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Introducing MONSTALINER™ UV Permanent DIY Roll On Bed LineZone Offroad Body and Suspension Lift Kits, Brackets, DiscBilstein Shock Upgrade Kits, Jeep JK TJ XJ Wranglers and C

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Unread 09-02-2005, 11:49 AM   #31
Meerkat
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1996 ZJ 
 
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Heated Seat - Inoperative Repair Procedure
1. Position the seatback in the half recline position to gain access to the fasteners.
2. Disconnect the wire harness from the seat assembly.
3. Remove the seat attaching nuts and remove the seat from the vehicle.
4. Remove the seat cushion side cover trim.
5. Remove the recliner to seat cushion bolts and inboard seat back to seat cushion bolt. Remove the seat back.
CAUTION :CARE MUST BE USED WHEN REMOVING THE COVER FROM THE SEAT BOTTOM. THE SEAT IS ATTACHED TO THE FOAM CUSHION WITH HOOK AND LOP FASTENERS. THESE CAN BE TORN WHEN THE COVER IS REMOVED. USE CARE TO CAREFULLY REMOVE THE COVER TO AVOID TEARING THE HOOK AND LOOP FASTENER FROM THE FOAM. IF THE FASTENER IS TORN IT MUST BE ATTACHED TO THE FOAM USING A SUITABLE ADHESIVE SUCH AS MOPAR SPRAY ADHESIVE, P/N 04856957 OR EQUIVALENT.
6. Disengage the seat cover J straps from the frame. Carefully remove the cover from the seat bottom making sure not to damage the hook and loop fastener on the foam cushion.
7. The system contains two heating elements per seat. Unplug the two wire connectors and check the continuity between the two terminals in each connector to determine which heating element is open (See Figure 1). The resistance should be .9 to 1.4 ohms. An infinite resistance indicates an open circuit. Each repair kit will repair one element. It is recommended that both elements be repaired even if only one is open.


8. Trace the wires into the foam and carefully slit the foam using a sharp knife, following the wires until the heating element solder joint is located (See Figure 2). This is the location the open circuit is usually found. Cut the harness from the element as close to the solder joint as possible. If the seat cover has a gray lining, it may be necessary to trim some of the fabric around the glue until the element is exposed. Remove all loose debris. It is not necessary to remove the glue from the cover. Do not discard the original harness. Some vehicles will require the use of the original two wire connector later.


9. There were two types of heating element used in production (See Figure 3). One has insulation on the wire and one does not. If the element has insulation on the wire, carefully strip one inch of the insulation from the element to allow for soldering. Pull the elements away from the cover enough to clear the foam for soldering. Trim the foam as necessary to provide adequate clearance for soldering.


10. The soldering procedure requires a technician skilled in soldering fine electrical/electronic wiring. Using a soldering iron and rosin core, solder the new harness to the heating element as shown in Figure 4. Do not use any soldering equipment utilizing an open flame for this procedure. This could damage the foam cushion. Make sure utilize the proper soldering procedures and heat the wire hot enough to melt the solder to avoid a cold solder joint. Cut piece of heat shrink tubing in half and install it on the wire as shown. Shrink the tubing using a heat gun.
11. Peel of the paper backing from the adhesive patch on the new harness and secure the harness to the cover as shown. The elements require at least one inch clearance between each other to eliminate the possibility of them shorting together. Make sure to route the wires as shown and install the cover patch to fully secure the new harness to the cover. Trim the cover patch as necessary to clear the hook and loop fasteners.


12. The new harness will plug into most of the existing seat harnesses. Some vehicles utilized a red insulator, which is keyed differently than the green insulator provided on the new harness. If the vehicle utilizes the red connector, it will have to be removed from the original harness and installed on the new harness using solder and heat shrink tubing as shown in Figure 5. Be sure to stagger the splices as shown.
13. Check continuity at both of the two wire connectors to assure good solder joint.
14. Repeat this process for the second heating element.
15. Install the seat cover to the seat bottom.
16. Install the seat back.
17. Install the seat and connect the harness.

