sensor DODGE RAM 1999 Service Repair Manual

Crankcase Ventilation (PCV) system, but does not use a vacuum
controlled valve. See POSITIVE CRANKCASE VENTILATION (PCV).
EVAPORATIVE (EVAP) EMISSIONS SYSTEM
This system stores fuel vapors from fuel tank, preventing
vapors from reaching the atmosphere. As fuel evaporates inside fuel
tank, vapors are routed through vent hoses to charcoal canister where
they are stored until engine is started.
Evaporative Canister Purge Control Solenoid (EVAP-CPCS)
Charcoal canister purging is controlled by PCM through an
EVAP-CPCS. During engine warm-up and for a short period after hot
restarts, PCM energizes EVAP-CPCS, interrupting engine vacuum signal
to charcoal canister.
After engine reaches a predetermined operating temperature
and PCM internal timer has expired, PCM will de-energize EVAP-CPCS,
allowing engine vacuum to purge charcoal canister. EVAP-CPCS will also
be de-energized during certain idle conditions so PCM can update fuel
delivery calibration.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV system uses a vacuum operated valve. A closed engine
crankcase breather/filter, with a hose connecting it to air filter
housing, provides source of air for system. Crankcase blow-by gases
are removed from crankcase through PCV valve with manifold vacuum.
These gases are introduced into incoming air/fuel mixture and become
part of the calibrated mixture.
A non-vacuum operated Crankcase Ventilation (CCV) system is
used on some engines, see CRANKCASE VENTILATION (CCV) SYSTEM.
SELF-DIAGNOSTIC SYSTEM
The PCM monitors several different circuits of engine control
system. If a problem is sensed with a monitored circuit, PCM will
store a Diagnostic Trouble Code (FTC) to aid technician in diagnosis
of system. The Malfunction Indicator Light (MIL), or a scan tool can
be used to read DTCs. For additional information, see SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.
MALFUNCTION INDICATOR LIGHT
Malfunction Indicator Light (MIL) comes on and remains on for\
3 seconds as a bulb test each time ignition switch is turned to ON
position. If PCM receives an incorrect signal or receives no signal
from battery voltage input, charging system, ECT sensor, MAP sensor or
TP sensor, MIL will come on. MIL will also come on if certain
emission-related faults exist. This warns driver that PCM is in limp-
in mode and immediate repairs are necessary. See LIMP-IN MODE under
MISCELLANEOUS CONTROLS. MIL can also be used to display Diagnostic
Trouble Codes (DTCs). For additional information, see SELF-DIAGNOSTICS\
- JEEP, TRUCKS & RWD VANS article.
SERIAL COMMUNICATIONS INTERFACE (SCI)
SCI circuit is used by PCM to send data to and receive data
and sensor activation signals from scan tool. Scan tool uses signals
sent on SCI to display fault messages or Diagnostic Trouble Codes
(DTCs), sensor voltages and device states (On/Off). Scan tool uses S\
CI
to send solenoid and switch activation commands to PCM so that devices
and circuits can be tested. SCI is also used to write SRI mileage to

