 - 24.021 mm 0.9448 - 0.9457 in. CAMSHAFT DESCRIPTION

SPECIFICATION

Metric Standard Cam Journal Diameter Front Intake Cam 29.964 - 29.980 mm 1.1797 - 1.1803 in. Front Exhaust Cam 35.984 - 36.000 mm 1.4166 - 1.4173 in. Cam Journal Diameter No. 1-4 23.954 - 23.970 mm 0.943 - 0.944 in. Bearing Clearance - Diametrical Front Intake Journal 0.020 - 0.057 mm 0.0008 - 0.0022 in. Front Exhaust Journal 0.019 - 0.051 mm 0.0007 - 0.0020 in. All Others 0.020 - 0.067 mm 0.0008 - 0.0026 in. End Play 0.11 - 0.25 mm 0.004 - 0.009 in. Max Lift @ 0.2 mm (0.007 in.) lash Intake 9.2 mm 0.362 in. Max Lift @ 0.28 mm (0.011 in.) lash Exhaust 8.42 mm 0.331 in. Intake Valve Timing w/VVT in lock-pin position* Closes (ABDC) 49.3° Opens (ATDC) 10.3° Duration 219° Exhaust Valve Timing w/VVT in lock-pin position* user Monday, June 04, 2012 10:44:37 AM

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Closes (BTDC) 8.45° Opens (BBDC) 45° Duration 216.55° Valve Overlap @ 0.5 mm (0.019 18.75° in.) w/ VVT in lock-pin position * All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift. CYLINDER HEAD DESCRIPTION Material Gasket Thickness (Compressed) Valve Tappet Bore I.D. Valve Tappet O.D.

SPECIFICATION Metric Standard Cast Aluminum - Heat treated 0.54 mm 0.021 in. 32.000 - 32.025 mm 1.2598 - 1.2608 in. 31.964 - 31.980 mm 1.2584 - 1.2590 in.

VALVE SEAT DESCRIPTION

SPECIFICATION Metric

Angle Seat Outer Diameter - Intake Seat Outer Diameter - Exhaust Runout (Max.) Intake Service Limit Exhaust Service Limit

44.75° - 45.10° 34.45 - 34.61 mm 28.04 - 28.20 mm 0.05 mm Valve Seat Width 1.16 - 1.46 mm 2.0 mm 1.35 - 1.65 mm 2.5 mm

VALVE GUIDE DESCRIPTION Diameter I.D. Guide Bore Diameter Guide Height (spring seat to guide tip)

Standard 1.3562 - 1.3625 in. 1.1039 - 1.1102 in. 0.002 in. 0.0456 - 0.0574 in. 0.079 in. 0.0531 - 0.0649 in. 0.098 in.

SPECIFICATION Metric 5.500 - 5.518 mm 10.983 - 11.001 mm

Standard 0.2165 - 0.2172 in. 0.432 - 0.4331 in.

14.6 - 15.2 mm

0.5748 - 0.5984 in.

VALVES DESCRIPTION

SPECIFICATION Metric

Face Angle - Intake and Exhaust Head Diameter - Intake

Standard 45.25° - 45.75°

34.9 - 35.1 mm

1.374 - 1.3818 in.

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Head Diameter - Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

28.9 - 29.1 mm Valve Lash 0.17 - 0.23 mm 0.27 - 0.33 mm Valve Length (Overall) 113.18 mm 105.887 mm Valve Stem Diameter 5.465 - 5.480 mm 5.458 - 5.470 mm

VALVE MARGIN DESCRIPTION

1.1377 - 1.1456 in. 0.006 - 0.009 in. 0.010 - 0.012 in. 4.455 in. 4.168 in. 0.2151 - 0.2157 in. 0.2148 - 0.2153 in.

SPECIFICATION Metric 0.672 mm 0.744 mm

Intake Exhaust VALVE STEM TIP DESCRIPTION

Standard 0.0264 in. 0.02929 in.

SPECIFICATION Metric 48.04 mm 47.99 mm

Intake Exhaust VALVE STEM TO GUIDE CLEARANCE DESCRIPTION Intake Max. Allowable Exhaust Max. Allowable

SPECIFICATION

Metric 0.020 - 0.053 mm 0.076 mm 0.030 - 0.060 mm 0.101 mm

VALVE SPRINGS DESCRIPTION Free Length (Approx.) Nominal Force (Valve Closed) Nominal Force (Valve Open) Installed Height Number of Coils Wire Diameter

Standard 1.891 in. 1.889 in.

Standard 0.0008 - 0.0021 in. 0.003 in. 0.0012 - 0.0024 in. 0.004 in.

SPECIFICATION Metric Standard 47.0 mm 1.850 in. 179.5 N ± 9 @ 35.0 mm 40.35 lbs. @ 1.38 in. 364.8 N ± 17 N @ 29.25 mm 82.01 lbs. ± 3.82 lbs. @ 1.152 in. 35.00 mm 1.378 in. 8.5 ± 0.1 2.90 mm ± 0.03 0.114 in ± 0.001 in.

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OIL PRESSURE DESCRIPTION At Curb Idle Speed* At 3000 RPM

SPECIFICATION Metric 25 kPa 170 - 550 kPa

Standard 4 psi min. 25 - 80 psi

CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 RPM.