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Unread 09-02-2005, 11:49 AM   #32
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Heated Seat - Inoperative Repair Procedure continued
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Unread 09-02-2005, 11:51 AM   #33
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Engine - Spark Knock/Oil Consumption

NUMBER:
09-05-00
GROUP:
Engine
DATE:
Feb.25, 2000
MODELS:
1994 - 1999 (AB) Ram Van
1994 - 1999 (AN) Dakota
1994 - 1999 (BRIBE) Ram Truck
1998 - 1999 (DN) Durango
1994 - 1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT:
Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak
OVER VIEW:
This bulletin involves the replacement of the engine intake manifold plenum pan gasket.
NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE.
SYMPTOM/CONDITION:
An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine.
DIAGNOSIS:
Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed.
NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT.
Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free.
If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by.
1. Allow the engine to reach normal operating temperature.
2. Stop the engine.
3. Disconnect the breather hose from the air cleaner.



4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1).
5. Disconnect the PCV valve hose from the intake manifold.

6. Seal off the intake manifold PCV valve hose port opening.



7. Seal off the open end of the PCV valve hose (Figure 2).
NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE.
8. Start the warmed engine and observe the vacuum gauge.
9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase.
10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required.
11. If an internal vacuum leak is present then perform the Repair Procedure.
PARTS REQUIRED:
For the 5.2L / 5.9L:
1 04897383AC Package, Intake Manifold Flange Gasket and Bolts

1 05017208AA Gasket, Intake Manifold Plenum Pan

15 06034583 Bolt, Intake Manifold Plenum Pan

1 53030541 Gasket, Throttle Body

2(AR) 04318001 Conditioner, Combustion Chamber

For the 3.9L:

1 04897382AC Package, Intake Manifold Flange Gasket and Bolts

1 05017207AA Gasket, Intake Manifold Plenum Pan

14 06034583 Bolt, Intake Manifold Plenum Pan

1 53030541 Gasket, Throttle Body

2(AR)04318001 Conditioner, Combustion Chamber
REPAIR PROCEDURE:
1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions.
NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER.
NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS.






3.9L Bolt Tightening Sequence and Torque Procedure:


3.9 Plenum Pan Bolt Torque Procedure


3.9 Intake Manifold Flange Bolt Torque Procedure






5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure:


5.2L / 5.9L Plenum Pan Bolt Torque Procedure


5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure
2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance.
3. Start the engine and allow it to warm to normal engine operating temperature.
4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions.
NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS.
NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET.
5. Verify proper engine oil level.
POLICY: Reimbursable within the provisions of the warranty.


Time Allowance
FAILURE CODE: P8- New Part
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Unread 09-02-2005, 11:51 AM   #34
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Engine - Spark Knock/Oil Consumption
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Unread 09-02-2005, 11:53 AM   #35
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Engine - Spark Knock/Oil Consumption
continued...
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Unread 09-02-2005, 11:53 AM   #36
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Engine - Spark Knock/Oil Consumption
continued - - -
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Unread 09-02-2005, 11:54 AM   #37
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TCM - MIL ON/DTC P1763 Set

NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS.
SUBJECT:
Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
**1996** - 1998 (ZJ) Grand Cherokee
NOTE :THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX).
SYMPTOM/CONDITION:
Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive.
The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998.
Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure.
NOTE :WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6000 Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE :THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER.
REPAIR PROCEDURE:
1. Log onto the MDS2 system.
2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN.
NOTE :ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION.
5. Select the FLASH tab on the MDS2.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button.
NOTE :IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process.
NOTE UE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED.
NOTE :THE FOLLOWING STEPS ARE REQUIRED BY LAW.


9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay.


10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-42-99 0.5 Hrs.
FAILURE CODE: FM - Flash Module
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Unread 09-02-2005, 05:50 PM   #38
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Air Bag System - ON-OFF Switch Availibility

NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT:
Airbag On-Off
Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE :THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization.


















