Chrysler 2004 Pacifica Service Manual Download Page 3578

Page: 3578 / 3603

CLUTCH HOUSING FLUID CHANGE -

STANDARD PROCEDURE,
OVERRUNNING . . . . . . . . . . . . . . . . . . . . . . . 3-49

CLUTCH RELAY - DESCRIPTION, A/C

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-12

CLUTCH RELAY - DIAGNOSIS AND

TESTING, COMPRESSOR . . . . . . . . . . . . . . . 24-13

CLUTCH RELAY - INSTALLATION, A/C

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-13

CLUTCH RELAY - OPERATION, A/C

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-12

CLUTCH RELAY - REMOVAL, A/C

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-13

CLUTCH/COIL - INSPECTION,

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-10

CLUTCHES - DESCRIPTION, DRIVING

. . . . . 21-92

CLUTCHES - DESCRIPTION, HOLDING

. . . 21-112

CLUTCHES - OPERATION, DRIVING

. . . . . . 21-92

CLUTCHES - OPERATION, HOLDING

. . . . . 21-112

COAT/CLEARCOAT FINISH -

DESCRIPTION, BASE . . . . . . . . . . . . . . . . . 23-112

CODE - DESCRIPTION, PAINT

. . . . . . . . . . 23-112

CODE CHARTS - SPECIFICATIONS,

COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-111

CODE PLATE - DESCRIPTION, BODY

. . . . Intro.-1

CODES - STANDARD PROCEDURE,

ERASING TRANSMITTER . . . . . . . . . . . . . . . 8M-8

CODES - STANDARD PROCEDURE,

OBTAINING DIAGNOSTIC TROUBLE . . . . . . 8E-10

CODES - STANDARD PROCEDURE,

SETTING TRANSMITTER . . . . . . . . . . . . . . . 8M-8

COIL - DIAGNOSIS AND TESTING,

COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-11

COIL CAPACITOR - DESCRIPTION,

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4

COIL CAPACITOR - INSTALLATION,

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-5

COIL CAPACITOR - REMOVAL, IGNITION . . . . 8I-4
COLOR CODE CHARTS -

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 23-111

COLUMN - DIAGNOSIS AND TESTING,

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-11

COLUMN FASTENER TORQUE,

SPECIFICATIONS - STEERING . . . . . . . . . . . 19-14

COLUMN OPENING COVER -

INSTALLATION, STEERING . . . . . . . . . . . . . 23-82

COLUMN OPENING COVER - REMOVAL,

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-82

COMBUSTION PRESSURE LEAKAGE

TEST - DIAGNOSIS AND TESTING,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

COMMUNICATION - DESCRIPTION

. . . . . . . . 8E-3

COMMUNICATION - OPERATION

. . . . . . . . . . 8E-3

COMMUNICATION RECEIVE - PCM INPUT

- OPERATION, DATA BUS . . . . . . . . . . . . . . 8E-10

COMPASS CALIBRATION - STANDARD

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8M-3

COMPASS DEMAGNETIZING -

STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-3

COMPASS MINI-TRIP COMPUTER -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8M-6

COMPASS MINI-TRIP COMPUTER -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8M-7

COMPASS MINI-TRIP COMPUTER -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8M-7

COMPASS MINI-TRIP COMPUTER -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6

COMPASS MINI-TRIP COMPUTER -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7

COMPASS VARIATION ADJUSTMENT -

STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-4

COMPRESSION LINK - INSTALLATION

. . . . . 2-27

COMPRESSION LINK - REMOVAL

. . . . . . . . . 2-26

COMPRESSION PRESSURE TEST -

DIAGNOSIS AND TESTING, CYLINDER . . . . . . 9-9

COMPRESSOR - DESCRIPTION, A/C

. . . . . . 24-45

COMPRESSOR - INSTALLATION, A/C

. . . . . 24-46

COMPRESSOR - OPERATION, A/C . . . . . . . . 24-45
COMPRESSOR - REMOVAL, A/C

. . . . . . . . . 24-45

COMPRESSOR CLUTCH - DESCRIPTION,

A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-7

COMPRESSOR CLUTCH - OPERATION,

A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8

COMPRESSOR CLUTCH AIR GAP -

STANDARD PROCEDURE . . . . . . . . . . . . . . . . 24-8

COMPRESSOR CLUTCH BREAK-IN -

STANDARD PROCEDURE . . . . . . . . . . . . . . . . 24-8

COMPRESSOR CLUTCH COIL -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-11

COMPRESSOR CLUTCH RELAY -

DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-12

COMPRESSOR CLUTCH RELAY -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-13

COMPRESSOR CLUTCH RELAY -

INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-13

COMPRESSOR CLUTCH RELAY -

OPERATION, A/C . . . . . . . . . . . . . . . . . . . . . 24-12

COMPRESSOR CLUTCH RELAY -

REMOVAL, A/C . . . . . . . . . . . . . . . . . . . . . . 24-13

COMPRESSOR CLUTCH/COIL -

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 24-10

COMPRESSOR MOUNT - INSTALLATION,

A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-47

COMPRESSOR MOUNT - REMOVAL, A/C

. . 24-47

COMPRESSOR NOISE DIAGNOSIS -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-45

COMPUTER - DESCRIPTION, COMPASS

MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6

COMPUTER - DIAGNOSIS AND TESTING,

COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . . 8M-7

COMPUTER - INSTALLATION, COMPASS

MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7

COMPUTER - OPERATION, COMPASS

MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6

COMPUTER - REMOVAL, COMPASS

MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7

CONCENTRATION TESTING - DIAGNOSIS

AND TESTING, COOLANT . . . . . . . . . . . . . . . 7-15

CONDENSER - DESCRIPTION, A/C

. . . . . . . 24-47

CONDENSER - INSTALLATION, A/C . . . . . . . . 24-48
CONDENSER - OPERATION, A/C

. . . . . . . . . 24-47

CONDENSER - REMOVAL, A/C

. . . . . . . . . . 24-47

CONDITION CHECK, STANDARD

PROCEDURE - FLUID LEVEL . . . . . . . . . . . 21-104

CONNECTING ROD - DESCRIPTION,

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

CONNECTING ROD - INSTALLATION,

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65

CONNECTING ROD - OPERATION,

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

CONNECTING ROD - REMOVAL, PISTON

. . . 9-65

CONNECTING RODS AND BEARINGS -

STANDARD PROCEDURE . . . . . . . . . . . . . . . . 9-54

CONNECTOR - INSTALLATION

. . . . . . . 8W-01-11

CONNECTOR - REMOVAL

. . . . . . . . . . . 8W-01-11

CONNECTOR, GROUND AND SPLICE

INFORMATION - DESCRIPTION . . . . . . . . 8W-01-7

CONNECTOR/GROUND/SPLICE LOCATION

- DESCRIPTION . . . . . . . . . . . . . . . . . . . . 8W-91-1

CONSOLE - DESCRIPTION, OVERHEAD

. . . . 8M-1

CONSOLE - DIAGNOSIS AND TESTING,

OVERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-2

CONSOLE - INSTALLATION, FRONT

FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-90

CONSOLE - INSTALLATION, REAR FLOOR

. 23-98

CONSOLE - REMOVAL, FRONT FLOOR

. . . . 23-90

CONSOLE - REMOVAL, OVERHEAD

. . . . . . . 8M-4

CONSOLE - REMOVAL, REAR FLOOR

. . . . . 23-97

CONSOLE BASE ASSEMBLY -

INSTALLATION, FLOOR . . . . . . . . . . . . . . . . 23-91

CONSOLE BASE ASSEMBLY - REMOVAL,

FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-91

CONSOLE CLOSEOUT PANEL -

INSTALLATION, CENTER . . . . . . . . . . . . . . . 23-87

CONSOLE CLOSEOUT PANEL -

REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 23-87

CONSOLE DUCTS - INSTALLATION,

FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-41

CONSOLE DUCTS - REMOVAL, FLOOR

. . . . 24-40

CONSOLE, SPECIAL TOOLS - OVERHEAD

. . 8M-5

CONTAINER - DESCRIPTION, COOLANT

RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-16

CONTAINER - INSTALLATION, COOLANT

RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-16

CONTAINER - OPERATION, COOLANT

RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-16

CONTAINER - REMOVAL, COOLANT

RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-16

CONTAMINATION - DIAGNOSIS AND

TESTING, BRAKE FLUID . . . . . . . . . . . . . . . . 5-26

CONTINUITY - STANDARD PROCEDURE,

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9

CONTROL ARM - INSPECTION, LOWER

. . . . . 2-9

CONTROL ARM - INSTALLATION, LOWER

. . 2-10

CONTROL ARM - REMOVAL, LOWER

. . . . . . . 2-9

CONTROL CALIBRATION - STANDARD

PROCEDURE, HEATER-A/C . . . . . . . . . . . . . 24-13

CONTROL INFORMATION LABEL -

DESCRIPTION, VEHICLE EMISSION . . . . . . . 25-1

CONTROL MODULE - DESCRIPTION,

BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-1

CONTROL MODULE - INSTALLATION,

BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-2

CONTROL MODULE - OPERATION, BODY

. . . 8E-2

CONTROL MODULE - REMOVAL, BODY

. . . . 8E-2

CONTROL MOTOR - INSTALLATION, IDLE

AIR . . . . . . . . . . . . . . . . . . . . . . . . . . 14-39,14s-15

CONTROL MOTOR - REMOVAL, IDLE AIR

. 14-39,

14s-14

CONTROL RELAY - DESCRIPTION,

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-166

CONTROL RELAY - OPERATION,

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-166

CONTROL SWITCH - DESCRIPTION,

LUMBAR . . . . . . . . . . . . . . . . . . . . . 8N-31,8Ns-29

CONTROL SWITCH - DIAGNOSIS AND

TESTING, LUMBAR . . . . . . . . . . . . . 8N-31,8Ns-30

CONTROL SWITCH - INSTALLATION

. . . . . 23-156

CONTROL SWITCH - OPERATION,

LUMBAR . . . . . . . . . . . . . . . . . . . . . 8N-31,8Ns-30

CONTROL SWITCH - REMOVAL

. . . . . . . . 23-156

CONTROL SYSTEM - OPERATION,

EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . . 25-6

CONTROLLER - DESCRIPTION,

OCCUPANT RESTRAINT . . . . . . . . . . . . . . . 8O-25

CONTROLLER - INSTALLATION,

OCCUPANT RESTRAINT . . . . . . . . . . . . . . . 8O-26

CONTROLLER - OPERATION, OCCUPANT

RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-25

CONTROLLER - REMOVAL, OCCUPANT

RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26

CONTROLLER ANTILOCK BRAKE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8E-4

CONTROLLER ANTILOCK BRAKE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 8E-5

CONTROLLER ANTILOCK BRAKE -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-4

CONTROLLER ANTILOCK BRAKE -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-5

CONVENTIONAL BATTERY CHARGING -

STANDARD PROCEDURE . . . . . . . . . . . . . . . . 8F-8

CONVERTER - DESCRIPTION, CATALYTIC

. . . 11-5

CONVERTER - DESCRIPTION, TORQUE . . . 21-160
CONVERTER - INSTALLATION, CATALYTIC

. . 11-6

CONVERTER - INSTALLATION, TORQUE

. . 21-165

CONVERTER - OPERATION, CATALYTIC

. . . . 11-5

CONVERTER - OPERATION, TORQUE

. . . . 21-163

CONVERTER - REMOVAL, CATALYTIC

. . . . . . 11-6

CONVERTER - REMOVAL, TORQUE

. . . . . . 21-165

CONVERTER HOUSING FLUID LEAKAGE -

DIAGNOSIS AND TESTING, TORQUE . . . . . . 21-14

COOL DOWN TEST - DIAGNOSIS AND

TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . . . 24-2

COOLANT - DESCRIPTION, ENGINE

. . . . . . . 7-15

COOLANT - DESCRIPTION, ENGINE

. . . . . . . . 0-3

COOLANT - STANDARD PROCEDURE,

ADDING ADDITIONAL . . . . . . . . . . . . . . . . . . . 7-3

COOLANT CONCENTRATION TESTING -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 7-15

COOLANT LEVEL CHECK - STANDARD

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

COOLANT RECOVERY PRESS

CONTAINER - DESCRIPTION . . . . . . . . . . . . . 7-16

COOLANT RECOVERY PRESS

CONTAINER - INSTALLATION . . . . . . . . . . . . 7-16

COOLANT RECOVERY PRESS

CONTAINER - OPERATION . . . . . . . . . . . . . . . 7-16

COOLANT RECOVERY PRESS

CONTAINER - REMOVAL . . . . . . . . . . . . . . . . 7-16

COOLANT SERVICE - STANDARD

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

COOLANT TEMP SENSOR -

DESCRIPTION, ENGINE . . . . . . . . . . . . . . . . . 7-19

COOLANT TEMP SENSOR -

INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-19

COOLANT TEMP SENSOR - REMOVAL,

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

COOLANT THERMOSTAT -

INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-19

COOLANT THERMOSTAT - REMOVAL,

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

COOLER - DESCRIPTION, ENGINE OIL

. . . . . 9-75

COOLER - INSTALLATION, ENGINE OIL

. . . . 9-75

INDEX

Description

Group-Page

Description

Group-Page

Description

Group-Page

«
...
3576
3577
3578
3579
3580
...
»

Summary of Contents for 2004 Pacifica

Page 1: ... FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufac tured Litho in U S A Copyri...

Page 2: ...nts section that lists major topics within the group If you are not sure which Group contains the information you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide DaimlerChrysler Corporation with your comments and suggestions Tightening torques are provided as ...

Page 3: ...Welcome 2004 CS Pacifica Technical Publications Click on the icon for the desired manual Service Manual Gas Powertrain Body Chassis Transmission ...

Page 4: ...DIAGNOSTIC TROUBLE CODES 11 3 3 1 HARD CODE 11 3 3 2 INTERMITTENT CODE 12 3 3 3 STARTS SINCE SET COUNTER 12 3 3 4 DISTANCE SINCE MI SET 12 3 4 USING THE DRBIIIT 12 3 5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 12 3 5 1 DRBIIIT DOES NOT POWER UP 12 3 5 2 DISPLAY IS NOT VISIBLE 13 4 0 DISCLAIMERS SAFETY WARNINGS 13 4 1 DISCLAIMERS 13 4 2 SAFETY 13 4 2 1 TECHNICIAN SAFETY INFORMATION 13 4 2 2 VEHICLE P...

Page 5: ... P0122 THROTTLE POSITION SENSOR 1 LOW 73 P0123 THROTTLE POSITION SENSOR 1 HIGH 76 P0125 INSUFFICIENT COOLANT TEMP FOR CLOSED LOOP FUEL CONTROL 79 P0128 THERMOSTAT RATIONALITY 81 P0129 BAROMETRIC PRESSURE OUT OF RANGE LOW 86 P0131 O2 SENSOR 1 1 VOLTAGE LOW 89 P0137 O2 SENSOR 1 2 VOLTAGE LOW 89 P0132 O2 SENSOR 1 1 VOLTAGE HIGH 92 P0138 O2 SENSOR 1 2 VOLTAGE HIGH 92 P0133 O2 SENSOR 1 1 SLOW RESPONSE ...

Page 6: ...IT 188 P0481 COOLING FAN 2 CONTROL CIRCUIT 190 P0498 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW 192 P0499 NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH 193 P0501 VEHICLE SPEED SENSOR 1 PERFORMANCE 195 P0506 IDLE SPEED LOW PERFORMANCE 196 P0507 IDLE SPEED HIGH PERFORMANCE 196 P0508 IAC VALVE SENSE CIRCUIT LOW 198 P0509 IAC VALVE SENSE CIRCUIT HIGH 201 P0513 INVALID SKIM KEY 203 P0516 BATTERY TE...

Page 7: ...7 DOWN STREAM FUEL SYSTEM 1 2 RICH 277 P2302 IGNITION COIL 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 280 P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 280 P2308 IGNITION COIL 3 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 280 P2311 IGNITION COIL 4 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 280 P2314 IGNITION COIL 5 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 280 P2317 IGNITION COIL 6...

Page 8: ...WAY 338 COIL ON PLUG NO 1 LT GRAY 2 WAY 338 COIL ON PLUG NO 2 LT GRAY 2 WAY 338 COIL ON PLUG NO 3 LT GRAY 2 WAY 338 COIL ON PLUG NO 4 LT GRAY 2 WAY 339 COIL ON PLUG NO 5 LT GRAY 2 WAY 339 COIL ON PLUG NO 6 LT GRAY 2 WAY 339 CRANKSHAFT POSITION SENSOR BLACK 3 WAY 339 DATA LINK CONNECTOR BLACK 16 WAY 340 EGR SOLENOID BLACK 6 WAY 340 ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY 340 ENGINE OIL PRESSU...

Page 9: ... BLACK 3 WAY 351 OXYGEN SENSOR 1 1 UPSTREAM BLACK 4 WAY 351 OXYGEN SENSOR 1 2 DOWNSTREAM WHITE 4 WAY 351 POWERTRAIN CONTROL MODULE C1 BLACK BLACK 38 WAY 352 POWERTRAIN CONTROL MODULE C2 BLACK ORANGE 38 WAY 353 POWERTRAIN CONTROL MODULE C3 BLACK WHITE 38 WAY 354 POWERTRAIN CONTROL MODULE C4 BLACK GREEN 38 WAY 355 RADIATOR FAN MOTOR NO 1 BLACK 2 WAY 355 RADIATOR FAN MOTOR NO 2 BLACK 2 WAY 356 RADIAT...

Page 10: ...t 4 Once the DTC or customer complaint is identi fied locate the matching test in the Table of Contents and begin to diagnose the symptom All component location views are in Section 8 0 All connector pinouts are in Section 9 0 All system schematics are in Section 10 0 An placed before the symptom description indi cates a customer complaint When repairs are required refer to the appropri ate servic...

Page 11: ...a may be a range of engine rpm engine temperature and or input voltage to the PCM If a problem is sensed with a monitored circuit and all of the criteria or arming conditions are met then a trouble code will be stored in the PCM It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred This may happen because one of the...

Page 12: ...ntrol Short To Ground Oxygen Sensor Heater System For Short To Voltage Oxygen Sensor Response Fuel System Lean Fuel System Rich Inputs Checked For Requires 3 Consecutive Rationality Catalytic Converter Fuel System Good Trips To Efficiency Except EWMA Extinguish The MIL Outputs Checked For up to 6 tests per trip Functionality and a one trip fault EGR System Misfire Monitor Evaporative Emission Moni...

Page 13: ...each monitor Each monitor has a Pre Test screen to assist in running the monitor For additional information refer to the Chrysler Corporation Technical Training Workbook titled On Board Diagnostics OBDII EOBD part number 81 699 01050 The most efficient order to run the monitors has been outlined below including suggestions to aid the process A Natural Vacuum Leak Detection with Purge Monitor This ...

Page 14: ...ed through the sensor return line NATURAL VACUUM LEAK DETECTION NVLD The Natural Vacuum Leak Detection NVLD system is the next generation evaporative leak detection system that will first be used on vehicles equipped with the Powertrain Control Module PCM or Next Generation Controller NGC start ing in 2002 M Y This new system replaces the leak detection pump as the method of evaporative sys tem le...

Page 15: ...r a specified delay after key off perhaps 5 minutes the switch closes or is closed the test will be pass indicating that there is no leak The PCM records the switch closure The NVLD circuit in the PCM will shut down for the remainder of that particular engine off soak period When the engine is started the switch closure is recorded as a 9Pass 9 and the timers that are recording accumulated time ar...

Page 16: ...O vacuum of the NVLD for a specific time while tracking the standard purge flow rate Turn purge off and determine how long it takes to decay the tank vacuum and reopen the switch Determine the leak size from the time it took to reopen the switch Note Fuel level is an impor tant determining factor If the switch does not close a more aggressive purge flow will be applied to determine if it is a very...

Page 17: ...FIGURE 2 8 GENERAL INFORMATION ...

Page 18: ... PCM cannot detect if a fuel injector is clogged the pintle is sticking or the wrong injectors are installed Fuel Requirements Poor quality gasoline can cause problems such as hard starting stalling and stumble Use of methanol gasoline blends may re sult in starting and driveability problems See indi vidual symptoms and their definitions in Section 6 0 Glossary of Terms PCM Grounds The PCM cannot ...

Page 19: ...waits 3 5 seconds for a PCM status mes sage from the PCM If the PCM does not respond with a valid key message to the SKREEM a fault is detected and a trouble code is stored The SKREES incorporates a VTSS LED located on the instrument panel upper cover The LED receives switched ignition voltage and is hardwired to the body control module The LED is actuated when the SKREEM sends a PCI Bus message t...

Page 20: ... is learned to a SKREEM it the key cannot be transferred to another vehicle If ignition key programming is unsuccessful the DRBIIIt will display one of the following messages Programming Not Attempted The DRBIIIt attempts to read the programmed key status and there are no keys programmed in the SKIM mem ory Programming Key Failed Possible Used Key From Wrong Vehicle SKREEM is unable to pro gram ke...

Page 21: ...dard data link connector This feature works as follows 1 If the MI is illuminated due to a fault the distance count is updated i e it is counting 2 If there is a stale MI fault i e the fault is still frozen in memory but the MI has been extin guished due to 3 good trips the distance count is held i e frozen 3 If the distance count is being held due to Item 2 and the fault is cleared the distance i...

Page 22: ... an inad vertent electrical contact When diagnosing a powertrain system problem it is important to follow approved procedures where applicable These procedures can be found in ser vice manual procedures Following these proce dures is very important to the safety of individuals performing diagnostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged b...

Page 23: ...BIIIT from the rear view mirror or operate it yourself Have an assistant available to operate the DRBIIIT 4 3 2 VEHICLE DAMAGE CAUTIONS Before disconnecting any control module make sure the ignition is off Failure to do so could damage the module When testing voltage or continuity at any control module use the terminal side not the wire end of the connector Do not probe a wire through the insulati...

Page 24: ...is opened LDP leak detection pump MAP manifold absolute pressure sensor MIL malfunction indicator lamp MTV manifold tuning valve NGC next generation controller O2S oxygen sensor PCI programmable communication inter face PCM powertrain control module PCV positive crankcase ventilation PEP peripheral expansion port poor fuel economy There is significantly less fuel mile age than other vehicles of th...

Page 25: ...NOTES 16 ...

Page 26: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 17 ...

Page 27: ... PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH7058 Cable to Probe adapter CH7062 and the red and black test probes Connect the scope input cable to the channel one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input ca...

Page 28: ...ssary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIIIt from the DLC Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the SCI Transmit PCM circuit at the Data Link harness connector cav 7 Is the voltage above 1 0 volt All Yes Repair the...

Page 29: ...he ignition off Disconnect the PCM harness connector Disconnect the DRBIIIt from the DLC Measure the resistance between ground and the SCI Receive PCM circuit in the Data Link harness connector cav 12 Is the resistance below 5 0 ohms All Yes Repair the SCI Receive PCM circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the PCM harn...

Page 30: ...the resistance of the SCI Transmit PCM circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the SCI Transmit PCM circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 9 If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module i...

Page 31: ... 12 volt test light connected to 12 volts probe the Ground circuit Is the test light illuminated All Yes Go To 3 No Repair the ground circuit for an open Perform SKREEM VERIFICATION TEST VER 1A 3 Turn the ignition off Disconnect the SKREEM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Ignition Switch Output circuit Is the test light illuminated All...

Page 32: ...a Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the SKREEM connector Turn the ignition on Observe the voltage display on the DRBIIIt Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To ...

Page 33: ... ate symptom Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connect...

Page 34: ...RANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to 12 volts probe each ground circuit in the appropr...

Page 35: ...ve Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 6 No ...

Page 36: ...n the ignition on Using the DRB attempt to communicate with the following control modules Airbag Control Module Body Control Module MIC INSTRUMENT CLUSTER Was the DRBIIIt able to communicate with one or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect...

Page 37: ...ignition on Measure the voltage of the PCI Bus circuit at the Data Link Connector DLC Is the voltage above 7 0 volts All Yes Go To 5 No Go To 6 5 Turn the ignition off Using a voltmeter connect one end to the PCI Bus circuit at the DLC and the other end to ground Note When performing the next step turn the ignition off wait one minute before disconnecting any module When the module is disconnected...

Page 38: ...us resistance to ground thru all of the modules is typically between 350 to 1000 ohms The more modules on the bus the lower the total bus resistance will be Is the resistance below 150 0 ohms with all the modules disconnected All Yes Repair the PCI Bus circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the module that when disconnected the short to ground was eliminated ...

Page 39: ...ken wires and broken bent pushed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Inspect and clean all PCM engine and chassis grounds If numerous trouble codes were set use a wire schematic to help you find any...

Page 40: ...ECTION INTERMITTENT CKP SIGNAL CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR TEST ACTION APPLICABILITY 1 WARNING 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 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt erase DTCs Sta...

Page 41: ...ignition off Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found All Yes Repair or replace the Tone Wheel Pulse Ring as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 If there are no possible causes remaining view repair All Repair Replace the Camshaft Position Sensor Perform POWERTRA...

Page 42: ...hed out or corroded terminals Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s tight Refer to any TSBs that may apply Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 9 9 Turn the ignition off Remove the Crankshaft Position Sensor Inspect the Tone Wheel F...

Page 43: ...n the Crank Position Sensor and wiggle the CKP Sensor Turn the ignition off Inspect the Sensor harness connector PCM harness connector Sensor connector and PCM connector for loose bent corroded or pushed out pins terminals Inspect the related wire harness and the splices in the K24 CKP circuits Were any problems found All Yes Repair the wiring connector concerns as needed or replace the Crankshaft...

Page 44: ...f acceptable range Below 0 0926 of a volt One Trip Fault P0037 O2 SENSOR 1 2 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition The PCM detects the O2 Heater voltage is out of acceptable range Below 0 0926 of a volt One Trip Fault POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER CONTROL CIRCUIT O2 HEATER CONT...

Page 45: ...TRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBIIIt actuate the O2 Heater Test Using a 12 volt test light connected to ground probe the O2 Heater Control circuit in the O2 Sensor harness connector Does the test illuminate brightly and flash on and off All Yes Replace the O2 Sensor Perform POWERTRAIN VE...

Page 46: ...is out of range high One trip fault P0038 O2 SENSOR 1 2 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition The O2 heater voltage is out of range high One trip fault POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER GROUND CIRCUIT OPEN O2 SENSOR O2 HEATER CONTROL SHORTED TO VOLTAGE O2 HEATER CONTROL CIRCUIT O...

Page 47: ...fication 1 1 and 1 2 O2 Sensor 2 1 to 2 7 ohms Is the O2 Sensor Heater element within specification All Yes Go To 4 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBIIIt actuate the O2 Heater Test Using a 12 volt test light connected to ground probe the O2 Heater Con...

Page 48: ...BING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the O2 Heater Control circuit from the O2 Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes NOTE Before continuing check the PCM harness connector ...

Page 49: ...thin a predetermined time an error will be detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO HIGH RESISTANCE IN MAP K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K6 5 VOLT SUPPLY CIRCUIT MAP SENSOR HIGH RESISTANCE IN K1 MAP SIGNAL CIRCUIT RESISTANCE TO GROUND IN K1 MAP SIGNAL CIRCUIT HIGH RESISTANCE IN K4 MAP GROUND CIRCUIT PCM TP SENSOR OPERATION HIGH RESISTANCE IN TP SENSOR ...

Page 50: ...owly depressing the throttle pedal from the idle position to the wide open throttle position Does the voltage start approximately at 0 8 volts and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 Turn the ignition off Disconnect the TP Sensor harness connector Dis...

Page 51: ... ignition off Disconnect the TP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K22 TP Signal circuit from the TP Sensor harness connector to t...

Page 52: ...on Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K...

Page 53: ...special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 15 No Repair the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 15 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance above 100k ohms All Y...

Page 54: ...inal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 45 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION Continued ...

Page 55: ...nsors an error is detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO K25 AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE AMBIENT AIR TEMPERATURE SENSOR VOLTAGE BELOW 1 0 VOLT K25 AAT SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN K25 AAT SIGNAL CIRCUIT SHORTED TO GROUND K25 AAT SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 Ignition on engine ...

Page 56: ...e Sensor harness connector Using a jumper wire jumper across the Ambient Air Temperature Sensor harness connector Ignition on engine not running With the DRBIIIt read the Ambient Air Temperature voltage Is the voltage below 1 0 volt All Yes Replace the Ambient Air Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the Ambient Air Tempera...

Page 57: ...ST VER 5 NGC 7 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K25 AAT Signal circuit Is the resistance below 100 ohms All Yes Repair the short to ground in the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 8 8 Turn the ignition off Disconnect th...

Page 58: ...ERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Ignition on engine not running With the DRBIIIt read Ambient Air Temperature Sensor voltage Is the voltage above 1 0 volt All Yes Replace the Ambient Air Temperature Sensor Perform POWERTRAIN VERIFICATION TES...

Page 59: ...ms All Yes Repair the K4 Sensor ground shorted to the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with t...

Page 60: ...ABILITY 1 Ignition on engine not running With the DRBIIIt read the Ambient Air Temperature Sensor voltage Is the voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Ignition on engine not running Measu...

Page 61: ...15 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN ...

Page 62: ...CUIT SHORTED TO GROUND K1 MAP SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT PCM K6 5 VOLT SUPPLY CIRCUIT PCM K1 MAP SENSOR SIGNAL CIRCUIT TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt read the MAP Sensor voltage Is the voltage below 078 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER...

Page 63: ...MAP Signal circuit and the K4 Sensor ground circuit in the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the K4 Sensor ground shorted to the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no pos...

Page 64: ...MAP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open in the K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 9 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view...

Page 65: ...RCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt read the MAP Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness ...

Page 66: ...HE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K1 MAP Signal circuit from the MAP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K1 MAP Signal circuit Perform ...

Page 67: ...n damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 58 DRIVEABILITY NGC P0108 MAP SENSOR HIGH Continued ...

Page 68: ... SIGNAL SHORTED TO GROUND K21 IAT SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TE...

Page 69: ...rness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WI...

Page 70: ...t the PCM harness connector Measure the resistance between the K4 Sensor ground circuit and the K21 IAT Sensor Signal circuit at the IAT Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the K4 Sensor ground circuit shorted to the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No NOTE Before continuing check the PCM harness connector terminals for corr...

Page 71: ...low 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the IAT harness connector Ignition on engine not running With the DRBIIIt read IAT Sensor voltage Is the voltage above 1 0 volt All Yes Replace the IAT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go T...

Page 72: ... K4 Sensor ground shorted to the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informatio...

Page 73: ...SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read the IAT Sensor voltage Is the voltage above 4 6 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the IAT Sensor harness connector Ignition on engine not runn...

Page 74: ...pair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM D...

Page 75: ...IT SHORTED TO BATTERY VOLTAGE ECT SENSOR VOLTAGE BELOW 1 0 VOLT K2 ECT SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN K2 ECT SIGNAL CIRCUIT SHORTED TO GROUND K2 ECT SIGNAL SHORTED TO K4 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 NOTE Due to the fact that the PCM compares the IAT AAT and ECT sensor to see if they are within a calibrated temp of one another the use of a block heat...

Page 76: ...ensor harness connector Using a jumper wire jumper across the ECT Sensor harness connector Ignition on engine not running With the DRBIIIt read the ECT Sensor voltage Is the voltage below 1 0 volt All Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the ECT Sensor harness connector Disconnect the PCM harness connector CAUTION D...

Page 77: ...ct the ECT Sensor harness connector Turn the ignition off Disconnect the PCM harness connector Measure the resistance between ground and the K2 ECT Signal circuit in the ECT Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 8 8 Turn the ignition off Disconnect the ECT Sen...

Page 78: ... voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the ECT harness connector Ignition on engine not running With the DRBIIIt read ECT Sensor voltage Is the voltage between 4 8 and 5 2 volts All Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION ...

Page 79: ...nsor ground shorted to the K2 ECT Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informatio...

Page 80: ...N K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read the ECT Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the ECT Sensor harness connector Ignition on engine not...

Page 81: ...epair the open in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the ECT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM D...

Page 82: ...EN TP SENSOR INTERNAL FAILURE K22 TP SIGNAL CIRCUIT SHORTED TO GROUND K22 TP SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT PCM K6 5 VOLT SUPPLY CIRCUIT PCM K22 TP SENSOR SIGNAL TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read the Throttle Position Sensor voltage Is the voltage below 0 2 of a volt All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect th...

Page 83: ...ignal circuit and the K4 Sensor ground circuit in the TPS harness connector Is the resistance below 100 ohms All Yes Repair the short to K4 Sensor ground in the K22 TP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible cause...

Page 84: ... the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 10 Ignition on engine not running With the DRBIIIt monitor the Throttle Position Sensor voltage...

Page 85: ...GNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the throttle is fully closed and free from binding or carbon build up Start the engine With the DRBIIIt read the TP Sensor voltage Is the voltage above 4 5 volts All Yes Go To 2 No Go To 8 2 Turn the ignition off Disconnect the TP Sensor harness connector Disconnect the PCM harness connector Measure the res...

Page 86: ...PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K22 TP Signal circuit from the TP harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K22 TP Signal circuit Perform POWERTRAIN ...

Page 87: ...VER 5 NGC 8 Ignition on engine not running With the DRBIIIt monitor the TP Sensor voltage Slowly open the throttle from the idle position to the wide open throttle position Does voltage start at approximately 0 7 of a volt and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC N...

Page 88: ...DTC is set along with this code diagnose the ECT DTC first NOTE Inspect the ECT terminals and related PCM terminals Ensure the terminals are free from corrosion and damage NOTE The best way to diagnose this DTC is to allow the vehicle to sit overnight outside in order to have a totally cold soaked engine Note Extremely cold outside ambient temperatures may have caused this DTC to set WARNING Never...

Page 89: ...oper temperature All Yes Go To 3 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 3 Ignition on engine not running With the DRBIIIt read the ECT Sensor temperature value If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temperature Note If engine coolant temperature is above 82 C 180 ...

Page 90: ...NE COOLANT TEMPERATURE TEMPERATURE SENSOR VOLTAGE BELOW 1 0 VOLT SIGNAL CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 NOTE If any ECT AAT CMP or CKP sensor DTCs have set along with P0128 diagnose them first before continuing NOTE Ensure that Pinion Factor has been programmed correctly in...

Page 91: ...th the DRBIIIt monitor the Engine Coolant temperature If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temperature NOTE If engine coolant temperature is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the Engine During engine warm up monitor the ECT Deg value on the DRBIIIt The t...

Page 92: ...al operating temperature monitor the Temperature sensor parameters while wiggling the wire harness Look for parameter values to change Visually inspect the related wire harness Look for any chafed pierced pinched partially broken wires and broken bent pushed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RE...

Page 93: ...gnal circuit from the Temperature Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 11 No Repair the open in the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 Turn the ignition off Disconnect the applicable Temperature Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM ...

Page 94: ...re Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the Signal circuit and the Sensor ground circuit in the Temperature Sensor harness connector Is the resistance below 100 ohms All Yes Repair the Sensor ground shorted to the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No NOTE Before continuing check the PCM harness connector terminals ...

Page 95: ... 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN MAP SENSOR INTERNAL FAILURE K1 MAP SIGNAL CIRCUIT OPEN K1 MAP SIGNAL CIRCUIT SHORTED TO GROUND PCM K6 5 VOLT SUPPLY CIRCUIT PCM K1 MAP SIG CIRCUIT TEST ACTION APPLICABILITY 1 NOTE Refer to any TSBs that may apply to this DTC before proceeding Ignition on engine not running With the DRBIIIt read the MAP Sensor voltage Is the vol...

Page 96: ...ition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harness con...

Page 97: ...WERTRAIN VERIFICATION TEST VER 5 NGC 10 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 Start the engine NOTE If...

Page 98: ...tion The oxygen sensor signal voltage is below 2 402 volts for 9 seconds Two trip Fault P0137 O2 SENSOR 1 2 VOLTAGE LOW When Monitored Engine Running Set Condition The oxygen sensor signal voltage is below 2 402 volts for 9 seconds Two trip Fault POSSIBLE CAUSES O2 SENSOR BELOW 1 5 VOLTS O2 SENSOR O2 RETURN CIRCUIT SHORTED TO GROUND O2 SIGNAL CIRCUIT SHORTED TO GROUND O2 SIGNAL CIRCUIT SHORTED TO ...

Page 99: ... engine not running With the DRBIIIt monitor the O2 Sensor voltage Is the O2 Sensor voltage above 4 8 volts All Yes Go To 3 No Go To 5 3 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector Is the voltage at 2 5 volts All Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATI...

Page 100: ...orted to the O2 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 7 7 Turn the ignition off Disconnect the O2 Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the O2 Signal circuit and the Heater ground circuit in the O2 Sensor harness connector Is the resistance below 100 ohms All Yes Repair the Heater Ground circuit shorted to the ...

Page 101: ...er than 10 99 volts Set Condition The Oxygen Sensor voltage is above 3 7 volts for 60 seconds Two trip fault P0138 O2 SENSOR 1 2 VOLTAGE HIGH When Monitored The engine running for 119 seconds O2 Sensor Heater Temperature is greater than 350 C 662 F Battery voltage greater than 10 99 volts Set Condition The Oxygen Sensor voltage is above 3 7 volts for 60 seconds Two trip fault POSSIBLE CAUSES O2 SE...

Page 102: ...ne to idle Measure the voltage on the O2 Sensor Signal circuit in the O2 Sensor harness connector NOTE Measure the voltage in reference to ground not the O2 Sensor Return circuit Is the voltage above 5 2 volts All Yes Repair the short to voltage in the O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Turn the ignition off Disconnect the O2 Sensor harness connect...

Page 103: ...or harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the O2 Sensor Return circuit from the O2 Sensor harness connector to the appropriate terminal of specia...

Page 104: ...or The PCM will then compare the differences between both readings if the differences are greater than a calibrated amount the PCM will record a fault Two trip failure P0139 O2 SENSOR 1 2 SLOW RESPONSE When Monitored Start and drive vehicle greater than 20 MPH and less than 60 MPH Throttle open for a minimum 120 seconds Coolant Temp greater than 70 C 158 F RPM between 1200 to 2000 Vacuum between 5...

Page 105: ...e the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the voltage on the O2 Signal circuit in the O2 Sensor harness connector Is the voltage between 4 5 and 5 0 volts All Yes Go To 4 No Check the O2 Signal circuit for damage short to ground open or ...

Page 106: ...thin 90 second during monitoring conditions Two Trip Fault P0141 O2 SENSOR 1 2 HEATER PERFORMANCE When Monitored Engine Running and Heater duty cycle greater than 0 Set Condition O2 Heater Temperature does not reach 575 C 959 F within 45 second during monitoring conditions Two Trip Fault POSSIBLE CAUSES O2 SENSOR HEATER OPERATION O2 HEATER ELEMENT O2 HEATER GROUND CIRCUIT OPEN O2 HEATER CONTROL CI...

Page 107: ...nsor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the O2 Sensor harness connector Measure the resistance between an engine ground and the O2 Heater Ground circuit in the O2 Sensor harness connector Is the resistance below 0 5 of an ohm All Yes Go To 5 No Repair the open high resistance in the O2 Heater Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 N...

Page 108: ...e terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 99 DRIVEABILITY NGC P0135 O2 SENSOR 1 1 HEATER PERFORMANCE Continued ...

Page 109: ...GGED FUEL PUMP MODULE O2 SENSOR O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT O2 SENSOR HEATER OPERATION THROTTLE POSITION SENSOR SWEEP MAP SENSOR OPERATION ECT SENSOR OPERATION ENGINE MECHANICAL PROBLEM FUEL CONTAMINATION EXHAUST LEAK TEST ACTION APPLICABILITY 1 NOTE Check for contaminants that may have damaged the O2 Sensor contaminated fuel unapproved silicone oil and coolant NOTE Diagnose any Misfire DT...

Page 110: ...rned to normal follow the diagnostic procedure for the remaining O2 Sensors Start the engine Allow the engine to reach normal operating temperature With the DRBIIIt read the O2 Sensor voltage Is the voltage switching between 2 5 and 3 4 volts All Yes Go To 4 No Go To 9 4 Turn the ignition off NOTE Allow the O2 Sensor to cool down before continuing the test The O2 voltage should stabilize at 5 0 vo...