TORQUE DESCRIPTION Balance Shaft Module Bell Housing-Bolts Camshaft Bearing Cap-Bolts

N.m

M6 Bolts M8 Bolts Coils Connecting Rod Cap-Bolts Coolant Temperature Sender Crankshaft Main Bearing Cap-Bolts Crankshaft Damper-Bolt Cylinder Head-Bolts Cylinder Head Cover-Bolts Engine Support Bracket-Bolts Exhaust Manifold-Bolts Exhaust Manifold Heat Shield-Bolts M6x25mm Bolts M6x70mm Bolts Flex Plate to Crankshaft-Bolts Intake Manifold-Bolts Ladder Frame Oil Cooler Connector Bolt Oil Filter Oil Filter Nipple Oil Jet Fastener Oil Pan-Bolts M6 Bolts M8 Bolts Oil Pan Drain-Plug Oil Pressure Switch PCV Valve

48 12 30 8 20 + 90° 18 210

40 34 7 9 29 + 51° 24 22 49 14 49 12 9 24 40 8 5

Ft. Lbs. Refer to Procedure 35 22 15 + 90° 13 Refer to Procedure 155 Refer to Procedure Refer to Procedure 30 25 22 + 51° 18 16 36 10 36 18 30 -

In. Lbs. 106 71 -

62 80 106 80 71 44

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Phaser to Camshaft-Bolt Spark Plugs Timing Chain Cover

59 27 9 26 12 12

M6 Bolts M8 Bolts Timing Chain Tensioner Assembly-Bolts Timing Chain Guides

44 20 19 -

239 80 106 106

SPECIAL TOOLS SPECIAL TOOLS

Fig. 45: GAUGE, PRESSURE - C-3292A Courtesy of CHRYSLER LLC

Fig. 46: DRIVER HANDLE, UNIVERSAL - C-4171 Courtesy of CHRYSLER LLC

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Fig. 47: BLOC-CHEK-KIT - C-3685-A Courtesy of CHRYSLER LLC

Fig. 48: TESTER, COOLING SYSTEM - 7700-A Courtesy of CHRYSLER LLC

Fig. 49: INSTALLER, OIL SEAL - 9506 user Monday, June 04, 2012 10:44:37 AM

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Courtesy of CHRYSLER LLC

Fig. 50: HOLDER, VIBRATION DAMPER - 9707 Courtesy of CHRYSLER LLC

Fig. 51: WEDGE, LOCKING - 9701 Courtesy of CHRYSLER LLC

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Fig. 52: INSTALLER, OIL SEAL - 9509 Courtesy of CHRYSLER LLC

Fig. 53: INSTALLER, REAR MAIN SEAL - 9706 Courtesy of CHRYSLER LLC

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Fig. 54: PIN, TENSIONER - 9703 Courtesy of CHRYSLER LLC

PLATE, IDENTIFICATION DESCRIPTION DESCRIPTION

Fig. 55: Serial Number Courtesy of CHRYSLER LLC The engine serial number (1) is located between the oil pan and the bellhousing. The serial number contains engine build date, build location, and displacement. Example: 8CAP1339710217 user Monday, June 04, 2012 10:44:37 AM

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8 Model Year

2008

GAS ENGINE P1 339 Engine Engine Displacement Plant P1 = Engine Build A = 1.8L GEMA Variation Julian North (with oil Day of cooler, turbo, Year P2 = for MMNA) B = 2.0L GEMA South C = 2.4L C

A

7

1

0217

Julian Year 2007

Shift

Build Sequence Number

AIR INTAKE SYSTEM AIR CLEANER Removal REMOVAL

Fig. 56: AIR FILTER ELEMENT Courtesy of CHRYSLER LLC 1. Lift air cleaner housing cover (1). 2. Remove filter element (2). 3. If necessary, clean the inside of the air cleaner housing. Installation INSTALLATION

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Fig. 57: AIR FILTER ELEMENT Courtesy of CHRYSLER LLC 1. Install new filter element (2). 2. Lower cover (1) and snap in place. BODY, AIR CLEANER Removal REMOVAL

Fig. 58: Air Cleaner Housing Retaining Bolt Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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1. Remove air cleaner housing retaining bolt (2). 2. Remove clean air hose from air cleaner housing. 3. Lift air cleaner housing (1) upwards and remove. Installation INSTALLATION

Fig. 59: Air Cleaner Housing Courtesy of CHRYSLER LLC 1. Position air cleaner housing (1) in place. 2. Install retaining bolt (2). 3. Install clean air hose.

CYLINDER HEAD DESCRIPTION DESCRIPTION

The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder. The valves are arranged in two inline banks. The intake valves face toward the front of the vehicle. The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts. Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve mechanisms. user Monday, June 04, 2012 10:44:37 AM

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NOTE:

Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash buckets, and camshafts.

DIAGNOSIS AND TESTING CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water jacket or from an oil passage to the exterior of the engine. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: z z z

Loss of engine power Engine misfiring Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: z z z z

Engine overheating Loss of coolant Excessive steam (white smoke) emitting from exhaust Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test. See CYLINDER COMPRESSION PRESSURE TEST. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP user Monday, June 04, 2012 10:44:37 AM

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FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident. CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using combustion leak tester C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit. REMOVAL REMOVAL

Fig. 60: Engine Cover Courtesy of CHRYSLER LLC 1. Remove engine cover (1) by pulling upward. 2. Perform fuel system pressure release procedure. Refer to Fuel System/Fuel Delivery - Standard Procedure . 3. Disconnect and isolate the negative battery cable.

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Fig. 61: Air Cleaner Housing Courtesy of CHRYSLER LLC 4. Drain cooling system. Refer to Cooling - Standard Procedure . 5. Remove clean air hose and air cleaner housing (2). See Engine/Air Intake System/BODY, Air Cleaner - Removal.

Fig. 62: Coolant Reservoir Courtesy of CHRYSLER LLC 6. Remove coolant recovery bottle (1). Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Removal . 7. Remove and reposition power steering reservoir (2). 8. Remove accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .

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Fig. 63: Right Engine Mount Bracket Retaining Bolts Courtesy of CHRYSLER LLC 9. Remove power steering hose hold down (3).

