SPEED CONTROL

PT CRUISER

INSTALLATION INSTRUCTIONS Read entire instructions thoroughly before starting. References to the service manual may be required for adjustments, fastener torques, and diagnosis.

TOOLS REQUIRED: • • • • •

Large flathead screwdriver • 10mm wrench • Phillips screwdriver • 13/16" socket 90° internal snap ring pliers • Pocket screwdriver • 7mm socket • 10mm socket Socket wrench • Steering wheel puller tool • Floor jack • 1/2" drill bit • Drill motor Utility knife • Wire routing tool • Electrical tape • Silicone sealant • Hooked pick tool Needle nose pliers • Torque wrench • 3/32" bit • Pin drill

Item Qty.

CONTENTS:

10

6 1

11 12 13 7

Description

1

1

Overlay Harness

2

10

Tie Straps

3

1

Bolt Plate

4

4

Hex Flange Nuts

5

1

Servo Mounting Bracket

6

1

Servo Assembly

7

1

Vacuum Harness

8

1

Vacuum Reservoir

9

2

Reservoir Mounting Screws

10

1

Clockspring

11

2

Back Shroud

12

1

Speed Control Switch

13

3

Switch Mounting Screws

14

1

Installation Instructions

9 2 8

4 14 5

3

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CAUTION !

Upper Column Shroud

Using a 10mm wrench, disconnect and isolate the negative battery (ground) cable before beginning any airbag system component removal procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for one minute before removing any airbag components.

Lower Column Shroud

1)

Center the steering wheel and make sure the front wheels are pointed straight ahead.

2)

Pull down and remove the knee blocker. Remove two push-in retainers and sound deadener pad from the lower I/P brace.

3)

Remove two phillips screws then disengage and remove the upper and lower steering column shrouds.

4)

Using a pair of 90° internal snap ring pliers or equivalent, pry open two retaining clips (one at a time) on the back of the steering wheel metal brace.

5)

Pull or press rearward on the airbag module while prying open the clips (one at a time). This will slightly release the locking pins.

6)

Continue to hold the clips open (one at a time) while gently prying the pins away from the clips using a pocket screwdriver so it can slide through the middle of the clip.

7)

Pull the airbag module rearward to expose the underside. Unplug the squib and horn feed.

8)

Remove bolt from steering column shaft with a 13/16" socket.

9)

Using the appropriate puller tool, remove the steering wheel.

Retaining Clip Locking Pin

Retaining Clip Locking Pin

NOTE: Pocket Screwdriver

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90° Snap Ring Pliers

Be sure to fully engage threads of the puller bolts as you are working with magnesium. 11/15/02

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10)

Pull back on red locking tab and disconnect the 7-way clockspring connector. Look for existing wire in cavity 6.

11)

Look for existing foam taped covered 4-way servo connector located on top of and at the back of the right frame rail next to the A/C lines.

Cavity 6

NOTE:

7-Way Clockspring Connector

If there is existing wiring present at these locations, it means that the vehicle has been pre-wired for speed control. Proceed to Step 29.

Clutch Master Cylinder Grommet

NOTE: If wiring is not present at these locations, the speed control overlay harness will have to be installed. Proceed with Step 12. Overlay Harness

Vehicles with automatic transmission: 12)

Drill a 1/2" hole through the unused clutch master cylinder bulkhead grommet from the driver's compartment outwards.

Vehicles with manual transmission: Main Wire Harness Grommet

12a) Open a 1/2" slit in the main wire harness bulkhead grommet from the driver’s compartment outwards. 13)

Using a wire routing tool, pull the overlay harness (Item 1) into the driver’s compartment just past “Y” in the harness.

14)

Important: Close opening in the grommet with silicone sealant to prevent noise and odor intrusion.

15)

Unlock and disconnect the 6-way brake light switch connector. Carefully remove the green locking wedge.

16)

Insert blue/red and yellow/red overlay harness wires as shown. Re-install locking wedge and plug in/lock the connector.

Cavity 3 Cavity 4

Blue/Red

6-Way Brake Light Switch Connector

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Yellow/Red

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17)

Carefully remove red locking wedge from the 7-way clockspring connector.

18)

Insert red/lt. green overlay harness wire as shown. Re-install locking wedge and connector.

19)

Using a few of the supplied tie straps (Item 2), secure overlay harness to steering column harness and I/P harness.

20)

Open the hood and locate engine control module on the upper left (driver’s side) area of bulkhead.

21)

Un-plug the C3 connector (black cover/white insulator) and remove wire cover.

22)

Route four terminaled wires from wiring harness overlay to the engine control module.