Page 111: ...monitor the ECT Sensor value The temperature value change should be a smooth transition from start up to normal operating temperature 82 C 180 F The value should reach at least 82 C 180 F Did the ECT value increase with a smooth transition and did it reach at least 82 C All Yes Go To 8 No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 8 Check for any o...

Page 112: ...1 No Check the O2 Signal circuit for a short to ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the v...

Page 113: ...tion is 400 KPa 34 KPa 58 psi 5 psi Is the fuel pressure within specification All Yes Repair or replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 13 Caution Stop All Actuations 13 Turn the ignition off Warning The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel sy...

Page 114: ...LE CAUSES GOOD TRIP EQUAL TO ZERO O2 SENSOR HEATER OPERATION O2 SENSOR EVAP PURGE SOLENOID OPERATION O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT MAP SENSOR OPERATION ECT SENSOR OPERATION ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR PCM TEST ACTION APPLICABILITY 1 NOTE Check for contaminants that may have damaged the O2 Sensor contaminated fuel unapproved silicone oil and coolant Ignition on en...

Page 115: ...readings have not returned to normal follow the diagnostic procedure for the remaining O2 Sensors Start the engine Allow the engine to reach normal operating temperature With the DRBIIIt read the O2 Sensor voltage Is the voltage switching between 2 5 and 3 4 volts All Yes Go To 4 No Go To 9 4 Turn the ignition off NOTE Allow the O2 Sensor to cool down before continuing the test The O2 voltage shou...

Page 116: ... Coolant Temperature value The temp value change should be a smooth transition from start up to normal operating temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Coolant Temperature value increase a smooth transition and did it reach at least 82 C All Yes Go To 8 No Replace the Engine Coolant Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 8 Check for any...

Page 117: ...ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 11 11 Turn the ignition off Disconnect the O2 Sensor harness connector Turn the ignition on Measure the voltage on the O2 Return circuit in the O2 Sensor harness c...

Page 118: ... One Trip Fault P0203 FUEL INJECTOR 3 When Monitored With battery voltage greater than 10 volts Auto Shutdown Relay energized Engine speed less than 3000 rpm Set Condition No inductive spike is detected after injector turn off One Trip Fault P0204 FUEL INJECTOR 4 When Monitored With battery voltage greater than 10 volts Auto Shutdown Relay energized Engine speed less than 3000 rpm Set Condition No...

Page 119: ... not running With the DRBIIIt actuate the ASD Relay Using a 12 volt test light connected to ground backprobe the F42 ASD Relay Output circuit at the Fuel Injector harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the open or high resistance in the F42 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 3 Turn the ignition off Disconnect the Fue...

Page 120: ...POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Fuel Injector harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the Injector Control circuit at the Fuel Injector harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5...

Page 121: ...itored Any time the engine is running and the Target Learning Coefficient has been successfully updated Set Condition When more than a 1 0 misfire rate is measured during two trips P0302 CYLINDER 2 MISFIRE When Monitored Any time the engine is running and the Target Learning Coefficient has been successfully updated Set Condition When more than a 1 0 misfire rate is measured during two trips P0303...

Page 122: ...et Condition When more than a 1 0 misfire rate is measured during two trips POSSIBLE CAUSES INTERMITTENT MISFIRE VISUAL AND PHYSICAL INSPECTION ASD RELAY OUPUT CIRCUIT COIL ENGINE MECHANICAL PROBLEM IGNITION COIL COIL CONTROL CIRCUIT SPARK PLUG CHECKING FUEL PRESSURE FUEL PUMP INLET STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP MODULE CHECKING FUEL LEAK DOWN FUEL INJECTOR OPERATION ASD RE...

Page 123: ...il etc Vacuum leaks Restricted Air Induction system NOTE Read the CKP SYNC state on the DRB If the CKP SYNC does not indicate IN SYNC perform the Crankshaft Position Sensor Circuit chart NOTE Verify the integrity of the powers and grounds for the PCM Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Turn the ignition of...

Page 124: ...essure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 NOTE Before continuing visually and physically inspect the fuel delivery system for external leaks or damage Repair replace as necessary Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be...

Page 125: ...t be free of any restrictions or leaks ENGINE PCV SYSTEM must flow freely TORQUE CONVERTER STALL SPEED must be within specifications POWER BRAKE BOOSTER no internal vacuum leaks FUEL must be free of contamination Are there any engine mechanical problems All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 17 9 Turn the ignition off Disconnect the Fuel Injector harnes...

Page 126: ... at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pressure test gauge to the T fitting on the tool 6539 Ignition on engine not running With the DRBIIIt actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 400 KPa 34 KPa 58 psi 5 psi Is the fuel press...

Page 127: ...ce the Ignition Coil Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 16 16 Turn the ignition off Disconnect the Ignition Coil harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSI...

Page 128: ...hed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Inspect and clean all PCM engine and chassis grounds NOTE Reviewing the vehicle repair history may aid in the repair of the misfire condition Visually and phy...

Page 129: ...M battery disconnect to reset the PCM Start the engine If the MIL has not yet illuminated test drive the vehicle to try to get the code to reset Does the code reset while cranking or during the test drive All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Visually inspect the CKP wire harness Look for any cha...

Page 130: ... movement Were any problems found All Yes Repair or replace the Tone Wheel Flex Plate as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 If there are no possible causes remaining view repair All Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 121 DRIVEABILITY NGC P0315 NO CRANK SENSOR LEARNED Continued ...

Page 131: ...CIRCUIT OPEN K42 KS SIGNAL CIRCUIT SHORTED TO K45 KS RETURN CIRCUIT K45 KS RETURN CIRCUIT OPEN KNOCK SENSOR TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICAT...

Page 132: ... the open in the K42 KS Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Knock Sensor harness connector Measure the resistance between the K42 KS Signal circuit and the K45 KS Return circuit in the Knock Sensor harness connector Is the resistance below 100 ohms All Yes Repair the K42 KS Signal circuit for a short to K45 KS Return circuit Perform ...

Page 133: ...IIt read DTC s Does the DRBIIIt display the DTC that was previously erased All Yes NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Test Complete 124 DRIVEABILITY NGC P0325 KNOCK ...

Page 134: ...CKP SIGNAL K6 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN K6 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL CIRCUIT SHORTED GROUND K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL SHORTED TO K6 5 VOLT SUPPLY CIRCUIT K4 SENSOR GROUND CIRCUIT OPEN PCM K6 5 VOLT SUPPLY PCM K24 CKP SIGNAL CRANKSHAFT POSITION SENSOR TEST ACTION APPL...

Page 135: ... 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 Ignition on engine not running Wiggle the related wire harness and lightly tap on the Crank Position Sensor Observe the lab scope screen Look for any pulses generated by the CKP Sensor Start the engine Allow the engine to idle Observe the lab scope...

Page 136: ...ION TEST VER 5 NGC 8 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K24 CKP Signal circuit in the CKP Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 9 9 Turn the igni...

Page 137: ... and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 13 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K6 5 Volt Supply circuit in the CKP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the s...

Page 138: ...he K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIF...

Page 139: ...ECTION CHECKING CAMSHAFT POSITION SENSOR SIGNAL WITH THE DRBIIIt LAB CRANKSHAFT POSITION SENSOR K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORT TO GROUND K24 CKP SIGNAL CIRCUIT SHORTED TO B K24 CKP SIGNAL CIRCUIT SHORT TO K6 5 VOLTS PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter di...

Page 140: ...ls Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are tight Refer to any TSBs that may apply Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 Turn the ignition off Disconnect the CKP Sensor connector Ignition on engine not running Measure the voltag...

Page 141: ...Disconnect the CKP Sensor connector Disconnect the PCM connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance in the K24 CKP Signal circuit between the CKP harness connector and the appropriate terminal of spe...

Page 142: ...K6 5 Volt Supply circuit and the K24 CKP signal circuit at the CKP Sensor harness connector Wiggle the related wire harness while taking this measurement Is the resistance below 5 0 ohms All Yes Repair the short to the K6 5 Volt Supply circuit in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 12 12 NOTE Before continuing check the PCM harness connector terminals...

Page 143: ...ON SENSOR SIGNAL INTERMITTENT CAMSHAFT POSITION SENSOR SIGNAL K6 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN K6 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL CIRCUIT SHORTED GROUND K44 CMP SIGNAL CIRCUIT OPEN K44 CMP SIGNAL CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL SHORTED TO K6 5 VOLT SUPPLY CIRCUIT K4 SENSOR GROUND CIRCUIT OPEN PCM K6 5 VOLT SUPPLY PCM K44 CMP...

Page 144: ...E 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 Ignition on engine not running Wiggle the related wire harness and lightly tap on the Camshaft Position Sensor Observe the lab scope screen Start the engine Allow the engine to idle Observe the lab scope screen Did the CMP Sensor generate any erratic pulses All Y...

Page 145: ...AIN VERIFICATION TEST VER 5 NGC 8 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K44 CMP Signal circuit in the CMP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 9 9 ...

Page 146: ... the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 13 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K6 5 Volt Supply circuit in the CMP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to grou...

Page 147: ...the K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERI...

Page 148: ...PPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off With the DRBIIIt lab scope probe and the Miller special tool 6801 back...

Page 149: ...RIFICATION TEST VER 5 NGC 5 Turn the ignition off Carefully disconnect the Battery Ground cable Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found All Yes Repair or replace the Tone Wheel Pulse Ring as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE An intermittent glitch in the ...

Page 150: ...l circuit in the CMP Sensor harness connector Wiggle the related wire harness while monitoring the resistance value Does the resistance stay below 100 ohms All Yes Repair the short to ground in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 10 10 Turn the ignition off Disconnect the CMP Sensor connector Ignition on engine not running Measure the voltage on the K...

Page 151: ... terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 142 DRIVEABILITY NGC P0344 CAMSHAFT POSITION SENSOR INTERMITTENT Continued ...

Page 152: ...al reading fueling samples If a larger than expected variation is detected a soft failure is recorded Three soft failures set a one trip failure After two failed trips a DTC is set and the MIL is illuminated POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO EGR VALVE OPEN AT IDLE EGR VALVE ASSEMBLY INSPECTION EGR SOLENOID ASSEMBLY EGR SOLENOID GROUND CIRCUIT OPEN EGR SOLENOID CONTROL CKT SHORT TO GND EGR SO...

Page 153: ... holes in the EGR tube s Carbon build up on or near the EGR pintle and passage ways Obstruction in the EGR tubes Were any problem found All Yes Repair or replace the EGR Assembly as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Measure the voltage on the EGR Solenoid Control circuit in ...

Page 154: ...EGR Solenoid harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the EGR Solenoid Control circuirt Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 10 10 Turn the ignition off Disconnect the PCM harness connector Disconnect the EGR Solenoid harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE TH...

Page 155: ...CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Tu...

Page 156: ...GR Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the PCM harness connector Disconnect the EGR Solenoid harness connector Measure the resistance between ground and the EGR Solenoid Control circuit at the EGR Solenoid harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the EGR Solenoid Contro...

Page 157: ... Solenoid harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the EGR Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 8 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining v...

Page 158: ...RTED TO GROUND SENSOR GROUND CIRCUIT OPEN EGR ASSEMBLY GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 NOTE Diagnose all oth...

Page 159: ...t the EGR Solenoid harness connector Disconnect the PCM harness connector Measure the resistance of the EGR Sensor Signal circuit in the EGR Solenoid harness connector to ground Is the resistance below 5 0 ohms All Yes Repair the short to ground in the EGR Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Replace the EGR Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 NGC...

Page 160: ... for broken bent pushed out or corroded terminals Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Test Complete 7 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Measure the voltage of the EGR Sensor Signal circuit at the EGR Solenoid harness connector Is the voltage above 4 30 volts All...

Page 161: ...N VERIFICATION TEST VER 5 NGC 10 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the PCM harness connector Measure the resistance between ground and the EGR Sensor Signal circuit in the EGR Solenoid harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the EGR Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No G...

Page 162: ...D CIRCUIT PCM 5 VOLT SUPPLY CIRCUIT PCM EGR POSITION SENSOR SIGNAL TEST ACTION APPLICABILITY 1 NOTE When monitoring EGR valve position on the DRBIIIt during actua tion a delay in valve movement will occur until enough duty cycle is applied to overcome the spring force in the EGR valve this is to be considered normal operation Turn the ignition on With the DRBIIIt read the EGR Position Sensor volta...

Page 163: ... the EGR Position Sensor Signal circuit and the Sensor ground circuit in the EGR Position harness connector Is the resistance below 100 ohms All Yes Repair the short to Sensor ground in the EGR Position Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair a...

Page 164: ... terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 10 NOTE The engine will run rough and possibly stall in the following test Feather the accelerator pedal to keep the engi...

Page 165: ...nitoring EGR valve position on the DRBIIIt during actua tion a delay in valve movement will occur until enough duty cycle is applied to overcome the spring force in the EGR valve this is to be considered normal operation Start the engine With the DRBIIIt read the EGR Position Sensor voltage Is the voltage above 4 5 volts All Yes Go To 2 No Go To 8 2 Turn the ignition off Disconnect the EGR Solenoi...

Page 166: ...G THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the EGR Position Sensor Signal circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the EGR Position...

Page 167: ...un rough and possibly stall in the following test Feather the accelerator pedal to keep the engine from stalling Start the engine With the DRBIIIt enter Engine System Test and then EGR System Test Push the 4 VARIABLE function Monitor the EGR voltage while slowly pushing the up arrow Is the voltage change smooth All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perfor...

Page 168: ...K ENGINE MECHANICAL CONDITION AGING O2 SENSOR CATALYTIC CONVERTER TEST ACTION APPLICABILITY 1 NOTE A new rear O2 Sensor along with an aging front O2 Sensor may cause the DTC to set Review the repair history of the vehicle before continuing NOTE If an O2 Sensor or Fuel System Lean DTC s is set along with the Catalytic Converter Efficiency DTC diagnose the O2 Sensor DTC s before continuing NOTE Chec...

Page 169: ...eplace the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 Check the exhaust for excessive smoke caused by an internal problem in the engine Is a engine mechanical condition present All Yes Repair the engine mechanical condition as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 A new rear O2 Sensor along with an aging front O2 S...

Page 170: ...OOD TRIP EQUAL TO ZERO VISUAL AND PHYSICAL INSPECTION EVAP PURGE SOLENOID VACUUM SUPPLY INSPECTION EVAP PURGE SOLENOID STUCK CLOSED NVLD SWITCH OPERATION Z1 GROUND CIRCUIT OPEN NVLD ASSEMBLY K107 NVLD SWITCH SIGNAL CIRCUIT OPEN EVAPORATIVE EMISSION LEAK DETECTION PCM PCM TEST ACTION APPLICABILITY 1 NOTE If any of the following DTCs are set P0443 P0452 P0453 P0498 or P0499 diagnose them first befor...

Page 171: ...ATION TEST VER 5 NGC No Go To 4 4 Disconnect the vacuum supply hoses form the EVAP Purge Solenoid Using a hand vacuum pump apply 10 in Hg to the 9CAN9 side of the EVAP Purge Solenoid Ignition on engine not running Observe the vacuum gauge With the DRBIIIt actuate the EVAP Purge Solenoid Does the vacuum drop when the solenoid is actuated All Yes Go To 5 No Replace the Evap Purge Solenoid Perform PO...

Page 172: ... tester s control panel Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote button The EELD is now calibrated the flow meter in liters per minute Install the service port adapter 8404 14 on the vehicle s service port if equipped or install the 8404 ADP service adapter in the...

Page 173: ... smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that are left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister ...

Page 174: ...SULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K107 NVLD Switch Signal circuit from the NVLD electrical harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms All Yes NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push o...

Page 175: ... P0498 or P0499 diagnose them first before continuing with P0441 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 NOTE After disconnecting the Evap Purge va...

Page 176: ...ge Solenoid Inspect the vacuum port at the throttle body for any damage or plugging Were any problems found All Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 167 DRIVEABILITY NGC P0441 EVAP PURGE SYSTEM PERFORMANCE Continued...

Page 177: ...e EVAP system If the NVLD switch reopens before the calibrated amount of time for a Medium leak an error is detected Two Trip Fault P0455 EVAP SYSTEM LARGE LEAK When Monitored Engine Running Cold start test Fuel Level greater than 12 Ambient Temperature between 4 C and 32 C 39 F and 89 F Close Loop fuel system Test runs when small leak test is maturing Set Condition The PCM activates the EVAP Purg...

Page 178: ...ord the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 7 2 Perform a visual and physical inspection of the entire Evaporative Emission system Check for the follow conditions Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap gasket seal Were any of the above conditions found All Yes...

Page 179: ...nel based on DTC leak size Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote button The EELD is now calibrated the flow meter in liters per minute to the size leak indicated by the DTC set in the PCM Install the service port adapter 8404 14 on the vehicle s service port if...

Page 180: ...a leak is concealed from view i e top of fuel tank release the remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that is left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the vent si...

Page 181: ...BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Review the DRBIIIt Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply NOTE A loose gas cap could have caused this DTC to set Make sure gas cap is tight and in good condition Ensure the gas cap meets OEM specifications Perform a visual and physical inspec...

Page 182: ...HORTED TO GROUND POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the...

Page 183: ... Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the Evap Purge Solenoid harness connector Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFOR...

Page 184: ...e or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 175 DRIVEABILITY NGC P0443 EVAP PURGE SOLENOID CIRCUIT Continued ...

Page 185: ...UND EVAP PURGE SOLENOID LEAKS STUCK OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect t...

Page 186: ...ERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition on Using the DRBIIIt monitor the NVLD Switch State Disconnect the NVLD electrical connector Does the Switch change from CLOSED to OPEN All Yes Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connec...

Page 187: ... resistance below 5 0 ohms All Yes Repair the short to ground in the K52 EVAP Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFIC...

Page 188: ...g the DRBIIIt perform the NVLD FORCED MONITOR TEST Monitor the NVLD Switch state NOTE As the test runs the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the test is complete Did the NVLD Switch operate as described above All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To ...

Page 189: ... Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the Z1 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN C...

Page 190: ... APPLICABILITY 1 NOTE The difference in ambient temperature outside temp VS shop temp may conceal a leak it is best to perform this test after the vehicle s temperature has stabilized in the work area Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 4 2 Perform a visual a...

Page 191: ...ght 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that are left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister the smoke or dye may or may not be visual Introducing smoke...

Page 192: ...s not see a change in the fuel level of 1765 over a set amount of miles the test will fail Two Trip Fault P2066 FUEL LEVEL SENSOR 2 PERFORMANCE When Monitored TEST 1 With the ignition on the fuel level is compared to the previous key down after a 20 second delay TEST 2 The PCM monitor the fuel level at ignition on Set Condition TEST 1 If the PCM does not see a difference in fuel level of greater t...

Page 193: ...rness connector Measure the resistance between ground and the Fuel Level Signal circuit at the Fuel Pump Module harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the Fuel Level Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 Turn the ignition off Disconnect the Fuel Pump Module harness connector Disconnect the BCM harness connector ...

Page 194: ...dule Visually inspect the inside of the Fuel Tank for any obstructions or deformities Inspect the Fuel Pump Module Float arm for damage Inspect the Siphon hose for blockage kinks or disconnected Were any problems found All Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 7 7 If there are no possible causes remaining view repair All Repair Replace the Fuel ...

Page 195: ...UEL LEVEL SENSOR 1 HIGH When Monitored Ignition on and battery voltage above 10 4 volts Set Condition The fuel level sensor signal voltage at the PCM goes above 4 7 volts for more than 5 seconds One Trip Fault P2067 FUEL LEVEL SENSOR 2 LOW When Monitored Ignition on and battery voltage above 10 4 volts Set Condition The fuel level sensor signal voltage goes below 0 1961 volts for more than 5 secon...

Page 196: ...ro All Yes Refer to the Instrument Cluster Category and perform the appro priate symptoms Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 187 DRIVEABILITY NGC P0462 FUEL LEVEL SENSOR 1 LOW Continued ...

Page 197: ...ROL CIRCUIT SHORT TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt actuate the Radiator Fan Relay Is the Low Speed Radiator Fan Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the Low Speed Radiator Fan Relay from the PDC...

Page 198: ...om the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C24 Low Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the Low Speed Radiator Fan Relay from the PDC Disconnect the PCM harness connector Measure the resistance between ground and the C24 Low Speed ...

Page 199: ...Y CONTROL CIRCUIT SHORT TO GROUND PCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt actuate the High Speed Radiator Fan Relay Is the High Speed Radiator Fan Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the High Speed Radiator Fan Relay fro...

Page 200: ...e resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C27 High Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the High Speed Radiator Fan Relay from the PDC Disconnect the PCM harness connector Measure the resistance between ground and the C27 High Speed Rad Fan Relay Control circuit in the PDC Is the resistance bel...

Page 201: ...ition off Disconnect the NVLD electrical harness connector Measure the resistance of the NVLD Solenoid coil Is the resistance between 7 5 to 8 5 ohms All Yes Go To 3 No Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 3 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K1...

Page 202: ...Z1 GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the NVLD Assembly h...

Page 203: ...the K106 NVLD Sol Control circuit from the NVLD Assembly harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K106 NVLD Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the NVLD Assembly harness connector Measure the resistance between the Z1 Ground circuit ...

Page 204: ...gnition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition on With the DRBIIIt check the Transmission DTCs Are there any Transmission DTCs present All Ye...

Page 205: ...ED HIGH PERFORMANCE When Monitored Engine Running During an idle condition Set Condition If the engine RPM does not come within a calibratable high limit of the target idle speed a failure timer will increment When the appropriate failure timer reaches its maximum threshold without sign of RPM trending towards control a soft fail is generated When a calibratable number of the soft fails is reached...

Page 206: ...ernal vacuum leaks Were any vacuum leaks found All Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Inspect the Air Induction System for the following problems Restrictions Dirty Air Cleaner Foreign material trapped in the air intake tube etc Leaks Air Intake tube connection Air Cleaner housing etc Were any problems found All Yes Repair or replace...

Page 207: ...gine will not idle maintain an engine speed between 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIIIt read the IAC Current Is the IAC Current below 146 mA All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the IAC Motor harness connector Remove the IA...

Page 208: ...circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the K39 IAC Motor Control circuit in the IAC Motor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K39 IAC Motor Control circuit Perform POWER...

Page 209: ...e or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 200 DRIVEABILITY NGC P0508 IAC VALVE SENSE CIRCUIT LOW Continued ...

Page 210: ...UIT PCM TEST ACTION APPLICABILITY 1 NOTE If the engine will not idle maintain an engine speed between 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIIIt read the IAC Current Is the IAC Current above 999 mA All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Discon...

Page 211: ...volt All Yes Repair the short to voltage in the K39 IAC Motor Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connector Measure the resistance across the IAC Motor harness connector Is the resistance below 5 0 ohms All Yes Repair the K60 IAC Motor Signal circuit short to the K39 IAC Motor Control circuit Perform POW...

Page 212: ... With the DRBIIIt attempt to communicate with the SKREEM Turn the ignition on Can the DRBIIIt communicate with the SKREEM All Yes Go To 3 No Refer to the No Communication category Perform SKREEM VERIFICATION TEST VER 1A 3 Turn the ignition on With the DRBIIIt check for SKREEM DTCs Are any DTCs present in the SKREEM All Yes Refer to SKREEM category for the related symptom s Perform SKREEM VERIFICAT...

Page 213: ...rogram the Powertrain Control Module in accordance with the Service Information Perform SKREEM VERIFICATION TEST VER 1A No Test Complete 7 NOTE You must obtain the SKREEM pin number NOTE This DTC could have been set if the SKREEM harness connector was disconnected or if the SKREEM was replaced recently NOTE All keys that the customer uses for this vehicle must be tested to verify they are operatin...

Page 214: ...he Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Battery Temp Sensor harness connector Ignition on engine not running With the DRBIIIt read Battery Temp Sensor voltage Does the Battery Temp Sensor voltage read approximately 5 0 volts All Yes Replace the Battery Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3...

Page 215: ...the Sensor ground shorted to the Battery Temp Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Servic...

Page 216: ...ion on engine not running With the DRBIIIt read the Battery Temp Sensor voltage Is the voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Battery Temp Sensor harness connector Ignition on engine not running Measure the voltage of the Battery Temp Si...

Page 217: ... 5 0 ohms All Yes Go To 5 No Repair the open in the Battery Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Battery Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTA...

Page 218: ...Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Ignition on engine not running With the DRBIIIt read Oil Pressure Sensor voltage Does the Oil Pressure Sensor voltage read approximately 5 0 volts All Yes Replace the Oil Pressure Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Turn the ignition off Disconn...

Page 219: ...TED TO K4 SENSOR GROUND CIRCUIT PCM K7 5 VOLT SUPPLY CIRCUIT PCM A C PRESSURE SENSOR SIGNAL TEST ACTION APPLICABILITY 1 NOTE Ensure the A C refrigerant System is properly charged per the Service Information Start the engine With the DRBIIIt read the A C Pressure Sensor voltage Is the voltage below 0 6 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability cate...

Page 220: ...essure Sensor Signal circuit and the K4 Sensor ground circuit in the A C Pressure Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to the K4 Sensor ground circuit in the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push o...

Page 221: ...ressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open in the K7 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 9 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining ...

Page 222: ...sure the A C refrigerant System is properly charged per the Service Information Start the engine With the DRBIIIt read the A C Pressure Sensor voltage Is the voltage above 4 6 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 2 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Di...

Page 223: ...HE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the C18 A C Pressure Sensor Signal circuit from the A C Pressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the C18 A C Pressure...

Page 224: ...age or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 215 DRIVEABILITY NGC P0533 A C PRESSURE SENSOR HIGH Continued ...

Page 225: ...ONTROL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the Battery is in good condition Using the Midtronics Battery Tester test the Battery before continuing NOTE Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Turn the ignition off NOTE Ensure the generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse i...

Page 226: ...ltage between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt test light jumper it across the Generator Field harness connector Ignit...

Page 227: ...DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K20 Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the K20 Gen Field Control circuit Perform POWERT...

Page 228: ... the generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse is found to be open use the wiring diagram schematic as a guide inspect the wiring and connectors for damage Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERM...

Page 229: ...oltage in the K20 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform PO...

Page 230: ...ymptom in the Diagnostic category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Remove the Brake Lamp Switch and disconnect the harness connector Measure the resistance between the Z1 Ground circuit terminal and the K29 Brake Switch Signal terminal at the Brake Lamp Switch Apply and release the brake pedal plunger while monitoring the ohmmeter Does the resistance change fr...

Page 231: ...as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 222 DRIVEABILITY NGC P0572 BRAKE SWITCH 1 CIRCUIT LOW Continued ...

Page 232: ...elated Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION in the symptom Diagnostic category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Measure the resistance between the Z1 Ground circuit terminal and the K29 Brake Switch Signal circuit terminal...

Page 233: ...CATION TEST VER 5 NGC 4 Measure the resistance between the Z2 Ground circuit and ground at the Brake Lamp Switch harness connector Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the Z1 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary ...

Page 234: ... read the Speed Control voltage Is the Speed Control voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 2 Ignition on engine not running With the DRBIIIt monitor the Speed Control Switch voltage Disconnect the Speed Control On Off Switch harness connector Did the voltage change to above 4...

Page 235: ...the Speed Control Resume Accel Switch harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the V37 S C Switch Signal circuit to the appropriate...

Page 236: ...th the DRBIIIt read the Speed Control voltage Is the Speed Control voltage above 4 8 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 2 Turn the ignition off Remove the Speed Control Switches from the steering wheel Measure the resistance across each Speed Control Switch Monitor the ohmmeter while pressi...

Page 237: ... harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K4 Sensor Ground circuit from the Speed Control harness connector to the appropriate terminal of spec...

Page 238: ...e DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt actuate the Speed Control Vacuum Solenoid and note operation Does the Speed Control Vacuum Solenoid actuate properly All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No Go To 2 2 Turn the ignition off Disconnect the Speed Control Servo harness...

Page 239: ...IN VERIFICATION TEST VER 4 NGC 4 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V36 S C Vacuum Solenoid Control circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the V36 S C Vacuum Sol Control circuit Perform POWERTRAIN VERIF...

Page 240: ...lated Freeze Frame data With the DRBIIIt actuate the Speed Control Vent Solenoid and note operation Does the Speed Control Vent Solenoid acutate properly All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No Go To 2 2 Turn the ignition off Disconnect the Speed Control Servo harness connector Ignition on engine not running...

Page 241: ...ERIFICATION TEST VER 4 NGC 4 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V35 S C Vent Sol Control circuit at the Speed Control Servo harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the V35 Speed Control Vent Solenoid Control circuit Perform POWERTRAIN VER...

Page 242: ...TEDTO GROUND V40 S C BRAKE SWITCH OUTPUT CIRCUIT OPEN BRAKE LAMP SWITCH PCM S C SOURCE CIRCUIT TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the Speed Control Servo harness connector Ignition on engine not running NOTE It is necessary to PRESS and HOLD the Speed Control Switch in the ON position while checking for voltage Using a 12 volt test light connected to ground probe the V40 ...

Page 243: ...itch harness connector Is the resistance below 100 ohms All Yes Go To 4 No Repair the short to ground in the V32 S C Power Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the Brake Switch harness connector Measure the resistance of the V40 S C Brake Switch Output circuit from the Brake Switch harness connec...

Page 244: ...ding Does the test light illuminate brightly All Yes Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 7 7 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance ...

Page 245: ...us communication failure between the Engine and Transmis sion processors P0601 INTERNAL MEMORY CHECKSUM INVALID When Monitored With the ignition on Set Condition Internal checksum for software failed does not match calculated value POSSIBLE CAUSES PCM INTERNAL OR SPI TEST ACTION APPLICABILITY 1 The Powertrain Control Module is reporting internal errors view repair to continue All Repair Replace an...

Page 246: ...TION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 2 2 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt...

Page 247: ... resistance below 100 ohms All Yes Repair the K20 Gen Field Control circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 6 6 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TE...

Page 248: ...fer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the Fuel Pump Relay from the PDC Ignition on engine not running Measure the voltage of the A14 Fused Ignition Switch Output circuit in the PDC Is the voltage above 11 0 volts All Yes Go To 3 No Repair the A14 Fused Ignition Switch Output ci...

Page 249: ...rcuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the Fuel Pump Relay from the PDC Measure the resistance between ground and the K31 Fuel Pump Relay Control circuit in the PDC Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K31 Fuel Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continu...

Page 250: ...ng temperature With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No The VIN has been successfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition switch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM with the applicable info...

Page 251: ... To 2 No The mileage has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition switch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM with the applicable information Start the vehicle and allow it to reach normal operating t...

Page 252: ...normal operating temperature With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No The SKIM KEY information has been succcessfully programmed into the PCM Test is complete Perform SKREEM VERIFICATION TEST VER 1A 2 NOTE The ignition switch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the...

Page 253: ...O GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt actuate the A C Clutch Relay Is the A C Clutch Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Go To 2 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Ignition on engine not running Measure the v...

Page 254: ... from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C28 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 5 Turn the ignition off Remove the A C Clutch Relay from the PDC Measure the resistance between ground and the C28 A C Clutch Control circuit in the PDC Is the resistance below 5...

Page 255: ...TV RELAY CONTROL CIRCUIT OPEN MANIFOLD TUNING VALVE SLOENOID PCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Manifold Tune Valve Solenoid harnes...

Page 256: ...nected to battery voltage probe the MTV Relay Ground circuit in the IPM Does the test light illuminate brightly All Yes Go To 6 No Repair the MTV Relay Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the MTV Relay from the IPM Turn the ignition on Using a 12 volt test light connected to ground probe the MTV Relay Control circuit in the IPM With the ...

Page 257: ...Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 10 Turn the ignition off Disconnect the MTV Solenoid harness connector Using a 12 volt test light connected to battery voltage probe the ground circuit in the MTV Solenoid harness connector Does the test light illuminate brightly All Yes Replace the Ma...

Page 258: ... Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the ASD Relay from the PDC Ignition on engine not running Measure the voltage of the A14 Fused B circuits in the PDC Is the voltage above 11 0 volts All Yes Go To 3 No Repair the A14 Fused B circuit Check and replace any open fuses P...

Page 259: ...t Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the ASD Relay from the PDC Measure the resistance between ground and the K51 ASD Relay Control circuit in the PDC Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K51 ASD Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harn...

Page 260: ...T CIRCUIT OPEN PCM NO START PCM START TEST ACTION APPLICABILITY 1 NOTE Diagnose P0685 Auto Shutdown Relay Control Circuit first if set along with this DTC With the DRBIIIt erase the DTC Attempt to start the engine If the engine will not start crank the engine for at least 15 seconds It may be necessary to repeat several times Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITIO...

Page 261: ...inal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Install a substitute relay in place of the ASD Relay Ignition on engine not running With the DRBIIIt erase DTCs Attempt to start the eng...

Page 262: ... Relay Output circuits at the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the ASD Relay Output circuit s Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 8 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view rep...

Page 263: ...now that a DTC s is stored in the Transmission Control Module Erase this DTC from the PCM after all Transmission DTC s have been repaired Using the DRBIIIt read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom PCM Diagnostic Information complete All Continue Test Complete 254 DRIVEABILITY NGC ...

Page 264: ...nicate with the TCM refer to the Communication Category and preform the appropriate symptom With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition on With the DRBIIIt check the Tr...

Page 265: ...N SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 NOTE Due to the fact that the PCM compares the IAT AAT and ECT sensors to see if they are within a calibrated temp of one another the use of a block heater can cause false readings for the PCM Check with the customer to see if they use a block heater Ignition on engine not runnin...

Page 266: ... Yes Go To 5 No Go To 6 5 Inspect the Temperature sensors for any physical damage Inspect the engine coolant Ensure the coolant is at the proper level Refer to the Service Information COOLING Ensure the Temperature sensors are properly mounted WARNING 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 CLOTHI...

Page 267: ...ble Temperature Sensor harness connector Using a jumper wire jumper across the Temperature Sensor harness connector Ignition on engine not running With the DRBIIIt read the Temperature voltage Is the voltage below 1 0 volt All Yes Replace the applicable Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 9 9 Turn the ignition off Disconnect the applicable Temperature Sensor ...

Page 268: ...ST VER 5 NGC 11 Turn the ignition off Disconnect the applicable Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the Signal circuit in the Temperature harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 12 12 Turn the ign...

Page 269: ...CUIT SHORTED TO BATTERY VOLTAGE V37 S C SIGNAL CIRCUIT OPEN K4 SENSOR GROUND OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt monitor each switch function for the Speed Control Switches Press and release each Speed Control Button Resume Accel Cancel Decel Coast On Off Set Does each switch function change status when pressing and then depressing each switch All Yes Refer to th...

Page 270: ...S PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V37 S C Signal circuit from the Speed Control harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms for both measurement All Yes Go To 5 No Repair the open i...

Page 271: ...chematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 262 DRIVEABILITY NGC P1593 SPEED CONTROL SWITCH STUCK Continued ...

Page 272: ...o The PCM has been successfully programmed Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition switch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM Start the vehicle and allow it to reach normal operating temperatures With the DRBIIIt read DTCs Does the DTC reset...

Page 273: ...ector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition to run Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output Off Run Start cavity C1 12 circuit at the appropriate terminal of the ...

Page 274: ... Monitored With the ignition on continuous Set Condition An attempt to program write to the internal EEPROM failed Also checks at power down POSSIBLE CAUSES DRB DISPLAYS WRITE FAILURE DRB DISPLAYS WRITE REFUSED 2ND TIME DRB DISPLAYS SRI MILEAGE INVALID COMPARE SRI MILEAGE WITH ODOMETER TEST ACTION APPLICABILITY 1 With the DRBIIIt perform the SRI Memory Test Does the DRBIIIt display Write Failure A...

Page 275: ... Complete 4 With the DRBIIIt perform the SRI Memory Test Does the DRBIIIt display SRI Mileage Invalid All Yes Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 5 5 Compare the SRI Mileage stored with the Instrument Panel Odometer Is the mileage within the specified range displayed on the DRBIIIt All Yes Test Complete No Update the mileage and retest t...

Page 276: ...ICABILITY 1 NOTE Diagnose any Fuel Gauge high or low DTCs first if set along with this DTC NOTE The following test must be performed on both Fuel Level Sensor Inspect the Fuel Pump Module harness connectors for any corrosion or damage Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To...

Page 277: ...ump Module harness connector Measure the resistance of the Ground circuit from the Fuel Pump Module harness connector to ground Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 WARNING The fuel system is under a constant pressure even with the engine off Before opening the fuel system the fuel pressure must b...

Page 278: ...ngine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the Short Runner Valve Solenoid harness connector Turn the ignition on Using a 12 volt test lig...

Page 279: ...nector Is the resistance below 100 ohms All Yes Repair the short to ground in the SRV Control circuirt Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 Turn the ignition off Disconnect the PCM harness connector Disconnect the SRV Solenoid harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR ...

Page 280: ... TRIP EQUAL TO ZERO VACUUM LEAK HIGH RESISTANCE IN MAP K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K6 5 VOLT SUPPLY CIRCUIT MAP SENSOR HIGH RESISTANCE IN K1 MAP SIGNAL CIRCUIT RESISTANCE TO GROUND IN K1 MAP SIGNAL CIRCUIT HIGH RESISTANCE IN K4 MAP GROUND CIRCUIT PCM TP SENSOR OPERATION HIGH RESISTANCE IN TP SENSOR K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN TP SENSOR K6 5 VOLT SUPPLY...

Page 281: ... vacuum leak is most likely the cause of this DTC Inspect the Intake Manifold for leaks and cracks Inspect the Power Brake Booster for any vacuum leaks Inspect the PCV system for proper operation or any vacuum leaks Were any vacuum leaks found All Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Start the engine With the DRBIIIt monitor the MAP Se...

Page 282: ...N VERIFICATION TEST VER 5 NGC 7 Turn the ignition off Disconnect the TP Sensor harness connector With the DRBIIIt monitor the TP Sensor voltage Ignition on engine not running Connect a jumper wire between the K22 TP Signal circuit and the K4 Sensor ground circuit Does the TP Sensor voltage change from approximately 4 9 volts to below 0 5 of a volt All Yes Replace the Throttle Position Sensor Perfo...

Page 283: ...r Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC ...

Page 284: ...ATION TEST VER 5 NGC No Go To 15 15 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K1 MAP Signal circ...

Page 285: ...ector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 18 No Repair the K4 Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 18 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and pr...

Page 286: ...term compensation to long term adaptive and a certain percentage is exceeded for two trips a freeze frame is stored the MIL illuminates and a trouble code is stored P2097 DOWN STREAM FUEL SYSTEM 1 2 RICH When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F and altitude below 8500 ft Set Condition If the PCM adds downstream short term compensatio...

Page 287: ...N SYSTEM must be free from leaks ENGINE VACUUM must be at least 13 inches in neutral ENGINE VALVE TIMING must be within specifications ENGINE COMPRESSION must be within specifications ENGINE EXHAUST SYSTEM must be free of any restrictions or leaks ENGINE PCV SYSTEM must flow freely TORQUE CONVERTER STALL SPEED must be within specifications POWER BRAKE BOOSTER no internal vacuum leaks FUEL must be ...

Page 288: ...IFICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the voltage on the O2 Return circuit in the O2 Sensor harness connector Is the voltage at 2 5 volts All Yes Check the fuel system for contaminants Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Check the O2 Return circuit for a short to ground open or short to volta...

Page 289: ...ION When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault P2308 IGNI...

Page 290: ...ABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 8 2 Turn the ignition off Remove the ignition coil NOTE Before continuing inspect the ignition coil for damage or carbon tracking coil or the spark plug insulator boot If a problem is found replace the ignition co...

Page 291: ... connector Measure the resistance of the Coil Control circuit between the Ignition Coil harness connector and the special tool 8815 terminal Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the Coil Control circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 6 Turn the ignition off Disconnect the Ignition Coil harness connector Disconnect the PCM harness connector Measure ...

Page 292: ...ap the bottom of the spark plug on a solid surface The electrode in the spark plug should not move Were any of the above condition present All Yes Replace the Spark Plug Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 283 DRIVEABILITY NGC P2302 IGNITION COIL 1 SECONDARY CIRCUIT...

Page 293: ...ION Z1 GEN FIELD GROUND CIRCUIT OPEN K20 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K20 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND K20 GEN FIELD CONTROL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Turn the ignition off NOTE The battery must be fully charged NOTE The Generator belt tension a...

