Home ReviewsRefund
Home/Jeep/Compass/Jeep Compass I (2006-2010)/Repair manual/Frames, Subframes & Crossmembers/Frames & Bumpers: Other
Contents Wiring diagrams Section: Frames, Subframes & Crossmembers All sections

Frames & Bumpers: Other Jeep Compass I

Frames, Subframes & Crossmembers 42 illustrations ~1701 words

Compass

  1. Install the fascia (4) onto the fasteners (5 and 6).
  2. Install the fasteners (1 and 2).
  3. Install the push pin fasteners (3).

Patriot

  1. Position the fascia (4) onto the front of the vehicle and install the push pin fasteners (1 and 2).
  2. Install the screws (3).
  3. Install the screws (5) from inside the wheel wells.
  4. Install the push pin fasteners (6) from inside the wheel wells.

Compass and Patriot

  1. Install the fasteners (4) and connect the electrical connectors (2 and 3).
  2. Install the fascia (2) to splash shield screws (1).

Scheme 13

Scheme 13: FASCIA-REAR
Scheme 13: FASCIA-REAR

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Remove the lower fasteners (3).
  2. Remove the fascia to splash shield fasteners (1).
  3. Loosen the fasteners (1 and 5)
  4. Remove the push pin fasteners (3) and remove the fascia (2).

FASCIA-REAR

  1. Install the fascia and line up the slots (4) with the screws (1 and 5) and seat fully.
  2. Tighten the screws (1 and 5).
  3. Install the push pin fasteners (3).
  4. Install the lower fasteners (3).
  5. Install the fascia to splash shield screws (1).

Scheme 16

Scheme 16: REMOVAL
Scheme 16: REMOVAL

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. Remove fascia, see «REMOVAL»(ref-304332-S29619515382008110700000) .
  2. Disconnect wire connector (2) and remove horn (1). Refer to «REMOVAL»(ref-304366-S24909762802008110700000) .
  3. Remove wire harness push pin fastener (1).
  4. Remove wire harness (1) from bottom of bumper reinforcement.
  5. Remove 8 fasteners (2) from bumper reinforcement (1).

Scheme 20

Scheme 20: INSTALLATION
Scheme 20: INSTALLATION

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Install fasteners (2) and tighten to 23 N.m (17 ft. lbs.).
  2. Connect wire connector (2) and install horn (1). Refer to «INSTALLATION»(ref-304366-S27258229822008110700000) .
  3. Install wiring harness push pin.
  4. Install wire connector (1) to bumper reinforcement.
  5. Install front fascia. See «INSTALLATION»(ref-304332-S15007650492008110700000) .

Scheme 24

Scheme 24: REMOVAL
Scheme 24: REMOVAL
  1. Remove rear fascia, see «REMOVAL»(ref-304332-S08996651102008110700000) .
  2. Remove seven bumper reinforcement nuts (1).
  3. Remove bumper reinforcement (2).

Scheme 25

Scheme 25: INSTALLATION
Scheme 25: INSTALLATION
  1. Place bumper reinforcement (2) up to frame locations.
  2. Install seven nuts (1) and tighten to 23 N.m (17 ft. lbs.).
  3. Install fascia, see «INSTALLATION»(ref-304332-S38892573972008110700000) .

WARNING - FRAME REPAIR

WARNINGBefore performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the Occupant Restraint Controller (ORC). Failure to take the proper precautions could result in accidental airbag deployment and other possible damage to the supplemental restraint system circuits and components. Use eye protection when grinding or welding metal, serious eye injury can result. Before proceeding with frame repair involving grinding or welding, verify that vehicle fuel system is not leaking or in contact with repair area, personal injury can result. Do not allow open flame or heat and metal spatter from arc welding, to contact plastic body panels. Fire or explosion can result. When welded frame components are replaced, ensure complete penetration weld is achieved during installation. If not, dangerous operating conditions can result. Stand clear of cables or chains on pulling equipment during frame straightening operations, personal injury can result. Do not venture under a hoisted vehicle that is not supported on safety stands, personal injury can result. No heat may be used if frame straightening is required. The use of heat is acceptable in those situations where the part being heated will be replaced. Failure to follow these instructions may result in personal injury.
CAUTIONDo not reuse damaged fasteners, quality of repair would be suspect. Failure to use only production fasteners or fasteners of equivalent hardness can result in loosening or failure. Do not drill any holes in the frame that are not specifically outlined in this or other, DaimlerChrysler procedure as frame rail failure can result.

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.

DESCRIPTIONFIGURE
COMPASS AND PATRIOT
FRAME DIMENSIONS - PLAN VIEW(Scheme 26).
FRAME DIMENSIONS - SIDE VIEW(Scheme 27).