PCM.
MISCELLANEOUS CONTROLS
NOTE: Although not strictly considered part of engine performance
system, some controlled devices can adversely affect
driveability if they malfunction.
A/C CLUTCH RELAY
A/C clutch relay is controlled by PCM. When A/C or Defrost
mode is selected and PCM receives A/C request signal from evaporator
switch, PCM will cycle clutch on and off through A/C clutch relay.
When this relay is energized during engine operation, PCM will
determine correct engine idle speed through IAC motor.
When PCM senses low idle speed or wide open throttle through
TP sensor, PCM will de-energize A/C clutch relay, preventing A/C
operation.
AUTO SHUTDOWN (ASD) RELAY & FUEL PUMP RELAY
ASD relay and electric fuel pump relay are energized when
ignition is on. These relays are controlled through PCM by switching a
common ground circuit on and off. Following components are controlled
by ASD and fuel pump relays:
* Electric Fuel Pump
* Fuel Injectors
* Generator Field Winding
* Ignition Coil(s)
* HO2S Heating Element
When ignition switch is turned to RUN position, PCM energizes
ASD relay and electric fuel pump relay which powers these components.
If PCM does not receive a CMP and CKP sensor signal within one second
of engine cranking (start-up), PCM will turn ground circuit off and
de-energize ASD relay.
GENERATOR
Powertrain Control Module (PCM) regulates charging system
voltage.
LIMP-IN MODE
Limp-in mode is the attempt by PCM to compensate for failure
of certain components by substituting information from other sources
so that vehicle can still be operated. If PCM senses incorrect data or
no data at all from MAP sensor, TP sensor, ECT sensor or battery
voltage, system is placed into limp-in mode and Malfunction Indicator
Light (MIL) on instrument panel comes on.
If faulty sensor comes back on line, PCM will resume closed
loop operation. On some vehicles, MIL will remain on until ignition is
shut off and vehicle is restarted. To prevent damage to catalytic
converter, vehicle should NOT be driven for extended periods in limp-
in mode.
RADIATOR FAN RELAY
Electric cooling fan is used only on Dakota. Using
information supplied by A/C signal (if equipped), ECT sensor, and VSS,\

TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N

1999 D odge P ic ku p R 1500
1998-99 TRANSMISSION SERVICING
CHRY - Trans Removal & Installation - Trucks & RWD Vans
Dakota, Ram Pickup, Ram Van/Wagon
WARNING: 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. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
MANUAL TRANSMISSION
NOTE: For manual transmission replacement procedures, see
appropriate article in CLUTCHES.
AUTOMATIC TRANSMISSION
DAKOTA & DURANGO
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Disconnect and remove necessary skid plates and exhaust
components for transmission removal. Remove engine-to-transmission
struts (if equipped). These struts are located between front of
transmission and engine.
2) Ensure area around transmission oil cooler lines fitting
are clean. Disengage retainer on quick-disconnect cooler line fitting.
Pull cooler line from transmission oil cooler.
CAUTION: Crankshaft position sensor must be removed from transmission
housing before removing transmission to prevent damage to
crankshaft position sensor.
3) Remove starter. Disconnect electrical connector for
crankshaft position sensor. On 2.5L, crankshaft position sensor is
mounted on driver's side of transmission housing. See Fig. 1. On 3.9L,
5.2L and 5.9L, crankshaft position sensor is mounted on passenger's
side of transmission housing. See Fig. 2.
4) Remove crankshaft position sensor bolts or nuts. Remove
crankshaft position sensor from transmission housing. Remove dipstick,
dipstick tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft flanges for
installation reference. Remove drive shaft from transmission. On 4WD
models, disconnect drive shaft from transfer case. Disconnect shift
rod for transfer case from transfer case shift lever.
7) On all models, disconnect necessary control cables, wiring
harnesses, and shift linkage or cable from transmission. Support rear
of engine with jack stand. Using transmission jack, slightly raise
transmission to release pressure from rear mount and rear crossmember.
8) Remove bolts securing rear support and rear mount to
transmission and rear crossmember. Raise transmission slightly. Slide
exhaust hanger arm from bracket on rear support. Remove rear support
and rear mount.
9) Remove rear crossmember located below the transmission. On
4WD models, disconnect electrical connectors from transfer case. On

all models, remove transmission-to-cylinder block bolts. Slide
transmission rearward from dowels on cylinder block.
10) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Fig. 1: Locating Crankshaft Position Sensor (2.5L)
Courtesy of Chrysler Corp.
Fig. 2: Locating Crankshaft Position Sensor (3.9L, 5.2L & 5.9L
Gasoline)