Page 294: ...age between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt test light jumper it across the Generator Field harness connector Ignitio...

Page 295: ...ERIFICATION TEST VER 3 NGC No Go To 8 8 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K20 Gen F...

Page 296: ...CABILITY 1 NOTE If P1603 or P1604 are set along with this DTC diagnose them first before continuing with U0101 NOTE Before continuing inspect all fuses and ensure that all power and ground circuits are operating properly NOTE Check all powers and grounds to the PCM before continuing Turn the ignition on With the DRBIIIt erase DTCs Start the engine allow the engine to run for at least 20 seconds wi...

Page 297: ...used Ignition Switch Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 3 Note Determine which modules this vehicle is equipped with before begin ning Note When attempting to communicate with any of the modules on this vehicle the DRB will display 1 of 2 different communication errors a NO RESPONSE message or a BUS SIGNALS OPEN message Turn the ignition on Using the DRB attempt ...

Page 298: ...he engine on and off several times Leave the engine running for at least 20 second each time With the DRBIIIt read DTC s Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIIIt attempt to communicate with the BCM Can communication be established with the BCM All...

Page 299: ...AGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI BUS circuit between the Special Tool 8815 and the BCM harness connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST ...

Page 300: ...veability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIIIt attempt to communicate with the Instrument cluster Can communication be established with the Instrument Cluster All Yes Go To 3 No Refer to the Communication Category and perform the appropri ate symptom related to no communication with cluster Perform POWERTRAIN VERIFICATION TEST VER 1 ...

Page 301: ... is operational from the DLC to the SKIM Was the DRB III able to communicate with the SKIM All Yes Go To 3 No Refer to symptom BUS SIGNAL OPEN FROM SKIM in the COMMUNICATION category Perform SKREEM VERIFICATION TEST VER 1A 3 Turn the ignition off Disconnect the PCM harness connectors Disconnect the SKIM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNE...

Page 302: ...e DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wire harness Look for parameter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under wh...

Page 303: ...0 second each time With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIIIt attempt to communicate with the BCM Can communication be established with the BCM All Yes Go To 3 No Refer to the Communication Category and perform t...

Page 304: ...ALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit from the BCM harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Replace BCM in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No Repair the PCI Bus circuit between the PCM and the BCM for an open Perform POWERTR...

Page 305: ... THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connected to ground probe the A41 PCM Fused Ignition Switch Output circuit in the Pinout Box Does the test light illuminate brightly All Yes Go To 3 No Repair ...

Page 306: ...arness connector to ground Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 3 Disconnect the A C Clutch harness connector Turn the ignition on With the DRBIIIt actuate the A C Clutch Relay Measure the voltage of the A C Clutch Relay Output circuit in the A C Clutch harness connector Is the voltage above 11 0 vo...

Page 307: ...3 A C Clutch Relay Output circuit between the PDC and the A C Clutch harness connector Is the resistance below 5 0 ohms All Yes Replace the A C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Repair the C3 A C Clutch Relay Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 298 DRIVEABILITY NGC CHECKING THE A C RELAY OUTPUT Continued ...

Page 308: ...er is not reset by the micro controller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the write operation RAM FAILURE When Monitored With the ignition on Set Condition The RAM fails a test that checks the RAM s ability to retain memory ROM FAULT When Monitored With the igniti...

Page 309: ... DTCs and then erase the SKIM DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the SKIM DTCs Did the same SKIM DTC return All Yes Replace and program the SKREEM in accordance with the Service Information Perform SKREEM VERIFICATION TEST VER 1A No Test Complete 300 SKREEM ANTENNA FAILURE Continued ...

Page 310: ...hake that occurs with the PCM due to a SKIM reset or during SECRET KEY transfers to the PCM Set Condition When the SKIM does not receive an expected PCI BUS message trans mission acknowledgement from the PCM after 3 transmit attempts POSSIBLE CAUSES INTERMITTENT WIRING HARNESS PROBLEM WIRING HARNESS INSPECTION SKREEM PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the PCM has proper power and ground c...

Page 311: ...CM and SKREEM DTC s Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the SKREEM DTCs Does the code appear All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKREEM VERIFICATION TEST VER 1A No Test Complete 4 Turn the ignition off Note Visually inspect the related wiring h...

Page 312: ...eceived by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the PCM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the PCM does not match the VIN stored in the SKIM s EEPROM POSSIBLE CAUSES VERIFYING PCM VIN REPLACE SKREEM AND CHECK DTC S INTERMITTENT WIRING HARNESS PROBLEM PCM TEST ACTION APPLICABILITY 1 With the DRBIIIt era...

Page 313: ...M and SKREEM DTC s Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle With the DRBIIIt check for SKREEM DTCs Does the DRBIIIt display the same DTC All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKREEM VERIFICATION TEST VER 1A No The repair is complete Perform SKREEM VERIFICATION TEST VER 1A 4 Turn the ig...

Page 314: ...ve a transponder response after 8 consec utive transponder read attempts within 2 0 seconds TRANSPONDER ID MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When the transponder ID read by the SKIM does not match any of the transponder ID s stored in the SKIM s memory TRANSPONDER RESPONSE MISMATCH When Monitored At ignition on and during Key Programming Mode Set ...

Page 315: ...on With the DRBIIIt read the SKREEM DTCs Is the DTC present for all ignition keys All Yes Replace and program the Sentry Key Remote Entry Module in accordance with the Service Information Perform SKREEM VERIFICATION TEST VER 1A No Replace the ignition key s that cause the SKIM DTC Perform SKREEM VERIFICATION TEST VER 1A 4 With the DRBIIIt attempt to reprogram the ignition keys to the SKREEM With t...

Page 316: ...ly inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair wiring harness connectors as necessary Perform SKREEM VERIFICATION TEST VER 1A No ...

Page 317: ...N APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt program the SKREEM in accordance with the Service Information With the DRBIIIt erase SKREEM DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read SKREEM DTCs Did this DTC set again All Yes Replace the Sentry Key Remote Entry Module in accordance with the Service Info...

Page 318: ...2 No Go To 5 Caution Stop All Actuations 2 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install a fuel gauge Turn the ignition on With the DRBIIIt actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure spe...

Page 319: ...uel system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet Strainer Perform POWERTRAIN VERIFICATION TEST VER 1 No Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the fuel pump module harness connector Turn the ignition on With t...

Page 320: ... Perform POWERTRAIN VERIFICATION TEST VER 1 9 Turn the ignition off Remove the Fuel Pump Relay from the PDC Disconnect the Fuel Pump Module harness connector NOTE Check connectors It is critical that the connector is free from any signs of corrosion or deformities Measure the resistance of the A141 Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector Is the res...

Page 321: ...esting or servicing any fuel system hose fitting or line the fuel system pressure must be released Install special 5 16 fuel line adapter tool 6539 Attach a fuel pressure test gauge to the T fitting on the tool 6539 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 400 KPa 34 KPa 58 psi 5 psi Using special tool C4390 Hose Clamp Pl...

Page 322: ...n Go To 4 2 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Raise vehicle on hoist and disconnect the fuel supply line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel p...

Page 323: ...ant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install special 5 16 fuel line adapter tool 6539 Attach a fuel pressure test gauge to the T fitting on the tool 6539 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 400 KPa 34 KPa 58 ps...

Page 324: ...ommunicates with the DRB and that there are no DTC s stored in the PCM memory If the PCM reports a No Response condition refer to the Communication category for the proper tests Read the PCM DTC s with the DRB If any DTC s are present they must be repaired before continuing with any other No Start diagnostic tests Refer to the Symptom list for the related P code that is reported by the PCM Ensure ...

Page 325: ...Yes Go To 4 No Go To 9 Caution Stop All Actuations 4 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install a fuel gauge Turn the ignition on With the DRBIIIt actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pr...

Page 326: ... even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Gain access to the Fuel Pump Module driver side and the Fuel Tank Module passenger side Visually and Physically inspect the fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module Look for disconnected and or damage lines or hoses Were the fue...

Page 327: ...the test light illuminate brightly All Yes Go To 10 No Go To 12 Caution Stop All Actuations 10 Turn the ignition off Disconnect the Fuel Pump Module harness connector Note Check connectors It is critical that the connector is free from any signs of corrosion or deformities Clean repair as necessary Using a test light connected to battery voltage probe the Fuel Pump ground circuit at the Fuel Pump ...

Page 328: ...ny signs of corrosion or deformities Measure the resistance of the Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector Is the resistance below 5 0 ohms All Yes Replace the Fuel Pump Relay Perform POWERTRAIN VERIFICATION TEST VER 1 No Repair the open fuel pump relay output circuit Perform POWERTRAIN VERIFICATION TEST VER 1 319 STARTING ENGINE CRANKS DOES NOT ST...

Page 329: ... seized Is the engine able to turn over All Yes Go To 2 No Repair the mechanical condition preventing the starter motor from cranking Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors Move the Gear selector through all gear positions from Park to 1st and back While moving the gear selector through each gear measure the resistance between groun...

Page 330: ...he engine may be cranked in the next step Keep away from moving engine parts Briefly connect a jumper wire between Starter Relay B circuit and the Starter Relay Output Circuits Did the Starter Motor crank the engine All Yes Go To 6 No Go To 9 6 Turn the ignition off Remove the Starter Relay from the PDC Turn the ignition on Using a 12 volt test light probe the Ignition Switch Output circuit in the...

Page 331: ...ce of the Starter Relay Output circuit between the Relay and the Solenoid harness connector Is the resistance below 5 0 ohms All Yes Go To 10 No Repair Starter Relay Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 10 Turn the ignition off Remove the Starter Relay from the PDC Using a 12 volt test light connected to ground probe the Fused B circuit at the Starter Relay termina...

Page 332: ...ition off Disconnect the PCM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the PCM Fused Ignition Switch Output circuit in the PCM harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the Ignition Switch Output circuit Perform POWERTRAIN VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the PCM harness connector ...

Page 333: ...urn the ignition on With the DRBIIIt read DTC s Are any DTCs present All Yes Refer to the Driveability Category and perform the appropriate symptom Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on NOTE If you are unable to communicate with the SKIM refer to the Communication Category and perform the appropriate symptom With the DRBIIIt read the SKIM codes Are there any ...

Page 334: ...le on hoist and disconnect the fuel pressure line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pressure test gauge to the T fitting on the tool 6539 Turn the ignition on With the DRBIIIt actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 400 KP...

Page 335: ...e is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the engine During engine warm up monitor the Engine Coolant Temperature value The temperature value change should be a smooth transition from start up to normal operating temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Temperature value increase smoothly and did it reach at least 82 C 180 F A...

Page 336: ...tor 9 Road test the vehicle With the DRBIIIt monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 degrees 10 Below 25 MPH make 5 to 8 wide open throttle kickdowns to 1st gear Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown 11 For a specific DTC drive the vehicle to the Sym...

Page 337: ... from ALL modules Are any DTC s present or is the original condition still present All Yes Repair is not complete refer to the appropriate symptom No Repair is complete POWERTRAIN VERIFICATION TEST VER 1 APPLICABILITY 1 NOTE After completing the Powertrain Verification Test the Transmission Verifi cation Test must be performed 2 NOTE If the PCM has been replaced and the correct VIN and mileage hav...

Page 338: ...f there are no DTCs present and all components are functional properly the repair is complete Are any DTCs present All Yes Repair is not complete refer to appropriate symptom No Repair is complete POWERTRAIN VERIFICATION TEST VER 3 NGC APPLICABILITY 1 NOTE After completing the Powertrain Verification Test the Transmission Verifi cation Test must be performed 2 NOTE If the PCM has been replaced and...

Page 339: ...ol did not disengage the repair is not complete Check for TSBs that pertain to speed control problem and then if necessary return to Symptom List 11 Bring the vehicle speed back up to 35 MPH 12 Press the RESUME ACCEL switch If the speed control did not resume the previously set speed the repair is not complete Check for TSBs that pertain to speed control problem and then if necessary return to Sym...

Page 340: ...rform steps 5 8 If a Major OBDII Monitor DTC was repaired skip those steps and continue verification 10 After the ignition has been off for at least 10 seconds restart the vehicle and run 2 minutes 11 If the Good Trip counter changed to one or more and there are no new DTC s the repair was successful and is now complete Erase DTC s and disconnect the DRBIIIt 12 If the repaired DTC has reset the re...

Page 341: ...the repair is complete Did the indicator ball indicate the a leak is present All Yes Repeat the DTC test to identify the leak and repair No Repair is complete SKREEM VERIFICATION TEST VER 1A APPLICABILITY 1 Reconnect all previously disconnected components and connectors 2 Obtain the vehicle s unique Personal Identification Number PIN assigned to it s original SKIM This number can be obtained from ...

Page 342: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES 8 2 CONTROL AND SOLENOIDS C O M P O N E N T L O C A T I O N S 333 COMPONENT LOCATIONS ...

Page 343: ...TYPICAL VIEW C O M P O N E N T L O C A T I O N S 334 COMPONENT LOCATIONS 8 2 CONTROL AND SOLENOIDS Continued ...

Page 344: ...8 3 SENSOR C O M P O N E N T L O C A T I O N S 335 COMPONENT LOCATIONS ...

Page 345: ...8 4 FUEL SYSTEM AND EVAP SYSTEM 8 5 SWITCHES C O M P O N E N T L O C A T I O N S 336 COMPONENT LOCATIONS ...

Page 346: ...CTION 1 K900 20DB DG SENSOR GROUND 2 F855 20PK YL 5 VOLT SUPPLY 3 C18 20LB BR A C PRESSURE TRANSDUCER SIGNAL 4 AMBIENT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G31 20OR VT AAT SIGNAL 2 K900 20DB DG SENSOR GROUND BATTERY TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K91 20DB YL BATTERY TEMP SIGNAL 2 K900 20DB DG SENSOR GROUND C O N N E C T O R P I N O U T S 337 CONNECTOR PINOUT...

Page 347: ...K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K19 16DB DG COIL CONTROL NO 1 COIL ON PLUG NO 2 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K17 16DB TN COIL CONTROL NO 2 COIL ON PLUG NO 3 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K18 16DB OR COIL CONTROL NO 3 C O N N E C T O R P I N O U T S 338 CONNECTOR PINOUTS ...

Page 348: ...WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K16 16DB YL COIL CONTROL NO 5 COIL ON PLUG NO 6 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K10 16DB OR COIL CONTROL NO 6 CRANKSHAFT POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F855 20PK YL 5 VOLT SUPPLY 2 K900 20DB DG SENSOR GROUND 3 K24 20BR LB CKP SIGNAL C O N N E C T O R P I N O U T S 339 CONNECTOR PINOUTS ...

Page 349: ...SMIT TCM 16 A105 20DB RD FUSED B EGR SOLENOID BLACK 6 WAY CAV CIRCUIT FUNCTION 1 K34 20DB LG EGR SIGNAL 2 F855 20PK YL 5 VOLT SUPPLY 3 K900 20DB DG SENSOR GROUND 4 Z335 18BK WT GROUND 5 6 K35 18DB VT EGR SOL CONTROL ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K2 18VT OR ECT SIGNAL ENGINE OIL PRESSURE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G6...

Page 350: ...L INJECTOR NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 16BR YL INJECTOR CONTROL NO 1 FUEL INJECTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 16BR DB INJECTOR CONTROL NO 2 C O N N E C T O R P I N O U T S 341 CONNECTOR PINOUTS ...

Page 351: ... NO 3 FUEL INJECTOR NO 4 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K14 16BR TN INJECTOR CONTROL NO 4 FUEL INJECTOR NO 5 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 16BR OR INJECTOR CONTROL NO 5 C O N N E C T O R P I N O U T S 342 CONNECTOR PINOUTS ...

Page 352: ... RELAY OUTPUT 2 N4 20DB YL FUEL LEVEL SENSOR SIGNAL NO 1 3 N5 20DB WT FUEL LEVEL SENSOR SIGNAL NO 2 4 5 Z210 20BK LB GROUND 6 Z201 16BK GROUND GENERATOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z20 18BR BK GROUND 2 K20 18BR GY GEN FIELD CONTROL INTAKE AIR TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K21 20BR WT IAT SIGNAL C O N N E C T O R P I N O U T S 343 CONNECTO...

Page 353: ...C O N N E C T O R P I N O U T S 344 CONNECTOR PINOUTS ...

Page 354: ...01 18BR RD LATE BUILD FUSED B 31 20A A100 18RD VT TRAILER TOW EARLY BUILD FUSED B 34 10A C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 35 36 20A INTERNAL FUSED B 37 25A INTERNAL FUSED B 38 20A INTERNAL FUSED B 39 20A A109 18OR RD FUSED B 40 40A F515 12PK LB FUSED DOOR NODE RELAY OUTPUT 41 40A F516 12PK FUSED DOOR NODE RELAY OUTPUT 42 40A C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT 44 25A F525 ...

Page 355: ...NING VALVE RELAY CAV CIRCUIT FUNCTION 30 INTERNAL FUSED B 85 INTERNAL GROUND 86 K36 20DB YL MTV CONTROL 87 K136 18BR MANIFOLD TUNING VALVE RELAY OUTPUT 87A STARTER MOTOR RELAY CAV CIRCUIT FUNCTION 30 INTERNAL FUSED B 85 T751 20YL IGNITION SWITCH OUTPUT START 86 T752 20DG OR STARTER RELAY CONTROL 87 T750 12YL GY STARTER MOTOR RELAY OUTPUT 87A C O N N E C T O R P I N O U T S 346 CONNECTOR PINOUTS ...

Page 356: ... 7 8 9 10 A107 12TN RD FUSED B 11 12 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 13 K136 18BR MANIFOLD TUNING VALVE RELAY OUTPUT 14 C3 18DB YL A C COMPRESSOR CLUTCH RELAY OUTPUT 15 INTEGRATED POWER MODULE C2 DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 2 3 A101 12VT RD FUSED B 4 F515 12PK LB FUSED DOOR NODE RELAY OUTPUT INTEGRATED POWER MODULE C3 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 2 A112 12OR RD FUSED B ...

Page 357: ...89 18WT YL FOG LAMPS LEFT FRONT FOG LAMP DRIVER 3 W1 18BR TN WASHER FLUID LEVEL SWITCH SENSE 4 5 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 6 L778 20WT LB RIGHT FRONT SIDE MARKER LAMP DRIVER 7 L777 20WT VT LEFT FRONT SIDE MARKER LAMP DRIVER 8 9 10 11 12 13 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 14 Z118 18BK YL GROUND 15 16 L44 16TN WT RIGHT LOW BEAM LAMP DRIVER 17 L90 18WT OR FOG LAMPS RIGHT FRO...

Page 358: ...NSMISSION CONTROL RELAY OUTPUT 10 K31 20BR FUEL PUMP RELAY CONTROL INTEGRATED POWER MODULE C8 WHITE 15 WAY CAV CIRCUIT FUNCTION 1 F516 12PK FUSED DOOR NODE RELAY OUTPUT 2 C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 3 W4 12BR OR FRONT WIPER HIGH LOW RELAY HIGH SPEED OUTPUT 4 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 5 A701 14BR RD EARLY BUILD FUSED B 5 A100 16RD VT TRAILER TOW LATE BUILD FUSED ...

Page 359: ...START 14 15 L3 18WT VT LICENSE LAMP DRIVER 16 F201 20PK LB ORC RUN START DRIVER 17 18 19 F2 18PK YL IGNITION SWITCH OUTPUT RUN START 20 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 21 22 23 24 N1 16DB OR FUEL PUMP RELAY OUTPUT 25 A105 18DB RD FUSED B 26 F525 16TN PK MIDDLE ROW HEATED SEATS FUSED RUN RELAY OUTPUT KNOCK SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K42 20DB OR KS SIGNAL 2 K942 20BR LG KS RETURN...

Page 360: ...SWITCH SIGNAL 3 K106 20VT LB NVLD SOL CONTROL OXYGEN SENSOR 1 1 UPSTREAM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z42 18BK LG GROUND 2 K99 18BR TN O2 1 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K41 18DB LB O2 1 1 SIGNAL OXYGEN SENSOR 1 2 DOWNSTREAM WHITE 4 WAY CAV CIRCUIT FUNCTION 1 Z43 18BK LB GROUND 2 K299 18BR OR O2 1 2 HEATER CONTROL 3 K904 20DB DG O2 RETURN DOWN 4 K141 20DB YL O2 1 2 SIGNAL C ...

Page 361: ...17 18 Z131 16BK DG GROUND 19 20 G6 16VT GY OIL PRESSURE SIGNAL 21 22 G31 20OR VT AAT SIGNAL 23 24 25 D20 20WT LG SCI RECEIVE PCM 26 D123 20WT BR FLASH PROGRAM ENABLE 27 28 29 A109 18OR RD FUSED B 30 T751 20YL IGNITION SWITCH OUTPUT START 31 K141 20DB YL O2 1 2 SIGNAL 32 K904 20DB DG O2 RETURN DOWN 33 34 35 36 D21 20WT GY SCI TRANSMIT PCM 37 D15 20BR WT SCI TRANSMIT TCM 38 D25 20WT VT PCI BUS C O N...

Page 362: ...2 16BR DB INJECTOR CONTROL NO 2 14 K11 16BR YL INJECTOR CONTROL NO 1 15 16 K36 20DB YL MTV CONTROL 17 18 K99 18BR TN O2 1 1 HEATER CONTROL 19 K20 18BR GY GEN FIELD CONTROL 20 K2 18VT OR ECT SIGNAL 21 K22 18BR OR TP SIGNAL 22 K34 20DB LG EGR SIGNAL 23 K1 20VT BR MAP SIGNAL 24 K942 20BR LG KS RETURN 25 K42 20DB OR KS SIGNAL 26 27 K900 20DB DG SENSOR GROUND 28 K961 20BR VT IAC RETURN 29 F855 20PK YL ...

Page 363: ...342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20DB WT EVAP PURGE CONTROL 21 22 23 B29 20DG WT BRAKE SWITCH SIGNAL 24 25 26 T44 20YL DG AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20DG YL AUTOSTICK UPSHIFT SWITCH SIGNAL 28 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K70 20DB BR EVAP PURGE RETURN 30 31 C18 20LB BR A C PRESSURE TRANSDUCER SIGNAL 32 K91 20DB YL BATTERY TEMP SIGNAL 33 34 V37 20V...

Page 364: ...VE PRESSURE SWITCH SENSE 23 24 25 26 27 T41 18YL DB TRS T41 SENSE 28 T16 16YL OR TRANSMISSION CONTROL RELAY OUTPUT 29 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 30 T47 18YL DG 2 4 PRESSURE SWITCH SENSE 31 32 T14 18DG BR OUTPUT SPEED SENSOR SIGNAL 33 T52 18DG WT INPUT SPEED SENSOR SIGNAL 34 T13 18DG VT SPEED SENSOR GROUND 35 T54 18DG OR TRANSMISSION TEMPERATURE SENSOR SIGNAL 36 37 T42 18DG YL TR...

Page 365: ...AY OUTPUT 3 Z723 18BK DG GROUND 4 K173 18BR VT RAD FAN RELAY CONTROL SHORT RUNNER VALVE SOLENOID GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K236 18DB LG SRV SOL CONTROL 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT SKREEM MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 20WT VT PCI BUS 3 4 F20 20PK GY IGNITION SWITCH OUTPUT RUN START 5 Z120 20BK WT GROUND 6 A118 20RD OR FUSED B C O N N E C T O R P I N O U...

Page 366: ...WAY CAV CIRCUIT FUNCTION 1 Z23 20BK VT SPEED CONTROL SWITCH GROUND 2 3 V37 20VT S C SWITCH SIGNAL SPEED CONTROL SWITCH RIGHT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z23 20BK VT SPEED CONTROL SWITCH GROUND 2 3 V37 20VT S C SWITCH SIGNAL THROTTLE POSITION SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K22 18BR OR TP SIGNAL 3 F855 20PK YL 5 VOLT SUPPLY C O N N E C T O R P I N O U T ...

Page 367: ...NOTES 358 ...

Page 368: ...10 0 SCHEMATIC DIAGRAMS 10 1 2004 CS 3 5L S C H E M A T I C D I A G R A M S 359 SCHEMATIC DIAGRAMS ...

Page 369: ...10 2 2004 CS 3 5L S C H E M A T I C D I A G R A M S 360 SCHEMATIC DIAGRAMS ...

Page 370: ...10 3 2004 CS 3 5L S C H E M A T I C D I A G R A M S 361 SCHEMATIC DIAGRAMS ...

Page 371: ...NOTES 362 ...

Page 372: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 363 CHARTS AND GRAPHS ...

Page 373: ...C H A R T S A N D G R A P H S 364 CHARTS AND GRAPHS ...

Page 374: ... 9 3 4 BODY CONTROL MODULE BCM 10 3 5 CHIME WARNING SYSTEM 10 3 5 1 CHIME PRIORITY 11 3 5 2 CHIME ON CONDITIONS 11 3 5 3 WARNING LAMP ANNOUNCEMENT 12 3 5 4 OTHER CHIME ON CONDITIONS 12 3 6 COMMUNICATION 13 3 7 DOOR AJAR SYSTEM 14 3 8 DOOR MODULES 15 3 8 1 POWER WINDOWS 15 3 8 2 POWER DOOR LOCKS 15 3 8 3 DOOR LOCK INHIBIT 16 3 8 4 REMOTE KEYLESS ENTRY 16 3 8 4 1 PANIC FUNCTION 16 3 8 4 2 ROLLING CO...

Page 375: ...EM ALERTS 26 3 12 3 6 1 3 SYSTEM FAULTS 26 3 12 3 6 1 4 SPARE WHEEL AUTO DETECT 26 3 12 3 6 1 5 DIAGNOSING AND CLEARING SYSTEM FAULTS 26 3 12 3 6 1 6 SYSTEM TEST 27 3 12 3 6 2 TRAINING THE SKREEM NORMAL BUILD 27 3 12 3 6 2 1 PRESSURE THRESHOLDS 27 3 12 3 2 2 ACTIVE FAULT AND SYSTEM ALERTS 27 3 12 4 COMPASS MINI TRIP COMPUTER 27 3 13 INSTRUMENT CLUSTER 28 3 13 1 INSTRUMENT CLUSTER SELF TEST EARLY B...

Page 376: ...S 36 4 2 4 DRBIIIT SAFETY INFORMATION 36 4 3 WARNINGS 37 4 3 1 VEHICLE DAMAGE WARNINGS 37 4 3 2 ROAD TESTING A COMPLAINT VEHICLE 37 5 0 REQUIRED TOOLS AND EQUIPMENT 37 6 0 GLOSSARY OF TERMS 37 7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 39 ADJUSTABLE PEDALS BROKEN CABLE MHSAPM MSAPM 40 BROKEN FORWARD CABLE MHSAPM MSAPM 40 BROKEN REARWARD CABLE MHSAPM MSAPM 40 LOSS OF HALL FORWARD SIGNAL MHSAPM MSAPM...

Page 377: ...AIN OR SEAT SQUIB CIRCUIT OPEN 116 LEFT CURTAIN OR SEAT SQUIB CIRCUIT SHORT 119 LEFT CURTAIN OR SEAT SQUIB SHORT TO BATTERY 122 LEFT CURTAIN OR SEAT SQUIB SHORT TO GROUND 124 LEFT FRONT IMPACT SENSOR INTERNAL 1 127 LEFT SIDE IMPACT SENSOR 1 INTERNAL 1 129 LEFT SIDE IMPACT SENSOR 2 INTERNAL 1 131 LEFT SIDE IMPACT SENSOR 3 INTERNAL 1 133 LOSS OF IGNITION RUN START 135 ORC RUN START DRIVER OPEN 135 O...

Page 378: ...OR 3 INTERNAL 1 239 VEHICLE BODY STYLE MISMATCH 241 AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 244 AUDIO ALL OUTPUTS SHORT 245 ANTENNA HARDWARE FAILURE SDARS 247 ANTENNA NOT CONNECTED SDARS 248 BUS BUSY SDARS 250 PCI BUS SHORTED TO BATTERY 250 PCI BUS SHORTED TO GROUND 250 PCI BUS SHORTED TO BATTERY MHSAPM 250 PCI BUS SHORTED TO GROUND MHSAPM 250 BUS LOW SDARS 252 CASSETTE PLAYER INOP 253 CD...

Page 379: ...80 PCM MESSAGES NOT RECEIVED AMPLIFIER 281 POWER AMP SHUTDOWN 282 RADIO MESSAGES NOT RECEIVED AMPLIFIER 284 REMOTE RADIO SWITCH OPEN 285 REMOTE RADIO SWITCH STUCK 288 SOFTWARE CHECKSUM FAILURE AMPLIFIER 291 AMPLIFIER PRETEST 292 INOP NO FAULT CODES SDARS 293 POOR RECEPTION SDARS 295 CHIME CHIME INOPERATIVE AT ALL TIMES 296 KEY IN IGNITION AND DRIVER S DOOR OPEN CHIME NOT OPERATING PROPERLY 297 PRO...

Page 380: ...DULE 350 NO RESPONSE FROM OVERHEAD CONSOLE 352 NO RESPONSE FROM PASSENGER DOOR MODULE 354 NO RESPONSE FROM PCM PCI BUS 356 NO RESPONSE FROM PCM PCM SCI ONLY 357 NO RESPONSE FROM POWER LIFTGATE MODULE 360 NO RESPONSE FROM RADIO 363 NO RESPONSE FROM SATELLITE RADIO RECEIVER 365 NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE 367 NO RESPONSE FROM TRANSMISSION CONTROL MODULE 369 PCI BUS COMMUNICATION ...

Page 381: ... 433 LEFT FRONT PARK LAMP SHORT TO GROUND IPM 435 LEFT FRONT SIDE MARKER LAMP OPEN IPM 437 LEFT FRONT SIDE MARKER LAMP SHORT TO GROUND IPM 439 LEFT FRONT TURN SIGNAL OUTPUT OPEN BCM 441 LEFT FRONT TURN SIGNAL OUTPUT SHORT BCM 443 LEFT HEADLAMP HIGH BEAM OPEN IPM 444 LEFT HEADLAMP HIGH BEAM SHORT TO GROUND IPM 446 LEFT HEADLAMP LOW BEAM OPEN IPM 448 LEFT HEADLAMP LOW BEAM SHORT TO GROUND IPM 450 LE...

Page 382: ...RESPONDING STORED 495 FRONT MODE DOOR TRAVEL TOO LARGE STORED 495 FRONT MODE DOOR TRAVEL TOO SMALL STORED 495 LEFT IR SENSOR NOT CALIBRATED STORED 495 LOOPBACK FAILURE STORED 495 NO COMMUNICATION WITH BCM STORED 495 NO COMMUNICATION WITH DDM STORED 495 NO COMMUNICATION WITH MIC STORED 495 NO COMMUNICATION WITH PCM STORED 495 NO COMMUNICATION WITH PDM STORED 495 OPS CHECKSUM ERROR STORED 495 OUTSID...

Page 383: ...OR MESSAGE MISSING ACTIVE 519 ENGINE SENSORS MESSAGE MISSING ACTIVE 520 EVAP TEMP SENSOR OPEN ACTIVE 521 EVAP TEMP SENSOR SHORTED ACTIVE 524 FRONT BLOWER RELAY OPEN 526 FRONT BLOWER RELAY SHORT TO BATT 527 FRONT MODE DOOR TRAVEL TOO SMALL ACTIVE 528 INVALID CONDITIONS FOR COOLDOWN TEST EVAP TEMPERATURE TOO LOW 530 NO COMMUNICATION WITH BCM ACTIVE 533 NO COMMUNICATION WITH DDM ACTIVE 533 NO COMMUNI...

Page 384: ...ORN INPUT STUCK IPM 592 HORN RELAY CONTROL CIRCUIT OPEN IPM 594 HORN RELAY CONTROL CIRCUIT SHORT TO BATTERY IPM 595 IGNITION MUX SWITCH INPUT OPEN BCM 596 IGNITION MUX SWITCH INPUT SHORT BCM 597 IGNITION RUN START INPUT MISMATCH IPM 598 IGNITION START INPUT MISMATCH IPM 602 PDM BATTERY VOLTS LOW PDM 605 RUN ONLY RELAY OPEN IPM 606 RUN ONLY RELAY SHORT TO BATTERY IPM 607 RUN ACCESSORY RELAY OPEN IP...

Page 385: ... 644 TRACTION CONTROL SWITCH STUCK BCM 645 INTERIOR LIGHTING BCM COURTESY LAMP 1 OUTPUT SHORT 646 BCM COURTESY LAMP 2 OUTPUT SHORT 647 DOME SWITCH INPUT OPEN BCM 648 DOME SWITCH INPUT SHORT BCM 649 READING LAMP OUTPUT SHORT BCM 650 SEAT SWITCH ILLUMINATION OUTPUT SHORT TO BATTERY DDM 651 SEAT SWITCH ILLUMINATION OUTPUT SHORT TO BATTERY PDM 652 SEAT SWITCH ILLUMINATION OUTPUT SHORT TO GROUND DDM 65...

Page 386: ...SENSOR CIRCUIT OPEN 696 AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND 698 CONTROL MODULE FAILURE INTERNAL FAILURE 700 INCOMPLETE LATCH CINCH NO PAWL TRANSITION 701 INCOMPLETE LATCH CINCH OVERCURRENT 703 INCOMPLETE LATCH RELEASE NO REVERSE TO UNLOAD CLUTCH 706 INCOMPLETE LATCH RELEASE RATCHET SWITCH FAILURE 707 INCOMPLETE LATCH RELEASE OVER CURRENT 709 INCOMPLETE LATCH RELEASE PAWL SWITCH FAIL...

Page 387: ...OPEN DDM 785 DRIVER MIRROR HORIZONTAL SENSOR CIRCUIT SHORT DDM 787 DRIVER MIRROR HORIZONTAL SENSOR CIRCUIT STUCK DDM 789 DRIVER MIRROR VERTICAL SENSOR CIRCUIT STUCK DDM 789 PASSENGER MIRROR HORIZONTAL SENSOR CIRCUIT STUCK PDM 789 PASSENGER MIRROR VERTICAL SENSOR CIRCUIT STUCK PDM 789 DRIVER MIRROR VERTICAL OUTPUT SHORT TO BATTERY DDM 791 DRIVER MIRROR VERTICAL OUTPUT SHORT TO BATTERY DDM 791 DRIVE...

Page 388: ...H STUCK DDM 839 DRIVER HORIZONTAL AND LUMBAR IN SWITCH SHORTED DDM 841 DRIVER HORIZONTAL SENSOR OUT OF RANGE HIGH MHSAPM 843 DRIVER HORIZONTAL SENSOR OUT OF RANGE LOW MHSAPM 846 DRIVER HORIZONTAL SWITCH STUCK DDM 849 DRIVER REAR RISER AND PEDAL BACK SWITCH SHORTED DDM 851 DRIVER REAR RISER SENSOR OUT OF RANGE HIGH MHSAPM 853 DRIVER REAR RISER SENSOR OUT OF RANGE LOW MHSAPM 856 DRIVER REAR RISER SW...

Page 389: ...STUCK UP DDM 910 PASSENGER REAR WINDOW EXPRESS DOWN SWITCH STUCK DDM 911 PASSENGER REAR WINDOW SWITCH MUX INPUT OPEN SHORT TO VOLTAGE PDM 912 PASSENGER REAR WINDOW SWITCH MUX INPUT SHORT TO GROUND PDM 914 PASSENGER REAR WINDOW SWITCH MUX INPUT STUCK PDM 916 PASSENGER REAR WINDOW SWITCH STUCK DOWN DDM 918 PASSENGER REAR WINDOW SWITCH STUCK UP DDM 919 WINDOW LOCKOUT SWITCH STUCK DDM 920 ANY PASSENGE...

Page 390: ... TRANSMIT FAILURE SKREEM 952 TIRE SENSOR 2 HIGH PRESSURE ALERT SKREEM 952 TIRE SENSOR 2 LOW PRESSURE ALERT SKREEM 952 TIRE SENSOR 2 TRANSMIT FAILURE SKREEM 952 TIRE SENSOR 3 HIGH PRESSURE ALERT SKREEM 952 TIRE SENSOR 3 LOW PRESSURE ALERT SKREEM 952 TIRE SENSOR 3 TRANSMIT FAILURE SKREEM 952 TIRE SENSOR 4 HIGH PRESSURE ALERT SKREEM 952 TIRE SENSOR 4 LOW PRESSURE ALERT SKREEM 952 TIRE SENSOR 4 TRANSM...

Page 391: ...T SHORT BCM 985 HIGH VOLTAGE DISABLE FRONT REAR WASHER 987 REAR WASHER OUTPUT OPEN IPM 988 REAR WASHER OUTPUT SHORT TO GROUND IPM 990 REAR WASHER SWITCH STUCK BCM 991 REAR WIPER OUTPUT OPEN SHORT TO GROUND BCM 992 REAR WIPER OUTPUT SHORT TO GROUND BCM 994 REAR WIPER PARK INPUT OPEN BCM 996 REAR WIPER PARK INPUT SHORT BCM 997 VERIFICATION TESTS VERIFICATION TESTS 998 8 0 COMPONENT LOCATIONS 1003 8 ...

Page 392: ...LLOW BLACK 2 WAY 1015 AIRBAG SQUIB DRIVER 2 YELLOW TAN 2 WAY 1016 AIRBAG SQUIB DRIVER KNEE BLOCKER YELLOW 4 WAY 1016 AIRBAG SQUIB LEFT CURTAIN YELLOW 2 WAY 1016 AIRBAG SQUIB PASSENGER YELLOW 4 WAY 1016 AIRBAG SQUIB RIGHT CURTAIN YELLOW 2 WAY 1017 AMPLIFIER C1 WHITE 18 WAY 1017 AMPLIFIER C2 WHITE 12 WAY 1017 AUTO TEMP CONTROL C1 BLACK 13 WAY 1018 AUTO TEMP CONTROL C2 NATURAL 13 WAY 1018 AUTOMATIC D...

Page 393: ...TOR AJAR SWITCH PASSENGER REAR BLACK 4 WAY 1035 DOOR MODULE DRIVER C1 GRAY 14 WAY 1036 DOOR MODULE DRIVER C2 BLACK 12 WAY 1036 DOOR MODULE DRIVER C3 BLACK 20 WAY 1036 DOOR MODULE PASSENGER C1 GRAY 14 WAY 1037 DOOR MODULE PASSENGER C2 BLACK 12 WAY 1037 DOOR MODULE PASSENGER C3 BLACK 20 WAY 1037 DVD SCREEN BLACK 12 WAY 1038 DVD CD CHANGER C1 BLACK 16 WAY 1038 DVD CD CHANGER C2 BLACK 12 WAY 1038 EVAP...

Page 394: ... INTEGRATED POWER MODULE C1 BLACK 15 WAY 1051 INTEGRATED POWER MODULE C2 DK GRAY 4 WAY 1051 INTEGRATED POWER MODULE C3 GRAY 2 WAY 1051 INTEGRATED POWER MODULE C4 GREEN 16 WAY 1052 INTEGRATED POWER MODULE C5 GRAY 26 WAY 1052 INTEGRATED POWER MODULE C6 GRAY 12 WAY 1053 INTEGRATED POWER MODULE C7 GRAY 10 WAY 1053 INTEGRATED POWER MODULE C8 WHITE 15 WAY 1053 INTEGRATED POWER MODULE C9 BLUE 26 WAY 1054...

Page 395: ... 3 WAY 1067 REAR BOOSTER FAN POWER MODULE C1 BLACK 4 WAY 1067 REAR BOOSTER FAN POWER MODULE C2 BLACK 2 WAY 1068 REAR BOOSTER FAN REAR CONTROL SWITCH BLACK 6 WAY 1068 REAR VIEW MIRROR BLACK 12 WAY 1068 RECIRCULATION DOOR ACTUATOR GRAY 2 WAY 1069 SATELLITE RADIO MULTIPLEXER C1 DK GRAY 22 WAY 1069 SATELLITE RADIO MULTIPLEXER C2 DK GRAY 10 WAY 1069 SATELLITE RADIO RECEIVER BLACK 12 WAY 1070 SEAT BELT ...