Fig. 64: POWER STEERING PUMP - GAS Courtesy of CHRYSLER LLC 10. Remove the three power steering pump mounting bolts (1) through the openings in the pulley (3) and reposition the pump.

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Fig. 65: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC 11. Remove the cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal. 12. Remove ignition coils from the cylinder head cover.

Fig. 66: Top Dead Center Courtesy of CHRYSLER LLC 13. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 14. Remove the frame cover portion of the right splash shield. Refer to Body/Exterior/SHIELD, Splash Removal . 15. Set engine to TDC (1).

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Fig. 67: A/C COMPRESSOR Courtesy of CHRYSLER LLC 16. Remove lower A/C compressor bolts if equipped. 17. Remove lower A/C compressor mount (2) if equipped.

Fig. 68: Accessory Drive Belt Idler Pulley Courtesy of CHRYSLER LLC 18. Remove accessory drive belt lower idler pulley (2).

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Fig. 69: Right Side Engine Mount Bracket Bolt Courtesy of CHRYSLER LLC 19. Remove crankshaft damper (2). See Engine/Engine Block/DAMPER, Vibration - Removal. 20. Remove three bolts and water pump pulley (4) from water pump. 21. Remove lower bolt from right side engine mount bracket (1).

Fig. 70: TIMING CHAIN COVER LOWER BOLTS Courtesy of CHRYSLER LLC 22. Remove timing chain cover lower bolts (1).

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Fig. 71: Catalytic Converter Courtesy of CHRYSLER LLC 23. Remove exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust - Removal. 24. Lower vehicle. 25. Support engine with suitable jack.

Fig. 72: Right Engine Mount Bracket Retaining Bolts Courtesy of CHRYSLER LLC 26. Remove right engine mount bracket retaining bolts (4). 27. Remove retaining nuts (2) and reposition mount bracket (1).

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Fig. 73: Accessory Drive Belt Idler Pulley Courtesy of CHRYSLER LLC 28. Remove accessory drive upper idler pulley (1).

Fig. 74: Right Side Engine Mount Bracket Bolt Courtesy of CHRYSLER LLC 29. Remove right upper engine mount bracket (1). 30. Remove accessory drive belt tensioner. 31. Remove upper timing chain cover retaining bolts.

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Fig. 75: TIMING CHAIN COVER PRY POINTS Courtesy of CHRYSLER LLC 32. Remove timing chain cover using pry points (1,2,3).

Fig. 76: TIMING DRIVE Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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33. Remove tensioner (5) and timing chain (2). See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Removal. 34. Remove timing chain guide (4) and timing chain pivot guide (6).

Fig. 77: FUEL LINE AT RAIL Courtesy of CHRYSLER LLC 35. Disconnect the fuel line from the fuel rail. Refer to Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure .

Fig. 78: Electrical Connectors From Fuel Injectors Courtesy of CHRYSLER LLC 36. Unlock and disconnect the electrical connectors from the fuel injectors. user Monday, June 04, 2012 10:44:37 AM

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Fig. 79: RAIL REMOVAL/INSTALL Courtesy of CHRYSLER LLC 37. Remove two fuel rail retaining bolts and remove fuel rail.

Fig. 80: COOLANT ADAPTER Courtesy of CHRYSLER LLC 38. Disconnect electrical connectors from coolant temperature sensor (1), oil temperature sensor, variable valve timing solenoids, camshaft position sensors, MAP sensor, manifold tuning valve, ignition interference suppressor (2) and electronic throttle control.

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Fig. 81: Throttle Body Support Bracket Courtesy of CHRYSLER LLC 39. Remove wiring harness retainer from intake manifold (2) and reposition harness. 40. Remove throttle body support bracket (1). 41. Disconnect vacuum lines at intake.

Fig. 82: Intake Manifold Retaining Bolts Torque Sequence Courtesy of CHRYSLER LLC 42. Remove intake manifold retaining bolts and remove intake manifold.

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Fig. 83: COOLANT ADAPTER Courtesy of CHRYSLER LLC 43. Remove four bolts and reposition coolant adapter (3).

Fig. 84: GROUND STRAP Courtesy of CHRYSLER LLC 44. Remove ground strap (1) at right rear of cylinder head if equipped.

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Fig. 85: Front Camshaft Cap Removal Sequence Courtesy of CHRYSLER LLC NOTE:

Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>". CAUTION: DO NOT use a number stamp or a punch to mark camshaft bearing caps. Damage to bearing caps could occur.

45. 46. 47. 48.

Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap. Remove the front camshaft bearing cap. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time. Remove the camshafts.

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Fig. 86: FRONT HEAD BOLT WASHERS Courtesy of CHRYSLER LLC NOTE:

All of the cylinder head bolts have captured washers EXCEPT the front two (1).

49. Remove cylinder head bolts and two uncaptured washers. 50. Remove cylinder head from engine block. 51. Inspect and clean cylinder head and block sealing surfaces. See Engine/Cylinder Head - Inspection. See Engine/Cylinder Head - Cleaning. NOTE:

Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

CLEANING CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block. See Engine - Standard Procedure. Be careful not to gouge or scratch the aluminum head sealing surface. Clean all engine oil passages. INSPECTION user Monday, June 04, 2012 10:44:37 AM

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INSPECTION

NOTE:

Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, tappets, and camshafts.