Courtesy of Chrysler Corp.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift cable or
linkage, throttle valve cable and transfer case shift linkage if
necessary. See AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM PICKUP
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Disconnect and remove necessary skid plates and exhaust
components for transmission removal. Remove engine-to-transmission
struts (if equipped). These struts are located between front of
transmission and engine.
2) Ensure area around transmission oil cooler lines fitting
are clean. Disengage retainer on quick-disconnect cooler line fitting.
Pull cooler line from transmission oil cooler. Remove starter.
CAUTION: On 3.9L, 5.2L and 5.9L gasoline models, crankshaft position
sensor must be removed from transmission housing before
removing transmission to prevent damage to crankshaft
position sensor.
3) On 3.9L, 5.2L and 5.9L gasoline models, disconnect
electrical connector for crankshaft position sensor. Crankshaft
position sensor is mounted on passenger's side of transmission
housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft flanges for
installation reference. Remove drive shaft from transmission. On 4WD
models, disconnect drive shaft from transfer case. Disconnect shift
rod for transfer case from transfer case shift lever.
7) On all models, disconnect necessary control cables, wiring
harnesses, and shift linkage from transmission. Support rear of engine
with jack stand. Using transmission jack, slightly raise transmission
to release pressure from rear mount and rear crossmember.
8) Remove bolts securing rear support and rear mount to
transmission and rear crossmember. Raise transmission slightly. Slide
exhaust hanger arm from bracket on rear support. Remove rear support

and rear mount.
9) Remove rear crossmember located below the transmission. On
4WD models, disconnect electrical connectors from transfer case. On
all models, remove transmission-to-cylinder block bolts. Slide
transmission rearward from dowels on cylinder block.
10) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, consult parts
department to ensure proper length bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift linkage,
throttle valve cable and transfer case shift linkage if necessary. See
AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM VAN/WAGON
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Remove engine-to-transmission struts. These struts are
located between front of transmission and engine.
2) Remove starter and oil cooler line bracket. Ensure area
around transmission oil cooler lines fitting are clean. Disengage
retainer on quick-disconnect cooler line fitting. Pull cooler line
from transmission oil cooler.
CAUTION: Crankshaft position sensor must be removed from transmission
housing before removing transmission to prevent damage to
crankshaft position sensor.
3) Disconnect electrical connector for crankshaft position
sensor. Crankshaft position sensor is mounted on passenger's side of
transmission housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft yokes for installation
reference. Remove drive shaft from transmission. Disconnect necessary
wiring harnesses and control cables from transmission. Support rear of
engine with hoist. Using transmission jack, slightly raise
transmission to release pressure from rear mount and crossmember.
7) Remove rear mount-to-rear crossmember bolts. Remove bolts
and rear crossmember located below the transmission. Remove engine oil

filter (if necessary). Remove transmission-to-cylinder block bolts.
Slide transmission rearward from dowels on cylinder block.
8) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Ensure proper length torque converter bolts are used in
accordance with torque converter diameter and number of torque
converter bolt lugs on front of torque converter. See TORQUE CONVERTER
BOLT APPLICATION table.
TORQUE CONVERTER BOLT APPLICATION









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Torque Converter Diameter Bolt Length
In. (mm)\
9.50" (241.0 mm) 3-Bolt Lug Torque Converter ............ .46 (11.7\
)
9.50" (241.0 mm) 4-Bolt Lug Torque Converter ............ .52 (13.2\
)
10.00" (254.0 mm) 4-Bolt Lug Torque Converter ........... .52 (13.2\
)
10.75" (273.0 mm) 4-Bolt Lug Torque Converter ........... .44 (11.2\
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3) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft yokes are aligned. Adjust shift cable and
throttle valve cable if necessary. See AUTOMATIC TRANSMISSION - TRUCKS
& RWD VANS article.
4) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (DAKOTA & DURANGO)








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Application Ft. Lbs.
Crankshaft Position Sensor Bolt/Nut
2.5L ..................................................... 14 (19)\
3.9L, 5.2L & 5.9L ............................................ ( 1)
Front Drive Shaft Universal Joint Strap-To-Transfer
Case Flange Bolt ......................................... 20 (27)\
Rear Crossmember Bolt ...................................... 50 (68)\
Rear Drive Shaft Center Bearing-To-Crossmember Bolt ........ 50 (68)\
Rear Drive Shaft Universal Joint Strap-To-Rear
Axle Flange Bolt ......................................... 14 (19)\
Starter Bolt
2.5L ..................................................... 33 (45)\

3.9L, 5.2L & 5.9L ........................................ 50 (68)\
Torque Converter Bolt ...................................... 23 (31)\
Transmission-To-Cylinder Block Bolt ............................ (2)
( 1) - Tighten bolts to 70 INCH lbs. (7.9 N.m).
( 2) - Information is not available from manufacturer.