Page 396: ...EXTERIOR LIGHTS FRONT LIGHTING 1087 10 9 HEATING A C 1088 10 9 1 AUTOMATIC TEMPERATURE CONTROL SYSTEM 1088 10 10 IGNITION POWER ACCESSORY 1089 10 10 1 IGNITION SWITCH 1089 10 11 INSTRUMENT CLUSTER 1090 10 11 1 NAVIGATION BCM SWITCH POD 1090 10 11 2 FUEL LEVEL SENSORS 1091 10 12 INTERIOR LIGHTING 1092 10 13 NAVIGATION SYSTEM 1093 10 14 OVERHEAD CONSOLE 1094 10 15 POWER DOOR LOCKS RKE 1095 10 16 POW...

Page 397: ...NOTES xxiv ...

Page 398: ...SE A VEHICLE DIAGNOSTIC TROUBLE CODE It is recom mended that you review the entire manual to be come familiar with all the new and changed diag nostic procedures This book reflects many suggested changes from readers of past issues After using this book if you have any comments or suggestions please fill out the form in the back of this book and mail it back to us 1 1 SYSTEM COVERAGE This manual c...

Page 399: ...djustable Pedal Module MSAPM is located under the driver s seat and controls the adjustable pedals The adjustable pedals control switch is located on the driver door trim panel This switch is hardwired to the Driver Door Module DDM When the operator actuates the switch on the DDM sends a message via the PCI Bus to the MHSAPM MSAPM requesting pedal adjustment The MHSAPM MSAPM retains the memory rec...

Page 400: ...G THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRB...

Page 401: ... refer to the Hazardous Substance Control System for Proper Disposal Dispose of deployed air bags in a manner consistent with state provincial local and federal regulations Use the following table to identify the status of the Airbag Squib AIRBAG SQUIB STATUS 1 Using a DRBIII read Airbag DTC s if the following active codes are present ACTIVE DTC CONDITIONS SQUIB STATUS Driver Squib 1 open Driver S...

Page 402: ...e passenger airbag infla tor or inflators discharge the gas directly into the cushion The airbag module cannot be repaired and must be replaced if deployed or in any way damaged WARNING THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17000 kPa 2500 PSI DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR DO NOT PUNCTURE INCINERATE OR BRING INTO CONTACT WITH ELECTR...

Page 403: ...ib 2 open is NOT an ac tive code Passenger Squib 1 was used Passenger Squib 2 is live If Passenger Squib 2 open AND IF Passenger Squib 1 open is NOT an ac tive code Passenger Squib 1 is live Passenger Squib 2 was used If neither of the following codes is an active code ACTIVE DTC SQUIB STATUS Passenger Squib 1 open Status of Airbag is Unknown Passenger Squib 2 open 3 2 4 SEAT BELT TENSIONERS Front...

Page 404: ...e three 3 Left impact Sensors three 3 Right impact Sensors side impact sensors are electronic accelerometers that sense the rate of vehicle decel eration and when combined with the ACM Acceler ometer provides verification of the direction and severity of a side impact Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor ...

Page 405: ...tored When and if the malfunc tion ceases to exist an ignition cycle count will be initiated for that code If the ignition cycle count reaches 254 without a reoccurrence of the same malfunction the diagnostic trouble code is erased and that ignition cycle counter is reset to zero If the malfunction reoccurs before the count reaches 254 then the ignition cycle counter will be reset and diagnostic t...

Page 406: ...ides control over all of the CD DVD Changer features except for the CD DVD load function and the CD DVD eject function Buttons on the front of the CD DVD Changer controls these two functions The radio also supplies the PCI Bus left and right speaker output through a single cable All features you would expect such as Disc Up Down Track Up Down Random and Scan are controlled by the radio which also ...

Page 407: ...are not turned off by the driver Provides Compass Minitrip support Provides interior lighting courtesy reading lamps Provides diagnostic reporting Provides electronic liftgate release with power door locks Provides exterior lighting Provides headlamp time delay with without auto headlamps Provides automatic headlamps with electro chromatic mirror Provides illuminated entry Provides a fade to off f...

Page 408: ... After 5 seconds the chime will stop but the lamp will remain illuminated for an additional 3 seconds The Enhanced Seat Belt Reminder cycles for a total of 12 times 96 seconds After the 12th time the Seat Belt Lamp will remain on without any chime Buck ling the driver seat belt at anytime will cancel the Fasten Seat Belt Reminder announcement Exterior Lights On Chime sounds if the ignition is in t...

Page 409: ...tal of 12 times 96 seconds After the 12th time the Seat Belt Lamp will remain on without any chime Buck ling the driver seat belt at anytime will cancel the Fasten Seat Belt Reminder announcement Check Engine Lamp The cluster will sound a single chime after illumi nating the indicator Engine Temperature Lamp The cluster will sound a single chime when the indicator first illuminates at 252 F 122 C ...

Page 410: ...e violet in order to distinguish between differ ent module connections The modules are wired in parallel Connections are made in the harness using splices The following modules are used on CS vehicles Body Control Module Integrated Power Module IPM Powertrain Control Module PCM Mechanical Instrument Cluster MIC Airbag Control Module ORC Overhead Console Controller Antilock Brake CAB Automatic Temp...

Page 411: ...nd circuits The DRBIIIt may display 9BUS SIGNAL OPEN9 or 9NO RESPONSE9 to indicate a communication problem These same messages will be displayed if the vehicle is not equipped with that particular module The CCD error message is a default message used by the DRBIIIt and in no way indicates whether or not the PCI Bus is operational The message is only an indication that a module is either not respo...

Page 412: ...pective switch is inactive An other feature allows power window operation to continue from any power window switch for 45 seconds after turning off the ignition but only if the front doors remain closed Still another power window feature is the Express Down feature This feature works on all four windows and is activated by pressing the power window switch into the second detent Once activated the ...

Page 413: ...ter one time the driver door lock will unlock the illuminated entry will turn on the courtesy lamps and the vehicle theft security system if equipped will disarm After pressing the unlock button a second time the remaining door locks will unlock The EVIC or the DRBIIIt can reprogram this feature to unlock all of the door locks with one press of the unlock button If the vehicle is equipped with the...

Page 414: ...g the Memory Set Switch 1 or 2 the DDM receives and interprets the analog signal and then sends a PCI Bus message to the Passenger Door Module PDM the Memory Heated Seat Adjustable Pedal Module and the Audio System to set or recall the Memory mirror position 1 or 2 The DDM and the PDM store the setting for the respec tive mirror s position Memory seat position 1 or 2 The MHSAPM MSAPM stores the se...

Page 415: ...p voltage to provide the desired illu mination The DRLs will automatically extinguish when the hazards are activated and will come back on when the hazards are deactivated 3 10 2 HEADLAMP SWITCH The Headlamp Switch uses a multiplexed MUX circuit to the Body Control Module BCM The Headlamp Switch controls the Fog lamp relay Park lamps and the Low and High Beam head lamps The BCM then sends a signal...

Page 416: ...rol Mod ule PCM disable A C compressor operation while the Automatic Temperature Control ATC is set in an automatic mode The PCM disables the A C compressor if the A C is too low if the A C pressure is too high if engine overheating is immanent or if an engine overheating condition exists For ATCs with version 17 software the ATC clamps the blower speed if the PCM has disabled the A C compressor F...

Page 417: ...the ATC Module The Dual Zone ATC system uses two two wire electric blend door actuators one two wire electric front mode door actuator one two wire electric recirculation door actua tor one two wire electric rear mode door actuator System Relays The Integrated Power Module IPM houses and provides power to the A C Clutch Relay EBL Relay Front Blower Motor Relay and Rear Booster Fan Relay Ambient Te...

Page 418: ...te instantly upon ignition on However if the vehicle is turned off for less than 2 hours and the outside air temperature increases the OAT display may display a value that is colder than the actual outside air temperature This is due to filtering which does not allow for instantaneous updates for warmer outside air temperatures Also if the vehicle is driven for an extended period of time below 20 ...

Page 419: ... NAV CAN CEL ENTER scroll left scroll up scroll right and scroll down The Vehicle Theft Alarm light is a red oval located under the EVIC reset button The Analog Clock consists of an hour and minute hands with one time adjust button The Hazard switch is designated with a red triangle and is a push on push off switch 3 12 3 ELECTRONIC VEHICLE INFORMATION CENTER EVIC The Electronic Vehicle Informatio...

Page 420: ... Pressing the RESET button once will clear the trip function displayed except Distance to Service and cause the EVIC to send a PCI Bus beep request to the BCM If the RESET button is pressed again within 3 seconds the EVIC will reset ALL of the trip functions The trip function that may be reset is the Average Fuel Economy A reset will only occur if a trip function that may be reset is displayed Dis...

Page 421: ... ignition is On and the EVIC receives PCI Bus data indicating that engine RPM is greater than zero auto calibration is performed continuously If the calibration information stored in the compass module memory is not within the normal range after a power up cycle the compass will display 9COMPASS CALIBRATING 9 The EVIC will enter into the fast cal mode until cali bration is complete To enter the co...

Page 422: ...SENSORS Y N using the EVIC MENU button Use the STEP button to select and the MENU button to confirm YES The CMTC will initiate the following procedure 2 A display will prompt the user to TRAIN DRIVER FRONT SENSOR At this point the user must set the left front tire Sensor Transmitter to learn mode by positioning a magnet Relearn Mag net special tool 8821 over the valve stem for at least 5 seconds T...

Page 423: ...an active fault code B Request a chime C Display 9SERVICE TIRE SYSTEM SOON 9 Use the DRBIIIt Inputs Outputs function to further isolate the specific concern The DRBIIIt can be queried to determine the status and battery condition for each Sensor Transmitter 3 12 3 6 1 4 SPARE WHEEL AUTO DETECT If the spare tire is mounted on the vehicle the CMTC will 1 Detect the change after 15 minutes at or abov...

Page 424: ... fail to train replace the SKREEM 3 12 3 6 2 1 PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor Transmitters and deter mine if any tire has gone below the low pressure or exceeded the high pressure thresholds Refer to the tables below LOW TIRE PRESSURE THRESHOLDS SYSTEM STATUS INDICATOR TIRE PRESSURE ON 193 kPa 28 PSI OFF 227 kPa 43 PSI HIGH TIRE PRESSURE THRES...

Page 425: ...both the customer and the service techni cian by allowing them to view the odometer with out turning the ignition on The cluster has the following warning indicators Turn Signals green High Beam blue Check Engine amber Oil Pres sure red Seat Belt red Charging System red Airbag red Low Fuel amber Engine Tempera ture Red Brake Park Brake red ABS amber Traction Control amber Front Fog green Tire Pres...

Page 426: ...7 of the C5 connector for the left side marker lamp Front fog lamps When the IPM receives a message for front fog lamps on the IPM will supply power to pin 17 of the C5 connector for the right lamp and pin 2 of the C5 connector for the left lamp License plate lamp When the IPM senses that the park lamps switch is closed the IPM will supply power through a high side driver of the IPM Transmission C...

Page 427: ...ow side control internal to the IPM Under normal operating conditions if the horn is pressed for longer than 30 seconds the IPM will automatically deactivate the horn to prevent damage to it The IPM will re activate control of the relay after a 25 second cool down period This circuit is electroni cally controlled and continuously monitors the coil side of the relay for malfunctions Front Blower Re...

Page 428: ...he SHIP PING position there will be no RKE or door lock functions Flash programming voltage When a DRBIIIt is connected and the proper flash reprogramming sequence is selected the 20 volt signal will be applied through pin 5 of connector C9 CAUTION The IPM will learn several Learned Features when it is connected to a vehicle therefore it is not recommended that IPM s be swapped from one vehicle to...

Page 429: ...ed on vehicle via PCI Bus with a DRBIIIt diagnostic tool The DRBIIIt can read all inputs actuate all outputs read module information and read diagnostic trouble codes As a reminder some DTC s can be set during normal PLG operation 3 16 3 SYSTEM INHIBITORS 1 Battery voltage too high or too low above 16V below 9 5V 2 Vehicle in gear 3 Vehicle speed 0 mph 0 km h 4 Outside temperature too high above 1...

Page 430: ...or the position of the mirror motors by measuring the voltage on each signal circuit When a memory position is set the DDM and PDM monitor and store the position of the outside mirrors The DDM and PDM adjust the mirrors to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory recall switch 3 18 TELECOMMUNICATIONS 3 18 1 HANDS FREE PHONE OVE...

Page 431: ...owing features lo hi speed mist wipers inter mittent wipers and wipe after wash The front wiper system is only active when the ignition switch is in the RUN ACC position The vehicle operator selects the front wiper function using the front wiper switch a resistive multiplexed stalk switch which is integral to the Multi Function Switch The front wiper switch is hardwired to the Body Control Module ...

Page 432: ...l dis play one of only two error messages user requested WARM Boot or User Requested COLD Boot If the DRBIIIt should display any other error message record the entire display and call the STAR Center This is a sample of such an error message display ver 2 14 date 26 Jul93 file key_iff cc date Jul26 1993 line 548 err 0xi User Requested COLD Boot Press MORE to switch between this display and the app...

Page 433: ...s in the service manual should be serviced 4 2 4 DRBIIIT SAFETY INFORMATION WARNING EXCEEDING THE LIMITS OF THE DRBIIIT MULTIMETER IS DANGEROUS READ ALL DRBIIIT INSTRUCTIONS BEFORE USING THE MULTIMETER FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH Follow the vehicle manufacturer s service speci fications at all times Do not use the DRBIIIt if it has been damaged Do no...

Page 434: ...QUIPMENT FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIIIt diagnostic read out box Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 9001 RF Detector 6 0 GLOSSARY OF TERMS ABS antilock brake system ACM airbag control module AECM airbag electronic control module ACM APM adjustab...

Page 435: ...ulated RKE remote keyless entry SAB seat airbag SBT seat belt tensioner SDAR satellite digital audio receiver SIACM side impact airbag control module SKREEM Sentry Key RemotE Entry Module SM seat module SQUIB also called initiator located inside airbag SRS supplemental restraint system TCM transmission control module TCS traction control system TPMS tire pressure monitor system UGDO universal gara...

Page 436: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 39 ...

Page 437: ...Adjustable Pedal Hall Sensor and Adjustable Pedal Sensor counts are not synchronized in one travel direction BROKEN REARWARD CABLE MHSAPM MSAPM When Monitored Ignition On Continuously Set Condition The MHSAPM MSAPM detects the Adjustable Pedal Hall Sensor and Adjustable Pedal Sensor counts are not synchronized in one travel direction LOSS OF HALL FORWARD SIGNAL MHSAPM MSAPM When Monitored Ignition...

Page 438: ...TION TEST VER 1 2 Turn ignition on With the DRBIIIt in Inputs Outputs read the Adjustable Pedal Hall Sensor state Operate the Adjustable Pedal Switch to move the pedals Does the DRBIIIt switch between HIGH and LOW All Yes Go To 3 No Check for open or shorted wiring conditions between sensor and MHSAPM Inspect for Adjustable Pedal Assembly failure Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 3...

Page 439: ...tween the two pedals Is there any damaged or worn components All Yes Replace the Adjustable Pedal Assemby in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 No Replace the Memory Heated Seat Adjustable Pedal Module in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 42 ADJUSTABLE PEDALS BROKEN CABLE MHSAPM MSAPM Con...

Page 440: ...APM MSAPM When Monitored Ignition On Continuously Set Condition The MHSAPM MSAPM detects voltage higher than 4 7 volts on the Adjustable Pedal Hall Signal circuit PEDAL HALL INPUT SHORTED LOW MHSAPM MSAPM When Monitored Ignition On Continuously Set Condition The MHSAPM MSAPM detects voltage between 2 5 and 3 0 volts on the Adjustable Pedal Hall Signal circuit POSSIBLE CAUSES STORED DIAGNOSTIC TROU...

Page 441: ... Pedal Motor Hall Sense circuit at the Adjustable Pedal Motor connector Is the voltage above 4 5 volts All Yes Go To 3 No Go To 6 3 Turn ignition off Disconnect the Adjustable Pedal Motor Connector Disconnect the MHSAPM C1 Connector Measure the resistance of the Adjustable Pedal Hall Signal circuit between the Adjustable Pedal Motor connector and the MHSAPM C1 connector Is the resistance below 5 0...

Page 442: ...or Measure the resistance of the Adjustable Pedal Motor Hall Sense circuit between the Adjustable Pedal Motor connector and the MHSAPM C1 connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the Adjustable Pedal Motor Hall Sense circuit for an open Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 7 Turn ignition off Disconnect the MHSAPM C1 connector Measure the resistance of the ...

Page 443: ...ously Set Condition The MHSAPM MSAPM detects message longer than 35 seconds from the DDM POSSIBLE CAUSES PEDAL FORWARD SWITCH STUCK TEST ACTION APPLICABILITY 1 View repair All Repair This DTC is for reference only Check for DTC s in the Driver Door Module and refer to the symptom list Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 46 ADJUSTABLE PEDALS ...

Page 444: ...TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the adjustable pedal s and memory system Turn the ignition switch to the OFF position then start the engine and let run for one minute Operate the adjustable pedal s to both stop limits With the DRB check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go...

Page 445: ...sure the MHSAPM is fully connected before proceeding Turn ignition on Measure the voltage of the Adjustable Pedal Hall Signal circuit at the MHSAPM C1 connector Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Adjustable Pedal Assembly in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 6 Ensure all connectors are connected and Adjustable Pedal...

Page 446: ...dal Motor connector and the MHSAPM C1 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 No Repair the Adjustable Pedal Hall Sense Return circuit for an open Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 49 ADJUSTABLE PEDALS PEDAL HALL INPUT SHORTE...

Page 447: ...uously Set Condition The MHSAPM MSAPM detects message longer than 35 seconds from the DDM POSSIBLE CAUSES PEDAL REARWARD SWITCH STUCK TEST ACTION APPLICABILITY 1 View repair All Repair This DTC is for reference only Check for DTC s in the Driver Door Module and refer to the symptom list Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 50 ADJUSTABLE PEDALS ...

Page 448: ... TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the adjustable pedal s and memory system Turn the ignition switch to the OFF position then start the engine and let run for one minute Operate the adjustable pedal s to both stop limits With the DRB check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes G...

Page 449: ...r Ensure the MHSAPM is fully connected before proceeding Turn ignition on With the DRBIIIt in MHSAPM Sensors Read the Adjustable Pedal Sensor voltage Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Adjustable Pedal Sensor in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 6 Ensure all connectors are connected and Adjustable Pedal Motor is ope...

Page 450: ...al Sensor connector and the MHSAPM C1 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 No Repair the Adjustable Pedal Sensor Return circuit for an open Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 53 ADJUSTABLE PEDALS PEDAL SENSOR OUT OF RANGE H...

Page 451: ...rase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the OFF position then start the engine and let run for one minute Operate the adjustable pedal s to both stop limits With the DRBIIIt check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go To 2 No Using the wiring diagram schemat...

Page 452: ... proceeding Disconnect the Adjustable Pedal Sensor Connector Connect a jumper wire between Adjustable Pedal Sensor Feed and Adjustable Pedal Sensor Signal circuits Turn ignition on With the DRBIIIt select MHSAPM Sensors Read the Adjustable Pedal Sensor voltage Is the voltage above 4 5 volts All Yes Replace the Adjustable Pedal Sensor in accordance with the Service Information Perform ADJUSTABLE PE...

Page 453: ...stance below 100 0 ohms All Yes Repair the Adjustable Pedal Sensor Feed circuit for a short to ground Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 No Replace the Memory Heated Seat Adjustable Pedal Module in accordance with the Service Information Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 56 ADJUSTABLE PEDALS PEDAL SENSOR OUT OF RANGE LOW MHSAPM MSAPM Continued ...

Page 454: ...Run Operate the Adjustable Pedal Switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PEDAL SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 2 Disconnect the Dr...

Page 455: ...tch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Adjustable Pedal Switch MUX circuit as necessary Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform ADJUSTABLE PEDALS VERIFICATION TEST VER 1 58 ADJUSTABLE PEDALS PEDAL SWITCH STUCK DDM Continued ...

Page 456: ...tinuously performs internal circuit tests Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 2 When Monitored With the ignition on the module on board diagnostics continuously performs internal circuit tests Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 3 When Monitored With the ignition on the mod...

Page 457: ...ICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM Select the appropriate module and DTC type combination All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 2 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AV...

Page 458: ...bag lamp driver has failed AIRBAG WARNING INDICATOR OPEN When Monitored With ignition on the ACM monitors the PCI Bus for a message from the MIC containing the airbag warning indicator status The ACM request the warning lamp status from the MIC once every second Set Condition This DTC will set immediately if the indicator status is OPEN AIRBAG WARNING INDICATOR SHORT When Monitored With ignition o...

Page 459: ...lect PASSIVE RESTRAINTS AIRBAG and MONITOR DIS PLAY Using the DRBIIIt read the WARNING LAMP MONITOR screen Select the LAMP STATUS displayed on the DRB monitors screen Observe the Lamp Driver State and Actual Lamp State Is the LAMP DRIVER and ACTUAL LAMP STATE OK All YES Go To 4 NO Replace Instrument Cluster Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN T...

Page 460: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 461: ...NDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnecte...

Page 462: ...any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you ...

Page 463: ... MISMATCH STORED CODE OR INTERMITTENT CONDITION ACM CLUSTER MESSAGE MISMATCH ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the...

Page 464: ...L INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent pr...

Page 465: ...BAG SQUIB 1 CIRCUIT OPEN DRIVER KNEE BLOCKER SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM DRIVER KNEE BLOCKER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM...

Page 466: ...E IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Driver Knee Blocker Airbag connector Disconnect the Airbag Control Module connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the Airbag Control Module connector Measure the resistance of the Driver Knee Blocker Squib 1 Line 1 a...

Page 467: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 468: ...R SQUIB 1 CIRCUIT SHORT ACM DRIVER KNEE BLOCKER SQUIB 1 CIRCUIT SHORT DRIVER KNEE BLOCKER SQUIB 1 LINE 1 SHORT TO LINE 2 STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM A...

Page 469: ...SONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Driver Knee Blocker Airbag connector Disconnect the Airbag Control Module connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adapter to the Airbag Control Module connector Measure the resistance between Driver...

Page 470: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 471: ...TO BATTERY DRIVER KNEE BLOCKER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER KNEE BLOCKER SQUIB 1 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ...

Page 472: ...d Tool from the Driver Knee Blocker Airbag connector Disconnect the Airbag Control Module connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the Airbag Control Module connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION ON THEN RECONNECT THE BATTERY Measure the voltage on the Driver Knee Blocker Squib 1 Line 1 and Line 2 ci...

Page 473: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 474: ...SHORT TO GROUND DRIVER KNEE BLOCKER SQUIB 1 LINE 1 AND LINE 2 SHORT TO GROUND ACM DRIVER KNEE BLOCKER SQUIB 1 CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE Connect the appropriate Load Tool to the Driver Knee Blocker Airbag connector SELECT ACTIVE or STORED DTC Al...

Page 475: ... TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Driver Knee Blocker Airbag connector Disconnect the Airbag Control Module connector NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool ACM Adaptor to the Airbag Control Module connector Measure the resistance of the Driver Knee Blocker Squib 1 Line...

Page 476: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 477: ...will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 NOTE Ensure the battery is fully charged WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect...

Page 478: ...sistance below 1 0 ohms on both circuit All Yes Go To 4 No Repair open or high resistance in Driver Seat Belt Tensioner Line 1 Line 2 circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILUR...

Page 479: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or com...

Page 480: ... be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connector NOT...

Page 481: ...0K Ohms All Yes Repair Driver Seat Belt Tensioner Line 1 circuit short to Driver Seat Belt Tensioner Line 2 circuit Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PR...

Page 482: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or com...

Page 483: ...l be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connector NO...

Page 484: ...he Driver SBT connector and ground Is there any voltage present All Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuit short to battery Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE...

Page 485: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 486: ... will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connecto...

Page 487: ... below 10K ohms on either circuit All Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuits short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE ...

Page 488: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 489: ...KSPRING SQUIB 1 CIRCUIT OPEN DRIVER SQUIB 1 LINE 1 OR LINE 2 CIRCUITS OPEN ACM DRIVER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 A...

Page 490: ...ol from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRBIIIt show DRIVER SQUIB 1 CIRCUIT OPEN All ...

Page 491: ...nnectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt m...

Page 492: ... SQUIB 1 CIRCUITS SHORT DRIVER AIRBAG SQUIB 1 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB LINE 1 SHORT TO LINE 2 STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2...

Page 493: ...onnect the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRBIIIt show DRIVER SQUIB 1...

Page 494: ...nectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt mo...

Page 495: ...SQUIB 1 SHORT TO BATTERY DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 1 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED ACM DTC All ACM ACTIVE DTC Go...

Page 496: ...DTC s Does the DRBIIIt show DRIVER SQUIB 1 SHORT TO BATTERY All Yes Go To 3 No Replace the Driver Airbag in accordance with the Service Infor mation Perform __AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Driver Airbag connector s Disconnect the Clock...

Page 497: ... present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminal...

Page 498: ...RIVER SQUIB 1 SHORT TO GROUND DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC G...

Page 499: ...ect the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRBIIIt show DRIVER SQUIB 1 SHORT ...

Page 500: ...tors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monit...

Page 501: ...ING DRIVER SQUIB 2 CIRCUIT OPEN DRIVER SQUIB 2 LINE 1 OR LINE 2 CIRCUITS OPEN ACM DRIVER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To ...

Page 502: ...or Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRBIIIt show DRIVER SQUIB 2 CIRCUIT OPEN All Yes Go To 4 No Replace the Clockspring ...

Page 503: ...onnectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt ...

Page 504: ...RIVER SQUIB 2 CIRCUIT SHORT DRIVER SQUIB 2 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB 2 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORE...

Page 505: ...ct the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 CIRCUIT...

Page 506: ...nectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt mo...

Page 507: ...QUIB 2 SHORT TO BATTERY DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 2 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2...

Page 508: ...bag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 SHORT TO BATTERY All Yes Go To 4 No Replace...

Page 509: ...ctors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt moni...

Page 510: ...IVER SQUIB 2 SHORT TO GROUND DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO GROUND ACM DRIVER SQUIB 2 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go T...

Page 511: ... the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 SHORT TO ...

Page 512: ...ectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt mon...

Page 513: ...OR SEAT SQUIB CIRCUIT OPEN LEFT CURTAIN OR SEAT SQUIB LINE 1 OR LINE 2 CIRCUIT OPEN ACM LEFT CURTAIN OR SEAT SQUIB CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC Al...

Page 514: ... Information Perform __AIRBAG VERIFICATION TEST VER 1 3 WARNING TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Left Curtain or Seat Airbag connector Disconnect the Airbag Control Module Connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adapter to the Airbag Control Module c...

Page 515: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or com...

Page 516: ... OR SEAT SQUIB CKT SHORT LEFT CURTAIN OR SEAT SQUIB LINE 1 SHORTED TO LINE 2 ACM LEFT CURTAIN OR SEAT SQUIB CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ...

Page 517: ... TEST VER 1 3 WARNING TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERI OUS OR FATAL INJURY Disconnect the Load Tool from the Left Curtain or Seat Airbag connector Disconnect the Airbag Control Modul...

Page 518: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 519: ...DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Left Curtain or Seat Airbag connector NOTE Check connectors Clean repair as necessary WARNING DO NOT PLACE AN INTACT UND...

Page 520: ...are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated termi...

Page 521: ...IB SHORT TO GROUND LEFT CURTAIN OR SEAT SQUIB LINE 1 OR LINE 2 SHORTED TO GROUND ACM LEFT CURTAIN OR SEAT SQUIB SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC Al...

Page 522: ...ION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERI OUS OR FATAL INJURY Disconnect the Load Tool from the Left Curtain or Seat Airbag connector Disconnect the Airbag Control Module connector s NOTE Check connect...

Page 523: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 524: ...eferred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Left Front Impact Sensor 1 Reconnect the vehicle wire harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected comp...

Page 525: ...tors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monit...

Page 526: ...d to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Left Side Impact Sensor 1 Reconnect the vehicle wire harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components ...

Page 527: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 528: ...d to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Left Side Impact Sensor 2 Reconnect the vehicle wire harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components ...

Page 529: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 530: ...s an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Left Side Impact Sensor 3 Reconnect the vehicle body harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components except...

Page 531: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 532: ...ces a diagnostic voltage on the ORC Run Only circuit for 60 seconds An open high side driver HSD circuit voltage is between 2 4 and 5 0 volts Set Condition This code will set within 8 second Note the diagnostic voltage will only last for 60 seconds after the ignition is turned off ORC RUN START DRIVER SHORT TO GROUND When Monitored The IPM uses a microprocessor controlled transistor high side driv...

Page 533: ...be turned off and the battery must be disconnected 2 With the DRBIIIt read the active IPM DTC s Are there any active ORC RUN START DRIVER DTC s All Yes Go To 3 No WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEED ING Replace the Airbag Control Module in accordance with Service Instructions Perform __AIRBAG VERIFICATION TEST VER 1 3 Select the IPM active RUN S...

Page 534: ...TED THEN WAIT TWO MINUTES BEFORE PROCEEDING Replace the Airbag Control Module in accordance with Service Instruc tions Perform __AIRBAG VERIFICATION TEST VER 1 5 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the IPM connector NOTE Check connectors Clean and repair as necessary Measure the resistance of the...

Page 535: ...g the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH ...

Page 536: ...agnostic voltage on the ORC Run Only circuit for 60 seconds An open high side driver HSD circuit voltage is between 2 4 and 5 0 volts Set Condition This code will set within 8 second Note the diagnostic voltage will only last for 60 seconds after the ignition is turned off ORC RUN ONLY DRIVER SHORT TO GROUND When Monitored The IPM uses a microprocessor controlled transistor high side driver to sup...

Page 537: ... Go To 5 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connector...

Page 538: ...VOID PERSONAL INJURY OR DEATH IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED AT ANY TIME IT MUST BE REPLACED NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connector Measure the resistance of the ORC Run Only Driver circuit between the IPM C7 connector and ground Is the resistance below 500K ohms All Yes Repair the ORC Ru...

Page 539: ...nected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit...

Page 540: ...E PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Turn the ignit...

Page 541: ...CEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJU...

Page 542: ...CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND LEFT FRONT SENSOR 1 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM LEFT FRONT IMPACT SENSOR 1 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM a...

Page 543: ...ed for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Left Front Impact Sensor 1 Signal and Sensor Ground circuits at the Left Front Impact Sensor 1 connector Is the resistance below 100K ohms All Yes Repair the Left Front Impact Sensor 1 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropria...

Page 544: ... and read active codes and if there are none present read the stored codes DID the active Driver Side Impact Sensor DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT M...

Page 545: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 546: ...SIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND LEFT SIDE SENSOR 1 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM LEFT SIDE IMPACT SENSOR 1 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AE...

Page 547: ...orted for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Driver Side Impact Sensor Signal and Sensor Ground circuits at the Left Side Impact Sensor 1 connector Is the resistance below 100K ohms All Yes Repair the Left Side Impact Sensor 1 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropria...

Page 548: ...and read active codes and if there are none present read the stored codes DID the active Left Side Impact Sensor 1 DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MU...

Page 549: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 550: ...SIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND LEFT SIDE SENSOR 2 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM LEFT SIDE IMPACT SENSOR 2 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AE...

Page 551: ...ted for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Left Side Impact Sensor 2 Signal and Sensor Ground circuits at the Left Side Impact Sensor 2 connector Is the resistance below 100K ohms All Yes Repair the Left Side Impact Sensor 2 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropriate...

Page 552: ...and read active codes and if there are none present read the stored codes DID the active Left Side Impact Sensor 2 DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MU...

Page 553: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 554: ...ations POSSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND LEFT SIDE SENSOR 3 CIRCUITS SHORTED TOGETHER SIGNAL CIRCUIT OPEN ACM LEFT SIDE IMPACT SENSOR 3 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC...

Page 555: ...he Left Side Impact Sensor 3 Signal circuit between the Left Side Impact Sensor 3 connector and ground Is the resistance below 100K ohms All Yes Repair the Left Side Sense 3 Signal circuit shorted for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Passenger Side Impact Sensor Signal and Sensor Ground circuits at the Passenger Side Impact ...

Page 556: ...and read active codes and if there are none present read the stored codes DID the active Left Side Impact Sensor 3 DTC return All Yes Go To 7 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 7 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MU...

Page 557: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 558: ...CTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM Turn the ignition on SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Connect the DRBIIIt to th...

Page 559: ...RNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH If there are no possible causes remaining view repair All Repair Replace the Air...

Page 560: ...connected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circ...

Page 561: ...will be referred to as an ACM From the list below select the appropriate module and DTC type for this diagnostic trouble code DETERMINE ACTIVE OR STORED DTC All ACM ACTIVE Go To 2 ACM STORED Go To 3 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH DISCONNECT THE BATTERY AND WAIT TWO MINU...

Page 562: ...connected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circ...

Page 563: ...CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND RIGHT FRONT SENSOR 1 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM PASSENGER SIDE IMPACT SENSOR REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AEC...

Page 564: ... a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Right Front Impact Sensor 1 Signal and Sensor Ground circuits at the Right Front Impact Sensor 1 connector Is the resistance below 100K ohms All Yes Repair the Right Front Impact Sensor circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropriate Lo...

Page 565: ...and read active codes and if there are none present read the stored codes DID the active Right Front Impact Sensor 1 DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT ...

Page 566: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 567: ...SSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND RIGHT SIDE SENSOR 1 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM RIGHT SIDE IMPACT SENSOR 1 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the...

Page 568: ... a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Right Side Impact Sensor 1 Signal and Sensor 1 Ground circuits at the Right Side Impact Sensor 1 connector Is the resistance below 100K ohms All Yes Repair the Right Side Impact Sensor 1 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropriate L...

Page 569: ...nd read active codes and if there are none present read the stored codes DID the active Right Side Impact Sensor 1 DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MU...

Page 570: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 571: ...SSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND RIGHT SIDE SENSOR 2 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM RIGHT SIDE IMPACT SENSOR 2 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the...

Page 572: ... circuit shorted for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Right Side Impact Sensor 2 Signal and Sensor 2 Ground circuits at the Right Side Impact Sensor 2 connector Is the resistance below 100K ohms All Yes Repair the Right Side Impact Sensor 2 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Conne...

Page 573: ...d read active codes and if there are none present read the stored codes DID the active Right Side Impact Sensor 2 DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUS...

Page 574: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 575: ...SSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND RIGHT SIDE SENSOR 3 CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM RIGHT SIDE IMPACT SENSOR 3 REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the...

Page 576: ...d for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Right Side Impact Sensor 3 Signal and Sensor 3 Ground circuits at the Right Side Impact Sensor 3 connector Is the resistance below 100K ohms All Yes Repair the Right Side Impact Sensor 3 circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropri...

Page 577: ...gnition Off and wait 15 seconds before turning the Ignition On Wait one minute and read active codes and if there are none present read the stored codes DID the active Right Side Impact Sensor 3 DTC return All Yes Go To 8 No Test Complete 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL M...

Page 578: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 579: ...ECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat B...

Page 580: ...ance below 1 0 ohms on either circuit All Yes Go To 4 No Repair open or high resistance in Passenger Seat Belt Tensioner Line 1 or Line 2 circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FA...

Page 581: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 582: ...les will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Tensioner co...

Page 583: ...Is the resistance below 10K ohms All Yes Repair the Passenger Seat Belt Tensioner Line 1 short to Line 2 circuit Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPE...

Page 584: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 585: ...odules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Tensioner...

Page 586: ...Seat Belt Tensioner connector and ground Is there any voltage on either circuit All Yes Repair the Passenger Seat Belt Tensioner Line 1 or Line 2 short to battery Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY ...

Page 587: ...onents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compone...

Page 588: ... ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Ten...

Page 589: ...e resistance below 10K Ohms on either circuit All Yes Repair the Passenger Seat Belt Tensioner Line 1 or Line 2 short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO...

Page 590: ...ponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 591: ...UIB 1 CIRCUIT OPEN PAB SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PAB SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go ...

Page 592: ...CT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control module connector s NOTE Check connectors Clean and repair as necessary Connect the Load Tool ACM Adaptor to the Airbag Control Module connector s Measure the resistance of the Passenger Squib 1 Line 1 and Line 2 circuit between the ACM Adaptor and the ...

Page 593: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 594: ...1 CIRCUIT SHORT PAB SQUIB 1 LINE 1 SHORT TO LINE 2 ACM PAB SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE...

Page 595: ... IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adapter to the Airbag Control Module connec tor s Measure the resistance between Passenger Squib 1 Line 1 and Line 2 circuit...

Page 596: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 597: ...ATTERY PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PAB SQUIB 1 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC...

Page 598: ...MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s WARNING AVOID PERSONAL INJURY OR DEATH TURN IGNITION ON THEN RECONNECT THE BATTERY Measure the voltage on the Passenger Squib...

Page 599: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 600: ...S SHORT TO GROUND PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO GROUND ACM PAB SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DT...

Page 601: ...FF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connector Measure the resistance of the Passenger Squib 1 Line 1 or Line 2 circuit between the Passenge...

Page 602: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 603: ...QUIB 2 CIRCUIT OPEN PASSENGER SQUIB 2 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PASSENGER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM S...

Page 604: ...ONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool adaptor to the Airbag Control Module connec tor s Measure the resistance of the Passenger Squib 2 Line 1 and Line 2 circuits between the ACM Ad...

Page 605: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 606: ... 2 CIRCUIT SHORT PASSENGER SQUIB 2 LINE 1 SHORT TO LINE 2 ACM PASSENGER SQUIB 2 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC...

Page 607: ... TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s Measure the resistance between the Passenger Squib 2 Line 1 and line 2 circuits...

Page 608: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or...

Page 609: ...ATTERY PASSENGER SQUIB 2 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PASSENGER SQUIB 2 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 AC...

Page 610: ...T TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY Measure the voltage on the P...

Page 611: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 612: ...ORT TO GROUND PASSENGER SQUIB 2 LINE 1 OR LINE 2 SHORT TO GROUND ACM PASSENGER SQUIB 2 CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To...

Page 613: ...PERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s M...

Page 614: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 615: ... Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM Repair all Ignition Run and Run Start circuit DTCs before performing this test SELECT ACTIVE OR STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected ...

Page 616: ...tart circuits at the ACM adaptor The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly on both circuits All Yes Go To 4 No Repair the high resistance in the Fused Ignition Switch Output Run and Run Start circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN TH...

Page 617: ...nected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit...

Page 618: ...AUSES RIGHT SEAT AIRBAG CIRCUIT OPEN RIGHT SEAT SQUIB LINE 1 OR LINE 2 CIRCUIT OPEN ACM RIGHT SEAT SQUIB CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DT...

Page 619: ... the Service Infor mation Perform __AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Passenger Seat Airbag connector Disconnect the Airbag Control Module Connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool A...

Page 620: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 621: ...S RIGHT SEAT SQUIB CIRCUIT SHORT PASSENGER SEAT SQUIB LINE 1 SHORT TO LINE 2 ACM PASSENGER SEAT SQUIB CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC ...

Page 622: ...Seat Airbag connector s Disconnect the Airbag Control Module connector NOTE Check connectors Clean and repair as necessary WARNING TO AVOID PERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Connect the appropriate Load Tool ACM Adaptor to the ACM connector s Measure the resistance betw...

Page 623: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 624: ... SHORT TO BATTERY RIGHT CURTAIN OR SEAT SQUIB LINE 1 OR LINE 2 SHORTED TO BATTERY ACM RIGHT CURTAIN OR SEAT SQUIB SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ...

Page 625: ...AIRBAG VERIFICATION TEST VER 1 3 WARNING TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Right Curtain or Seat Squib connector Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the ACM connector WARNING TURN IGNITION ON THEN RE...

Page 626: ...ponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 627: ... CURTAIN SQUIB SHORT TO GROUND PASSENGER SEAT SQUIB LINE 1 OR LINE 2 SHORT TO GROUND ACM RIGHT SEAT SQUIB SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIV...

Page 628: ... the Load Tool from the Right Seat Airbag connector s NOTE Check connectors Clean and repair as necessary WARNING TO AVOID PERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Connect the appropriate Load Tool ACM Adaptor to the ACM connector s Measure the resistance of the Right Curtain ...

Page 629: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 630: ...CT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Right Front Impact Sensor 1 Reconnect the vehicle body harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components except the Batter...