Cavity 6

7-Way Clockspring Connector Red/Lt. Green

C3 Engine Controller Connector

23)

Carefully pry out two side tabs to remove the terminal cover from connector.

24)

Using a 3/32” bit and pin drill, open up holes through red seal at the four locations shown below.

25)

Insert overlay harness wires as shown. Be sure that terminals go in fully and lock into place.

26)

Apply silicone sealant to the four connector cavities that have been drilled.

27)

Re-install terminal cover and wire cover to the connector. Plug and lock connector back into the engine control module.

Yellow/Red Cavity 7

Lt. Green/Red Cavity 5

Tan/Red Cavity 12 Red/Lt. Green Cavity 34 C3 Engine Controller Connector (Pin Side)

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Servo Connector

28)

Attach ground eyelet to existing ground on the right motor mount using a 10mm socket.

29)

Using the supplied bolt plate (Item 3) and hex flange nuts (Item 4), install servo mounting bracket (Item 5) as shown with a 10mm socket.

30)

Route cable from the servo assembly (Item 6) through opening in existing accelerator cable guide.

31)

Plug and lock 4-way electrical connector into the servo.

32)

Using the two remaining hex flange nuts, install servo to the mounting bracket.

33)

Disconnect and remove accelerator cable from the throttle cam.

34)

Attach servo cable as shown, then re-install the accelerator cable.

Servo Assembly Ground Eyelet

Cable Guide

Bolt Plate

Servo Cable

CAUTION ! Throttle Cam

Operate throttle cam by hand to make sure the throttle opens smoothly with no binding and that it returns to idle.

Accelerator Cable

Vacuum Harness

In-Line Clip

35)

Route reservoir end of vacuum harness (Item 7) downward through opening in the right inner fender.

36)

Attach in-line clip to hole in right engine mount flange.

37)

Attach in-line vacuum fitting to port on the servo.

38)

Remove and discard cap from fitting on the engine vacuum harness, then attach check valve fitting.

Vacuum Fitting

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Vacuum Reservoir Bolts (2)

Right Frame Rail

39)

Ensure that steering column is unlocked, then raise and secure the vehicle on a lift.

40)

Position the right front tire outwards. Using a 7mm socket, remove two forward-most screws and one push-in fastener from the wheelhouse splash guard.

41)

Carefully bend the horn brackets downward to access mounting holes for the vacuum reservoir (Item 8).

42)

Using two supplied bolts (Item 9), install vacuum reservoir with a 10mm socket.

43)

Attach the previously routed vacuum harness fitting to port on reservoir.

44)

Bend the horn brackets back to their proper position.

45)

Re-install four fasteners to the wheelhouse splash guard.

46)

Position front wheels straight ahead, then lower the vehicle.

47)

Remove and discard the existing clockspring. Install supplied clockspring (Item 10), then pull out the T-handle.

48)

Remove and discard back shroud from the steering wheel. Install supplied back shroud (Item 11) using three existing phillips screws.

49)

Install speed control switch (Item 12) using three supplied screws (Item 13) as shown.

Vacuum Harness Fitting

Back Shroud

NOTE: Speed Control Switch

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The 2003 switch has new resistance values and will not interchange with 2002 vehicles.

11/15/02

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2-Way Clockspring Connector

Speed Control Switch

50)

Re-install steering wheel assembly to column. Tighten mounting bolt to 40 ± 5 ft.-lbs.

51)

Plug 3-way clockspring connector into the speed control switch.

52)

Connect and re-install the driver’s airbag module. Be sure the two pins fully engage the retaining clips.

53)

Re-install I/P sound deadener pad, knee blocker, upper/lower steering column shrouds, and engine manifold cover.

54)

With the ignition set to the ON position, reconnect negative battery cable. Re-install air cleaner assembly.

55)

Test drive your work!

56)

Refer customer to the owner’s manual for speed control operation procedures.

TROUBLESHOOTING NOTE: Refer to the service manual, diagnostic repair manual, or the MDS system. This system is identical to the factory installed system.

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Note: “Cruise” light in I/P activated by the engine controller via bus. Brake switch and speed sensor input are independent of speed Control and must function for speed control to work. The Powertrain Control Module (PCM) senses Speed Control Switch input by sensing different voltage levels thru the different resistors in the switch. The PCM then will send 12V out on pin 7, thru the normally closed brake switch, to the Speed Control Servo. Throttle apply and release are controlled thru pin 5 and pin 12. When the brake is applied, the voltage supply is removed from the servo. The servo releases vacuum and returns the throttle to idle. This system is identical to the factory system. Use the DRB III and service manual to troubleshoot the system. K 6 8 5 8 7 3 9

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