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TORQUE SPECIFICATIONS (RAM VAN/WAGON)








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Application Ft. Lbs.
Drive Shaft Universal Joint Strap-To-Rear
Axle Flange Bolt ......................................... 14 (19)\
Engine-To-Transmission Strut Bolt
Bolt At Cylinder Block ............................. 20-40 (27-54)\
Bolt At Transmission ............................... 35-65 (47-88)\
Rear Crossmember Bolt ...................................... 50 (68)\
Starter Bolt/Nut ........................................... 50 (68)\
Torque Converter Bolt ( 1)
9.50" (241.0 mm) 3-Bolt Lug Torque Converter ............. 40 (54\
)
9.50" (241.0 mm) 4-Bolt Lug Torque Converter ............. 55 (75\
)
10.00" (254.0 mm) 4-Bolt Lug Torque Converter ............ 55 (75\
)
10.75" (273.0 mm) 4-Bolt Lug Torque Converter ............ 23 (31\
)
Transmission-To-Cylinder Block Bolt
Large Bolt ......................................... 35-65 (47-88)\
Small Bolt ......................................... 20-40 (27-54)\
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ........................... 70 (7.9)\
( 1) - Bolt torque is determined by diameter of torque converter and
number of torque converter bolt lugs on front of torque
converter.









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TORQUE SPECIFICATIONS (RAM PICKUP)








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Application Ft. Lbs.
Front Drive Shaft-To-Front Axle Flange Bolt ................ 14 (19)\
Front Drive Shaft Flange-To-Transfer Case Flange Bolt ...... 65 (88)\
Rear Crossmember Bolt ...................................... 50 (68)\
Rear Drive Shaft Center Bearing-To-Crossmember Bolt ........ 50 (68)\
Rear Drive Shaft Universal Joint Strap-To-Rear
Axle Flange Bolt
Dana Axle ............................................... 22 (30)\
9 1/4" Axle ............................................. 14 (19)\
Starter Bolt
5.9L Diesel .............................................. 32 (43)\
All Others ............................................... 50 (68)\
Torque Converter Bolt ( 1)
10.75" (273.0 mm) Torque Converter ....................... 23 (31\
)
12.20" (273.0 mm) Torque Converter ....................... 35 (47\
)
Transmission-To-Cylinder Block Bolt ............................ ( 2)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt
3.9L, 5.2L & 5.9L Gasoline .............................. 70 (7.9)\
( 1) - Bolt torque is determined by diameter of torque converter.