Page 631: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 632: ... as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Right Side Impact Sensor 1 Reconnect the vehicle body harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components exc...

Page 633: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 634: ...to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Right Side Impact Sensor 2 Reconnect the vehicle body harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components e...

Page 635: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 636: ...and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Right Side Impact Sensor 3 Reconnect the vehicle wire harness to the impact sensor Remove any special tools or jumper wires and reconnect all pre...

Page 637: ...ors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monito...

Page 638: ...E OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must...

Page 639: ...G TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH If there are no possible causes remaining view repair All Repair Replace the Airbag ...

Page 640: ...ected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit ...

Page 641: ...DRBIIIt select the PASSIVE RESTRAINTS AIRBAG MONITOR DIS PLAY and read the WARNING LAMP STATES With no active DTCs Does the LAMP REQ by ACM monitor show ON All Yes Replace the Airbag Control Module in accordance with Service Instructions Perform __AIRBAG VERIFICATION TEST VER 1 No Refer to INSTRUMENT CLUSTER CATEGORY symptom list for problems related to Instrument Cluster Perform __AIRBAG VERIFICA...

Page 642: ...he ignition switch from off to on and wait 10 seconds With the DRBIIIt read the audio DTC s Does the DRBIIIt display ALL OUTPUTS SHORT All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Amplifier C2 harness connector Turn the ignition on Turn the radio on Wit...

Page 643: ...etween ground and each radio right and left circuit Is the resistance below 1000 0 1K ohms All Yes Repair the radio right or left circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Amplifier C2 harness connector Disconnect the Radio C1 on premium harness connector Measure the resistance between each radio circuit and each radio circ...

Page 644: ...he related wiring terminals for corrosion damage or terminal push out Repair as necessary NOTE Disconnect the Satellite Receiver Antenna connector and check the related wiring terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits Check the Antenna asse...

Page 645: ...s the resistance below 5 0 ohms All Yes Go To 2 No Repair the TERR Signal circuit for an open Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Satellite Receiver Antenna connector Disconnect the Satellite Radio Receiver harness connectors Measure the resistance between ground and the TERR Signal circuit Is the resistance below 5 0 ohms All Yes Repair the TERR Signal circ...

Page 646: ... guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits Replace the Satellite Receiver Antenna in accordance with the service information Turn the ignition and the radio on and place the radio in Satellite mode Does the DTC return All Yes Go To 6 No Repair is complete Perform BODY VERIFICATION TEST VER 1 6 NOTE Disconnect the Satellite Radio Receive...

Page 647: ...hen Monitored Continuously Set Condition Anytime the module detects a short to battery on the PCI Bus circuit DTC will mature immediately PCI BUS SHORTED TO GROUND When Monitored Continuously Set Condition Anytime the module detects a short to ground on the PCI Bus circuit DTC will mature immediately PCI BUS SHORTED TO BATTERY MHSAPM When Monitored Continuously Set Condition Anytime the module det...

Page 648: ... intermittent condition With the engine running at normal operating temperature wiggle the wiring harnesses This is to try and duplicate the complete bus failure condition Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look fo...

Page 649: ...be necessary to replace the module NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature wiggle the wiring harnesses This is to try and duplicate the complete bus failure condition Refer to any Technical Service Bulletins TSB that may apply Visually inspect the ...

Page 650: ...ll symptoms listed above are diagnosed using the same tests The title for the tests will be CASSETTE PLAYER INOP When Monitored and Set Condition CASSETTE PLAYER INOP When Monitored Continuously with the ignition and radio turned on Set Condition The code will set if the radio detects a internal cassette failure CD MECHANICAL FAILURE When Monitored Continuously with the ignition and CD player turn...

Page 651: ... DTC is set erase the DTC and attempt to reset the DTC If DTC resets follow this test This is an internal radio failure View repair All Repair Replace the Radio Perform BODY VERIFICATION TEST VER 1 254 AUDIO CASSETTE PLAYER INOP Continued ...

Page 652: ...Changer turned on Set Condition The code will set if the CD Changer detects a mechanical failure POSSIBLE CAUSES INTERNAL FAILURE TEST ACTION APPLICABILITY 1 NOTE Erase DTC and attempt to reset If DTC resets follow this test This is an internal CD Changer failure View repair All Repair Replace the CD Changer Perform BODY VERIFICATION TEST VER 1 255 AUDIO ...

Page 653: ... is not formatted as a music CD is installed in the CD Changer POSSIBLE CAUSES CD CHANGER READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio on and select the good CD With the DRBIIIt read DTC s Does the DRBIIIt display CD CHANGER READ FAILURE All Yes Replace the CD Changer Perform BODY VERIFICATION TEST VER 1 No Test Complete 256 ...

Page 654: ...PLICABILITY 1 With the DRBIIIt erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors and open the doors to allow the inside temperature to stabilize The CD Changer will operate between 23 C and 65 C 10 F and 145 F With the DRBIIIt read DTC s Does the DRBIIIt display CD C...

Page 655: ...at is not formatted as a music CD or is scratched dirty so the radio can not play the CD POSSIBLE CAUSES CD PLAY FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio CD player on With the DRBIIIt read DTC s Does the DRBIIIt display CD PLAY FAILURE All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Test Complete 258 AUDIO ...

Page 656: ...f a CD that is not formatted as a music CD is installed in the radio CD player POSSIBLE CAUSES CD READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio CD player on With the DRBIIIt read DTC s Does the DRBIIIt display CD READ FAILURE All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Test Complete 259 AUDIO ...

Page 657: ... APPLICABILITY 1 With the DRBIIIt erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors and open the doors to allow the inside temperature to stabilize The radio CD player will operate between 30 C and 85 C 22 F and 185 F With the DRBIIIt read DTC s Does the DRBIIIt disp...

Page 658: ...t condition must be present to continue diagnosis Use the DRBIIIt to perform the Amplifier pretest to verify the fault condition is present before continuing diagnosis Turn the ignition on With the DRBIIIt perform the Amplifier pretest Is the fault condition present All Yes Replace the Amplifier in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Refer to the wiring ...

Page 659: ...d the loop back test POSSIBLE CAUSES INTERNAL FAILURE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Replace the Amplifier in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 262 AUDIO ...

Page 660: ...Condition Internal bus communication failure between processors POSSIBLE CAUSES INTERNAL SDARS FAILURE TEST ACTION APPLICABILITY 1 The Satellite Radio Receiver is reporting internal errors view repair to continue All Repair Replace the Satellite Radio Receiver in accordance with the service information Perform BODY VERIFICATION TEST VER 1 263 AUDIO ...

Page 661: ...or run position Set Condition Internal failure is detected POSSIBLE CAUSES INTERNAL RECEIVER FAILURE TEST ACTION APPLICABILITY 1 The Satellite Radio Receiver is reporting internal errors view repair to continue All Repair Replace the Satellite Radio Receiver in accordance with the service information Perform BODY VERIFICATION TEST VER 1 264 AUDIO ...

Page 662: ...nnectors Disconnect the Satellite Radio Multiplexer harness connectors Measure the resistance between ground and the Audio Bus 2 circuit Is the resistance below 100 ohms All Yes Repair the Audio Bus 2 circuit for a short to ground between the Satellite Receiver Module and the Multiplexer Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Satellite Receiver Modul...

Page 663: ... to ground between the Radio and the Multiplexer Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Radio harness connector Disconnect the Satellite Radio Multiplexer harness connectors Measure the resistance of the Audio Bus 1 circuit between the Radio and the Multiplexer Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the Audio Bus 1 circuit for an ...

Page 664: ...ect the wire harness and connectors repair as necessary Pay particular attention to all Power and Ground circuits Replace the Satellite Radio Multiplexer in accordance with the service information Reconnect harness connectors and start the engine Attempt to reset the DTC Does the DTC reset All Yes Go To 8 No Test Complete 8 Replace the Satellite Receiver Module in accordance with the service infor...

Page 665: ...ion and repair as neces sary Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio C1 harness connector Start the engine Measure the voltage of the Fused B circuit Is the voltage above or approximately 14 volts All Yes Go To 3 No Repair the circuit for high resistance Perform BODY VERIFICATION TEST VER 1 3 Note Reconnect all previously disconnected components Turn the i...

Page 666: ...he ignition on With the DRBIIIt attempt to communicate with the navigation module Was the DRBIIIt able to I D or communicate with the NAV All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC...

Page 667: ...o 2 No Repair Antenna connection as needed Perform BODY VERIFICATION TEST VER 1 2 Refer to the Audio System in the service information and test the Antenna in accordance with the service procedure Is the Antenna ok All Yes Go To 3 No Repair or replace the Antenna assembly as necessary Perform BODY VERIFICATION TEST VER 1 3 NOTE Reconnect all previously disconnected components Turn the ignition and...

Page 668: ...FIER RADIO TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the Amplifier Was the DRBIIIt able to I D or communicate with the Amplifier All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minu...

Page 669: ...TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the Body Control Module Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With...

Page 670: ...to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 2 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio C2 harness connector Disconnect the CD DVD Changer harness connector Visually inspect the connectors for damage Check for open circuits in the wiring harness between the Radio and the CD DVD Cha...

Page 671: ... Changer on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 4 No Replace the Radio Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the CD DVD Changer harness connector Turn the ignition on Turn the Radio and the CD DVD Changer on Using a 12 volt test light connected to ground probe the Ignition RUN ACC ...

Page 672: ...E RADIO TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the navigation module Was the DRBIIIt able to I D or communicate with the NAV All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minut...

Page 673: ...ule harness connector Visually inspect the connectors for damage Check for open circuits in the wiring harness between the Radio and the Satellite Radio Receiver Measure the resistance of the each circuit between the Radio C2 connector and the Satellite Radio Receiver connector Check for shorted circuits in the wiring harness between the Radio and the Satellite Radio Receiver Measure the resistanc...

Page 674: ...age pulse from 0 to approximately 7 5 volts All Yes Go To 3 No Replace the Radio Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Satellite Radio Receiver harness connector NOTE If vehicle is equipped with a satellite radio multiplexer check connectors This device is a pass through for the satellite radio receiver circuits Turn the ignition on Turn the Radio and place th...

Page 675: ...ime The following list may help in identifying the intermittent condition With the engine running at normal operating temperature wiggle the wiring harnesses This is to try and duplicate the complete bus failure condition Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually ins...

Page 676: ...RANSMISSION TEST ACTION APPLICABILITY 1 Turn the ignition on Turn the Radio on With the DRBIIIt erase the audio DTC s Cycle the ignition switch from off to on and wait 10 seconds With the DRBIIIt read the audio DTC s Did this DTC reset All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Refer to the wiring diagrams located in the service information to help isolate a possible short P...

Page 677: ...e If this code continues to set and the DRB can still communicate with the module it will be necessary to replace the module WARNING 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 NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the int...

Page 678: ...urn the ignition on With the DRBIIIt attempt to communicate with the PCM Was the DRBIIIt able to communicate with the PCM All Yes Go To 3 No Refer to the communication category and perform the appropriate symptom Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL D...

Page 679: ...he ignition switch from off to on and wait 10 seconds With the DRBIIIt read the audio DTC s Does the DRBIIIt display POWER AMP SHUTDOWN All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Amplifier C2 harness connector Turn the ignition on Turn the radio on Wi...

Page 680: ...etween ground and each radio right and left circuit Is the resistance below 1000 0 1K ohms All Yes Repair the radio right or left circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Amplifier C2 harness connector Disconnect the Radio C1 on premium harness connector Measure the resistance between each radio circuit and each radio circ...

Page 681: ...ition on Turn the Radio on With the DRB attempt to communicate with the Radio Was the DRB able to I D or communicate with the Radio All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes...

Page 682: ...IO CONTROL MUX CIRCUIT OPEN RADIO CONTROL MUX RETURN CIRCUIT BODY CONTROL MODULE OPEN INTERNAL TEST ACTION APPLICABILITY 1 Turn the ignition and radio on Operate both remote radio switches Are both remote radio control switches inoperative All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the Clockspring C2 harness connector Turn the ignition on With the DRB enter Body Computer then Se...

Page 683: ...dio Control MUX circuit between the BCM connector and the Clockspring connector Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Radio Control MUX circuit for an open between the clockspring and the BCM Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Clockspring C2 harness connector Disconnect the BCM C4 harness connector Measure the resistance of the Radi...

Page 684: ... Turn the ignition off disconnect the battery and wait 2 minutes before proceeding CAUTION Do not place an intact undeployed airbag module face down on a hard surface the airbag module will propel into the air if accidently deployed Remove the Driver Airbag Module Disconnect both remote radio switch harness connectors Disconnect the Clockspring harness connector Measure the resistance of the Radio...

Page 685: ...ith the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short Perform BODY VERIFICATION TEST VER 1 2 WARNING Turn the ignition off disconnect the battery and wait 2 minutes before proceeding CA...

Page 686: ...ly 5 0 volts All Yes Go To 5 No Go To 6 5 Turn the ignition off Disconnect the Clockspring harness connector NOTE Ensure both remote radio switches are disconnected Measure the resistance between ground and each Radio Control MUX circuit at the clockspring harness connector Is the resistance below 5 0 ohms All Yes Repair the Radio Control MUX circuit for a short to ground between the clockspring a...

Page 687: ...ct the Clockspring C2 harness connector Disconnect the BCM C4 and C5 harness connectors Measure the resistance between the Radio Control MUX circuit and the Radio Control MUX Return circuit Is the resistance below 5 0 ohms All Yes Repair the Radio Control MUX circuit for a short to the Radio Control MUX Return circuit between the clockspring and the BCM Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 688: ...e fault condition must be present to continue diagnosis Use the DRBIIIt to perform the Amplifier pretest to verify the fault condition is present before continuing diagnosis Turn the ignition on With the DRBIIIt perform the Amplifier pretest Is the fault condition present All Yes Replace the Amplifier in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Refer to the w...

Page 689: ...display any fault messages NOTE The PCI Amplifier Test will detect a Software Checksum Failure and will a display fault message NOTE The Identify EQ Test will return the current EQ mode and will display a fault message NOTE The Input test will detect activity on the amplifier input channels This test will verify the integrity of the input channels Did the DRBIIIt display a fault message All Yes Pe...

Page 690: ...circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Fused B circuit for an open Check related fuses if fuse is open repair short to ground Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Satellite Radio Receiver harness connectors Turn the ignition and the radio on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Does the...

Page 691: ...If there are no other possible causes remaining view repair All Repair Replace Satellite Radio Receiver in accordance with the service information Perform BODY VERIFICATION TEST VER 1 294 AUDIO INOP NO FAULT CODES SDARS Continued ...

Page 692: ...hop NOTE The SDARS antenna must be be free of damage and not be covered by any objects NOTE Large buildings in downtown areas can block the satellite signal and cause poor reception NOTE Check DTC s and record them Repair any DTC s prior to continuing with test Inspect SDARS antenna for damage Drive vehicle outside of shop and attempt to verify poor reception complaint Verify good reception in you...

Page 693: ...IBLE CAUSES INSTRUMENT CLUSTER TEST ACTION APPLICABILITY 1 If there are no possible causes remaining view repair All Repair Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 296 CHIME ...

Page 694: ...No Replace the Instrument Cluster Perform BODY VERIFICATION TEST VER 1 3 Open the driver door With the DRBlllt in Driver Door Module Input Outputs read the 9DOOR AJAR9 state Does the DRBIIIt display 9DOOR AJAR AJAR 9 All Yes Go To 4 No Refer to symptom list for problems related to Door Ajar Perform BODY VERIFICATION TEST VER 1 4 With the DRBIIIt in BCM Inputs Outputs read the Ignition Status while...

Page 695: ...rning chime is for Gulf Coast Countries only With the DRBIIIt in Miscellaneous check the Body Control Module country code setting Is the country code incorrect All Yes Program the correct country code setting Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 298 CHIME ...

Page 696: ...Y 1 Turn the ignition on With the DRBIIIt attempt to communicate with the Controller Antilock Brake Module Was the DRBIIIt able to I D or communicate with the CAB All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIII...

Page 697: ...ONTROL MODULE MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB enter Body then Automatic Temp Control Was the DRB able to I D or communicate with the ATC module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute W...

Page 698: ...MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on Turn the Radio on With the DRB attempt to communicate with the Radio Was the DRB able to I D or communicate with the Radio All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute Wit...

Page 699: ...LITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the Body Control Module Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC...

Page 700: ... communication DTC s that may have set along with this DTC must be diagnosed before continuing With the DRBIIIt erase the DTC Cycle the ignition on and off several times leaving the ignition on for at least 15 seconds With the DRBIIIt read DTCs Did this DTC reset All Yes Go To 2 No Go To 4 2 Turn the ignition on With the DRBIIIt attempt to communicate with the CMTC Module Can communication be esta...

Page 701: ... HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Refer t...

Page 702: ...LICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the CMTC Was the DRBIIIt able to I D or communicate with the CMTC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did t...

Page 703: ...river door module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 NOTE If any window switch related DTC s are set perform them first before continuing with this test With the DRB erase DTC s Cycle the ignition switch from off to on Operate the window up down and express switches from the driver door module With the DRB read DT...

Page 704: ...nition on With the DRBIIIt attempt to communicate with the Driver Door Module Was the DRBIIIt able to I D or communicate with the DDM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on operate the door locks from the driver s door and wait approximately 1 minut...

Page 705: ...LURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the BCM in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 308 COMMUNICATION ...

Page 706: ...LURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the DDM in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 309 COMMUNICATION ...

Page 707: ...LURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the IPM in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 310 COMMUNICATION ...

Page 708: ...LURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the PDM in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 311 COMMUNICATION ...

Page 709: ...N APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the IPM Was the DRB able to I D or communicate with the IPM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset...

Page 710: ...ted to the Liftgate wakeup circuit Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt erase DTC s Operate the liftgate with either the key fob or the overhead console With the DRBIIIt read BCM DTC s Did this DTC reset All Yes Go To 3 No The condition that caused this DTC is currently not present Use the wiring diagrams schematic as a guide and inspect the relat...

Page 711: ...minute Operate the liftgate with either the key fob or the overhead console With the DRB read DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 314 COMMUNICATION LIFTGATE MODULE MESSAGES NOT RECEIVED Continued ...

Page 712: ...he DRB able to I D or communicate with the memory seat module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB read the door module DTC s Are any seat switch related DTCs set All Yes Refer to the appropriate category and perform the related symp tom Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 With the DRB era...

Page 713: ...ll Yes Replace the Memory Seat Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Check the circuits between the seat switch and the door module If ok replace the seat switch and retest If after replacement of the seat switch condition is not corrected replace the door module that set this DTC Perform BODY VERIFICATION TEST VER 1 316 COMMUNICATION MEMORY SEAT...

Page 714: ...ed to the cluster wakeup circuit Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt erase DTC s With the DRBIIIt read DTC s Did this DTC reset All Yes Go To 3 No The condition that caused this DTC is currently not present Use the wiring diagrams schematic as a guide and inspect the related wiring harness for a possible intermittent Perform BODY VERIFICATION TES...

Page 715: ...om off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Replace the module which set the DTC in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 318 COMMUNICATION MIC MESSAGES NOT RECEIVED Continued ...

Page 716: ... Was the DRB able to I D or communicate with the memory seat module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on Reset the memory positions Operate the memory system With the DRB read DTC s Did this DTC reset All Yes Replace the Memory Seat Module in accordan...

Page 717: ... on With the DRBIIIt attempt to communicate with the Memory Seat Module Was the DRBIIIt able to I D or communicate with the MSM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Operate the memory seat system Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt re...

Page 718: ...LE ORC MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the ORC Was the DRB able to I D or communicate with the ORC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read ...

Page 719: ...ely POSSIBLE CAUSES PCI INTERNAL FAULT TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on With the DRB read DTC s Did this DTC reset All Yes Replace the module which set the DTC in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 322 COMMUNI...

Page 720: ... VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt attempt to communicate with the PCM Was the DRBIIIt able to communicate with the PCM All Yes Go To 3 No Refer to the communication category and perform the appropriate symptom Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PR...

Page 721: ...ule Was the DRB able to I D or communicate with the passenger door module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on Reset the memory positions Operate the memory system With the DRB read DTC s Did this DTC reset All Yes Replace the Passenger Door Module in...

Page 722: ...tion on With the DRBIIIt attempt to communicate with the Passenger Door Module Was the DRBIIIt able to I D or communicate with the PDM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on operate the door locks from the passenger s door and wait approximately 1 m...

Page 723: ... the DRB able to I D or communicate with the radio All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on Reset the memory positions Operate the memory system With the DRB read DTC s Did this DTC reset All Yes Replace the Radio in accordance with the Service Informatio...

Page 724: ...EST ACTION APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the SKREEM Was the DRB able to I D or communicate with the SKREEM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read DTC s Did...

Page 725: ...s POSSIBLE CAUSES SPI INTERNAL COMMUNICATION TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase DTC s Turn the ignition off then turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the module which set the DTC in accordance with the service information Perform BODY VERIFICATION T...

Page 726: ... on With the DRBIIIt attempt to communicate with the Transmission Control Module Was the DRBIIIt able to I D or communicate with the TCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC ...

Page 727: ...O RESPONSE condition Is the test light illuminated on both circuits All Yes Go To 2 No Repair the ORC Run Driver and the ORC Run Start Driver circuits for an open Perform __AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting airbag system components the ignition must be turned off and the battery must be disconnected 2 Ensure that the battery is fully charged WARNING TO AVOID PERSONAL INJURY OR ...

Page 728: ... leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Airbag Control Module conn...

Page 729: ...d to no communica tion with the Radio Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Amplifier C2 harness connector Using a 12 volt test light connected to 12 volts probe both ground circuits Is the test light illuminated for both circuits All Yes Go To 3 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect th...

Page 730: ...and black test probes Connect the scope input cable to the channel one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connec...

Page 731: ...d circuit Is the test light illuminated All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the ATC C1 harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 4 No Repair the Fused B circuit for an open or short Refer to the wiring diagrams in ...

Page 732: ...Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the ATC connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 6 No...

Page 733: ...R 1 2 Turn the ignition off Disconnect the BCM C1 and C2 harness connectors Using a 12 volt test light connected to ground probe each Fused B circuit Is the test light illuminated for each circuit All Yes Go To 3 No Check fuses in the IPM for an open If ok repair the Fused B circuit s for an open or short Refer to the wiring diagrams in the service information Perform BODY VERIFICATION TEST VER 1 ...

Page 734: ...ble to the channel one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect t...

Page 735: ...fer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts probe both ground circuits Is the test light illuminated for each circuit All Yes Go To 3 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VE...

Page 736: ...elect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the CAB connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes...

Page 737: ...oor Node Relay Output circuit Is the test light illuminated All Yes Go To 2 No Repair the Fused Door Node Relay Output circuit for an open or short refer to the wiring diagrams in the service information Perform BODY VERIFICATION TEST VER 1 2 Note Ensure there is PCI Bus communication with other modules on the vehicle before proceeding If not refer to the symptom list from the menu and repair as n...

Page 738: ... scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Driver Door Module connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approxim...

Page 739: ... ground circuit Is the test light illuminated All Yes Go To 3 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Hands Free Module harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 4 No Check IPM fuse 48 for an open If OK repair the Fused B circuit ...

Page 740: ...It select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Hands Free Module connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does ...

Page 741: ... To 2 No Refer to the symptom list for problems related to no communica tion with the BCM Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Measure the voltage between the Fused B circuit and ground Is the voltage below 10 5 volts All Yes Repair the Fused B circuit for an open If the fuse is open make sure to check for a short to gr...

Page 742: ...ltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 5 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Reconnect the Instrument Cluster C1 harness connector Disconnect the BCM C4 harness connector Measure the amperage between the Instrument Cluster Wake Up Signal circuit and ground Does the ...

Page 743: ...ODY VERIFICATION TEST VER 1 2 Turn the ignition off Gain access to the underside of the IPM Using a 12 volt test light connected to ground probe the Fused B circuit large positive terminal under the IPM Is the test light illuminated All Yes Go To 3 No Check the battery connection If ok repair the Fused B circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect th...

Page 744: ...nect the IPM C4 harness connector Disconnect the DRBIIIt from the DLC Measure the resistance of the PCI Bus circuit between the IPM C4 connector and the DLC Is the resistance below 5 0 ohms All Yes Replace the Integrated Power Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 347 COM...

Page 745: ...T VER 1 2 Turn the ignition off Disconnect the Memory Heated Seat Adjustable Pedal Module C4 harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 3 No Check the Power Seat Circuit Breaker for an open or short If ok repair the Fused B circuit for an open or short Perform BODY VERIFICATION TEST VER 1 3 Turn the ignitio...

Page 746: ... Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Memory Heated Seat Adjustable Pedal Module connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 ...

Page 747: ...onnected to 12 volts probe the ground circuit Is the test light illuminated All Yes Go To 3 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Navigation Module harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 4 No Check IPM fuse 48 for an open If ...

Page 748: ...It select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Navigation Module connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does ...

Page 749: ... ground circuit Is the test light illuminated All Yes Go To 3 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Overhead Console harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 4 No Check IPM fuse 48 for an open If OK repair the Fused B circuit f...

Page 750: ...IIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Overhead Console connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does ...

Page 751: ...d Door Node Relay Output circuit Is the test light illuminated All Yes Go To 2 No Repair the Fused Door Node Relay Output circuit for an open or short refer to the wiring diagrams in the service information Perform BODY VERIFICATION TEST VER 1 2 Note Ensure there is PCI Bus communication with other modules on the vehicle before proceeding If not refer to the symptom list from the menu and repair a...

Page 752: ...ope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Passenger Door Module connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approxim...

Page 753: ... PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH7058 Cable to Probe adapter CH7062 and the red and black test probes Connect the scope input cable to the channel one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input ca...

Page 754: ...ssary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIIIt from the DLC Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the SCI Transmit PCM circuit at the Data Link harness connector cav 7 Is the voltage above 1 0 volt All Yes Repair the...

Page 755: ...e ignition off Disconnect the PCM harness connector Disconnect the DRBIIIt from the DLC Measure the resistance between ground and the SCI Receive PCM circuit in the Data Link harness connector cav 12 Is the resistance below 5 0 ohms All Yes Repair the SCI Receive PCM circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the PCM harne...

Page 756: ...he resistance of the SCI Transmit PCM circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the SCI Transmit PCM circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 9 If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in...

Page 757: ...ore proceeding Was the DRB able to I D or communicate with the BCM All Yes Go To 2 No Refer to the symptom list for problems related to no communica tion with the BCM Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Power Liftgate Module C1 harness connector Measure the voltage of the Fused B circuit Is the voltage above 10 0 volts All Yes Go To 3 No Repair the Fused B c...

Page 758: ...air the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the BCM C3 harness connector Measure the voltage between the Liftgate Module Wake Up Signal circuit and ground Is the voltage above 10 0 volts All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Disconnect the Body Control Module C3 ...

Page 759: ... are no possible causes remaining view repair All Repair Replace the Power Liftgate Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 362 COMMUNICATION NO RESPONSE FROM POWER LIFTGATE MODULE Continued ...

Page 760: ...VER 1 2 Turn the ignition off Disconnect the Radio C1 on premium harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Accessory Relay Output circuit Is the test light illuminated All Yes Go To 3 No Check fuse 25 in the IPM for an open If ok repair the Fused Accessory Relay Output circuit for an open or short Refer to the wiring diagrams located in t...

Page 761: ...nector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus...

Page 762: ... for open circuits in the wiring harness between the Radio and the Satellite Radio Receiver Measure the resistance of the each circuit between the Radio C2 connector and the Satellite Radio Receiver connector Check for shorted circuits in the wiring harness between the Radio and the Satellite Radio Receiver Measure the resistance between each circuit at the Radio C2 connector NOTE If vehicle is eq...

Page 763: ...e from 0 to approximately 7 5 volts All Yes Go To 3 No Replace the Radio Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Satellite Radio Receiver harness connector NOTE If vehicle is equipped with a satellite radio multiplexer check connectors This devise is a pass through for the satellite radio receiver circuits Turn the ignition on Turn the Radio on and place the rad...

Page 764: ... 12 volt test light connected to 12 volts probe the Ground circuit Is the test light illuminated All Yes Go To 3 No Repair the ground circuit for an open Perform SKREEM VERIFICATION TEST VER 1A 3 Turn the ignition off Disconnect the SKREEM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Ignition Switch Output circuit Is the test light illuminated All...

Page 765: ... Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the SKREEM connector Turn the ignition on Observe the voltage display on the DRBIIIt Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 6...

Page 766: ...ate symptom Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connecte...

Page 767: ...ANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to 12 volts probe each ground circuit in the appropri...

Page 768: ...ve Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 6 No ...

Page 769: ... the ignition on Using the DRB attempt to communicate with the following control modules Airbag Control Module Body Control Module MIC INSTRUMENT CLUSTER Was the DRBIIIt able to communicate with one or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect ...

Page 770: ...ignition on Measure the voltage of the PCI Bus circuit at the Data Link Connector DLC Is the voltage above 7 0 volts All Yes Go To 5 No Go To 6 5 Turn the ignition off Using a voltmeter connect one end to the PCI Bus circuit at the DLC and the other end to ground Note When performing the next step turn the ignition off wait one minute before disconnecting any module When the module is disconnected...

Page 771: ...s resistance to ground thru all of the modules is typically between 350 to 1000 ohms The more modules on the bus the lower the total bus resistance will be Is the resistance below 150 0 ohms with all the modules disconnected All Yes Repair the PCI Bus circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the module that when disconnected the short to ground was eliminated P...

Page 772: ...r Switch Ground circuit for an open top the Driver Door Module Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Driver Door Lock Motor Ajar Switch connector With the DRBIIIt in Inputs Outputs read the DRVR DOOR AJAR SW state Connect a jumper wire between Sense circuit and the Ground circuit Does the DRBIIIt display DRVR DOOR AJAR SW CLOSED All Yes Replace the Driver Door Lock Motor Ajar Switc...

Page 773: ...ate Does the Switch State change from CLOSED to OPEN All Yes Replace the Driver Door Lock Motor Ajar Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the DDM harness connector Disconnect the Driver Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light connected to 12 volts check the Sense circuit Does the Test Light i...

Page 774: ...e Driver Door Module Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Left Rear Door Lock Motor Ajar Switch harness connector Connect a jumper wire between the Sense circuit and the Ground circuit With the DRBIIIt in Inputs Outputs read the LR DOOR AJAR SW state Does the DRBIIIt display CLOSED All Yes Replace the Left Rear Door Lock Motor Ajar Switch in accordance with the Service Information...

Page 775: ...W state Does the Switch State change from CLOSED to OPEN All Yes Replace the Left Rear Door Lock Motor Ajar Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Left Rear Door Lock Motor Ajar Switch harness connector Disconnect the BCM C2 connector Using a 12 volt Test Light connected to 12 volts check the Sense circuit Does the Test Li...

Page 776: ...onnec tor Using a 12 volt Test Light connected to 12 volts check the Ground circuit Does the test light illuminate All Yes Go To 3 No Repair the Liftgate Ajar Switch Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Liftgate Ajar Switch Liftgate Cinch Release Motor harness connec tor Disconnect the BCM C3 harness connector Measure the resistance of the Sense circuit ...

Page 777: ... the LIFTGATE AJAR SW state Does the Switch State change from CLOSED to OPEN All Yes Replace the Liftgate Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the BCM C3 harness connector Disconnect the Liftgate Ajar Switch Liftgate Cinch Release Motor harness connec tors Using a 12 volt Test Light connected to 12 volts check the Sense circuit Does the Test Light illuminate All...

Page 778: ...or an open to the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Passenger Door Lock Motor Ajar Switch harness connector With the DRBIIIt in Inputs Outputs read the PASS DOOR AJAR SW state Connect a jumper wire between the Sense circuit and the Ground circuit Does the DRBIIIt display PASS DOOR AJAR SW CLOSED All Yes Replace the Passenger Door Lock Motor Ajar Switch in ...

Page 779: ...tate change from CLOSED to OPEN All Yes Replace the Passenger Door Lock Motor Ajar Switch door latch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the PDM harness connector Disconnect the Passenger Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light connected to 12 volts check the Sense circuit Does the Test Light illum...

Page 780: ...o Repair the ground circuit for an open to the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Right Rear Door Lock Motor Ajar Switch harness connector Connect a jumper wire between the Sense circuit and the Ground circuit With the DRBIIIt in Inputs Outputs read the RR DOOR AJAR SW state Does the DRBIIIt display CLOSED All Yes Replace the Right Rear Door Lock Motor Ajar...

Page 781: ...ate Does the Switch State change from CLOSED to OPEN All Yes Replace the Right Rear Door Lock Motor Ajar Switch in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the BCM C3 harness connector Disconnect the Right Rear Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light connected to 12 volts check the Sense circuit Does the ...

Page 782: ... the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Operate the switch indicated by the DRBlllt in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display the same DTC All Yes Go To 2 No The condition that caused this code to set is not present at this time Review wiring schematics and inspect related wiring for an intermittent condition Perform BODY VERIFICAT...

Page 783: ...round Is the resistance below 5 0 ohms All Yes Replace the Driver Seat Switch Perform BODY VERIFICATION TEST VER 1 No Repair the Seat Switch MUX Return for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Driver Seat Switch connector Disconnect the Driver Door Module C2 connector Inspect the Seat Switch MUX circuit that had the DTC for a possible short to voltage...

Page 784: ...rom Off to Run Operate the suspect switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER HEATED SEAT SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch connector Turn the ignition on With the DRBIIIt erase DTCs Cycle the igni...

Page 785: ...itch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Heated Seat Switch MUX circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 388 ELECTRICALLY HEATED SYSTEMS DRIVER HEATED SEAT SWITCH SHORT DDM Continued ...

Page 786: ... Off to Run Operate the Heated Seat Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER HEATED SEAT SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat...

Page 787: ...itch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Heated Seat Switch MUX circuit as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 390 ELECTRICALLY HEATED SYSTEMS DRIVER HEATED SEAT SWITCH STUCK DDM Continued ...

Page 788: ... the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go To 2 No Using the wiring schematic as a guide inspect the wiring and connectors for an intermittent condition Check for an intermit tent open cushion or seat back element by applying pressure to seat with ...

Page 789: ... the Driver Heated Seat Back 2 way connector Measure the resistance of the SEAT CUSHION HEATER ELEMENT by connecting one lead to the Heated Seat Driver terminal at the 2 way and the other lead to the Driver Seat Heater B Driver terminal in the Heated Seat Cushion 4 way Cushion Side connector Is the resistance below 2 5 ohms All Yes Go To 6 No Replace the Driver Heated Seat Cushion Element as neces...

Page 790: ...TER B DRIVER WIRE SHORT TO GROUND FROM MHSAPM TO 4 WAY MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the...

Page 791: ... Heated Seat Cushion 4 way connector cushion side to body ground Is the resistance below 1000 0 ohms All Yes Replace the Driver Heated Seat Cushion Element as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Disconnect the Driver Heated Seat Back 2 way connector Measure the resistance of the Heated Seat Driver circuit in the Driver Heated Seat Back 2 way connector seat back side to body...

Page 792: ...E TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wir...

Page 793: ...1 No Replace the Memory Heated Seat Adjustable Pedal Module Perform BODY VERIFICATION TEST VER 1 4 Disconnect the Driver Heated Seat Cushion 4 way connector Disconnect the Memory Heated Seat Adjustable Pedal Module C2 connector Turn ignition on Measure the voltage between Driver Seat Temperature Sensor Input circuit and ground Is there ANY voltage on the Driver Seat Temperature Sensor Input circui...

Page 794: ...EMORY HEATED SEAT ADJUSTABLE PEDAL MODULE MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC res...

Page 795: ...emperature Sensor Input circuit to ground Is the resistance below 1000 0 ohms All Yes Repair the Driver Seat Temperature Sensor Input circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Disconnect the Driver Heated Seat Cushion 4 way connector Turn ignition off Measure the resistance between the Driver Seat Temperature Sensor 5 Volt Supply circuit and the Driver Seat Te...

Page 796: ...5 Volt Supply wire between the MHSAPM connector and the driver heated seat cushion connector harness side Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module Perform BODY VERIFICATION TEST VER 1 No Repair the open Driver Seat Temperature Sensor 5 Volt Supply circuit Perform BODY VERIFICATION TEST VER 1 399 ELECTRICALLY HEATED SYSTEMS DRIVER THERMISTOR OU...

Page 797: ...ins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Check fuse 5 in the IPM Is the fuse open All Yes Replace the fuse Check for a short to ground in the Rear Window Defogger Relay Output circuit from the IPM to the defogger grid Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the...

Page 798: ... SHORT TO BAT TERY All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the Rear Window Defogger Relay EBL With the DRBIIIt erase ...

Page 799: ... the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Operate the switch that had the DTC in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display the same DTC All Yes Go To 2 No The condition that caused this code to set is not present at this time Review wiring schematics and inspect related wiring for intermittent open condition Perform...

Page 800: ...resistance below 5 0 ohms All Yes Replace the Passenger Seat Switch Perform BODY VERIFICATION TEST VER 1 No Repair the Seat Switch MUX Return for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Passenger Seat Switch connector Disconnect the Passenger Door Module C2 connector Inspect the Seat Switch MUX circuit that had the DTC for a possible short to voltage Wer...

Page 801: ...from Off to Run Operate the suspect switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER HEATED SEAT SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Passenger Power Seat Switch connector Turn the ignition on With the DRBIIIt erase DTCs Cycle t...

Page 802: ...itch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Passenger Heated Seat Switch MUX circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 405 ELECTRICALLY HEATED SYSTEMS PASSENGER HEATED SEAT SWITCH SHORT PDM Continued ...

Page 803: ...from Off to Run Operate the Heated Seat Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER HEATED SEAT SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Passenger ...

Page 804: ...itch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Passenger Heated Seat Switch MUX circuit as neces sary Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 407 ELECTRICALLY HEATED SYSTEMS PASSENGER HEATED SEAT SWITCH STUCK PDM Continued ...

Page 805: ...e Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go To 2 No Using the wiring schematic as a guide inspect the wiring and connectors for an intermittent condition Check for an intermit tent open cushion or seat back element by applying pressure to seat with the...

Page 806: ...nect the Passenger Heated Seat Back 2 way connector Measure the resistance of the SEAT CUSHION HEATER ELEMENT by connecting one lead to the Heated Seat Driver terminal at the 2 way and the other lead to the Passenger Seat Heater B Driver terminal in the Heated Seat Cushion 4 way Cushion Side connector Is the resistance below 2 5 ohms All Yes Go To 6 No Replace the Passenger Heated Seat Cushion Ele...

Page 807: ...AT HEATER B DRIVER WIRE SHORT TO GROUND FROM MHSAPM TO 4 WAY MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM D...

Page 808: ...Heated Seat Cushion 4 way connector cushion side to body ground Is the resistance below 1000 0 ohms All Yes Replace the Passenger Heated Seat Cushion Element as neces sary Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Disconnect the Passenger Heated Seat Back 2 way connector Measure the resistance of the Heated Seat Driver circuit in the Passenger Heated Seat Back 2 way connector seat back sid...

Page 809: ...LICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC reset All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connector...

Page 810: ...ted Seat Adjustable Pedal Module Perform BODY VERIFICATION TEST VER 1 4 Disconnect the Passenger Heated Seat Cushion 4 way connector Disconnect the Memory Heated Seat Adjustable Pedal Module C1 connector Turn ignition on Measure the voltage between Passenger Seat Temperature Sensor Input circuit in the harness side connector and body ground Is there any voltage on the Passenger Seat Temperature Se...

Page 811: ...ND MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position then start the engine and let run for one minute Operate the heated seat system With the DRBIIlt check for the same DTC to reset in the MHSAPM Did the same DTC...

Page 812: ...TEST VER 1 No Go To 5 5 Disconnect the Passenger Heated Seat Cushion 4 way connector Disconnect the Memory Heated Seat Adjustable Pedal Module C1 connector Turn ignition off Measure the resistance of the Passenger Seat Temperature Sensor Input circuit to ground Is the resistance below 1000 0 ohms All Yes Repair the Passenger Seat Temperature Sensor Input circuit for a short to ground Perform BODY ...

Page 813: ...o Go To 8 8 Disconnect the Passenger Heated Seat Cushion 4 way connector Disconnect the Memory Heated Seat Adjustable Module C1 connector Turn ignition off Measure the resistance of the Passenger Seat Temperature Sensor 5 Volt Supply wire between the MHSAPM connector and the driver heated seat cushion connector harness side Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Ad...