Fig. 87: Checking Cylinder Head Flatness Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Check cylinder head warpage with a straight edge (2) and feeler gauge (1). Cylinder head must be flat within 0.1 mm (0.004 in.). Verify that the valve tappets move freely in theirs bores and that they have been rotating. Inspect camshaft bearing journals for scoring. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. Inspect the following components and verify that they are within specification. See Engine Specifications: z Camshafts z Valve Tappets z Springs z Valve Seats z Valve Guides z Valves 7. Prior to installing cylinder head, the cylinder block should be checked for flatness. See Engine/Engine Block - Inspection. INSTALLATION INSTALLATION user Monday, June 04, 2012 10:44:37 AM

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Fig. 88: Checking Cylinder Head Bolts for Stretching (Necking) Courtesy of CHRYSLER LLC CAUTION: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced. 1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.

Fig. 89: Variable Valve Timing Filter Screen Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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NOTE:

Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged. CAUTION: Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.

2. Replace the variable valve timing filter screen (3).

Fig. 90: Two Dots Of Mopar® Engine Sealant RTV On Cylinder Block Courtesy of CHRYSLER LLC NOTE:

When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE:

When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

3. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown in illustration.

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Fig. 91: Two Dots Of Mopar® Engine Sealant RTV On Cylinder Head Gasket Courtesy of CHRYSLER LLC 4. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block. 5. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as shown in illustration. NOTE:

The head must be installed within 15 minutes before the RTV skins.

6. Position cylinder head onto engine block.

Fig. 92: CYLINDER HEAD BOLT IDENTIFICATION Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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CAUTION: This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2). 7. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm (5/16") and the long bolt head (2) measures 13 mm (1/2"). 8. Identify whether your engine has the short head design (1) or the long head design (2).

Fig. 93: Washer Courtesy of CHRYSLER LLC NOTE:

The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.

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Fig. 94: FRONT HEAD BOLT WASHERS Courtesy of CHRYSLER LLC 9. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up.

Fig. 95: CYLINDER HEAD TORQUE SEQUENCE Courtesy of CHRYSLER LLC NOTE:

Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

10. Install the cylinder head bolts and tighten in the sequence shown in illustration.

Fig. 96: CYLINDER HEAD BOLT IDENTIFICATION Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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11. If your bolt has the short head (1), use the following torque specifications: z First: All to 30 N.m (25 ft. lbs.) z Second: All to 61 N.m (45 ft. lbs.) z Third: All to 61 N.m (45 ft. lbs.) z Fourth: All an additional 90° CAUTION: Do not use a torque wrench for the Fourth step.

12. If your bolt has the long head (2), use the following torque specifications: z First: All to 30 N.m (25 ft. lbs.) z Second: All to 73 N.m (54 ft. lbs.) z Third: All to 73 N.m (54 ft. lbs.) z Fourth: All an additional 90° CAUTION: Do not use a torque wrench for the Fourth step.

13. Clean excess RTV from the timing chain cover sealing surface.

Fig. 97: COOLANT ADAPTER Courtesy of CHRYSLER LLC 14. Install coolant adapter (3) with new seals. Tighten bolts to 18.1 N.m (159 in. lbs.).

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Fig. 98: Camshaft Cap Bearing Identification Courtesy of CHRYSLER LLC 15. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.

Fig. 99: Camshaft Bearing Identification Courtesy of CHRYSLER LLC 16. Install the corresponding select fit front exhaust camshaft bearing (1). 17. Oil all of the camshaft journals with clean engine oil.

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Fig. 100: Camshaft Timing Courtesy of CHRYSLER LLC 18. Position exhaust camshaft (1) and intake camshaft (2) on bearing journals in the cylinder head. 19. Align camshaft timing marks (3) so that they are facing each other and are in line with the cylinder head cover sealing surface. CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result. NOTE:

If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.

Fig. 101: Camshaft Cap Torque Sequence user Monday, June 04, 2012 10:44:37 AM

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Courtesy of CHRYSLER LLC 20. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N.m (85 in. lbs.) in the sequence shown in illustration.

Fig. 102: Front Camshaft Cap Torque Sequence Courtesy of CHRYSLER LLC NOTE:

Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.

21. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence shown in illustration.

Fig. 103: TIMING DRIVE user Monday, June 04, 2012 10:44:37 AM

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Courtesy of CHRYSLER LLC 22. Install timing chain guide (4) and tighten bolts to 12 N.m (105 in. lbs.). 23. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 N.m (105 in. lbs.). 24. Install timing chain (2) and tensioner (5). See Engine/Valve Timing/CHAIN and SPROCKETS, Timing - Installation. 25. Install timing chain cover, engine mount, pulleys and accessory drive belt. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.

Fig. 104: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC 26. Install cylinder head cover and ignition coils. See Engine/Cylinder Head/COVER(S), Cylinder Head Installation.

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Fig. 105: Catalytic Converter Courtesy of CHRYSLER LLC 27. Install exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust - Installation.

Fig. 106: GROUND STRAP Courtesy of CHRYSLER LLC 28. Install ground strap (1) at right rear of cylinder head if equipped.

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Fig. 107: INTAKE TORQUE SEQUENCE Courtesy of CHRYSLER LLC 29. Install intake manifold, vacuum lines and fuel rail. See Engine/Manifolds/MANIFOLD, Intake Installation.

Fig. 108: COIL CONNECTOR Courtesy of CHRYSLER LLC 30. Connect coil (1) and injector (4) electrical connectors.

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Fig. 109: COOLANT ADAPTER Courtesy of CHRYSLER LLC 31. Connect electrical connectors to coolant temperature sensor (1), camshaft position sensors, oil temperature sensor, variable valve timing solenoids, MAP sensor, manifold tuning valve, ignition interference suppressor (2) and electronic throttle control.

Fig. 110: Coolant Reservoir Courtesy of CHRYSLER LLC 32. Install power steering pump reservoir (2). Tighten mounting screw to 12 N.m (106 in. lbs.). 33. Install coolant recovery reservoir (1). Tighten mounting bolts to 10 N.m (89 in. lbs.).