PARTS REQUIRED:
NOTE :SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:


1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records.
NOTE :ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
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Unread 09-02-2005, 05:51 PM   #39
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Air Bag System - ON-OFF Switch Availibility continued
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Unread 09-02-2005, 05:52 PM   #40
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A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
SUBJECT:
Vehicle Bucking During Wide Open Throttle Acceleration
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1996 - 1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee (International Markets)
NOTE : THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION.
SYMPTOM/CONDITION:
Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift.
DIAGNOSIS:
Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin.
NOTE : ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS.
Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made.
If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure.
PARTS REQUIRED:
1 56041403AA Sensor, Governor Pressure
REPAIR PROCEDURE:
This bulletin involves installing a newly designed governor pressure sensor.


1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1).
2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-96-06-90 1.1 Hrs.
FAILURE CODE: P8 - New Part
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Unread 09-02-2005, 05:54 PM   #41
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Ignition System - Cross Fire/Ignition Wire Induction
NO: 18-48-98
GROUP: Vehicle Performance
DATE: Dec. 30, 1998
SUBJECT:
Ignition System
Cross Fire/Secondary
Ignition Wire Induction
MODELS:
1994 - 1999 (AN) Dakota
1994 - 1999 (BR/BE)Ram Truck
1998 - 1999 (DN) Durango
1995 - 1998 (ZG) Grand Cherokee (International Market)
1994 - 1998 (ZJ) Grand Cherokee
NOTE :THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE.
AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED).
SYMPTOM/CONDITION:
Some vehicles may exhibit one or more of the following:
Spark knock complaints when the vehicle is under load.
Various single cylinder misfire (1, 3, 7), especially 5 and/or 8.
Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph).
Perceived torque converter EMCC engagement/disengagement around 45 mph.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure.
NOTE :THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED.
PARTS REQUIRED:
3 56028186 Clip, Single Wire
2 06503441 Clip, Wire To Hose (5.2L & 5.9L)
1 04364375 Convolute, 10 ft Roll
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs.

08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.
FAILURE CODE: 9X - Routed Improperly
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Unread 09-02-2005, 05:57 PM   #42
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Ignition System - Cross Fire/Ignition Wire Induction

5.2L and 5.9L Engine Procedures



1. Coil Wire Routing (Figure 1 and 2)
A. Remove the coil wire from the distributor cap coil wire tower terminal.

B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover.

C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1).


NOTE :SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS.
D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end.
E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs).
F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.).
G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs).
H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2).
NOTE :THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD.
I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal.
J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine.


2. No.8 Cylinder Plug Wire Routing (Figure 3)
A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal.

B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover.

C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3).
D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components.

E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models).


NOTE :MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS.
F. Install the No.8 cylinder plug wire to its distributor cap terminal.







3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5)
A. Remove the No.4 cylinder plug wire from the distributor cap terminal.

B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5).



C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips.
NOTE :EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES.
D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead.

NOTE :MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE.


E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7).







4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9)
A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years.
B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9).

NOTE :MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE.


5. No. 5 Cylinder Plug Wire Routing (Figure 10)
A. Remove the No.5 cylinder plug wire from its distributor cap terminal.

B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover.

C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow.
D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose.

NOTE :MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS.
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Unread 09-02-2005, 05:58 PM   #43
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Ignition System - Cross Fire/Ignition Wire Induction

5.2L and 5.9L Engine Procedures
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Unread 09-02-2005, 06:02 PM   #44
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Ignition System - Cross Fire/Ignition Wire Induction

5.2L and 5.9L Engine Procedures
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Unread 09-02-2005, 06:03 PM   #45
Meerkat
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Posts: 4,930
Ignition System - Cross Fire/Ignition Wire Induction

5.2L and 5.9L Engine Procedures
continued - - -
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