Page 814: ...nning Set Condition When the Memory Heated Seat Adjustable Pedal Module receives a high charging system voltage message over the PCI Bus CHARGING VOLTAGE LOW MESSAGE MHSAPM When Monitored With the engine running Set Condition When the Memory Heated Seat Adjustable Pedal Module receives a low charging system voltage message over the PCI Bus POSSIBLE CAUSES PCM TROUBLE CODES STORED CODE COMMUNICATIO...

Page 815: ...sually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any technical service bulletins that may apply Were any problems found All No Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICAT...

Page 816: ...attempt to communicate with the MHSAPM and check for PCI bus communication DTC s Were there any problems found All Yes Refer to the Communication symptom list Perform BODY VERIFICATION TEST VER 1 No Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 419 ELECTRICALLY HEATED...

Page 817: ...hafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the inoperative rear tail lamp harness connector Using a 12 volt test light connected to 12 volts check the ground circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground Circuit Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect ...

Page 818: ...mp harness connector Measure the resistance of the Backup Lamp Driver Circuit Is the resistance above 5 0 ohms All Yes Repair the Backup Lamp Driver Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 421 EXTERIOR LIGHTING BACKUP LAMP OUTPUT OPEN BCM Continued ...

Page 819: ...artially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on Engine OFF Place the transmission in reverse Using a 12 volt test light connected to ground check the Backup Lamp Output circuit Does the test light illuminate brightly All Yes Replace the Backup Lamp Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Body Control Module C2 harness...

Page 820: ... the Hazard Battery Power Feed circuit Is the resistance below 5 0 ohms All Yes Repair the Hazard Battery Power Feed circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 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 Perform BODY VERIFICATI...

Page 821: ... between the IPM connector and the BCM connector Is the resistance below 5 0 ohms All Yes Replace the Integrated Power Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Hazard Battery Power Feed circuit for an open Perform BODY VERIFICATION TEST VER 1 424 EXTERIOR LIGHTING HAZARD BATTERY POWER OPEN Continued ...

Page 822: ...mp Switch harness connector Turn the ignition on With the DRBIIIt select Body Body Controller and read the Headlamp Switch volts Does the DRBIIIt Headlamp Switch Sensor voltage read less than 0 5 Volts All Yes Replace the Headlamp Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off to the lock position Disconnect the Body Contro...

Page 823: ... Repair the Headlamp Switch MUX Return circuit for an open Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 5 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while ch...

Page 824: ... select Body Body Control Module and read the Headlamp Switch voltage Does the DRB display a Headlamp Switch Voltage of more than 4 8 volts All Yes Replace the Headlamp Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off to the lock position Disconnect the Body Control Module C5 harness connector Disconnect the Headlamp Switch h...

Page 825: ...cuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 5 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circu...

Page 826: ...To 5 2 Turn the ignition off Disconnect the Left Front Fog Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VE...

Page 827: ...e the Left Front Fog Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded term...

Page 828: ... NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 829: ...IIIt display this DTC All Yes Go To 5 No Replace the original Left Front Fog Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left Front Fog Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER ...

Page 830: ...o 2 No Go To 5 2 Turn the ignition off Disconnect the Left Front Park Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICAT...

Page 831: ...the Left Front Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded termi...

Page 832: ... NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 833: ...It display this DTC All Yes Go To 5 No Replace the original Left Front Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left Front Park Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER ...

Page 834: ...es Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Left Front Side Marker Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform ...

Page 835: ...eplace the Left Front Side Marker Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or ...

Page 836: ...ion off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 ...

Page 837: ...e DRBIIIt display this DTC All Yes Go To 5 No Replace the original Left Side Marker Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left Front Side Marker Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VE...

Page 838: ...ition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Left Front Turn Signal harness connector Using a 12 volt test light connected to 12 volts check the ground circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground Circuit Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition...

Page 839: ... resistance of the Left Front Turn Signal Output Circuit and ground Is the resistance above 5 0 ohms All Yes Repair the Left Front Turn Signal Lamp Driver Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 442 EXTERIOR LIGHTING LEFT FRONT TURN SIGNAL OUTPUT OPEN BCM Continued ...

Page 840: ...ATION TEST VER 1 2 Turn the ignition off Disconnect the Left Front Turn Signal Lamp connector Disconnect the BCM C2 harness connector Measure the resistance between the Left Front Turn Signal Lamp Driver circuit and ground Is the resistance below 100 0 ohms All Yes Repair the Left Front Turn Signal Lamp Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the...

Page 841: ...PM DTC s Does the DRBIIIt read Left Headlamp High Beam Open All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Left Headlamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To ...

Page 842: ... High Beam Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals ...

Page 843: ... this DTC present All Yes Go To 3 No Go To 2 2 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All ...

Page 844: ... position With the DRBIIIt read IPM DTC s Does the DRBIIIt display this DTC All Yes Go To 5 No Replace the original Left High Beam Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left High Beam Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integr...

Page 845: ...C s Does the DRBIIIt read Left Headlamp Low Beam Open All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Left Headlamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No R...

Page 846: ...Left Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note R...

Page 847: ...DTC present All Yes Go To 3 No Go To 2 2 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Re...

Page 848: ...h position With the DRBIIIt read IPM DTC s Does the DRBIIIt display this DTC All Yes Go To 5 No Replace the original Left Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left Low Beam Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power...

Page 849: ...n All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Left Rear Park Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform B...

Page 850: ...ft Rear Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NO...

Page 851: ...ition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER ...

Page 852: ... DRBIIIt display this DTC All Yes Go To 5 No Replace the original Left Rear Park Marker Lamp Bulbs Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Left Tail Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TE...

Page 853: ...ition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Left Rear Turn Signal harness connector Using a 12 volt test light connected to 12 volts check the ground circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground Circuit Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition ...

Page 854: ...esistance of the Left Rear Turn Signal Driver Circuit to ground Is the resistance above 5 0 ohms All Yes Repair the Left Rear Turn Signal Lamp Driver Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 457 EXTERIOR LIGHTING LEFT REAR TURN SIGNAL OUTPUT OPEN BCM Continued ...

Page 855: ... VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Left Rear Turn Signal Lamp connector Disconnect the BCM harness connector Measure the resistance between the Left Rear Turn Signal Driver circuit and ground Is the resistance below 100 0 ohms All Yes Repair the Left Rear Turn Signal Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignitio...

Page 856: ... All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the License Plate Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform BOD...

Page 857: ...the License Plate Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded termina...

Page 858: ...nition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER...

Page 859: ...Does the DRBIIIt display this DTC All Yes Go To 5 No Replace the original License Plate Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the License Plate Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION...

Page 860: ...To 5 2 Turn the ignition off Disconnect the Right Front Fog Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST V...

Page 861: ...ce the Right Front Fog Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded te...

Page 862: ... NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 863: ...IIt display this DTC All Yes Go To 5 No Replace the original Right Front Fog Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right Front Fog Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER...

Page 864: ...o 2 No Go To 5 2 Turn the ignition off Disconnect the Right Front Park Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICA...

Page 865: ... the Right Front Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded ter...

Page 866: ... NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 867: ...t display this DTC All Yes Go To 5 No Replace the original Right Front Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right Front Park Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER...

Page 868: ...es Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Right Front Side Marker Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform...

Page 869: ...Replace the Right Front Side Marker Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out o...

Page 870: ...f NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go ...

Page 871: ...BIIIt display this DTC All Yes Go To 5 No Replace the original Right Front Side Marker Lamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right Front Side Marker Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VER...

Page 872: ...ble intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Right Front Turn Signal harness connector Using a 12 volt test light connected to 12 volts check the ground circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground Circuit Perform BODY VERIFICATION TEST VER...

Page 873: ...erform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Body Control Module C2 connector Measure the resistance of the Right Front Turn Signal Driver Circuit to ground Is the resistance above 5 0 ohms All Yes Repair the Right Front Turn Signal Driver Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERI...

Page 874: ...TION TEST VER 1 2 Turn the ignition off Disconnect the Right Front Turn Signal Lamp connector Disconnect the BCM C2 harness connector Measure the resistance between the Right Front Turn Signal Lamp Driver circuit and ground Is the resistance below 100 0 ohms All Yes Repair the Right Front Turn Signal Lamp Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn t...

Page 875: ...PM DTC s Does the DRBIIIt read Right Headlamp High Beam Open All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Right Headlamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go T...

Page 876: ...t High Beam Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals...

Page 877: ... this DTC present All Yes Go To 3 No Go To 2 2 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All ...

Page 878: ...position With the DRBIIIt read IPM DTC s Does the DRBIIIt display this DTC All Yes Go To 5 No Replace the original Right High Beam Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right High Beam Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integ...

Page 879: ...witch the headlamps between high beam and low beam several times pausing for 5 seconds in each position With the DRB read the IPM DTC s Does the DRBIIIt read Right Headlamp Low Beam Open All Yes Go To 3 No Go To 2 2 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiri...

Page 880: ... Driver circuit Is the resistance below 10 0 ohms All Yes Go To 5 No Repair the Right Low Beam Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Right Headlamp harness connector Using a 12 volt test light connected to ground check the Right Low Beam Driver circuit in the Right Headlamp harness connector NOTE The test light must illuminate bright...

Page 881: ... DTC present All Yes Go To 3 No Go To 2 2 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes R...

Page 882: ... position With the DRBIIIt read IPM DTC s Does the DRBIIIt display this DTC All Yes Go To 5 No Replace the original Right Headlamp Bulb Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right Low Beam Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Powe...

Page 883: ... All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Right Rear Park Lamp harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground circuit for an open Perform B...

Page 884: ...ght Rear Park Lamp Bulb Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals N...

Page 885: ...ion off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 ...

Page 886: ...DRBIIIt display this DTC All Yes Go To 5 No Replace the original Right Rear Park Marker Lamp Bulbs Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Inspect the wiring and connectors associated with the Right Tail Lamp Driver circuit Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Replace the Integrated Power Module Perform BODY VERIFICATION T...

Page 887: ...ok for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Right Rear Turn Signal harness connector Using a 12 volt test light connected to 12 volts check the ground circuit Does the test light illuminate brightly All Yes Go To 3 No Repair the Ground Circuit Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Dis...

Page 888: ...ar Turn Signal Driver Circuit and ground Is the resistance above 5 0 ohms All Yes Repair the Right Rear Turn Signal Lamp Driver Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 491 EXTERIOR LIGHTING RIGHT REAR TURN SIGNAL OUTPUT OPEN BCM Continued ...

Page 889: ...ATION TEST VER 1 2 Turn the ignition off Disconnect the Right Rear Turn Signal Lamp connector Disconnect the BCM C2 harness connector Measure the resistance between the Right Rear Turn Signal Lamp Driver circuit and ground Is the resistance below 100 0 ohms All Yes Repair the Right Rear Turn Signal Lamp Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the...

Page 890: ... 2 6 seconds or above 4 92 volts AC PRESSURE TOO HIGH When Monitored When executing the AC Cooldown Test Set Condition If the A C Pressure Sensor value is above 300 psi AC PRESSURE TOO LOW When Monitored When executing the AC Cooldown Test Set Condition If the A C Pressure Sensor value is below 50 psi POSSIBLE CAUSES POWERTRAIN CONTROL MODULE PCM DTC S PRESENT IMPROPER REFRIGERANT SYSTEM CHARGE AU...

Page 891: ...igerant system properly charged All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Recharge the refrigerant system in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 494 HEATING A C AC PRESSURE SENSOR FAULT ACTIVE Continued ...

Page 892: ...SENSOR NOT CALIBRATED STORED LOOPBACK FAILURE STORED NO COMMUNICATION WITH BCM STORED NO COMMUNICATION WITH DDM STORED NO COMMUNICATION WITH MIC STORED NO COMMUNICATION WITH PCM STORED NO COMMUNICATION WITH PDM STORED OPS CHECKSUM ERROR STORED OUTSIDE AIR TEMP MESSAGE MISSING STORED PAS FRONT DOOR MESSAGE MISSING STORED PASSENGER BLEND DOOR NOT RESPONDING STORED PASSENGER BLEND DOOR TRAVEL TOO LAR...

Page 893: ... Monitored With the ignition on and IOD fuse installed after a battery disconnect Set Condition This DTC will set if the calculated check sum does not match the stored value CALIBRATION CHECKSUM ERROR STORED When Monitored With the ignition on and IOD fuse installed after a battery disconnect Set Condition This DTC will set if the calculated check sum does not match the stored value COOLANT TEMPER...

Page 894: ...Door Module DDM for more than 5 seconds ENGINE SENSORS MESSAGE MISSING STORED When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC does not receive the message from the Powertrain Control Module PCM for more than 16 seconds This message provides A C Pressure Sensor Failure and Refrigerant Pressure Failure EVAP TEMP ...

Page 895: ...d FRONT MODE DOOR TRAVEL TOO LARGE STORED When Monitored With the ignition on and the IOD fuse installed Set Condition The Automatic Temperature Control ATC monitors the door s range of travel during system initialization If the measured range is greater than expected the DTC will set FRONT MODE DOOR TRAVEL TOO SMALL STORED When Monitored With the ignition on and the IOD fuse installed Set Conditi...

Page 896: ...ges from the Powertrain Control Module PCM for at least 5 seconds NO COMMUNICATION WITH PDM STORED When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC does not receive any messages from the Passenger Door Module PDM for at least 5 seconds OPS CHECKSUM ERROR STORED When Monitored With the ignition on and IOD fuse in...

Page 897: ... Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC detects a short to voltage on the PCI Bus circuit PCI BUS SHORTED LOW STORED When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC detects a short to ground on the PCI Bus circuit REAR F...

Page 898: ... the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC cannot read the IR sensor offset and gain values VEHICLE ODOMETER MESSAGE MISSING STORED When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC does not receive the Vehicle Odometer message from the Bod...

Page 899: ...DTC will set if the Automatic Temperature Control ATC does not receive the VIN message from the Powertrain Control Module PCM for more than 16 seconds POSSIBLE CAUSES CHECK FOR ACTIVE ATC DTCS AND COOLDOWN TEST FAULT MESSAGES STORED CODES TEST COMPLETE 502 HEATING A C AC PRESSURE SENSOR FAULT STORED Continued ...

Page 900: ...ode switch on so that it is in manual mode The word 9REAR9 should display on the ATC display panel The word 9AUTO9 should not be displayed Press the DUAL mode switch off The word 9DUAL9 should not be displayed on the ATC display panel This will allow the DRIVER BLEND mode switch to control both driver and pass temp settings Set the driver temperature to 60 F 16 C The passenger temperature should a...

Page 901: ...IBLE CAUSES NO COMMUNICATION WITH BCM DTC SET BODY CONTROL MODULE BCM DTC S PRESENT AUTOMATIC TEMPERATURE CONTROL ATC BODY CONTROL MODULE BCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read the active ATC DTCs Does the DRBIIIt display NO COMMUNICATION WITH BCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To ...

Page 902: ...W 9 9RT R DOOR AJAR SW 9 Is 9NO RESPONSE9 displayed after any of these messages All Yes Replace the Body Control Module BCM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 505 HEATING A C BODY STATUS MESSAGE MISSING ACTIVE Continued ...

Page 903: ...e stored value CALIBRATION CHECKSUM ERROR ACTIVE When Monitored With the ignition on and IOD fuse installed after a battery disconnect Set Condition This DTC will set if the calculated check sum does not match the stored value FRONT IR SENSOR CHANGE TOO LARGE ACTIVE When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control A...

Page 904: ...onitored With the ignition on and IOD fuse installed after a battery disconnect Set Condition This DTC will set if the calculated check sum does not match the stored value RIGHT IR SENSOR NOT CALIBRATED ACTIVE When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC cannot read the IR sensor offset and gain values POSSI...

Page 905: ...es the DRBIIIt display NO COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignit...

Page 906: ... This message will display if the A C system is unable to bring the evaporator temperature down either 6 7 C 20 F within two minutes at ambient temper atures of 21 C 70 F or above or bring the evaporator temperature down 9 4 C 15 F within two minutes at ambient temperatures below 21 C 70 F POSSIBLE CAUSES OTHER COOLDOWN TEST FAULT MESSAGES PRESENT AUTOMATIC TEMPERATURE CONTROL ATC DTC S PRESENT PO...

Page 907: ...ON The work area ambient temperature must be above 15 6 C 60 F and the evaporator temperature must be above 12 C 53 F in order to test A C system operation Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s After the repair is complete rerun the Cooldown Test Perform BODY VERIFICATIO...

Page 908: ...ay NO COMMUNICATION WITH MIC All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read MIC DTCs Does the DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With DRBIIIt in ATC Monito...

Page 909: ...C will set if the Automatic Temperature Control ATC does not receive feedback pulses within 5 seconds of the drive voltage being applied PASSENGER BLEND DOOR NOT RESPONDING ACTIVE When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC does not receive feedback pulses within 5 seconds of the drive voltage being applied...

Page 910: ... driver circuit with resistance below 10K ohms for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the ATC C2 harness connector NOTE Do NOT measure the resistance between the Door Driver circuits that connect to the same actuator Measure the resistance between the applicable Door Driver A circuit and each of the remaining Door Driver circuits Me...

Page 911: ...mation Perform BODY VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the ATC C2 harness connector Disconnect the applicable door actuator harness connector Measure the resistance of the Door Driver A circuit between the ATC C2 harness connector and the door actuator harness connector Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the Door Driver A circuit for an open Perform ...

Page 912: ...ion on and the IOD fuse installed Set Condition The Automatic Temperature Control ATC monitors the door s range of travel during system initialization If the measured range is greater than expected the DTC will set PASSENGER BLEND DOOR TRAVEL TOO LARGE ACTIVE When Monitored With the ignition on and the IOD fuse installed Set Condition The Automatic Temperature Control ATC monitors the door s range...

Page 913: ...on Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Remove the applicable door actuator from the A C Heater Housing assembly Inspect the door linkage for excessive wear disconnected missing and broken linkage Also inspect for a warped or broken door Rotate the door from stop to stop The door should rotate approximately 45 degrees Were any mechanical problems found All Yes Re...

Page 914: ...ead the active ATC DTCs Does the DRBIIIt display DRIVER BLEND DOOR NOT RESPONDING All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Driver Blend Door Actuator harness connector Connect a 12 volt Test Light between the Driver Blend Door Actuator harness connector cavities Turn the ignition on ...

Page 915: ...om stop to stop Does the driver blend door move smoothly in both directions All Yes Replace the Driver Blend Door Actuator in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair or replace the driver blend door as necessary in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 518 HEATING A C DRIVER BLEND DOOR TRAVEL TOO SMALL ACTIVE Con...

Page 916: ...DRBIIIt display NO COMMUNICATION WITH DDM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read DDM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With DRBIIIt ...

Page 917: ...DTCs Does the DRBIIIt display NO COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn th...

Page 918: ...TROL CIRCUIT AUTOMATIC TEMPERATURE CONTROL ATC EVAP TEMP SENSOR SIGNAL CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN EVAPORATOR TEMPERATURE SENSOR TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the ATC C1 harness connector Turn the ignition on Measure the voltage of the Evaporator Temperature Sensor Signal circuit Is the voltage above 0 2 volts All Yes Repair the Evaporator Temperature Sen...

Page 919: ...5 F 11 900 ohms 21 C 70 F 13 500 ohms 18 C 65 F 15 300 ohms 16 C 60 F 17 500 ohms 13 C 55 F 19 900 ohms 10 C 50 F 22 800 ohms 7 C 45 F 26 100 ohms 4 C 40 F 30 000 ohms 2 C 35 F 34 600 ohms 1 C 30 F Is the resistance within the specifications All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ig...

Page 920: ...e resistance below 5 0 ohms All Yes Check the wiring harness between the in line C202 harness connector HVAC side and the Evap Temp Sensor for an open Repair as necessary If Ok replace the Evaporator Temperature Sensor Perform BODY VERIFICATION TEST VER 1 No Repair the Sensor Ground circuit between the ATC C1 harness connector and the in line C202 harness connector IP side for an open Perform BODY...

Page 921: ... the ignition off Disconnect the in line C202 harness connector Turn the ignition on With the DRBIIIt read the active DTCs Does the DRBIIIt display EVAP TEMP SENSOR OPEN All Yes Check the Evap Temp Sensor Signal circuit between the in line C202 harness connector HVAC side and the Evap Temp Sensor for a short to ground Repair as necessary If Ok replace the Evaporator Temperature Sensor Perform BODY...

Page 922: ...t IP side Is the resistance above 100k ohms All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Evaporator Temperature Sensor Signal circuit be tween the ATC C1 harness connector and the in line C202 harness connector IP side for a short to Sensor Ground Perform BODY VERIFICATION TEST VER 1 525 HEATING ...

Page 923: ...e blower relay connector Is the test light illuminated All Yes Go To 2 No Check the B feed to the Integrated Power Module IPM for an open If OK replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the existing Front Blower Relay Turn the ignition on With the DRBIIIt erase DTCs Turn the ignitio...

Page 924: ...ODULE IPM TEST ACTION APPLICABILITY 1 Turn the ignition off Install a substitute relay in place of the existing Front Blower Relay Turn the ignition on With the DRBIIIt erase DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRBIIIt read IPM DTCs Does the DRBIIIt display FRONT BLOWER RELAY SHORT TO BATT All Yes Replace the Integrated Power Module IPM in accordance with ...

Page 925: ...DRBIIIt read the active ATC DTCs Does the DRBIIIt display FRONT MODE DOOR NOT RESPONDING All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Front Mode Door Actuator harness connector Connect a 12 volt Test Light between the Front Mode Door Actuator harness connector cavities Turn the ignition ...

Page 926: ...from stop to stop Does the front mode door move smoothly in both directions All Yes Replace the Front Mode Door Actuator in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair or replace the front mode door as necessary in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 529 HEATING A C FRONT MODE DOOR TRAVEL TOO SMALL ACTIVE Continued...

Page 927: ...NCE EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT HIGH RESISTANCE AUTOMATIC TEMPERATURE CONTROL ATC TEST ACTION APPLICABILITY 1 CAUTION The work area ambient temperature must be above 15 6 C 60 F and the evaporator temperature must be above 12 C 53 F in order to test A C system operation Start the engine Press the A C mode switch off The Snowflake should not be displayed on the ATC display panel Se...

Page 928: ...complete with the DRBIIIt erase the DTC s then cycle the ignition switch and then with the DRBIIIt actuate the AC Cooldown Test Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Evaporator Temperature Sensor harness connector Turn the ignition on With the DRBIIIt in Sensor Display read the Evaporator Temperature Sensor voltage Is the voltage above 4 9 volts All...

Page 929: ...porator Temperature Sensor harness connector is connected to the Evaporator Temperature Sensor NOTE Ensure the voltmeter leads meet the terminals in the connector and that there is good terminal to wire connection NOTE Ensure the voltmeter leads are connected for positive polarity Back probe the Evaporator Temperature Sensor Signal circuit between the Evapo rator Temperature Sensor harness connect...

Page 930: ...ntrol ATC does not receive any messages from the Driver Door Module DDM for at least 5 seconds NO COMMUNICATION WITH MIC ACTIVE When Monitored With the ignition on and the IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC does not receive any messages from the Instrument Cluster EMIC for at least 5 seconds NO COMMUNICATION WITH PCM ACTIVE When Monitored Wi...

Page 931: ...DRBIIIt able to ID or communicate with the module s All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Refer to the Communications category for the related symptom s Perform BODY VERIFICATION TEST VER 1 534 HEATING A C NO COMMUNICATION WITH BCM ACTIVE Continued ...

Page 932: ...the DRBIIIt display NO COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition...

Page 933: ...he DRBIIIt display NO COMMUNICATION WITH PDM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PDM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With DRBII...

Page 934: ...ead the active ATC DTCs Does the DRBIIIt display PASSENGER BLEND DOOR NOT RESPONDING All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Passenger Blend Door Actuator harness connector Connect a 12 volt Test Light between the Passenger Blend Door Actuator harness connector cavities Turn the ign...

Page 935: ...stop to stop Does the passenger blend door move smoothly in both directions All Yes Replace the Passenger Blend Door Actuator in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair or replace the passenger blend door as necessary in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 538 HEATING A C PASSENGER BLEND DOOR TRAVEL TOO SMALL A...

Page 936: ...he IOD fuse installed Set Condition This DTC will set if the Automatic Temperature Control ATC detects a short to ground on the PCI Bus circuit POSSIBLE CAUSES AUTOMATIC TEMPERATURE CONTROL ATC TEST ACTION APPLICABILITY 1 NOTE For this DTC to be active the DRBIIIt will not be able to communi cate with any modules on the vehicle except the Powertrain Control Module PCM NOTE Do NOT perform this test...

Page 937: ...nector Is the test light illuminated All Yes Go To 2 No Check the B feed to the IPM for an open If OK replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the existing Rear Booster Fan Relay Turn the ignition on With the DRBIIIt erase DTCs Turn the ignition off With the DRBIIIt read IPM DTCs D...

Page 938: ... Turn the ignition off Install a substitute relay in place of the existing Rear Booster Fan Relay Turn the ignition on With the DRBIIIt erase DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRBIIIt read IPM DTCs Does the DRBIIIt display REAR BOOSTER FAN RELAY SHORT TO BATT All Yes Replace the Integrated Power Module IPM in accordance with the Service Information Perfo...

Page 939: ...OL SWITCH AUTOMATIC TEMPERATURE CONTROL ATC TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the Rear Booster Fan Rear Control Switch harness connector Turn the ignition on Measure the voltage of the Rear Fan Sense Supply circuit Is the voltage above 5 3 volts All Yes Go To 2 No Go To 3 2 Turn the ignition off Disconnect the ATC C1 harness connector Disconnect the Rear Booster Fan Rear...

Page 940: ...n the ignition off Disconnect the ATC C1 harness connector Disconnect the Rear Booster Fan Rear Control Switch harness connector Measure the resistance of the Rear Fan Sense circuit between the ATC C1 harness connector and the Rear Booster Fan Rear Control Switch harness connector Is the resistance below 5 0 ohms All Yes Replace the Automatic Temperature Control ATC in accordance with the Service ...

Page 941: ... X10 Start the engine Press the ATC s PWR switch on Press the REAR fan mode switch on so that it is in manual mode The word 9REAR9 should display on the ATC display panel The word 9AUTO9 should not be displayed Turn the Rear Booster Fan Rear Control Switch to the AUTO position Using the X10 Scope Probe back probe the Rear Fan Sense circuit in the Rear Booster Fan Rear Control Switch harness connec...

Page 942: ...rn the ignition off Disconnect the ATC C1 harness connector Disconnect the Rear Booster Fan Rear Control Switch harness connector Measure the resistance between ground and the Rear Fan Sense Supply circuit Is the resistance above 100K ohms All Yes Go To 2 No Repair the Rear Fan Sense Supply circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the AT...

Page 943: ...R 1 5 Turn the ignition off Disconnect the ATC C1 harness connector Disconnect the ATC C2 harness connector Disconnect the Rear Booster Fan Rear Control Switch harness connector Measure the resistance between the Rear Fan Sense circuit and the Rear Fan Sense Return circuit Is the resistance above 100K ohms All Yes Go To 6 No Repair the Rear Fan Sense circuit for a short to the Rear Fan Sense Retur...

Page 944: ...RBIIIt read the active ATC DTCs Does the DRBIIIt display RECIRC DOOR NOT RESPONDING All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Recirculation Door Actuator harness connector Connect a 12 volt Test Light between the Recirculation Door Actuator harness connector cavities Turn the ignition...

Page 945: ...from stop to stop Does the recirculation door move smoothly in both directions All Yes Replace the Recirculation Door Actuator in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair or replace the recirculation door as necessary in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 548 HEATING A C RECIRC DOOR TRAVEL TOO SMALL ACTIVE Con...

Page 946: ...s Does the DRBIIIt display NO COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the i...

Page 947: ...DRBIIIt display NO COMMUNICATION WITH BCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read BCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With the DRBI...

Page 948: ...es the DRBIIIt display NO COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignit...

Page 949: ...ITY 1 Turn the ignition on With the DRBIIIt read the active ATC DTCs Does the DRBIIIt display NO COMMUNICATION WITH BCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read BCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perfor...

Page 950: ...Does the DRBIIIt display VF DIM MSG PRESENT YES All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module BCM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 553 HEATING A C VF DIMMING MESSAGE MISSING ACTIVE Continued ...

Page 951: ...O COMMUNICATION WITH PCM All Yes Return to the Heating A C symptom list and choose the symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read PCM DTCs Does the DRBIIIt display any DTCs All Yes Refer to the Powertrain Diagnostic Information for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With the DRBIIIt ...

Page 952: ... VER 1 No Go To 3 3 Turn the ignition off Rotate the Panel Lamps Dimmer switch to the off position Disconnect the ATC C1 harness connector Turn the park lamps on Measure the voltage of the Panel Lamps Driver circuit while rotating the Panel Lamps Dimmer switch from the off position to the full brightness position Does the voltage change from approximately 4 5 volts to 11 5 volts All Yes Go To 4 No...

Page 953: ... the ATC C1 harness connector and the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms All Yes Replace the Instrument Cluster EMIC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Panel Lamps Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 556 HEATING A C AUTOMATIC TEMPERATURE CONTROL ATC BACK LIGHTING INOP ERATIV...

Page 954: ...RCUIT FUSED FRONT BLOWER RELAY OUTPUT CIRCUIT OPEN TEST ACTION APPLICABILITY 1 NOTE Verify that the vehicle s odometer displays more than 3 miles If not drive the vehicle until the odometer displays more than 3 miles and then recheck blower motor operation If still inoperative proceed as follows Turn the ignition on With the DRBIIIt read IPM DTCs Does the DRBIIIt display any DTCs All Yes For Integ...

Page 955: ...rcuit in the Front Blower Power Module C1 harness connector and the Blower Motor Supply circuit in the Front Blower Power Module C2 harness connector Connect a jumper wire between the Ground circuit in the Front Blower Power Module C1 harness connector and the Blower Motor Ground circuit in the Front Blower Power Module C2 harness connector Turn the ignition on Does the Front Blower Motor operate ...

Page 956: ...wer Module C1 harness connector Disconnect the ATC C1 harness connector Measure the resistance of the Front Blower Motor Control circuit between the Front Blower Power Module C1 harness connector and the ATC C1 harness connector Is the resistance below 5 0 ohms All Yes Go To 10 No Repair the Front Blower Motor Control circuit for an open Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition of...

Page 957: ... high while observing the DRBIIIt display The voltage on the scope patten should cycle from approximately 0 volts duty cycle on to 12 0 volts duty cycle off for all blower speeds The duty cycle pattern should change smoothly as the blower speed changes from low to high Does the DRBIIIt display the voltage range and duty cycle as described above All Yes Go To 12 No Replace the Automatic Temperature...

Page 958: ...RIFICATION TEST VER 1 15 Turn the ignition off Make sure that the Front Blower Relay is installed Remove IPM Fuse 42 Front Blower Fuse Turn the ignition on NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground probe IPM Fuse 42 power input cavity Does the test light illuminate brightly All Ye...

Page 959: ...ressure immanent overheat detection or an overheat condition Verify that none of these conditions exist before diagnosing blower concerns Turn the ignition off Disconnect the Front Blower Power Module C1 harness connector Disconnect the ATC C1 harness connector Measure the resistance between ground and the Front Blower Motor Control circuit Is the resistance below 10K ohms All Yes Repair the Front...

Page 960: ...y cycle less time grounding the signal voltage NOTE As higher blower speeds are requested the ATC Module increases the duty cycle more time grounding the signal voltage NOTE When the highest blower speed is requested the duty cycle increases to where the signal pattern is almost a flat line with brief voltage spikes Set the blower speed to low then slowly raise the blower speed to high while obser...

Page 961: ...AND COOLDOWN TEST FAULT MESSAGES CHECK FOR HVAC RELATED DTCS IN THE POWERTRAIN CONTROL MODULE PCM TEST ACTION APPLICABILITY 1 With the DRBIIIt read PCM DTCs Are any HVAC related DTCs present All Yes Refer to the Powertrain Diagnostic Procedures for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 2 564 HEATING A C ...

Page 962: ...wer speed to low Press the REAR fan mode switch on so that it is in manual mode The word 9REAR9 should display on the ATC display panel The word 9AUTO9 should not be displayed Press the DUAL mode switch off The word 9DUAL9 should not be displayed on the ATC display panel This will allow the DRIVER BLEND mode switch to control both driver and pass temp settings Set the driver temperature to 60 F 16...

Page 963: ...RBIIIt read PCM DTC s Are any HVAC related DTCs present All Yes Refer to the Powertrain Diagnostic Procedures Manual for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Test Complete 566 HEATING A C HVAC SYSTEM TEST Continued ...

Page 964: ...actual outside air temp NOTE If the vehicle is driven for an extended time below 20 mph the OAT display will not update for warmer outside air temps If after this extended time the vehicle speed is increased to above 50 mph the OAT display may display an erroneous value Turn the ignition on With the DRBIIIt read the active ATC DTCs Does the DRBIIIt display any DTCs All Yes Return to the Heating A ...

Page 965: ...INTEGRATED POWER MODULE IPM OPEN CIRCUIT REAR BOOSTER FAN RELAY INTEGRATED POWER MODULE IPM OPEN CIRCUIT FUSED REAR BOOSTER FAN RELAY OUTPUT CIRCUIT OPEN TEST ACTION APPLICABILITY 1 Turn the ignition on Press the ATC s PWR switch on Press the REAR fan mode switch on so that it is in manual mode The word 9REAR9 should display on the ATC display panel The word 9AUTO9 should not be displayed Turn the...

Page 966: ...ster Fan in all speeds Start the engine and operate the ATC system in all modes and speeds Does the Rear Booster Fan operate properly without blowing the fuse All Yes Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short to ground condition Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Rear Booster Fan...

Page 967: ...n Fuse Perform BODY VERIFICATION TEST VER 1 7 Ensure IPM Fuse 34 Rear Booster Fan Fuse is installed Disconnect the Rear Booster Fan Power Module C1 harness connector Turn the ignition on NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground back probe the Fused Rear Booster Fan Relay Output c...

Page 968: ...ear Booster Fan Power Module C1 harness connector Reconnect the ATC C1 harness connector Start the engine Press the ATC s PWR switch on Press the REAR fan mode switch on so that it is in manual mode The word 9REAR9 should display on the ATC display panel The word 9AUTO9 should not be displayed Turn the Rear Booster Fan Rear Control switch to the low speed setting While back probing measure the vol...

Page 969: ...an speed to low then slowly raise the fan speed to high while observing the DRBIIIt display The voltage on the scope patten should cycle from approximately 0 volts duty cycle on to 12 0 volts duty cycle off for all fan speeds The duty cycle pattern should change smoothly as the fan speed changes from low to high Does the DRBIIIt display the voltage range and duty cycle as described above All Yes G...

Page 970: ...ERIFICATION TEST VER 1 16 Turn the ignition off Make sure that the Rear Booster Fan Relay is installed Remove IPM Fuse 34 Rear Booster Fan Fuse Turn the ignition on NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground probe IPM Fuse 34 power input cavity Does the test light illuminate bright...

Page 971: ... read BCM DTCs Does DRBIIIt display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Rotate the Panel Lamps Dimmer switch to the off position Disconnect the Rear Booster Fan Rear Control Switch harness connector Turn the park lamps on Measure the voltage of the Panel Lamps Driver circuit while rotat...

Page 972: ...the Rear Booster Fan Rear Control Switch harness connector and the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms All Yes Replace the Instrument Cluster EMIC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Panel Lamps Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 575 HEATING A C REAR BOOSTER FAN REAR CONTROL ...

Page 973: ...TC C2 harness connector Disconnect the Rear Booster Fan Rear Control Switch harness connector Measure the resistance between ground and the Rear Fan On Indicator Driver circuit Is the resistance below 10K ohms All Yes Repair the Rear Fan On Indicator Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the ATC C2 harness connector ...

Page 974: ...Fan Rear Control switch to AUTO for 30 seconds then slowly turn it from AUTO to high speed and then back to AUTO With the DRBIIIt read the active ATC DTCs Does the DRBIIIt display any DTCs All Yes Return to the Heating A C symptom list and choose the symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Rear Booster Fan Power Module C1 harness connector D...

Page 975: ...witch NOTE When the fan speed is set to low the ATC provides a short duty cycle less time grounding the signal voltage NOTE As higher fan speeds are requested the ATC increases the duty cycle more time grounding the signal voltage NOTE When the highest fan speed is requested the duty cycle increases to where the signal pattern is almost a flat line with brief voltage spikes Set the fan speed to lo...

Page 976: ...nnect the ATC C2 harness connector Turn the ignition on Measure the voltage between the Rear Mode Door Driver A circuit and ground Measure the voltage between the Rear Mode Door Driver B circuit and ground Is the voltage above 0 2 volts on either circuit All Yes Repair the Rear Mode Door Driver circuit with voltage above 0 2 volts for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go T...

Page 977: ...ordance with the Service Information Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the ATC C2 harness connector Disconnect the Rear Mode Door Actuator harness connector Measure the resistance of the Rear Mode Door Driver A circuit between the ATC C2 harness connector and the Rear Mode Door Actuator harness connector Is the resistance below 5 0 ohms All Yes Go To 6 No Repa...

Page 978: ...o To 8 No Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 8 Turn the ignition off Remove the rear booster fan blower housing Inspect the rear booster fan blower housing for a condition causing the rear mode doors or linkage to bind Inspect for disconnected missing or broken door linkage Inspect for warped or broken doors...

Page 979: ... VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt read the active ATC DTCs Does the DRBIIIt display any DTCs All Yes Return to the Heating A C symptom list and choose the symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on Press the ATC s PWR switch on NOTE Compare with a known good ATC Head Operate all ATC switches while looking at the ATC di...

Page 980: ...ase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs Did this DTC reset All Yes If there are no BCM Ignition MUX DTC s and this code resets replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer...

Page 981: ...formation for any possible intermittent wiring problems Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and inspect IPM fuse 48 Is the fuse open All Yes Replace fuse Check the Fused B circuit for a short refer to the wiring diagrams located in the service information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Body Control Module C2 ha...

Page 982: ...Unlock Run Start circuit Is there any voltage present All Yes Repair the IPM Output Unlock Run start circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BTSI Solenoid harness connector Turn the ignition on Measure the voltage between the IPM Output Unlock Run Start circuit and ground Is the voltage above 10 5 volts All Yes Go To 3 N...

Page 983: ...n Start circuit between the IPM C9 connector and the BTSI solenoid connector Is the resistance above 5 0 ohms All Yes Repair the IPM Output Unlock Run Start circuit for an open Perform BODY VERIFICATION TEST VER 1 No Replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 586 IGNITION POWER ACCESSORY BTSI OUTPUT OPEN SHORT TO VOLTAGE IPM Continued ...

Page 984: ...d DTCs Does the DRBIIIt display 9BTSI Output Open9 All Yes Replace the BTSI Solenoid in accordance with the Service Infor mation Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the IPM C9 harness connector Disconnect the BTSI Solenoid harness connector Measure the resistance between ground and the IPM Output Unlock Run Start circuit Is the resistance below 100 oh...

Page 985: ... With the DRBIIIt read DTCs Did this DTC reset All Yes If this DTC resets replace the BCM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Instrument Cluster C1 harness connector Measure the resistance between ground and the Instrument Cluster Wake Up Signal circuit Is the resis...

Page 986: ...for any possible intermittent wiring problems Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and inspect IPM fuse 47 Is the fuse open All Yes Replace fuse Check the Fused B circuit for a short refer to the wiring diagrams located in the service information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Driver Door Module C1 harness conne...

Page 987: ... for those codes before proceeding Does the DRBIIIt display DOOR NODE POWER RELAY OPEN All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove the Run Only Relay fro...

Page 988: ...RELAY SHORT TO BATTERY All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the existing Door Node Relay With the DRBIIIt erase DT...

Page 989: ...gnition off wait 30 seconds then turn the ignition on With the DRBIIIt read IPM DTCs Does the DRBIIIt display HORN INPUT STUCK All Yes Go To 2 No The condition that caused this symptom is currently not present Inspect the related wiring harness for a possible intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the IPM C4 connector Measure the resistance b...