INDEX

Scheme 26

Scheme 26: COMPASS AND PATRIOT
Scheme 26: COMPASS AND PATRIOT

Scheme 27

Scheme 27
Scheme 27

WELDING

CAUTIONAll welds should conform to DaimlerChrysler vehicle engineering process standard "PS 9472".
WELDING PROCESS*FLUX CORED ARCGAS METAL (MIG) ARCSHIELDED METAL ARC (STICK)
Material Thickness1.80 mm1.80 mm1.80 mm1.80 mm
Electrode TypeLincoln Electric Co. Product No. NP-211 MPLincoln Electric Co. Product No. NP-211 MP (Do Not Substitute)AWS ER70S-3 (Do Not Substitute)AWS E 7018
Electrodes Size Inches.035 Tubular.045 Tubular.035 Solid3/32
Polarity3/8"3/8" - 1/2"1/2" - 5/8"N/A
Shielding GasElectrode "-" Work Piece "+"Electrode "-" Work Piece "+"Electrode "+" Work Piece "-"Electrode "+" Work Piece "-"
Gas Flow RateN/AN/A75% Ar 25 - 35 CFHN/A
Wire Feed Speed (inches per minute)90 - 110 Vertical Down 60 - 70 Flat & Horizontal110 - 130 Vertical Down 70 - 90 Flat & Overhead245 - 250 Vertical Down 210 - 225 Flat & OverheadN/A
Approximate Amperage
Vertical110 - 120160 - 17017585 (3/32 Dia.)
Flat & Overhead50 - 60120 - 14015590 (3/32 Dia.)
Voltage15 - 1615 - 1819 - 20
Direction of Welding
VerticalVertical Down Hill (only)Vertical Down Hill (only)Vertical Down Hill (only)Vertical Up Hill (only)
Flat & OverheadFlat - Push or DragFlat - Push or DragFlat - Push or DragFlat - Drag

Welding Parameters

*First choice - Flux Cored Arc Welding Process: Butt joints - Vertical position welds - maintain end of electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into sleeve. This technique works for Gas Metal Arc (MIG) as well.

Note. If MIG welding process is selected the galvannealed coating must be removed from both sides of the material adjacent to the weld joint.

Scheme 28

Scheme 28: CROSSMEMBER-FRONT FORE/AFT
Scheme 28: CROSSMEMBER-FRONT FORE/AFT

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Raise and support the vehicle, refer to «STANDARD PROCEDURE»(ref-304322-S16806387812008110700000) .
  2. Remove the four wheel well screws.
  3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan.
  4. Remove the crossmember bolts (1, 2 and 3).
  5. Remove the engine roll mount (3) through bolt (2) and remove the fore/aft crossmember (4).

CROSSMEMBER-FRONT FORE/AFT

  1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2).
  2. Install the bolts (1, 2 and 3), and tighten using the following sequence: Tighten the bolt (1) to 78 N.m (58 ft. lbs.). Tighten the bolt (2) to 78 N.m (58 ft. lbs.). Tighten the bolt (3) to 129 N.m (95 ft. lbs.).
  3. Tighten the bolt (2) to 65 N.m (48 ft. lbs.).
  4. If equipped, install the belly pan.
  5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan.

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40
  1. Raise and support the vehicle, refer to «STANDARD PROCEDURE»(ref-304322-S16806387812008110700000) .
  2. Remove the four wheel well screws.
  3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan.
  4. Remove the rear roll mount (4) through bolt (2).
  5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount.
  6. Remove the for/aft crossmember (4). See «REMOVAL»(ref-304332-S35637950202008110700000) .
  7. Remove the front wheels (1), refer to «REMOVAL»(ref-304327-S20350210452008110700000) .
  8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5).
  9. Remove the bolt attaching the pressure line routing bracket to the steering gear.
  10. Remove the bolt attaching the return line to the crossmember.
  11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle.
  12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle.
  13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent.
  14. Support the crossmember with a suitable lifting device.
  15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle.
  16. Remove the lower control arm (3) front pivot bolts (2).
  17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1).