severe weakness that we will look at later). If an injector has a
fault where it occasionally skips a pulse, the meter registers it and
the reading changes accordingly.
Let's go back to figuring out dwell/duty readings by using
injector on-time specification. This is not generally practical, but
we will cover it for completeness. You NEED to know three things:
* Injector mS on-time specification.
* Engine RPM when specification is valid.
* How many times the injectors fire per crankshaft revolution.
The first two are self-explanatory. The last one may require
some research into whether it is a bank-fire type that injects every
360
of crankshaft rotation, a bank-fire that injects every 720, or
an SFI that injects every 720. Many manufacturers do not release this
data so you may have to figure it out yourself with a frequency meter.
Here are the four complete steps to convert millisecond on-
time:
1) Determine the injector pulse width and RPM it was obtained
at. Let's say the specification is for one millisecond of on-time at a
hot idle of 600 RPM.
2) Determine injector firing method for the complete 4 stroke
cycle. Let's say this is a 360
bank-fired, meaning an injector fires
each and every crankshaft revolution.
3) Determine how many times the injector will fire at the
specified engine speed (600 RPM) in a fixed time period. We will use
100 milliseconds because it is easy to use.
Six hundred crankshaft Revolutions Per Minute (RPM) divided
by 60 seconds equals 10 revolutions per second.
Multiplying 10 times .100 yields one; the crankshaft turns
one time in 100 milliseconds. With exactly one crankshaft rotation in
100 milliseconds, we know that the injector fires exactly one time.
4) Determine the ratio of injector on-time vs. off-time in
the fixed time period, then figure duty cycle and/or dwell. The
injector fires one time for a total of one millisecond in any given
100 millisecond period.
One hundred minus one equals 99. We have a 99% duty cycle. If
we wanted to know the dwell (on 6 cylinder scale), multiple 99% times
.6; this equals 59.4
dwell.
Weaknesses of Dwell/Duty Meter
The weaknesses are significant. First, there is no one-to-one
correspondence to actual mS on-time. No manufacturer releases
dwell/duty data, and it is time-consuming to convert the mS on-time
readings. Besides, there can be a large degree of error because the
conversion forces you to assume that the injector(s) are always firing\
at the same rate for the same period of time. This can be a dangerous
assumption.
Second, all level of detail is lost in the averaging process.
This is the primary weakness. You cannot see the details you need to
make a confident diagnosis.
Here is one example. Imagine a vehicle that has a faulty
injector driver that occasionally skips an injector pulse. Every
skipped pulse means that that cylinder does not fire, thus unburned O2
gets pushed into the exhaust and passes the O2 sensor. The O2 sensor
indicates lean, so the computer fattens up the mixture to compensate
for the supposed "lean" condition.
A connected dwell/duty meter would see the fattened pulse
width but would also see the skipped pulses. It would tally both and
likely come back with a reading that indicated the "pulse width" was
within specification because the rich mixture and missing pulses
offset each other.
This situation is not a far-fetched scenario. Some early GM

bolster. Remove CTM from bracket on inboard side of instrument panel
steering column opening. Disconnect harness connectors. To install,
reverse removal procedure.
INTERMITTENT WIPER RELAY
Removal & Installation
Intermittent wiper relay is located in Power Distribution
Center (PDC) in engine compartment. Remove cover and remove relay. To
install, reverse removal procedures
WIPER ARMS
Removal & Installation
Open hood. Lift wiper and slide latch to hold wiper off of
windshield. With a rocking motion, remove wiper arm. To install,
ensure wiper motor is in park position. Slide wiper arm on shaft.
Align wiper arms. See WIPER BLADES under ADJUSTMENTS.
WIPER MOTOR
NOTE: Wiper linkage and motor module is replaced as a unit.
Removal & Installation
1) Disconnect negative battery cable. Remove wiper arms. See
WIPER ARMS. Remove weatherstrip along front edge of cowl. Release
plastic anchor screws. Lift cowl grille from vehicle. Remove washer
hose from "Y" fitting. Set grille aside.
2) Remove wiper linkage mounting bolts. Turn linkage over and
disconnect harness connector from wiper motor. Remove wiper linkage
and motor module. To install, reverse removal procedure. Align wiper
arms. See WIPER BLADES under ADJUSTMENTS.
WIPER/WASHER SWITCH
NOTE: Wiper/washer switch is part of multifunction steering column
switch. If wiper/washer switch fails, entire multifunction
switch must be replaced.
Removal & Installation
1) Disconnect negative battery cable. Remove tilt lever (if
equipped). Remove steering column upper and lower covers to access
switch connector. Remove switch connector. Remove multifunction switch
tamperproof screws.
2) Gently pull switch away from column and loosen connector
screw (screw remains in connector). Remove switch. To install, reverse\
removal procedure. Tighten screws and nuts to specification. See
TORQUE SPECIFICATIONS. Ensure switch is functioning properly.
WASHER RESERVOIR
Removal & Installation
Disconnect negative battery cable. Drain cooling system.
Disconnect upper radiator hose from radiator. Disconnect harness
connectors from washer pump and washer fluid level sensor. Remove
washer supply hose from washer pump and drain washer fluid. While
pulling reservoir away from fan shroud, lift reservoir upward to
disengage mounting tabs from fan shroud. Remove washer reservoir. To
install, reverse removal procedure.
WASHER MOTOR
Removal & Installation