Page 990: ...rn switch as necessary Perform BODY VERIFICATION TEST VER 1 4 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERIOUS OR FATAL INJURY Disconnect the Clockspring C1 connector Disconnect the IPM C4 co...

Page 991: ...Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Check fuse 28 in the IPM Is the fuse open All Yes Replace the fuse Check for a short to ground in the Horn Relay Output circuit from the IPM to the horns Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn th...

Page 992: ...NTROL CIRCUIT SHORT TO BAT TERY All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the Horn Relay With the DRBIIIt erase DTCs Tu...

Page 993: ...witch Sense circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Ignition Switch harness connector Connect a jumper wire between Ignition Switch Sense circuit and ground Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display 9Ignition MUX Switch Input Short9 All Yes Go To 3 No Repair the Ignition Switch Sense circui...

Page 994: ...nd C5 harness connectors Measure the resistance of the between the Ignition Switch Sense circuit and the Sense Return circuit Is the resistance below 100 ohms All Yes Repair the Ignition Switch Sense circuit for a short to the Sense Return circuit Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Ignition Switch harness connector Disconnect the BCM C5 harness c...

Page 995: ... SWITCH SKREEM BCM IPM TEST ACTION APPLICABILITY 1 NOTE Ensure the battery is fully charged and battery cables are properly tightened NOTE Ensure the IPM battery and ground connections are clean and properly tightened Using the wiring diagram schematic as a guide measure the voltage between ground and the B circuit to Fuse 30 Is the voltage above 10 5 volts All Yes Go To 2 No Replace the IPM in ac...

Page 996: ... below 5 0 ohms for either terminal pin All Yes Replace the Ignition Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Disconnect the IPM C9 harness connector Disconnect the BCM C2 harness connector Disconnect the Ignition Switch harness connector Disconnect the SKREEM harness connector Using the wiring diagram schematic as a ...

Page 997: ...s time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness connectors and terminals Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition off While back probing measure the voltage of the Fused B circuit in the Ignition Switch harness connector Is the voltage above 10 5 volts...

Page 998: ...l Yes Replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness connectors and terminals Perform BODY VERIFICATION TEST VER 1 14 Turn the ignitio...

Page 999: ...ir any BCM Ignition MUX or IPM Ignition Run Start Mismatch DTC s before proceeding with this test Turn the ignition off Remove and inspect Fuse 30 in the IPM If fuse is open replace with proper rated fuse Remove the Starter Relay from the IPM Turn the ignition to the Start position for at least 5 seconds Turn the ignition off Remove and inspect Fuse 30 in the IPM Is IPM Fuse 30 open All Yes Go To ...

Page 1000: ...ime Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the IPM C4 harness connector Measure the voltage of the Ignition Switch Output Start circuit while holding the Ignition Switch i...

Page 1001: ...l Yes Replace the Ignition Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 604 IGNI...

Page 1002: ...or any possible intermittent wiring problems Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and inspect IPM fuse 46 Is the fuse open All Yes Replace fuse Check the Fused B circuit for a short refer to the wiring diagrams located in the service information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Passenger Door Module C1 harness con...

Page 1003: ...ding Does the DRBIIIt display RUN ONLY RELAY OPEN All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove the Run Only Relay from the IPM Using a 12 volt test light ...

Page 1004: ...LAY SHORT TO BATTERY All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the existing Run Relay With the DRBIIIt erase DTCs Turn ...

Page 1005: ...id this DTC reset All Yes Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove the Run Accessory Relay from the IPM Using a 12 volt test light connected to ground probe c...

Page 1006: ...30 seconds then turn the ignition on With the DRBIIIt read DTCs Did this DTC reset All Yes Replace the IPM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the original Run Accessory Relay in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 609 IGNITION POWER ACCESSORY RUN ACCESSORY RELAY OPEN IPM Continued ...

Page 1007: ...es Go To 2 No The condition that caused the symptom is not currently present Refer to any Technical Service Bulletins TSBs that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Install a substitute relay in place of the existing Run Accessory Relay With the DRBIIIt erase DTCs Turn the ignition on ...

Page 1008: ...or BCM Ignition MUX DTC s before proceeding with this test Using the wiring diagram schematic as a guide check the Ignition Switch Output Run Start circuit for an open between the BCM C2 harness connector and the Ignition Switch harness connector Was an open circuit condition found All Yes Repair the Ignition Switch Output Run Start circuit for an open Perform BODY VERIFICATION TEST VER 1 No With ...

Page 1009: ...Y 1 Turn the ignition on With the DRBIIIt record and erase IPM DTC s Turn the ignition off With the DRBIIIt read active IPM DTCs Does the DRBIIIt display Trans Ignition Feed Open or Short To BATT All Yes Go To 2 No The condition that caused this DTC to set is not currently present Using the wiring diagram as a guide inspect for chaffed pierced pinched and broken wires in the related wiring and con...

Page 1010: ...ge above 0 2 volts All Yes Repair the Ignition Unlock Run Start circuit for a short to volt age Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Reconnect the Powertrain Control Module C1 harness connector Leave the Autostick Switch harness connector and the Integrated Power Module IPM C6 harness connector disconnected Measure the voltage of the Ignition Unlock Run Start cir...

Page 1011: ... With the DRBIIIt read active IPM DTCs Does the DRBIIIt display Trans Ignition Feed Short To GND All Yes Go To 2 No The condition that caused this DTC to set is not currently present Using the wiring diagram as a guide inspect for chaffed pierced and pinched wires in the related wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIIIt attempt to communicat...

Page 1012: ...VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt actuate the Horn Relay Do the horns operate All Yes Go To 3 No Go To 7 3 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERIOUS OR FATAL INJURY...

Page 1013: ... the Integrated Power Module C4 connector NOTE Check connectors Clean repair as necessary Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Integrated Power Module C4 connector Is the resistance below 5 0 ohms All Yes Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 No Repair the Horn Switch Sense circuit for an open Perfor...

Page 1014: ...olts check the Ground circuits in the horn connectors Does the test light illuminate brightly All Yes Replace the Horns as necessary Perform BODY VERIFICATION TEST VER 1 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 617 IGNITION POWER ACCESSORY HORNS INOPERATIVE Continued ...

Page 1015: ...tion and when requested to illuminate by the ABS module Set Condition The Instrument Cluster software detects the voltage across the ABS indicator LED is below 0 3 volts when ON AIRBAG INDICATOR OPEN When Monitored With the ignition in the Run Start position and when requested to illuminate by the Airbag Control Module ACM Set Condition The Instrument Cluster software detects the voltage across th...

Page 1016: ...h the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs Did the Indicator Open or Short DTC reset All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Test Complete 619 INSTRUMENT CLUSTER ABS INDICATOR OPEN Continued ...

Page 1017: ...SAGES NOT RECEIVED When Monitored When the Instrument Cluster is powered up Set Condition This DTC will set if the Instrument Cluster does not receive PCI bus messages from the BCM for 5 seconds CMTC MESSAGES NOT RECEIVED When Monitored When the Instrument Cluster is powered up Set Condition This DTC will set if the Instrument Cluster does not receive a PCI bus message from the CMTC located in the...

Page 1018: ...CM for 0 5 seconds PDM MESSAGE NOT RECEIVED When Monitored When the Instrument Cluster is powered up Set Condition This DTC will set if the Instrument Cluster does not receive a PCI bus message from the Passenger Door Module PDM for 5 seconds SKREEM MESSAGE NOT RECEIVED When Monitored When the Instrument Cluster is powered up Set Condition This DTC will set if the Instrument Cluster does not recei...

Page 1019: ...nd wait approximately 1 minute With the DRBIIIt read DTCs Did the DTC reset All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wir...

Page 1020: ...t Condition This DTC will set if the Instrument Cluster internal memory checksum value does not equate to the calculated value This indicates that the Instrument Cluster internal memory is corrupted POSSIBLE CAUSES INSTRUMENT CLUSTER TEST ACTION APPLICABILITY 1 With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs When this code is s...

Page 1021: ...ignition off Disconnect the Clock Module harness connector Disconnect the Instrument Cluster C1 harness connector Measure the resistance of the EVIC NAV Switch Sense Return circuit Is the resistance above 5 0 ohms All Yes Repair the EVIC NAV Switch Sense Return circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Reconnect the Instrument Cluster C1 harness co...

Page 1022: ...ure the resistance of the EVIC Switch Sense circuit Is the resistance above 5 0 ohms All Yes Repair the EVIC Switch Sense circuit for an open Perform BODY VERIFICATION TEST VER 1 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 625 INSTRUMENT CLUSTER EVIC SWITCH INPUT CIRCUIT OPEN Continued ...

Page 1023: ...RBIIIt erase DTCs Turn the ignition off Disconnect the Instrument Panel Switch Pod harness connector Turn the ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9EVIC Switch Input Open9 All Yes Replace the Instrument Panel Switch Pod in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Instrument Cluster C1 h...

Page 1024: ...the resistance between ground and the EVIC Mux Signal circuit Is the resistance below 5 0 ohms All Yes Repair the EVIC Mux Signal circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 627 INSTRUMENT CLUSTER EVIC SWITCH INPUT CIRCUIT SHORT Continued ...

Page 1025: ...OTE Diagnose and repair any EVIC Switch Input Short or Open DTC s before proceeding with this test With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Wait 30 seconds Does the DRBIIIt display EVIC SWITCH INPUT STUCK All Yes Replace the Instrument Panel Switch Pod in accordance with the Service Information Perform BODY VERIFICATION TEST...

Page 1026: ...form BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Fuel Pump Module harness connector Connect a jumper wire between the Fuel Level Sense 1 circuit and ground Turn the ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9Fuel Sensor 1 Short9 All Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VE...

Page 1027: ... ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9Fuel Sensor 1 Open9 All Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Fuel Pump Module harness connector Disconnect the BCM harness connector Measure the resistance between ground and the Fuel Level Sense 1 circuit I...

Page 1028: ...form BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Fuel Pump Module harness connector Connect a jumper wire between the Fuel Level Sense 2 circuit and ground Turn the ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9Fuel Sensor 2 Short9 All Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VE...

Page 1029: ... ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9Fuel Sensor 2 Open9 All Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Fuel Pump Module harness connector Disconnect the BCM harness connector Measure the resistance between ground and the Fuel Level Sense 2 circuit I...

Page 1030: ...tempt to exchange or swap an Instrument Cluster or a BCM from one vehicle to another Module memory configuration damage may occur Refer to the Instrument Cluster Service Information Ensure that the Instrument Cluster has not been damaged or previously installed in a different vehicle With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read D...

Page 1031: ...the Left Turn Signal circuit and ground Is the voltage below 5 volts All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Instrument Cluster harness connector Measure the resistance of the Left Turn Signal circuit Is the resistance above 5 0 oh...

Page 1032: ... DTCs Does the LEFT TURN SIGNAL INDICATOR SHORT reset All Yes Replace the BCM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Instrument Cluster C1 harness connector Measure the resistance between ground and the Left Turn Signal circuit Is the resistance below 5 0 ohms All Yes ...

Page 1033: ...CABILITY 1 Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Disconnect the Instrument Cluster Switch Pod harness connector Measure the resistance of the EVIC NAV Mux Return circuit Is the resistance above 5 0 ohms All Yes Repair the EVIC NAV Mux Return circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Reconnect the Instrument Cl...

Page 1034: ...nector Measure the resistance of the NAV Mux Signal circuit Is the resistance above 5 0 ohms All Yes Repair the NAV Mux Signal circuit for an open Perform BODY VERIFICATION TEST VER 1 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 637 INSTRUMENT CLUSTER NAV SWITCH INPUT CIRCUIT OPEN Continued ...

Page 1035: ...N APPLICABILITY 1 With the DRBIIIt erase DTCs Turn the ignition off Disconnect the Instrument Cluster Panel Pod harness connector Turn the ignition on with the DRBIIIt read DTCs Does the DRBIIIt display 9NAV Switch Input Open9 All Yes Replace the Instrument Panel Switch Pod in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect...

Page 1036: ...e the resistance between ground and the NAV Mux Signal circuit Is the resistance below 5 0 ohms All Yes Repair the NAV Mux Signal circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 639 INSTRUMENT CLUSTER NAV SWITCH INPUT CIRCUIT SHORT Continued ...

Page 1037: ...CH POD TEST ACTION APPLICABILITY 1 NOTE Diagnose and repair any NAV Switch Input Short or Open DTC s before proceeding with this test With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Wait 30 seconds Does the DRBIIIt display NAV SWITCH INPUT STUCK All Yes Replace the Instrument Cluster Switch Pod in accordance with the Service Inform...

Page 1038: ...DTC will set if the Panel Lamps Driver circuit is open to all dimmed components Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Using the wiring diagram schematic as a guide inspect the wiring and connectors related to the Panel Lamps Driver circuit for an open circuit condition Was a Panel Lamps Driver circuit open condition found All Yes Repair the Panel Lamps Driver...

Page 1039: ...n accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Using the wiring diagram schematic as a guide inspect the wiring and connectors related to the Panel Lamps Driver circuit for a short to ground condition Was a Panel Lamps Driver circuit short to ground condition found All Yes Repa...

Page 1040: ...he Right Turn Signal circuit and ground Is the voltage below 5 0 volts All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Instrument Cluster harness connector Measure the resistance of the Right Turn Signal circuit Is the resistance above 5 0...

Page 1041: ... DTCs Does the RIGHT TURN SIGNAL INDICATOR SHORT reset All Yes Replace the BCM in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Instrument Cluster C1 harness connector Measure the resistance between ground and the Right Turn Signal circuit Is the resistance below 5 0 ohms All Ye...

Page 1042: ...on with the DRBIIIt read DTCs Did this DTC reset All Yes Go To 2 No Replace the Traction Control Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Traction Control Switch harness connector Disconnect the BCM C4 harness connector Measure the resistance between ground and the Traction Control Switch Sense circuit Is the resi...

Page 1043: ...ttent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Overhead Console harness connector Turn ignition on With the DRBIIIt read the active BCM DTCs Does the DRBIIIt display Overhead Lamp 1 Output Short All Yes Go To 3 No Replace the Overhead Console Perform BODY VERIFICATION TEST VER 1 3 Turn the ig...

Page 1044: ...d or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the four Rear Courtesy Lamps and the Liftgate Courtesy Lamp Turn the ignition on With the DRBIIIt read the active BCM DTCs Does the DRBIIIt display Courtesy Lamp 2 Output Short All Yes Go To 3 No Repair the appropriate Lamp Unit for a short to ground Perform BODY VERIFICATION TEST VER 1 3 Turn the i...

Page 1045: ...lly broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Body Control Module C5 harness connector Disconnect the Headlamp Switch harness connector Measure the resistance of the Panel Lamps Dimmer Signal Circuit Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Panel Lamps Dimmer Signal Circuit for an open condition Perform BODY VERIFICATION TEST VER...

Page 1046: ...orm BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Headlamp Switch harness connector Disconnect the Body Control Module C5 connector Measure the resistance of the Panel Lamps Dimmer Signal Circuit to ground Is the resistance below 1000 ohms All Yes Repair the Panel Lamps Dimmer Signal Circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the igni...

Page 1047: ...Go To 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 Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the BCM C3 harness connector Turn the reading lamps on Does the DTC reset All Yes Replace the Body Control Module Perform BODY ...

Page 1048: ... read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors 2 Turn the ignition off Disconnect the power seat switch connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ignition switch back Off and open the door With the DRBIIIt read DTC s D...

Page 1049: ...ead DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors 2 Turn the ignition off Disconnect the power seat switch connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ignition switch back Off and Open the door With the DRBIIIt read DTC s Did...

Page 1050: ...Off then back On Attempt to turn the heated seats on and wait 10 seconds With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors 2 Turn the ignition off Disconnect the Passenger Power Seat Switch connector Disconnect the Passenger Door Modu...

Page 1051: ...k On and wait 10 seconds Attempt to turn the heated seats on and wait 10 seconds With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors 2 Turn the ignition off Disconnect the Passenger Power Seat Switch connector Disconnect the Passenger D...

Page 1052: ...location With the DRBIIIt read DTCs Does the DRBIIIt display AMP MESSAGES NOT RECEIVED All No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 Turn the ignition ...

Page 1053: ...y BCM MESSAGES NOT RECEIVED All No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 Turn the ignition on With the DRBIIIt attempt to communicate with the BCM Wit...

Page 1054: ...then back to on Turn the Navigation System on and try to select a location With the DRBIIIt read DTCs Does the DRBIIIt display DISC READ ERROR All No The condition is not present at this time Try removing and reinstalling the disc several times and operating the Navigation System With the DRBIIIt recheck for any DTCs Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 NOTE Ensure the navigation uni...

Page 1055: ...d DTCs Does the DRBIIIt display GPS ANTENNA DISCONNECTED All No The condition that caused this code to set is not present at this time Check the antenna connections at the navigation unit and at the right A Pillar see service information Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 Turn the ignition off Gain access to the Navigation Unit in the rear of the vehicle Disconnect the Antenna conn...

Page 1056: ...e resistance of the Antenna circuit between the center of the connectors Measure the resistance of the Antenna Shield circuit by back probing both connec tors Is the resistance below 2 0 ohms on both circuits All Yes Replace the Antenna in accordance with service information Perform BODY VERIFICATION TEST VER 1 No Replace the Antenna Cable in accordance with service informa tion Perform BODY VERIF...

Page 1057: ... circuitry test Unit will stay off line unless loop back test is passed POSSIBLE CAUSES NAVIGATION UNIT TEST ACTION APPLICABILITY 1 With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs If this DTC resets view repair All Repair Replace the Navigation Unit in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1...

Page 1058: ...TCs Does the DRBIIIt display MIC MESSAGES NOT RECEIVED All No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 With the DRBIIIt attempt to communicate with the I...

Page 1059: ...th the DRBIIIt erase DTCs Cycle the ignition switch from on to off and then back to on Turn the Navigation System on and try to select a location With the DRBIIIt read DTCs Does the DRBIIIt display NAV SYSTEM OVER TEMP All No The condition is not present at this time Try removing and reinstalling the disc several times and operating the Navigation System With the DRBIIIt recheck for any DTCs Perfo...

Page 1060: ...ected periodic bus message is missing 5 consecutive times Set Condition A bus short to ground short to battery or an internal module fault is active PCI BUS SHORTED TO BATTERY When Monitored With the ignition on Set Condition The module detects no bus idle period for 1 125 seconds PCI BUS SHORTED TO GROUND When Monitored Module is able to detect ignition status and has passed the loop back test Se...

Page 1061: ... and then back to on With the DRBIIIt read DTCs Does the DRBIIIt display PCI BUS SHORTED TO GROUND All No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Replace the Navi...

Page 1062: ...MESSAGES NOT RECEIVED All No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 NOTE Diagnose and repair any PCM DTCs present before proceeding with this test Turn...

Page 1063: ...condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 Yes Go To 2 2 NOTE Diagnose and repair any TCM DTCs before proceeding with this test Turn the ignition on engine not running With ...

Page 1064: ...IC POSSIBLE CAUSES COMM FAULT PRESENT OVERHEAD CONSOLE TEST ACTION APPLICABILITY 1 With the DRBIIIt attempt to communicate with the BCM Was the DRBIIIt able to communicate with the BCM All Yes With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs If this code resets replace the Overhead Console in accordance with the Service Informat...

Page 1065: ...ion on for at least 15 seconds With the DRBIIIt read DTCs Did the DTC reset All Yes Go To 2 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Discon...

Page 1066: ...omatic Headlamp Signal circuit in the Overhead Console harness connector to ground Is the resistance below 5 0 ohms All Yes Repair the Automatic Headlamp Signal circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Automatic Day Night Mirror harness connector Disconnect the Overhead Console harness connector Using a 12 volt test light ...

Page 1067: ...ch ignition cycle Set Condition The OHC fails the module internal circuitry self test LOOPBACK FAILURE When Monitored During power up each ignition cycle Set Condition The OHC fails the internal PCI bus loop back test POSSIBLE CAUSES OVERHEAD CONSOLE TEST ACTION APPLICABILITY 1 When this code is set view repair All Repair Replace and program the Overhead Console Module in accordance with the Servi...

Page 1068: ... APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the MIC Was the DRBIIIt able to communicate with the MIC All Yes With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs If this code resets replace the Overhead Console in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No R...

Page 1069: ... APPLICABILITY 1 Turn the ignition on With the DRBIIIt attempt to communicate with the PCM Was the DRBIIIt able to communicate with the PCM All Yes With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read DTCs If this code resets replace the Overhead Console in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No R...

Page 1070: ...epair any TCM DTCs before proceeding with this test Turn the ignition on engine not running With the DRBIIIt monitor the Park Neutral Position Switch input state Move the gear selector through all gear positions Does the DRBIIIt display Park Neutral and Drive Reverse in the correct gear positions All Yes With the DRBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on Wi...

Page 1071: ... fault The outside temperature will display 40 TEMP SENSOR CIRCUIT SHORT When Monitored With the ignition on Set Condition The OHC receives a PCI bus message from the PCM indicating an ambient temperature sensor fault The outside temperature will display 130 POSSIBLE CAUSES PCM DTC PRESENT TEST ACTION APPLICABILITY 1 NOTE The ambient temperature sensor is hardwired to the PCM This code sets in res...

Page 1072: ...ecord and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Remove the key from the ignition and operate the Driver Cylinder Lock Switch several times while monitoring the DRBIIIt Wait 10 seconds Does the DRBIIIt display DRIVER CYLINDER LOCK SWITCH SHORT TO GROUND All Yes Go To 2 No Check for any binding condition with the cylinder lock and linkage Perform BODY...

Page 1073: ...Ground and the Driver Cylinder Lock Switch Mux circuit Is the resistance below 100 0 ohms All Yes Repair the Driver Cylinder Lock Switch Mux circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 676 POWER DOOR LOCKS RKE DRIVER CYLINDER LOCK SWITCH SHORT TO GROUND DDM Continued ...

Page 1074: ...isplay DRIVER CYLINDER LOCK SWITCH STUCK All Yes Go To 2 No Check for any binding condition with the cylinder lock and linkage Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Driver Cylinder Lock Switch connector Turn the ignition on With the DRBIIIt read the active DTCs Does the DRBIIIt display DRIVER CYLINDER LOCK SWITCH STUCK All No Replace the Driver Cylinder Lock Switch Perform BODY VER...

Page 1075: ...TION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Operate the Driver Door Lock Switch several times while observing the DRBIIIt Wait 10 seconds Does the DRBIIIt display DRIVER DOOR LOCK SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No Ensure the switch moves freely If it...

Page 1076: ...record and erase DTC s With the DRBIIIt read DTC s Operate the Liftgate Release several times from the Liftgate Handle Switch while monitoring the DRBIIIt Does the DRBIIIt display LIFTGATE POWER RELEASE OUTPUT OPEN All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Li...

Page 1077: ...connector and the Liftgate Release Motor connector Is the resistance below 5 0 ohms All Yes Disconnect the BCM harness connector s Check connectors Clean repair as necessary If okay replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Repair the Liftgate Release Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 680 POWER DOOR LOCKS RKE LIFTGATE POWER RELEASE OUTPUT...

Page 1078: ...R RELEASE OUTPUT SHORT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Body Control Module C3 connector Measure the resistance between ground and the Liftgate Release Driver circuit Is the resistance below 3 5 ohms All Yes Go To 3 No Disconnect the BCM harness conn...

Page 1079: ...E TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Operate the Passenger Door Lock Switch several times while observing the DRBIIIt Wait 10 seconds Does the DRBIIIt display PASSENGER DOOR LOCK SWITCH SHORTED All Yes Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 No Ensure the switc...

Page 1080: ...TION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Operate the Passenger Door Lock Switch several times while observing the DRBIIIt Wait 10 seconds Does the DRBIIIt display PASSENGER DOOR LOCK SWITCH STUCK All Yes Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 No Ensure the switch moves fre...

Page 1081: ...cess to the Passenger Door Module connector Disconnect the Passenger Door Module 9C19 connector Measure the resistance between Ground and the Door Lock Driver Circuit in the PDM 9C19 connector Is the resistance below 20 ohms All Yes Repair the Door Lock Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER ...

Page 1082: ... Measure the resistance of the Door Lock Driver circuit between the PDM connector and the door lock motor connector Is the resistance below 5 0 ohms All Yes Go To 2 No Repair the Door Lock Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 2 Remove the inner door trim panel to gain access to the Passenger Door Lock Motor Ajar Switch connector Disconnect the Passenger Door Lock Motor A...

Page 1083: ...to the Passenger Door Module connector Disconnect the Passenger Door Module 9C19 connector Measure the resistance between Ground and the Door Unlock Driver circuit in the PDM 9C19 connector Is the resistance below 20 ohms All Yes Repair the Door Unlock Driver Wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 68...

Page 1084: ...tatus Does the DRB show AUTO DOOR LOCKS ENABLED All Yes Go To 2 No With the DRBIII enable the Auto Door Locks and retest the System Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt read ENGINE DTC s Are there any TPS or VEHICLE SPEED DTC s present All Yes Refer to DRIVEABILITY for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIF...

Page 1085: ...e 9C19 connector Disconnect the Driver Door Module 9C19 connector Measure the resistance of the Driver Door Lock Driver circuit in the Driver Door Module 9C19 connector to body ground Is the resistance below 20 ohms All Yes Repair the Driver Door Lock Driver wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 688 PO...

Page 1086: ... To 2 2 Remove the inner door trim panel and gain access to the Door Lock Motor Ajar Switch connector Disconnect the Driver Door Module 9C19 connector Disconnect the Door Lock Motor Ajar Switch connector Measure the resistance of the Driver Door Unlock Driver circuit between the DDM connector and the door lock motor connector Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Driver Do...

Page 1087: ...le 9C19 connector Disconnect the Driver Door Module 9C19 connector Measure the resistance between ground and the Driver Door Unlock Driver circuit in the Driver Door Module 9C19 connector Is the resistance below 20 ohms All Yes Repair the Driver Door Unlock Driver Wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 ...

Page 1088: ...lace the Liftgate Release Motor Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Remove the liftgate inner door trim panel to gain access to the Liftgate Release Motor connector Disconnect the Liftgate Release Motor connector Measure the resistance between ground and the Ground circuit in the Liftgate Release Motor connector Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Ground ci...

Page 1089: ...9C29 connector and the Liftgate Handle Switch connector Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the Liftgate Handle Switch Sense circuit for an open Perform BODY VERIFICATION TEST VER 1 6 Remove the liftgate inner door trim panel to gain access to the Liftgate Release Motor connector Disconnect the Liftgate Release Motor connector Disconnect the Body Control Module 9C39 connecto...

Page 1090: ...en the 9Pass Unlock Relay9 and observe the test light Did the test light illuminate when the lock was actuated in both directions All Yes Replace the Door Lock Motor Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Remove the inner door trim panel and gain access to the Door Lock Motor Ajar Switch connector Disconnect the Door Lock Motor Ajar Switch connector Disconnect the Passenger Door Module ...

Page 1091: ... the Symptom List for the appropriate symptom Perform BODY VERIFICATION TEST VER 1 2 NOTE Ensure there is communication between the SKREEM BODY CON TROL MODULE and the DRIVER DOOR MODULE before proceeding Do you have access to the Miller Special Tool 99001 RF DETECTOR9 All No Go To 3 Yes Go To 8 3 Using a voltmeter test the Batteries in the RKE Transmitter Is the voltage above 3 0 volts in each ba...

Page 1092: ...cks respond properly to the Transmitter commands All Yes Replace the Transmitter Program all Transmitters that will be used with this Vehicle Perform BODY VERIFICATION TEST VER 1 No Replace the Sentry Key RemotE Entry Module Perform BODY VERIFICATION TEST VER 1 Note When repairs are complete ensure all transmitters used with this vehicle are programmed 8 Using the 9001 RF Detector follow the instr...

Page 1093: ...TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the liftgate several times With the DRBIIIt read DTCs Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY...

Page 1094: ...VER 1 4 Remove the power liftgate motor trim panel Disconnect the Power Liftgate Module C2 connector Disconnect the License Lamp light bar connector Measure the resistance of the Ground circuit between the PLG C2 connector cavity 20 and the License Lamp connector cavity 8 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Liftgate Temperature Sensor Ground wire for an open Perform BODY...

Page 1095: ...GROUND WIRE LIFTGATE TEMPERATURE SENSOR TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the liftgate several times With the DRBIIIt read DTCs Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and co...

Page 1096: ...er liftgate motor trim panel Disconnect the Power Liftgate Module C2 connector Disconnect the License Lamp light bar connector Measure the resistance of the liftgate Temperature Sensor Signal circuit to the Ground circuit cavity 20 in the PLG C2 connector Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Temperature Sensor Signal wire for a short to the Ground wire Perform BODY VERIF...

Page 1097: ... the module is awake Set Condition Whenever the module senses an internal failure EEPROM ROM ADC this code will set The module must be replaced POSSIBLE CAUSES POWER LIFTGATE MODULE INTERNAL FAILURE TEST ACTION APPLICABILITY 1 View repair All Repair Replace the Power Liftgate Module Perform BODY VERIFICATION TEST VER 1 700 POWER DOORS LIFTGATE ...

Page 1098: ...cord and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH CINCH NO PAWL TRANSI TION All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times ...

Page 1099: ...iftgate Cinch Release Motor connector Wiggle the harness while observing the ohmmeter Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Liftgate Pawl Switch Sense wire for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Cinch Release Motor connector Measure the resistance between ground and the Liftgate Pawl Swit...

Page 1100: ...nds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH CINCH OVERCURRENT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding or other obstruc tions Perform BO...

Page 1101: ...elow 5 0 ohms All Yes Go To 5 No Repair the Liftgate Latch Release Driver wire for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Cinch Release Motor connector Measure the resistance between ground and the Liftgate Latch Cinch Driver circuit Wiggle the harness and check for an intermittent short conditi...

Page 1102: ...urn the ignition off Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Cinch Release Motor connector Measure the resistance between the Ground circuit cavity 20 and the Liftgate Latch Release Driver circuit Wiggle the harness and check for an intermittent short condition Is the resistance below 1000 0 ohms All Yes Go To 9 No Repair the Liftgate Latch Release Driver wire for...

Page 1103: ...s Does the DRBIIIt display INCOMPLETE LATCH RELEASE NO REVERSE TO UNLOAD CLUTCH All Yes Go To 2 No Operate the liftgate several times and check for any binding or other obstructions To test the reverse action open the liftgate part way and continue holding the handle for 4 seconds The motor should run for approximately 2 seconds Perform BODY VERIFICATION TEST VER 1 2 Examine the liftgate for prope...

Page 1104: ...liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH RELEASE RATCHET SWITCH FAILURE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times and check for any binding or other obstruc tions Perform BODY VERIFICATION TEST VER 1 2 Examine th...

Page 1105: ...nnector cavity 20 and the Liftgate Cinch Release Motor connector cavity 1 Wiggle the harness while observing the ohmmeter Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Ground wire for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Cinch Release Motor connector latch assembly Measure the resistance of the Lif...

Page 1106: ...al times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH RELEASE OVER CURRENT All Yes Go To 2 No Check for any other PLG DTC s before proceeding If there are none operate the liftgate several times and check for any binding or other obstructions Perform BODY VERIFICATION TEST VER 1 2 Examine the liftgate for proper fit and alignment lose hard or torn seals w...

Page 1107: ...rform BODY VERIFICATION TEST VER 1 4 With the DRBIIIt in Inputs Outputs read the PAWL SW and the RATCHET SW states Open and close the liftgate manually and observe the Ratchet and Pawl Switch states Do both switches toggle from open to close All No Replace the Cinch Release Motor Latch Assembly Perform BODY VERIFICATION TEST VER 1 Yes Lubricate the latch and check for any sticking conditions If un...

Page 1108: ...he ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH RELEASE PAWL SWITCH FAILURE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times and check for any binding...

Page 1109: ...een the PLG C2 connector cavity 20 and the Liftgate Cinch Release Motor connector cavity 1 Wiggle the harness while observing the ohmmeter Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Ground wire for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Liftgate Control Module C2 connector Disconnect the Liftgate Cinch Release Motor connector latch assembly Measure the re...

Page 1110: ...TIVE DTCs Does the DRBIIIt display INCOMPLETE LATCH RELEASE SECTOR GEAR RETURN FAILURE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times and check for any binding or other obstruc tions Perform BODY VERIFICATION TEST VER 1 2 Examine the liftgate for proper fit and alignment loose hard or t...

Page 1111: ... With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE FULL OPEN SWITCH FAILURE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding cables or other obstructions Perform BODY VERIFICATION TEST VER 1 2 Examine the liftgate for proper fi...

Page 1112: ... Open Switch on the Power Liftgate Motor assembly Did the switch status ever change All Yes Repair the Liftgate Full Open Switch Sense circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 If there are no possible causes remaining view repair All Repair Replace the Full Open Switch Perform BODY VERIFICATION TEST VER 1 715 POWER DOORS LIFTGATE INCOMPLETE POWER CLOSE FULL O...

Page 1113: ... DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE EXCESSIVE OPTICAL COUNTS All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examine the liftgate for proper alignment worn or binding hin...

Page 1114: ...0 ohms All Yes Go To 5 No Repair the Liftgate Clutch Ground for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Power Liftgate Drive Unit connector Disconnect the Power Liftgate Module C2 connector Measure the resistance of the Liftgate Clutch Driver circuit between the Power Liftgate Drive Unit connector and the Power Liftgate Module C2 connector Is the resistance below 5 0 ohms All...

Page 1115: ...ps moving based on Optical Sensor inputs With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate over 10 times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE INVALID PAWL TRANSITION All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for ...

Page 1116: ...it Does the DRBIIIt display OPEN and CLOSE as the Liftgate is opened and closed All Yes Replace the Power Liftgate Module Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Cinch Release Motor connector Measure the resistance of the Liftgate Pawl Switch Sense circuit between the Module connector and the Motor connector Is the...

Page 1117: ...utch Pulsing This is where the module will cycle the Liftgate Clutch Driver until the gate stops moving based on Optical Sensor inputs NOTE The Ratchet Switch in the latch is connected by the Door Ajar circuit information only With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate over 10 times if possible With the DRBIIIt...

Page 1118: ...connected to 12 volts check the GROUND cavity 1 circuit The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery With the test light connected move the liftgate and wiggle the harness to see if the light flickers Does the test light illuminate brightly throughout the test All Yes Go To 4 No Repair the Ground circuit for an open Perform BODY VERIF...

Page 1119: ...GATE MODULE SHORT TO GROUND POWER LIFTGATE MOTOR TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE LIFTGATE DRIVER CIRCUIT SHORT TO GROUND All Yes Go To 2 No Using the wiring diagram schemat...

Page 1120: ...r circuit Is the resistance below 10000 0 ohms All Yes Repair the Liftgate Close Driver wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Power Liftgate Motor assembly Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Power Liftgate Drive Unit connector Ensure the Power Liftgate Module connectors are connected before proceeding Measure the resistance between the Gr...

Page 1121: ...OR SIGNAL 1 OR 2 WIRE OPEN OPTICAL SENSOR POWER LIFTGATE MODULE OPTICAL SENSE POWER LIFTGATE MODULE OPTICAL SENSOR SUPPLY OPEN TEST ACTION APPLICABILITY 1 NOTE NOTE When this code is set the module will abort the power close cycle and begin Clutch Pulsing This is where the module will cycle the Liftgate Clutch Driver until the gate stops moving based on Optical Sensor inputs With the DRBIIIt recor...

Page 1122: ... To 4 4 Disconnect the Power Liftgate Module C1 connector Disconnect the Power Liftgate Drive Unit connector Measure the resistance between the Liftgate Close Driver circuit and the Liftgate Open Driver circuit Is the resistance below 10000 0 ohms All Yes Repair the Liftgate Open Driver circuit for a short to the Liftgate Close Driver circuit Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 NOTE ...

Page 1123: ... C2 connector Is the resistance below 2 0 ohms on both circuits All Yes Replace the Optical Sensor Perform BODY VERIFICATION TEST VER 1 No Repair the Optical Sensor Signal 1 or 2 wire for an open Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition off Disconnect the Power Liftgate Drive Unit connector Disconnect the Power Liftgate Module C2 connector Measure the resistance between ground and...

Page 1124: ...IVER CIRCUIT SHORT TO HARNESS GROUND LIFTGATE CLUTCH DRIVER CIRCUIT SHORT TO GROUND LIFTGATE CLUTCH DRIVER CIRCUIT SHORT TO HARNESS GROUND DRIVE MOTOR LIFTGATE MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt disp...

Page 1125: ...t the Power Liftgate Module C1 connector Measure the resistance between ground and the Liftgate Close Driver circuit Wiggle the harness and check for an intermittent short circuit condition Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Close Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Power Liftgate M...

Page 1126: ...nector Measure the resistance between the Ground circuit cavity 20 and the Liftgate Clutch Driver circuit Wiggle the harness and check for an intermittent short condition Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Clutch Driver circuit for a short to the Ground circuit Perform BODY VERIFICATION TEST VER 1 No Go To 9 9 Ensure all module and motor connectors are connected at thi...

Page 1127: ... APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE TRANSISTOR SHORTED All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condit...

Page 1128: ...orm BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Power Liftgate Module C1 harness connector Disconnect the Power Liftgate Motor connector Measure the resistance between ground and the Liftgate Close Driver circuit Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Close Driver wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace ...

Page 1129: ...g based on Optical Sensor inputs With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate over 10 times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE UNDERCURRENT OVERHEAT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermi...

Page 1130: ...dule C1 connector Measure the resistance of the Liftgate Open Driver circuit between the Liftgate Drive Unit connector and the Power Liftgate Module connector Is the resistance below 1 0 ohms All Yes Go To 5 No Locate and repair the liftgate open driver circuit for high resis tance Perform BODY VERIFICATION TEST VER 1 5 NOTE Check all connectors for corrosion and proper fit and repair as necessary...

Page 1131: ...n Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE VOLTAGE BELOW MINIMUM LEVEL All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examin...

Page 1132: ...d B at the module to verify Does the voltage vary more than 1 6 volts when the liftgate is operating All Yes Using the wiring diagram schematic as a guide inspect the wiring and connectors Locate and repair the reason for the voltage drop Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Turn all lights and accessories off Open the Liftgate Remove the left rear trim panel to ...

Page 1133: ...ignition on Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE TIME OUT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examine the...

Page 1134: ...er than 0 5 volts backprobe the Fused B at the module to verify Does the voltage vary more than 0 5 volts All Yes Using the wiring diagram schematic as a guide inspect the wiring and connectors Locate and repair the reason for the voltage drop Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Turn all lights and accessories off With the DRBIIIt in 9Power Liftgate99 9Monitor D...

Page 1135: ...gnition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN FULL OPEN SWITCH FAILURE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding or obstructions Perform BODY VERIFICATIO...

Page 1136: ...the Power Liftgate Drive Unit connector Measure the voltage between Liftgate Full Open Switch Sense circuit and ground While measuring the voltage wiggle the harness from the PLG module to the Drive Unit connector Is the voltage constantly above 4 6 volts All Yes Replace the Full Open Switch Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Disconnect the Power Liftgate Drive Unit connector Discon...

Page 1137: ...al times from stop to stop if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN EXCESSIVE OPTICAL COUNTS All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examine the lif...

Page 1138: ...ground Perform BODY VERIFICATION TEST VER 1 No Replace the Power Liftgate Drive Unit Perform BODY VERIFICATION TEST VER 1 6 Disconnect the Power Liftgate Drive Unit connector Measure the resistance of the Ground circuit between the Drive Unit connector cavity 9 and ground Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the Liftgate Clutch Ground for an open Perform BODY VERIFICATION TES...

Page 1139: ...tion on Operate the power liftgate over 10 times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER CLOSE INVALID PAWL TRANSITION All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Especially check the C307 connector and the Liftgate Ajar circuit Perform BODY VERIFICATION TEST VER 1 2 Open t...

Page 1140: ...Go To 4 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 4 Disconnect the Liftgate Cinch Release Motor connector Disconnect the Power Liftgate Module C2 connector Measure the resistance of the Liftgate Pawl Switch Sense wire between the Module connector and the Motor connector While monitoring the ohmmeter wiggle the harness and connectors to check for an intermittent ...

Page 1141: ...ATE CLOSE DRIVER CIRCUIT LIFTGATE MODULE POWER LIFTGATE MOTOR POWER LIFTGATE MOTOR TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN LIFTGATE DRIVER CIRCUIT SHORT TO GROUND All Yes Go To 2 No...