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Fig. 111: Air Cleaner Housing Courtesy of CHRYSLER LLC 34. Install clean air hose (1) and air cleaner housing (2). See Engine/Air Intake System/BODY, Air Cleaner - Installation. 35. Fill cooling system. Refer to Cooling - Standard Procedure . 36. Install new oil filter and fill engine with oil. 37. Connect negative battery cable.

Fig. 112: Engine Cover Courtesy of CHRYSLER LLC 38. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for leaks and correct fluid levels. user Monday, June 04, 2012 10:44:37 AM

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39. Install engine cover (1). ASSEMBLY, VARIABLE VALVE TIMING Description DESCRIPTION

The Gas engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as camshaft phasers. Operation OPERATION

The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve timing by changing the relationship between the camshaft and the timing chain. An integral oil pressure activated pin is used to lock base camshaft timing for engine start up. Oil pressure releases the pin and allows the PCM to control cam timing once the engine is running. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Removal REMOVAL

NOTE:

Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble.

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Fig. 113: Camshafts Phaser Removal/Installation Courtesy of CHRYSLER LLC 1. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft. Installation INSTALLATION

Fig. 114: Camshafts Phaser Removal/Installation Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:37 AM

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CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Install phaser (2) assembly on camshaft. NOTE:

Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes.

2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 N.m (44 ft. lbs.). 3. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation. BUCKET, TAPPET Diagnosis and Testing MECHANICAL VALVE TAPPET NOISE DIAGNOSIS

A tappet-like noise may be produced from incorrect valve lash. See Engine/Cylinder Head/BUCKET, Tappet - Standard Procedure. Standard Procedure MEASURING VALVE LASH

Fig. 115: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC NOTE:

The engine must be cold to measure valve lash.

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1. Remove engine cover. 2. Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.

Fig. 116: LOBES VERTICAL Courtesy of CHRYSLER LLC 3. 4. 5. 6. 7.

Rotate camshaft so lobes are vertical (1). Check clearance using feeler gauges. Repeat for all tappets and record readings. If clearance was too small, refer to Clearance too Small. If clearance was too large, refer to Clearance too Large.

Clearance too Small

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Fig. 117: TAPPET IDENTIFICATION Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal. Specification - clearance = change. Decrease tappet thickness by change figure. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation. Verify that valve lash is correct.

Clearance too Large

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Fig. 118: TAPPET IDENTIFICATION Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal. Clearance - specification = change. Increase tappet thickness by change figure. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation. Verify that valve lash is correct.

Removal REMOVAL

Fig. 119: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC NOTE:

This procedure is for in-vehicle service with camshafts installed.

NOTE:

Camshaft tappets must be replaced if cylinder head or camshafts are replaced.

1. Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal. 2. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal.

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Fig. 120: TAPPET IDENTIFICATION Courtesy of CHRYSLER LLC 3. Remove camshaft tappets (1). 4. Repeat removal procedure for each camshaft tappet (1). 5. If reusing, mark each tappet for reassembly in original position. Installation INSTALLATION

Fig. 121: TAPPET IDENTIFICATION user Monday, June 04, 2012 10:44:38 AM

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Courtesy of CHRYSLER LLC NOTE: 1. 2. 3. 4.

If reinstalling original tappets they must go back in their original location or engine damage could result.

Apply a light coat of clean engine oil to camshafts tappets (1) prior to assembly. Install camshaft tappets (1) into cylinder head. Repeat installation procedure for each camshaft tappet. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation. NOTE:

If installing new tappets, the valve lash procedure must be performed.

Fig. 122: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC 5. Install cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation. CAMSHAFT, ENGINE Description DESCRIPTIONS

Both camshafts have five bearing journal surfaces and two cam lobes per cylinder. The two front journals are larger to allow for feeding oil to the variable valve timing (VVT) camshaft phasers. Flanges on the third smaller journal control camshaft end play. At the rear of each camshaft is an integral cam sensor target. CAMSHAFT BEARING CAPS

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Fig. 123: Camshaft Bearing Caps Courtesy of CHRYSLER LLC The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The front exhaust camshaft journal has a select fit bearing insert. This bearing is required to seal the oil passage to the camshaft phaser, because a portion of the lower bearing saddle is machined away for head bolt access. The select fit is required to minimize bearing clearance and oil leakage. An exhaust bearing grade (1, 2 or 3) is stamped into the front bearing cap adjacent to the exhaust cam journal. The bearings are also marked with the corresponding grade markings. If the bearing is replaced, the same grade must be used. Due to the unique purpose of this bearing, it may appear to have uneven wear patterns (1). Maximum wear of 0.05 mm (.002 in.) is acceptable. Unless the wear is excessive it is no cause for concern and the bearing should not be replaced. Cam bearing inspection should not be the sole reason for removal of the exhaust camshaft. The upper cam bearing may be replaced if the front bearing cap is removed. The lower cam bearing should be replaced if the camshaft is removed due to a failure of a component within the cylinder head. The front intake cam journal has a full lower bearing saddle, and therefore, no bearing insert is required. All small bearing caps have a formed-in arrow to assist in assembly. All small bearing cap arrows must point towards the center of the cylinder head. The small bearing caps are marked for position during the manufacturing process, and must be reinstalled in their original position. The #1 small cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small bearing journal, and into the camshaft as well. The hollow camshaft then distributes oil to the remainder of the small journals. Oil flowing out of each cam journal lubricates the valve tappets. The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has dowels for precise alignment. Operation OPERATION

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The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined lobes to provide accurate valve timing and duration. Standard Procedure MEASURING CAMSHAFT END PLAY

Fig. 124: Camshaft End Play Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5.

Using a suitable tool, move camshaft as far rearward as it will go. Zero dial indicator. Move camshaft as far forward as it will go. Record reading on dial indicator. For end play specification, see Engine - Specifications. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary.