CROSSMEMBER-FRONT SUSPENSION

  1. Install the lower control arms and install the rear pivot bolts (3).
  2. Install the front pivot bolts (2).
  3. Support the crossmember on a suitable lifting device.
  4. Raise the crossmember into position onto the vehicle.
  5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal.
  6. Tighten the bolts to 150 N.m (111 ft. lbs.).
  7. Position the steering gear back into place and install the bolts (1).
  8. Tighten the bolts to 70 N.m (52 ft. lbs.).
  9. Position the stabilizer bar (2) back into place and install the bushing bolts (1).
  10. Tighten the bolts to 61 N.m (45 ft. lbs.).
  11. Position the power steering lines back into place and install the support bracket (2) bolts (1).
  12. Tighten the bolts to 8 N.m (70 ft. lbs.).
  13. Connect the lower ball joint stud (6) to the knuckle (3).
  14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 N.m (60 ft. lbs.).
  15. Install the fore/aft crossmember (4), see «INSTALLATION»(ref-304332-S01467764682008110700000) .
  16. Install the front wheels (1), refer to «INSTALLATION»(ref-304327-S25080286652008110700000) .
  17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 N.m (91 ft. lbs.)
  18. Perform wheel alignment as necessary. Refer to «STANDARD PROCEDURE»(ref-304325-S12670711652008110700000) .
  19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember.
  20. Tighten the bolts (3) to 153 N.m (112 ft. lbs.).
  21. Install the through bolt (2) and tighten to 65 N.m (48 ft. lbs.).
  22. If equipped, install the belly pan.
  23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan.

Scheme 41

Scheme 41: CROSSMEMBER-REAR SUSPENSION
Scheme 41: CROSSMEMBER-REAR SUSPENSION

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54
  1. Remove the park brake shoes, refer to «REMOVAL»(ref-304326-S28093361232008110700000) .
  2. Park brake cable from lever.
  3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3).
  4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3).
  5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm.
  6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember, refer to «REMOVAL»(ref-304337-S02411211632008110700000) .
  7. If equipped, remove the rear drive module, refer to «REMOVAL»(ref-304331-S05303513082008110700000) .
  8. Remove the cotter pins (2), the nuts (3) and the washers (4).
  9. Remove both half shafts.
  10. Remove the lower strut bolts.
  11. Remove the trailing link bushing bolts.
  12. Support the rear cradle with a suitable lifting device.
  13. Remove the rear cradle bolts and lower the cradle assembly from vehicle.
  14. Remove the lower stabilizer link nuts (2).
  15. Remove the lower link bolts (5 and 6) at the cradle.
  16. Remove the upper link bolts (2) at the cradle.
  17. Remove the toe link cam bolts (1) at the cradle.
  18. Remove the suspension knuckle assemblies.
  19. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle.

CROSSMEMBER-REAR SUSPENSION

  1. Install the stabilizer bar and install the bushings and bolts (1).
  2. Tighten the bolts to 61 N.m (45 ft. lbs.).
  3. Position the suspension knuckle assemblies back into position onto the crossmember.
  4. Install the toe link cam bolts (1) at the cradle.
  5. Tighten the bolts to 35 N.m (26 ft. lbs.).
  6. Install the upper link bolts (2) at the cradle.
  7. Tighten the bolts to 90 N.m (70 ft. lbs.).
  8. Install the lower link bolts (5 and 6) at the cradle.
  9. Tighten the bolts to 90 N.m (70 ft. lbs.).
  10. Install the stabilizer link nuts (2).
  11. Tighten the nuts to 58 N.m (43 ft. lbs.).
  12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle.
  13. Install the cradle bolts (2 and 3): Tighten the front bolts (2) first to 110 N.m (81 ft. lbs.). Tighten the rear bolts (3) next to 110 N.m (81 ft. lbs.).
  14. Install the trailing link (1) bushing bolts (2 and 3): Tighten the inboard bolts (3) first to 110 N.m (81 ft. lbs.). Tighten the outboard bolts (2) next to 110 N.m (81 ft. lbs.).
  15. Install the lower strut bolts (1).
  16. Tighten the bolts to 99 N.m 73 ft. lbs.).
  17. If equipped, install the rear half shafts.
  18. Install the nuts (3) and washers (4).
  19. Tighten the nuts to 244 N.m (180 ft. lbs.).
  20. Install new cotter pins (2).
  21. Install the rear drive module (1), refer to «INSTALLATION»(ref-304331-S08498951692008110700000) .
  22. Install the wheel speed sensor back, refer to «INSTALLATION»(ref-304337-S03593113952008110700000) .
  23. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1).
  24. Tighten the bolts to 15 N.m (11 ft. lbs.).
  25. Position the brake lines (1) back into place, and install the bolts (2).
  26. Tighten the bolts to 23 N.m (17 ft. lbs.).
  27. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1).
  28. Connect the brake cable to the park brake lever.
  29. Install the park brake shoes, refer to «INSTALLATION»(ref-304326-S25125697012008110700000) .
  30. Check and adjust wheel alignment as necessary, refer to «STANDARD PROCEDURE»(ref-304325-S12670711652008110700000) .

More articles — Frames & Bumpers