Removal REMOVAL

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Fig. 125: Engine Cover Courtesy of CHRYSLER LLC 1. Remove engine cover (1) by pulling upward. 2. Disconnect and isolate the negative battery cable. 3. Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.

Fig. 126: Top Dead Center Courtesy of CHRYSLER LLC 4. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure . 5. Remove the frame cover portion of the right splash shield. Refer to Body/Exterior/SHIELD, Splash Removal . user Monday, June 04, 2012 10:44:38 AM

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6. Rotate engine to TDC (1).

Fig. 127: TIMING CHAIN TIMING MARKS Courtesy of CHRYSLER LLC 7. Make sure camshaft timing marks (3) are in line with the cylinder head cover sealing surface. 8. Mark the chain link corresponding to timing marks (1) with a paint marker.

Fig. 128: TENSIONER ACCESS PLUG Courtesy of CHRYSLER LLC 9. Remove timing tensioner plug (1) from front cover.

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Fig. 129: TENSIONER RESET Courtesy of CHRYSLER LLC 10. Insert small Allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push Allen wrench inward. Leave the Allen wrench installed during the remainder of this procedure.

Fig. 130: WEDGE TOOL Courtesy of CHRYSLER LLC 11. Insert Locking Wedge 9701 (1) between camshaft phasers. user Monday, June 04, 2012 10:44:38 AM

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Fig. 131: SEATING WEDGE TOOL Courtesy of CHRYSLER LLC 12. Lightly tap Locking Wedge 9701 (2) into place until it will no longer sink down.

Fig. 132: Front Camshaft Cap Removal Sequence Courtesy of CHRYSLER LLC NOTE:

Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>". CAUTION: DO NOT use a number stamp or a punch to mark camshaft bearing caps. Damage to bearing caps could occur.

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13. Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap. 14. Remove the front camshaft bearing cap. 15. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time.

Fig. 133: Raise Intake Camshaft Courtesy of CHRYSLER LLC 16. Remove intake camshaft (1) by lifting the rear of the camshaft upward.

Fig. 134: ROLL CAMSHAFT Courtesy of CHRYSLER LLC 17. Rotate the camshaft while lifting out of the front bearing cradle.

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Fig. 135: CHAIN REMOVAL Courtesy of CHRYSLER LLC 18. Lift the timing chain (2) off the sprocket (1). 19. Remove exhaust camshaft. 20. Secure timing chain with wire so that it does fall into the timing chain cover. Cleaning CLEANING

Clean camshafts with a suitable solvent. Inspection INSPECTION

1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE:

If camshaft is replaced due to lobe wear or damage, always replace the lash buckets.

Installation INSTALLATION

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Fig. 136: Camshaft Cap Bearing Identification Courtesy of CHRYSLER LLC 1. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.

Fig. 137: Camshaft Bearing Identification Courtesy of CHRYSLER LLC 2. Install the corresponding select fit front exhaust camshaft bearing (1). 3. Oil all of the camshaft journals with clean engine oil. 4. Install camshaft phasers on camshafts if removed. See Engine/Cylinder Head/ASSEMBLY, Variable Valve Timing - Installation.

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Fig. 138: Timing Chain Timing Marks Courtesy of CHRYSLER LLC 5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the sprocket and the painted chain link are aligned. 6. Position exhaust camshaft and on bearing journals in the cylinder head. 7. Align exhaust cam timing mark (3) so it is in line with the cylinder head cover sealing surface (2).

Fig. 139: Raise Intake Camshaft Courtesy of CHRYSLER LLC 8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain.

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Fig. 140: Timing Chain Timing Marks Courtesy of CHRYSLER LLC 9. Align the timing marks (1) on the intake cam sprocket with the painted chain link. 10. Position the intake camshaft into the bearing journals in the cylinder head. 11. Verify that the timing marks (1) are aligned on both camshafts and that the timing marks (3) are facing each other and are in line with the cylinder head cover sealing surface (2). CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result. NOTE:

If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.

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Fig. 141: Camshaft Cap Torque Sequence Courtesy of CHRYSLER LLC 12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N.m (85 in. lbs.) in the sequence shown in illustration.

Fig. 142: Front Camshaft Cap Torque Sequence Courtesy of CHRYSLER LLC NOTE:

Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.

13. Install the front intake and exhaust bearing cap and tighten bolts to 25 N.m (18 ft. lbs.) in the sequence shown in illustration.

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Fig. 143: TIMING CHAIN TIMING MARKS Courtesy of CHRYSLER LLC 14. Verify that all timing marks (1,3) are aligned. 15. Remove Allen wrench from timing chain tensioner.

Fig. 144: WEDGE TOOL Courtesy of CHRYSLER LLC 16. Remove Locking Wedge 9701 (1) by pulling straight upward on pull rope.

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Fig. 145: TENSIONER ACCESS PLUG Courtesy of CHRYSLER LLC 17. Apply MOPAR® thread sealant to timing tensioner plug (1) and Install. 18. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position.

Fig. 146: Camshaft Timing Courtesy of CHRYSLER LLC 19. Verify that the camshafts timing marks (3) are in the proper position and in line with the cylinder head cover sealing surface. If the marks do not line up, the timing chain is not correctly installed. 20. Install right splash shield. Refer to Body/Exterior/SHIELD, Splash - Installation . user Monday, June 04, 2012 10:44:38 AM

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Fig. 147: GASKET LOCATION Courtesy of CHRYSLER LLC 21. Remove RTV from gasket (1). 22. Inspect cylinder head cover gaskets (1,2) for damage. If no damage is present, gaskets can be reinstalled.

Fig. 148: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC 23. 24. 25. 26.

Install cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation. Connect negative battery cable. Fill cooling system. Refer to Cooling - Standard Procedure . Fill with oil.

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Fig. 149: Engine Cover Courtesy of CHRYSLER LLC 27. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct fluid levels. 28. Install engine cover (1). COVER(S), CYLINDER HEAD Removal REMOVAL

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Fig. 150: Engine Cover Courtesy of CHRYSLER LLC 1. Remove engine cover (1) by pulling upward. 2. Disconnect and isolate the negative battery cable.

Fig. 151: COIL CONNECTOR Courtesy of CHRYSLER LLC 3. Remove make up air hose (2). 4. Remove PCV hose (5). 5. Disconnect ignition coil electrical connectors (1).

Fig. 152: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:38 AM

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6. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal. 7. Remove cylinder head cover bolts. 8. Remove cylinder head cover from cylinder head. Installation INSTALLATION

Fig. 153: GASKET LOCATION Courtesy of CHRYSLER LLC 1. Install new cylinder head cover gaskets (1,2).

Fig. 154: STUD LOCATION Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:38 AM

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2. Install studs in cover as shown in illustration.

Fig. 155: Cylinder Head/Front Cover T-Joint Courtesy of CHRYSLER LLC 3. Clean all RTV from cylinder head. See Engine - Standard Procedure. NOTE:

When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE:

When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

4. Apply a dot of Mopar® engine sealant RTV or equivalent to cylinder head/front cover T-joint (1).

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Fig. 156: Cylinder Head Cover Torque Sequence Courtesy of CHRYSLER LLC 5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located as shown in illustration. 6. Tighten bolts in sequence shown in illustration using a 2 step torque method as follows: a. Tighten all bolts to 5 N.m (44 in. lbs.). b. Tighten all bolts to 10 N.m (90 in. lbs.).

Fig. 157: Coil Connector Courtesy of CHRYSLER LLC 7. Install ignition coils. Tighten fasteners to 8 N.m (70 in. lbs.). 8. If the PCV valve was removed, tighten PCV valve to 5 N.m (44 in. lbs.). 9. Connect coil electrical connectors (1). user Monday, June 04, 2012 10:44:38 AM

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10. Connect PCV hose (5) to PCV valve. 11. Connect make up air hose (2).

Fig. 158: Engine Cover Courtesy of CHRYSLER LLC 12. Connect negative battery cable. 13. Install engine cover (1) by pressing the rear of the cover down first. SPRING(S), VALVE Removal CYLINDER HEAD ON

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Fig. 159: VALVE REMOVAL Courtesy of CHRYSLER LLC 1. 2. 3. 4. 5. 6.

Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal. Mark valve tappet location for assembly. Remove valve tappets. Rotate crankshaft until piston is at TDC on compression. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.

7. Using metric valve keeper tool (1) such as Snap-on® GA317 (or equivalent), and remove valve spring keepers and retainer. 8. Remove valve spring(s). 9. Remove valve stem seal(s) by a using valve stem seal tool. CYLINDER HEAD OFF

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Fig. 160: VALVE REMOVAL Courtesy of CHRYSLER LLC 1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 2. Mark valve tappet location for assembly. 3. Remove valve tappets. 4. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) remover (1) , remove valve keepers with a downward push. 5. Remove retainer and springs. 6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and retainers to insure installation in original location. 7. Inspect the valves. See Engine/Cylinder Head/SPRING(S), Valve - Inspection. Inspection INSPECTION

1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: z Valve closed nominal load - 179.5 N ± 9 N @ 35.0 mm (40.35 lbs. ± 2 lbs. @ 1.38 in.). z Valve open nominal load - 364.8 N ± 17 N @ 29.25 mm (82 lbs. ± 3.8 lbs. @ 1.152 in.). 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. user Monday, June 04, 2012 10:44:38 AM

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Installation CYLINDER HEAD ON

CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.

Fig. 161: Valve Spring Assembly Courtesy of CHRYSLER LLC 1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size socket to seat it onto the valve guide. 2. Install valve spring (2) and retainer (4) with keepers (1).

Fig. 162: VALVE INSTALLATION Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:38 AM

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3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) installer (2) and remover (1) as a handle, install valve keepers with a downward push. 4. Remove air hose and install spark plugs. 5. Install valve tappets. 6. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation. 7. Install cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation. CYLINDER HEAD OFF

CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.

Fig. 163: Valve Spring Assembly Courtesy of CHRYSLER LLC 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat. The valve stem seals should be pushed firmly and squarely over valve guide. 3. Install valve springs (2). 4. Install keepers in retainer and place on valve spring.

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Fig. 164: VALVE INSTALLATION Courtesy of CHRYSLER LLC 5. Using metric valve keeper tool such as Snap-on® GA317 (or equivalent) installer (2) and remover (1) as a handle, push downward to install keepers.

Fig. 165: Spring Installed Height and Valve Tip to Spring Seat Dimensions Courtesy of CHRYSLER LLC 6. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification. 7. Install valve tappets. VALVES, INTAKE AND EXHAUST Description DESCRIPTION

The valves are made of heat resistant steel. They have nitrated stems to prevent scuffing. Viton rubber valve user Monday, June 04, 2012 10:44:38 AM

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stem seals are integral with the spring seats. The valves have a single bead lock keepers to retain the springs. Operation OPERATION

The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets which are actuated by the camshaft. Cleaning CLEANING

Clean all valves thoroughly and discard burned, warped and cracked valves. CAUTION: Due to the small margin on the valves, grinding is not recommended.

ENGINE BLOCK DESCRIPTION DESCRIPTION

The die cast aluminum cylinder block is a two-piece assembly, consisting of the cylinder block and ladder frame. The block is an open deck design with cast in place cast iron cylinder liners. The cast iron cylinder liners are recessed below the aluminum deck surface. The ladder frame bolts to the cylinder block and does not incorporate the main bearing caps. This design offers a much stronger lower end and increased cylinder block and transaxle rigidity. The rear oil seal retainer is integral with the block and ladder frame. The ladder frame and block are serviced as an assembly.

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Fig. 166: Serial Number Courtesy of CHRYSLER LLC The engine serial number (1) is located on the bottom of the ladder frame just behind the oil pan. The serial number can be seen with the oil pan in place. STANDARD PROCEDURE CYLINDER BORE HONING

Fig. 167: Cylinder Bore Cross-Hatch Pattern Courtesy of CHRYSLER LLC 1 - CROSS-HATCH PATTERN 2 - 40°-60° 1. Deglazing of the cylinder walls may be done using a quality commercially available flex hone, if the cylinder bore is straight and round. 20-60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, mineral spirits or kerosene. Inspect cylinder walls after each 20 strokes. 2. Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When hone marks intersect at 30-50 degrees, the cross hatch angle is most satisfactory for proper seating of rings . 3. A controlled hone motor speed between 200-300 RPM is necessary to obtain the proper cross-hatch angle. The number of up and down strokes per minute can be regulated to get the desired 30-50 degree angle. Faster up and down strokes increase the cross-hatch angle. 4. After honing, it is necessary that the block be cleaned again to remove all traces of abrasive. CAUTION: Ensure all abrasives are removed from engine parts after honing. It is user Monday, June 04, 2012 10:44:38 AM

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recommended that a solution of soap and hot water be used with a brush and the parts then thoroughly dried. The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean. Oil the bores after cleaning to prevent rusting. CLEANING CLEANING

Clean cylinder block thoroughly using a suitable cleaning solvent. INSPECTION INSPECTION ENGINE BLOCK

Fig. 168: Checking Cylinder Bore Size Courtesy of CHRYSLER LLC 1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. 2. Examine block and cylinder bores for cracks or fractures. 3. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm (0.002 in.). CYLINDER BORE

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NOTE:

The cylinder bores should be measured at normal room temperature, 21°C (70° F).

The cylinder walls should be checked for out-of-round and taper with Tool C119 or equivalent . See Engine Specifications. If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Measure the cylinder bore at three levels in directions A and B . Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. See Engine Specifications. BEARING(S), CONNECTING ROD Standard Procedure CONNECTING ROD - FITTING

Fig. 169: BEARING SELECTION Courtesy of CHRYSLER LLC There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the CONNECTING ROD BEARING SELECTION table for proper bearing selection. CONNECTING ROD BEARING SELECTION CONNECTING ROD CRANKSHAFT PIN DIMENSION BEARING DIAMETER GRADE CLASSIFICATION 1 48 mm 1 (Black) 2 48 mm 2 (No Color) 3 48 mm 3 (Green)

CONNECTING ROD BEARING DIMENSION 1.5 mm 1.5 mm 1.5 mm

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Fig. 170: Connecting Rod Bearing Clearance - Typical Courtesy of CHRYSLER LLC 1. For measuring connecting rod bearing clearance procedure and use of Plastigage, see Engine - Standard Procedure. For bearing clearance, refer to Engine - Specifications. NOTE:

The rod bolts should not be reused.

2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil. 3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step.

1. Tighten the bolts to 20 N.m (15 ft. lbs.). 2. Tighten the connecting rod bolts an additional 90°.

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Fig. 171: Connecting Rod Side Clearance Courtesy of CHRYSLER LLC 5. Using a feeler gauge, check connecting rod side clearance. Refer to Engine - Specifications. BEARING(S), CRANKSHAFT, MAIN Standard Procedure MAIN BEARING SELECTION

NOTE:

There are three different possibilities for the upper main bearings and five different lower main bearings. The upper and lower bearing shells are not interchangeable.

Fig. 172: BEARING SELECTION Courtesy of CHRYSLER LLC user Monday, June 04, 2012 10:44:38 AM

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2009 Dodge Journey SE 2009 ENGINE 2.4L Gas - Service Information - Journey

The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5 different bearing sizes available 0 through 4. CRANKSHAFT IDENTIFICATION JOURNAL DIMENSION DIAMETER GRADE 52 mm, -0.012 to 0 0.015 mm 52 mm, -0.015 to 1 0.018 mm 52 mm, -0.018 to 2 0.021 mm 52 mm, -0.021 to 3 0.024 mm 52 mm, -0.024 to 4 0.027 mm

LOWER CRANKSHAFT BEARING SELECTION LOWER MAIN LOWER MAIN BEARING BEARING SIZE CLASSIFICATION DIMENSION 0 (Pink or Red)

2 mm, 0 to -0.003 mm

1 (Black)

2 mm, +0.003 to 0 mm

2 (No Color) 3 (Green) 4 (Blue)

2 mm, +0.006 to +0.003 mm 2 mm, +0.009 to +0.006 mm 2 mm, +0.012 to +0.009 mm

Fig. 173: MAIN BEARING SELECTION CHART Courtesy of CHRYSLER LLC The upper main bearing shell identification (1) is located in the middle of cylinder block on the right side of the engine. There are three different size bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom. UPPER MAIN BEARING SELECTION CYLINDER BLOCK UPPER CRANKSHAFT BEARING SELECTION IDENTIFICATION user Monday, June 04, 2012 10:44:38 AM

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© 2006 Mitchell Repair Information Company, LLC.

2009 Dodge Journey SE 2009 ENGINE 2.4L Gas - Service Information - Journey

MAIN BEARING UPPER MAIN BEARING SIZE DIMENSION GRADE CLASSIFICATION 56.000