Page 1142: ...assembly Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Power Liftgate Module C1 connector Disconnect the Power Liftgate Drive Unit connector Measure the resistance between the Liftgate Close Driver circuit and the Liftgate Open Driver circuit Is the resistance below 10000 0 ohms All Yes Repair the Liftgate open Driver circuit for a short to the Liftgate Close Driver circuit Perform BODY VE...

Page 1143: ...R SIGNAL 1 OR 2 WIRE OPEN OPTICAL SENSOR POWER LIFTGATE MODULE OPTICAL SENSE POWER LIFTGATE MODULE OPTICAL SENSOR SUPPLY OPEN TEST ACTION APPLICABILITY 1 NOTE NOTE When this code is set the module will abort the power open cycle and begin Clutch Pulsing This is where the module will cycle the Liftgate Clutch Driver until the gate stops moving based on Optical Sensor inputs With the DRBIIIt record ...

Page 1144: ... To 4 4 Disconnect the Power Liftgate Module C1 connector Disconnect the Power Liftgate Drive Unit connector Measure the resistance between the Liftgate Close Driver circuit and the Liftgate Open Driver circuit Is the resistance below 10000 0 ohms All Yes Repair the Liftgate Open Driver circuit for a short to the Liftgate Close Driver circuit Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 NOTE ...

Page 1145: ...dule C2 connector Is the resistance below 2 0 ohms on both circuits All Yes Replace the Power Liftgate Optical Sensor Perform BODY VERIFICATION TEST VER 1 No Repair the Optical Sensor Signal 1 or 2 wire for an open Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition off Disconnect the Power Liftgate Drive Unit connector Disconnect the Power Liftgate Module C2 connector Measure the resistance...

Page 1146: ...RT TO HARNESS GROUND LIFTGATE OPEN DRIVER CIRCUIT SHORT TO GROUND LIFTGATE CLUTCH DRIVER CIRCUIT SHORT TO GROUND LIFTGATE CLUTCH DRIVER CIRCUIT SHORT TO HARNESS GROUND LIFTGATE MODULE POWER LIFTGATE MOTOR TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the D...

Page 1147: ...r Measure the resistance between ground and the Liftgate Latch Cinch Driver circuit Wiggle the harness and check for an intermittent shorted condition Is the resistance below 100 0 ohms All Yes Repair the Liftgate Latch Cinch Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Power Liftgate Module C2 connector Measure the res...

Page 1148: ...e the resistance between the Ground circuit cavity 20 and the Liftgate Clutch Driver circuit Wiggle the harness and check for an intermittent short condition Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Clutch Driver circuit for a short to the Ground circuit Perform BODY VERIFICATION TEST VER 1 No Go To 9 9 Ensure all connections to the module and liftgate motor are connected at...

Page 1149: ...APPLICABILITY 1 With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN TRANSISTOR SHORTED All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent conditio...

Page 1150: ...orm BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Power Liftgate Module C1 harness connector Disconnect the Power Liftgate Motor connector Measure the resistance between ground and the Liftgate Close Driver circuit Is the resistance below 1000 0 ohms All Yes Repair the Liftgate Close Driver wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace ...

Page 1151: ...egin Clutch Pulsing This is where the module will cycle the Liftgate Clutch Driver until the gate stops moving based on Optical Sensor inputs With the DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate over 10 times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN UNDERCURRENT OVERHEAT All Y...

Page 1152: ...dule C1 connector Measure the resistance of the Liftgate Open Driver circuit between the Liftgate Drive Unit connector and the Power Liftgate Module connector Is the resistance below 1 0 ohms All Yes Go To 5 No Locate and repair the liftgate open driver circuit for high resis tance Perform BODY VERIFICATION TEST VER 1 5 NOTE Check all connectors for corrosion and proper fit and repair as necessary...

Page 1153: ...he power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN VOLTAGE BELOW MINIMUM LEVEL All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the door several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examine the liftga...

Page 1154: ...he ignition off Turn all lights and accessories off With the DRBIIIt in 9Power Liftgate99 9Monitor Display9 9PCI Bus Info9 read the BATTERY VOLTAGE and compare it to the MODULE VOLTAGE Operate the power liftgate and observe the voltage difference NOTE If the difference is greater than 1 6 volts backprobe the Fused B at the module to verify Does the voltage vary more than 1 6 volts when the liftgat...

Page 1155: ...nition on Operate the power liftgate several times if possible With the DRBIIIt read DTCs Does the DRBIIIt display INCOMPLETE POWER OPEN TIME OUT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Operate the liftgate several times and check for any binding conditions Perform BODY VERIFICATION TEST VER 1 2 Examine the li...

Page 1156: ...er than 0 5 volts backprobe the Fused B at the module to verify Does the voltage vary more than 0 5 volts All Yes Using the wiring diagram schematic as a guide inspect the wiring and connectors Locate and repair the reason for the voltage drop Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Turn all lights and accessories off With the DRBIIIt in 9Power Liftgate99 9Monitor D...

Page 1157: ...LIFTGATE WAKE UP OUTPUT SHORT TO VOLTAGE All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the BCM C3 connector Using a 12 volt test light connected to ground check the Liftgate Module Wake Up Signal circuit in the BCM C3 harness connector Did the test light illuminate A...

Page 1158: ... DRBIIIt record and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the power liftgate several times from stop to stop if possible With the DRBIIIt read ACTIVE DTCs Does the DRBIIIt display LOOPBACK TEST FAILURE All Yes Replace the Power Liftgate Module Perform BODY VERIFICATION TEST VER 1 No Using the wiring diagram schematic as a guide inspect the wiring and c...

Page 1159: ... OF BCM MESSAGES TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt enter 9Body9 then 9Body Computer9 Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC r...

Page 1160: ...E POWER LIFTGATE MODULE LOSS OF PCM MESSAGES TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt select Engine Was the DRBIIIt able to I D or communicate with the Powertrain Control Module All Yes Go To 2 No Refer to the Communication category for the related symptom S 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB...

Page 1161: ...LIFTGATE MODULE LOSS OF TCM MESSAGES TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt select Transmission Was the DRBIIIt able to I D or communicate with the Transmission All Yes Go To 2 No Refer to the Communication category for the related symptom S 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s...

Page 1162: ... Disconnect the License Lamp connector light bar With the DRBIIIt read DTC s Does the DRBIIIt display OUTSIDE LIFTGATE HANDLE SWITCH SHORT All Yes Go To 2 No Replace the Liftgate Handle Switch Perform BODY VERIFICATION TEST VER 1 2 Disconnect the License Lamp connector Disconnect the Body Control Module C2 connector Measure the resistance between ground and the Liftgate Handle Switch Sense circuit...

Page 1163: ...RBIIIt erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on Wait 10 seconds With the DRBIIIt read DTCs Does the DRBIIIt display Outside Liftgate Handle Input Stuck All Yes Go To 2 No Replace the Liftgate Handle Switch Perform BODY VERIFICATION TEST VER 1 2 Disconnect the License Lamp connector Disconnect the Body Control Module C2 connector Measure the resistance between grou...

Page 1164: ...ORT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTCs Disconnect the Overhead Console Switch connector Turn the ignition off wait 10 seconds then turn the ignition on Wait 10 seconds With the DRBIIIt read DTCs Does the DRBIIIt display OVERHEAD LIFTGATE S...

Page 1165: ... To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTCs Disconnect the Overhead Console Switch connector Turn the ignition off wait 10 seconds then turn the ignition on Wait 10 seconds With the DRBIIIt read DTCs Does the DRBIIIt display OVERHEAD LIFTGATE SWITCH INPUT ST...

Page 1166: ... and erase DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the liftgate several times With the DRBIIIt read DTCs Does the DRBIIIt display PINCH SENSOR CIRCUIT OPEN All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Power Liftgate Module C...

Page 1167: ...m panel Disconnect the Power Liftgate Module C2 connector Disconnect the Liftgate Right Pinch Sensor connector Connect a jumper wire between the Right Pinch Sensor Signal circuit and the Ground circuit in the Liftgate Right Pinch Sensor connector Measure the resistance of the Pinch Sensor Signal circuit between the Pinch Sensor Signal and the Ground circuit cav 20 in the C2 connector Is the resist...

Page 1168: ...e Left Pinch Sensor connector Measure the resistance of the Pinch Sensor Signal circuit between the PLG C2 connector and the Liftgate Left Pinch Sensor connector Is the resistance below 5 0 ohms All Yes Test Complete No Repair the Pinch Sensor Signal wire for an open Perform BODY VERIFICATION TEST VER 1 771 POWER DOORS LIFTGATE PINCH SENSOR CIRCUIT OPEN Continued ...

Page 1169: ...e DTC s Turn the ignition off wait 10 seconds then turn the ignition on Operate the liftgate several times With the DRBIIIt read DTCs Does the DRBIIIt display PINCH SENSOR CIRCUIT SHORT TO GROUND All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Remove the left rear trim panel to g...

Page 1170: ...the Liftgate trim panel Disconnect the Right Pinch Sensor connector Disconnect the Left Pinch Sensor connector Measure the resistance between ground and the Right Pinch Sensor Signal circuit Is the resistance below 1000 0 ohms All Yes Repair the Right Pinch Sensor Signal wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Remove the left rear trim panel Remove the liftgate...

Page 1171: ...nition on With the DRBIIIt in Inputs Outputs read the CHIME state Does the DRBIIIt display CHIME DISABLED All Yes Replace the Power Liftgate Module Chime Disabled Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Remove the liftgate trim panel Disconnect the License Lamp connector Using a 12 volt test light connect one lead to the License Lamp Driver circuit and the other lead to the Ground cavity...

Page 1172: ...tgate Module C2 connector Measure the resistance of the Liftgate Chime Driver circuit between the License Lamp connector and the Module connector Is the resistance below 1 0 ohms All Yes Go To 6 No Repair the Liftgate Chime Driver circuit for an open Perform BODY VERIFICATION TEST VER 1 6 Remove the liftgate trim panel Disconnect the License Lamp connector Using a Voltmeter connect one lead to the...

Page 1173: ...WER LIFT GATE No Go To 3 3 This test will determine what inhibited the Power Liftgate from operating properly With the DRBIIIt select POWER LIFTGATE MISCELLANEOUS LAST INHIBIT MONITOR Does the DRBIIIt display any INHIBIT REASONS All Yes Check for any binding conditions or other restrictions that may prevent proper operation Using the wiring diagram schematic as a guide inspect the wiring and conne...

Page 1174: ...Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Using the DRBIIIt erase DTC s Turn the ignition on Cycle the ignitio...

Page 1175: ... the Driver Mirror Common Driver circuit Is the voltage above 1 0 volts All Yes Repair the Driver Mirror Common Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 778 POWER MIRROR DRIVER MIRROR COMMON OUTPUT SHORT TO BATTERY DDM Continued ...

Page 1176: ...f then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ignition ...

Page 1177: ...irror Common Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Driver Mirror Common Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 780 POWER MIRROR DRIVER MIRROR COMMON OUTPUT SHORT TO GROUND DDM Continued ...

Page 1178: ...witch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Using the DRBIIIt erase DTC s Turn the ignition on Cycle the i...

Page 1179: ...river Mirror Horizontal Driver circuit Is the voltage above 1 0 volts All Yes Repair the Driver Mirror Horizontal Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 782 POWER MIRROR DRIVER MIRROR HORIZONTAL OUTPUT SHORT TO BATTERY DDM Continued ...

Page 1180: ...tch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ign...

Page 1181: ...Horizontal Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Driver Mirror Horizontal Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 784 POWER MIRROR DRIVER MIRROR HORIZONTAL OUTPUT SHORT TO GROUND DDM Continued ...

Page 1182: ...LE SENSOR GROUND TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Driver Door Module Operate the power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the DDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the w...

Page 1183: ...Ground circuit Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Driver Power Mirror connector Disconnect the Driver Door Module C3 connector Turn the ignition on Measure the voltage of Driver Mirror Horizontal Position Signal circuit Is there any voltage present All Yes Repair the Driver Mirror Horizontal Position Signal circuit for a short to voltage Perform BODY VERIFI...

Page 1184: ...odule Operate the driver s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the DDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER...

Page 1185: ...tal Position Signal circuit to ground at the Driver Power Mirror harness side connector Is the resistance below 1000 0 ohms All Yes Repair the Driver Mirror Horizontal Position Signal wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 788 POWER MIRROR DRIVER MIRROR HORIZONTAL SENSOR CIRCUIT SHORT DDM Continued ...

Page 1186: ...e mirror does not reach it s memory set target in 10 seconds this code will set DRIVER MIRROR VERTICAL SENSOR CIRCUIT STUCK DDM When Monitored During memory system recall Set Condition If the mirror does not reach it s memory set target in 10 seconds this code will set PASSENGER MIRROR HORIZONTAL SENSOR CIRCUIT STUCK PDM When Monitored During memory system recall Set Condition If the mirror does n...

Page 1187: ...th the DRBIIIt read DTCs Does the DRBIIIt display the same DTC All Yes Check for an obstruction in the mirror rotation path if OK replace the Power Mirror Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present at this time Perform BODY VERIFICATION TEST VER 1 790 POWER MIRROR DRIVER MIRROR HORIZONTAL SENSOR CIRCUIT STUCK DDM Continued ...

Page 1188: ...d to battery DRIVER MIRROR VERTICAL OUTPUT SHORT TO BATTERY DDM When Monitored Whenever mirror is idle Set Condition Driver circuit is shorted to battery POSSIBLE CAUSES DTC PRESENT POWER MIRROR DRIVER MIRROR VERTICAL DRIVER SHORTED TO VOLTAGE DRIVER DOOR MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase DTCs Cycle the ignition switch Off then back On With the DRBIIIt read DTCs Did the sam...

Page 1189: ...OK replace the mirror Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Power Mirror connector Turn the ignition on Measure the voltage of the Driver Mirror Vertical Driver circuit Is the voltage above 1 0 volts All Yes Repair the Driver Mirror Vertical Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BOD...

Page 1190: ... Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the igniti...

Page 1191: ...or Vertical Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Driver Mirror Vertical Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 794 POWER MIRROR DRIVER MIRROR VERTICAL OUTPUT SHORT TO GROUND DDM Continued ...

Page 1192: ...SIGNAL TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Driver Door Module Operate the driver s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the DDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wi...

Page 1193: ...nsor Ground circuit Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Driver Power Mirror connector Disconnect the Driver Door Module C3 connector Turn the ignition on Measure the voltage of Driver Mirror Vertical Position Signal circuit Is there any voltage present All Yes Repair the Driver Mirror Vertical Position Signal circuit for a short to voltage Perform BODY VERIF...

Page 1194: ...the driver s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the DDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Turn the ...

Page 1195: ...ical Position Signal circuit to ground at the Driver Power Mirror harness side connector Is the resistance below 1000 0 ohms All Yes Repair the Driver Mirror Vertical Position Signal wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 798 POWER MIRROR DRIVER MIRROR VERTICAL SENSOR CIRCUIT SHORT DDM Continued ...

Page 1196: ...ion switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the Mirror Adjusting Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display MIRROR ADJUSTING SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present at this time Operate the sw...

Page 1197: ...witch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Using the DRBIIIt erase DTC s Turn the ignition on Cycle the i...

Page 1198: ...assenger Mirror Common Driver circuit Is the voltage above 1 0 volts All Yes Repair the Passenger Mirror Common Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 801 POWER MIRROR PASSENGER MIRROR COMMON OUTPUT SHORT TO BATTERY PDM Continued ...

Page 1199: ...tch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ign...

Page 1200: ...or Common Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Passenger Mirror Common Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 803 POWER MIRROR PASSENGER MIRROR COMMON OUTPUT SHORT TO GROUND PDM Continued ...

Page 1201: ...tion switch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Using the DRBIIIt erase DTC s Turn the ignition on Cycle...

Page 1202: ...er Mirror Horizontal Driver circuit Is the voltage above 1 0 volts All Yes Repair the Passenger Mirror Horizontal Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 805 POWER MIRROR PASSENGER MIRROR HORIZONTAL OUTPUT SHORT TO BATTERY PDM Continued ...

Page 1203: ... switch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the...

Page 1204: ...orizontal Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Driver Mirror Horizontal Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 807 POWER MIRROR PASSENGER MIRROR HORIZONTAL OUTPUT SHORT TO GROUND PDM Continued ...

Page 1205: ...LE SENSOR GROUND TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from the Passenger Door Module Operate the passenger power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the PDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a gu...

Page 1206: ...nd circuit Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Passenger Power Mirror connector Disconnect the Passenger Door Module C3 connector Turn the ignition on Measure the voltage of Passenger Mirror Horizontal Position Signal circuit Is there any voltage present All Yes Repair the Passenger Mirror Horizontal Position Signal circuit for a short to voltage Perform BOD...

Page 1207: ...or Module Operate the Passenger s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the PDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION T...

Page 1208: ...l Position Signal circuit to ground at the Passenger Power Mirror harness side connector Is the resistance below 1000 0 ohms All Yes Repair the Passenger Mirror Horizontal Position Signal wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 811 POWER MIRROR PASSENGER MIRROR HORIZONTAL SENSOR CIRCUIT SHORT PDM Cont...

Page 1209: ...n switch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Using the DRBIIIt erase DTC s Turn the ignition on Cycle th...

Page 1210: ...enger Mirror Vertical Driver circuit Is the voltage above 1 0 volts All Yes Repair the Passenger Mirror Vertical Driver circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 813 POWER MIRROR PASSENGER MIRROR VERTICAL OUTPUT SHORT TO BATTERY PDM Continued ...

Page 1211: ...switch Off then back On With the DRBIIIt read DTCs Did the same DTC return All Yes Go To 2 No The conditions required to set the code are currently not present Using the wiring diagram schematic as a guide inspect the wiring and connectors Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Using the DRBIIIt erase DTC s Cycle the ...

Page 1212: ...Vertical Driver circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Passenger Mirror Vertical Driver circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 815 POWER MIRROR PASSENGER MIRROR VERTICAL OUTPUT SHORT TO GROUND PDM Continued ...

Page 1213: ...ITION SIGNAL TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from the Passenger Door Module Operate the passenger s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the PDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guid...

Page 1214: ...nd circuit Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Passenger Power Mirror connector Disconnect the Passenger Door Module C3 connector Turn the ignition on Measure the voltage of Passenger Mirror Vertical Position Signal circuit Is there any voltage present All Yes Repair the Passenger Mirror Vertical Position Signal circuit for a short to voltage Perform BODY VE...

Page 1215: ...e the passenger s power mirror and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to return in the PDM Did the same DTC return All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Turn...

Page 1216: ...al Position Signal circuit to ground at the Passenger Power Mirror harness side connector Is the resistance below 1000 0 ohms All Yes Repair the Passenger Mirror Vertical Position Signal wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 819 POWER MIRROR PASSENGER MIRROR VERTICAL SENSOR CIRCUIT SHORT PDM Continu...

Page 1217: ...or Select Switch displays side selected With the DRBIIIt in I O s observe the Mirror Adjust Switch while depressing the switch in the inoperative direction Does the DRBIIIt switch displays match the switch positions All Yes Go To 3 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the power mirror connector Turn the ignition on Measure the vo...

Page 1218: ... Module connector Driver Mirror Common Driver Driver Mirror Horizontal Driver Driver Mirror Vertical Driver Is the resistance below 1 0 ohm for each of the driver circuits All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No Repair the mirror driver wire for an open Perform BODY VERIFICATION TEST VER 1 821 POWER MIRROR DRIVER SIDE VIEW MIRROR MOVEMENT INOPERATIVE FROM AD ...

Page 1219: ...sure the Side Mirror Select Switch displays side selected With the DRBIIIt in I O s observe the Mirror Adjust Switch while depressing the switch in the inoperative direction Does the DRBIIIt switch displays match the switch positions All Yes Go To 3 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the power mirror connector Turn the ignition...

Page 1220: ...r Module connector Passenger Mirror Common Driver Passenger Mirror Horizontal Driver Passenger Mirror Vertical Driver Is the resistance below 1 0 ohm for each of the driver circuits All Yes Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 No Repair the mirror driver wire for an open Perform BODY VERIFICATION TEST VER 1 823 POWER MIRROR PASSENGER SIDE VIEW MIRROR MOVEMENT INOP...

Page 1221: ...Y 1 Turn the ignition on With the DRBIIIt attempt to communicate with the Body Control Module Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIII...

Page 1222: ...mpt to communicate with the Driver Door Module Was the DRBIIIt able to I D or communicate with the DDM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on operate the door locks from the driver s door and wait approximately 1 minute With the DRBIIIt...

Page 1223: ... 9 volts for over 10 second this code will set DRIVER HORIZONTAL AND LUMBAR IN SWITCH OPEN DDM When Monitored Continuously Set Condition If the switch MUX circuit is over 4 9 volts for over 10 second this code will set DRIVER REAR RISER AND PEDAL BACK SWITCH OPEN DDM When Monitored Continuously Set Condition If the switch MUX circuit is over 4 9 volts for over 10 second this code will set DRIVER R...

Page 1224: ...itch voltage of the switch that had the DTC Select the voltage displayed All 4 4 to 5 1 volts Go To 3 Over 5 2 volts Go To 5 3 Disconnect the Driver Seat Switch connector Turn the ignition on Measure the voltage of the Switch MUX circuit indicated by the DRBlllt and ground Is the voltage between 4 4 and 5 1 volts All Yes Go To 4 No Repair the Switch MUX wire for an open Perform POWER SEAT SYSTEM V...

Page 1225: ...eat Switch MUX circuit that had the DTC for a possible short to voltage Were there any problems found All Yes Repair the MUX circuit for a short to voltage Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 828 POWER SEATS DRIVER FRONT RISER AND PEDAL FORWARD SWITCH OPEN DDM Continued ...

Page 1226: ...m Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER FRONT RISER AND PEDAL FORWARD SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch connector Turn the ignition on With the DRBIIIt ...

Page 1227: ...UX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Front Riser Pedal Forward Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 830 POWER SEATS DRIVER FRONT RISER AND PEDAL FORWARD SWITCH SHORT DDM Continue...

Page 1228: ... will be DRIVER FRONT RISER DOWN SWITCH MESSAGE STUCK MHSAPM When Monitored and Set Condition DRIVER FRONT RISER DOWN SWITCH MESSAGE STUCK MHSAPM When Monitored Continuously Set Condition If the switch is held in the on position for over 35 seconds this code will set DRIVER FRONT RISER UP SWITCH MESSAGE STUCK MHSAPM When Monitored Continuously Set Condition If the switch is held in the on position...

Page 1229: ...d Continuously Set Condition If the switch is held in the on position for over 35 seconds this code will set DRIVER RECLINER DOWN SWITCH MESSAGE STUCK MHSAPM When Monitored Continuously Set Condition If the switch is held in the on position for over 35 seconds this code will set DRIVER RECLINER UP SWITCH MESSAGE STUCK MHSAPM When Monitored Continuously Set Condition If the switch is held in the on...

Page 1230: ... MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE FRONT RISER HIGH STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRB check for the same DTC to reset in th...

Page 1231: ...sconnect the Driver Front Riser Seat Position Sensor Connector Ensure the MHSAPM is fully connected before proceeding Turn ignition on With the DRBIIIt in MHSAPM Sensors Read the Driver Seat Front Riser Sensor voltage Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Seat Track Assembly Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 6 Ensure all seat and sensor connectors are connec...

Page 1232: ...tween the Driver Front Riser Seat Position Sensor connector and the MHSAPM C2 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the open Driver Seat Position Sensor Ground wire Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 835 POWER SEATS DRIVER FRONT RISER SENSOR OUT OF RANGE HI...

Page 1233: ...HEATED SEAT ADJUSTABLE PEDAL MODULE STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBIIIt check for the same DTC to reset in the MHSAPM Did the same...

Page 1234: ...M is fully connected before proceeding Disconnect the Driver Front Riser Seat Position Sensor Connector Connect a jumper wire between Driver Seat Sensor 5 volt Supply and Driver Seat Front Riser Position Signal circuits Turn ignition on With the DRBIIIt select MHSAPM Sensors Read the Driver Seat Front Riser Sensor voltage Is the voltage above 4 5 volts All Yes Replace the Seat Track Assembly Perfo...

Page 1235: ...0 ohms All Yes Repair the Driver Seat Sensor 5 Volt Supply circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Go To 9 9 If there are no possible cause remaining view repair All Repair Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 838 POWER SEATS DRIVER FRONT RISER SENSOR OUT OF RANGE LOW MHSAPM Continued ...

Page 1236: ...tch from Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER FRONT RISER SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 D...

Page 1237: ...Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Front Riser Pedal Forward Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 840 POWER SEATS DRIVER FRONT RISER SWITCH STUCK DDM Continued ...

Page 1238: ... from Off to Run Operate the suspect switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER HORIZONTAL AND LUMBAR IN SWITCH SHORTED All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch connector Turn the ignition on With the DRB...

Page 1239: ...UX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Horizontal Lumbar In Switch MUX circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 842 POWER SEATS DRIVER HORIZONTAL AND LUMBAR IN SWITCH SHORTED DDM Continu...

Page 1240: ... MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE HORIZONTAL SENSOR HIGH STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBIIlt check for the same DTC to reset in...

Page 1241: ... ignition off Disconnect the Driver Horizontal Seat Position Sensor Connector Ensure the Memory Heated Seat Adjustable Pedal Module is fully connected before proceeding Turn ignition on With the DRBIIIt in MHSAPM Sensors Read the Driver Seat Horizontal Sensor voltage Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Seat Track Assembly Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 ...

Page 1242: ... Ground wire between the Horizontal Sensor connector and the C2 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the open Driver Seat Position Sensor Ground wire Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 845 POWER SEATS DRIVER HORIZONTAL SENSOR OUT OF RANGE HIGH MHSAPM Conti...

Page 1243: ...ABLE PEDALS MODULE HORIZONTAL LOW STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBIII check for the same DTC to reset in the MHSAPM Did the same DT...

Page 1244: ...ignition off Ensure the MHSAPM is fully connected before proceeding Disconnect the Driver Horizontal Seat Position Sensor Connector Connect a jumper wire between Driver Seat Sensor 5 volt Supply and Driver Seat Horizontal Position Signal circuits Turn ignition on With the DRBIIIt select MHSAPM Sensors Read the Driver Seat Horizontal Sensor voltage Is the voltage above 4 5 volts All Yes Replace the...

Page 1245: ... connector and the C2 connector Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the Driver Seat Sensor 5 Volt Supply circuit for an open Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 9 If there are no possible cause remaining view repair All Repair Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 848 POWER SEATS DRIVER HORIZONT...

Page 1246: ...h from Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER HORIZONTAL SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disc...

Page 1247: ...Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Horizontal Lumbar In Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 850 POWER SEATS DRIVER HORIZONTAL SWITCH STUCK DDM Continued ...

Page 1248: ...Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR RISER AND PEDAL BACK SWITCH SHORTED All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch connector Turn the ignition on With the DRBIIIt eras...

Page 1249: ...ch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Rear Riser Pedal Back Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 852 POWER SEATS DRIVER REAR RISER AND PEDAL BACK SWITCH SHORTED DDM Continued ...

Page 1250: ...ORT TO MOTOR MEMORY HEATED SEAT ADJUSTABLE MODULE STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBIIIt check for the same DTC to reset in the MHSAP...

Page 1251: ...sconnect the Driver Rear Riser Seat Position Sensor Connector Ensure the MHSAPM is fully connected before proceeding Turn ignition on With the DRBIIIt in Body MHSAPM Sensors Read the Driver Seat Rear Riser Sensor voltage Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Seat Track Assembly Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 6 Ensure all seat and sensor connectors are con...

Page 1252: ...etween the Driver Rear Riser Seat Position Sensor connector and the C2 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the Driver Seat Position Sensor Ground wire for an open Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 855 POWER SEATS DRIVER REAR RISER SENSOR OUT OF RANGE HIG...

Page 1253: ... HEATED SEAT ADJUSTABLE PEDAL MODULE REAR RISER LOW STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from the Memory Heated Seat Adjustable Pedal Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBIIIt check for the same DTC to reset in the...

Page 1254: ...d before proceeding Disconnect the Driver Rear Riser Seat Position Sensor Connector Connect a jumper wire between Driver Seat Sensor 5 volt Supply and Driver Seat Rear Riser Position Signal circuits Turn ignition on With the DRBIIIt select MHSAPM Sensors Read the Driver Seat Rear Riser Sensor voltage Is the voltage above 4 5 volts All Yes Replace the Seat Track Assembly Perform POWER SEAT SYSTEM V...

Page 1255: ... 0 ohms All Yes Repair the Driver Seat Sensor 5 Volt Supply circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Go To 9 9 If there are no possible cause remaining view repair All Repair Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 858 POWER SEATS DRIVER REAR RISER SENSOR OUT OF RANGE LOW MHSAPM Continued ...

Page 1256: ...tch from Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR RISER SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Di...

Page 1257: ...Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Front Riser Pedal Forward Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 860 POWER SEATS DRIVER REAR RISER SWITCH STUCK DDM Continued ...

Page 1258: ... from Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER RECLINE SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconne...

Page 1259: ...t Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 yes Repair the Driver Seat Recliner Lumbar Out Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 862 POWER SEATS DRIVER RECLINE SWITCH STUCK DDM Continued ...

Page 1260: ...oth positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER RECLINER AND LUMBAR OUT SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Swi...

Page 1261: ...MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Recliner Lumbar Out Switch MUX circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 864 POWER SEATS DRIVER RECLINER AND LUMBAR OUT SWITCH SHORT DDM Continued ...

Page 1262: ...JUSTABLE PEDAL MODULE RECLINER SENSOR HIGH STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedals Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to reset in the MHSAPM Did ...

Page 1263: ...ect the Driver Recliner Seat Position Sensor Connector Ensure the MHSAPM is fully connected before proceeding Turn ignition on With the DRBIIIt in MHSAPM Sensors Read the Driver Recliner Seat Position Sensor voltage Is the voltage above 0 2 volts All Yes Go To 6 No Replace the Seat Back Assembly Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 6 Ensure all seat and sensor connectors are connected...

Page 1264: ...eat Position Sensor Ground wire between the Recliner Sensor connector and the C2 connector Is the resistance below 5 0 ohms All Yes Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the open Driver Seat Position Sensor Ground wire Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 867 POWER SEATS DRIVER RECLINER SENSOR OUT OF RANGE HI...

Page 1265: ...T ADJUSTABLE PEDAL MODULE RECLINER LOW STORED DIAGNOSTIC TROUBLE CODE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedals Module MHSAPM Operate the driver s power seat and memory system Turn the ignition switch to the Off position then start the engine and let run for one minute With the DRBlllt check for the same DTC to reset in the MHSAPM Did the ...

Page 1266: ...ignition off Ensure the MHSAPM is fully connected before proceeding Disconnect the Driver Recliner Seat Position Sensor Connector Connect a jumper wire between Driver Seat Sensor 5 volt Supply and Driver Seat Recliner Position Signal circuits Turn ignition on With the DRBIIIt select MHSAPM Sensors Read the Driver Seat Recliner Sensor voltage Is the voltage above 4 5 volts All Yes Replace the Seat ...

Page 1267: ...connector and the C2 connector Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the Driver Seat Sensor 5 Volt Supply circuit for an open Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 9 If there are no possible cause remaining view repair All Repair Replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 870 POWER SEATS DRIVER RECLINER ...

Page 1268: ...Set Condition The Memory Heated Seat Adjustable Pedal Module has a internal EEPROM failure LOOPBACK FAILURE MHSAPM When Monitored With the ignition in the on position Set Condition The Memory Heated Seat Adjustable Pedal Module failed the internal loopback self test POSSIBLE CAUSES EEPROM CHECKSUM FAILURE TEST ACTION APPLICABILITY 1 If there are no possible causes remaining view repair All Repair ...

Page 1269: ...APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the IPM Was the DRB able to I D or communicate with the IPM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read DTC s Did thi...

Page 1270: ...le the ignition switch from Off to Run Operate the Seat Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display LUMBAR SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VE...

Page 1271: ...erform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Driver Power Seat Switch connector Disconnect the Driver Door Module C2 connector Inspect the Driver Seat Recliner Lumbar Out Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Driver Seat Recliner Lumbar ...

Page 1272: ...ff to Run Operate the Seat Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display MEMORY SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch connector Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to R...

Page 1273: ...ry Select Switch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Memory Select Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 876 POWER SEATS MEMORY SWITCH SHORT DDM Continued ...

Page 1274: ...from Off to Run Operate the Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display MEMORY SWITCH STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the switch several times to ensure it does not stick If the switch ever sticks replace it Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Driver Power Seat Switch...

Page 1275: ...elect Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Memory Select Switch MUX circuit as necessary Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 878 POWER SEATS MEMORY SWITCH STUCK DDM Continued ...

Page 1276: ...mory Seat Adjustable Pedal Module MSAPM installed on the vehicle matches the vehicle s equipment Is the correct module installed on the vehicle All No Replace with the correct Memory Heated Seat Adjustable Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 Yes Go To 2 2 With the DRBIIIt erase the DTC from Memory Heated Seat Adjustable Pedal Module Turn the ignition switch to the Off position...

Page 1277: ...ircuit is over 4 9 volts for over 10 second this code will set POSSIBLE CAUSES DTC PRESENT PASSENGER SEAT SWITCH MUX WIRE OPEN PASSENGER SEAT SWITCH MUX WIRE SHORT TO VOLTAGE SEAT SWITCH MUX RETURN PASSENGER DOOR MODULE PASSENGER SEAT SWITCH TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Operate the switch that had the DTC in ...

Page 1278: ...sure the resistance of the Seat Switch MUX Return circuit in the switch connector Is the resistance below 5 0 ohms All Yes Replace the Passenger Seat Switch Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the Seat Switch MUX Return for an open Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Passenger Seat Switch connector Disconnect the Passenge...

Page 1279: ...from Off to Run Operate the suspect switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER HORIZONTAL SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Passenger Power Seat Switch connector Turn the ignition on With the DRBIIIt erase ...

Page 1280: ...tch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Passenger Seat Horizontal Switch MUX circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 883 POWER SEATS PASSENGER HORIZONTAL SEAT SWITCH SHORT PDM Continued ...

Page 1281: ... 30 seconds this code will set POSSIBLE CAUSES DTC PRESENT PASSENGER POWER SEAT SWITCH PASSENGER SEAT RECLINER SWITCH MUX PASSENGER DOOR MODULE TEST ACTION APPLICABILITY 1 Check the seat switches mechanical operation and also check for a possible obstruc tion Correct if necessary Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Operate the Seat Switch in a...

Page 1282: ...ON TEST VER 1 3 Turn the ignition off Disconnect the Passenger Power Seat Switch connector Disconnect the Passenger Door Module C2 connector Inspect the Passenger Seat Recliner Switch MUX circuit for a partial short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Passenger Seat Recliner Switch MUX circuit as necessary Perform POWER SEAT S...

Page 1283: ... Off to Run Operate the suspect switch in both positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER RECLINER SWITCH SHORT All Yes Go To 2 No The condition that caused this code to set is not present at this time Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 Disconnect the Passenger Power Seat Switch connector Turn the ignition on With the DRBIIIt erase DTCs C...

Page 1284: ... Switch MUX circuit for a short to ground or to another circuit in the seat switch harness Were there any problems found All Yes Repair the Passenger Seat Recliner Switch MUX circuit for a short to ground Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 887 POWER SEATS PASSENGER RECLINER SWITCH SHORT PDM Continued ...

Page 1285: ...Monitored Continuously Set Condition If the switch is held in the on position for over 35 seconds this code will set PASSENGER SEAT HORIZONTAL REARWARD SWITCH MESSAGE STUCK MHSAPM When Monitored Continuously Set Condition If the switch is held in the on position for over 35 seconds this code will set PASSENGER SEAT RECLINER FORWARD SWITCH MESSAGE STUCK MH SAPM When Monitored Continuously Set Condi...

Page 1286: ...ng view repair All Repair This DTC is for reference only Check for DTC s in the Passenger Door Module and refer to the symptom list Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 889 POWER SEATS PASSENGER SEAT HORIZONTAL FORWARD SWITCH MESSAGE STUCK MHSAPM Continued ...

Page 1287: ...TRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt enter Instrument Cluster System Tests then PCM Monitor Does the DRBIIIt display PCM is active on BUS All Yes Erase the DTC if DTC resets replace the Memory Heated Seat Adjustable Pedal Module Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt attempt to communica...

Page 1288: ...R SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit between the DLC and the PCM connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 No Repair the PCI Bus circuit for an open Perform POWER SEAT SYSTEM VERIFICATION TEST VER ...

Page 1289: ...n on With the DRBIIIt attempt to communicate with the Passenger Door Module Was the DRBIIIt able to I D or communicate with the PDM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on operate the door locks from the passenger s door and wait approxi...

Page 1290: ...ith the DRBIIIt attempt to communicate with the Transmission Control Module Was the DRBIIIt able to I D or communicate with the TCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform POWER SEAT SYSTEM VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did t...

Page 1291: ...le the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the Driver Front Window Express Down Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER FRONT WINDOW EXPRESS DOWN SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to se...

Page 1292: ...nition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER FRONT WINDOW SWITCH STUCK DOWN All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present...

Page 1293: ...tion switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER FRONT WINDOW SWITCH STUCK UP All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present at ...

Page 1294: ... switch from Off to Run Check for any possible obstructions or sticky material within the switch and correct as necessary Operate the DDM Driver Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW EXPRESS DOWN SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused thi...

Page 1295: ... With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Check for any possible obstructions with the rear switch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW SWITCH MUX INPUT OPEN SHORT TO VOLTAGE All Yes Go To 2 No The condition that caused this code to set is not presen...

Page 1296: ...es the test light illuminate brightly All Yes Replace the Rear Window Switch Perform BODY VERIFICATION TEST VER 1 No Repair the Driver Rear Window Switch Ground for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Driver Rear Window Switch connector Disconnect the Driver Door Module C3 connector Measure the voltage between Driver Rear Window Switch Mux circuit an...

Page 1297: ...itch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW SWITCH MUX CIRCUIT SHORT TO GROUND All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the rear switch several times to ensure it does not stick If the switch ever sticks replace it Perform B...

Page 1298: ...ce between Ground and the Driver Rear Window Switch Mux circuit Is the resistance below 100 0 ohms All Yes Repair the Driver Rear Window Switch Mux circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 901 POWER WINDOWS DRIVER REAR WINDOW SWITCH MUX INPUT SHORT TO GROUND DDM Continued ...

Page 1299: ... with the rear switch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW SWITCH MUX CIRCUIT STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the rear switch several times to ensure it does not stick If the switch ever sticks replace it Pe...

Page 1300: ...e between Ground and the Driver Rear Window Switch Mux circuit Is the resistance below 30 000 30k ohms All Yes Repair the Driver Rear Window Switch Mux circuit for a partial short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 903 POWER WINDOWS DRIVER REAR WINDOW SWITCH MUX INPUT STUCK DDM Continued ...

Page 1301: ...nition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW SWITCH STUCK DOWN All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present ...

Page 1302: ...tion switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER REAR WINDOW SWITCH STUCK UP All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present at t...

Page 1303: ... the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the DDM Passenger Front Window Express Down Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER FRONT WINDOW EXPRESS DOWN SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this co...

Page 1304: ... erase DTCs Cycle the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER FRONT WINDOW SWITCH MUX INPUT SHORTED All Yes Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that c...

Page 1305: ...BIIIt erase DTCs Cycle the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER FRONT WINDOW SWITCH MUX INPUT STUCK All Yes Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 No The condition tha...

Page 1306: ...ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER FRONT WINDOW SWITCH STUCK DOWN All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not pr...

Page 1307: ...nition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER FRONT WINDOW SWITCH STUCK UP All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not presen...

Page 1308: ...he ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the DDM Passenger Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW EXPRESS DOWN SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this co...

Page 1309: ...Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Check for any possible obstructions with the rear switch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW SWITCH MUX INPUT OPEN SHORT TO VOLTAGE All Yes Go To 2 No The condition that caused this co...

Page 1310: ... test light illuminate brightly All Yes Replace the Rear Window Switch Perform BODY VERIFICATION TEST VER 1 No Repair the Passenger Rear Window Switch Ground for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Passenger Rear Window Switch connector Disconnect the Passenger Door Module C3 connector Measure the voltage between Passenger Rear Window Switch Mux circ...

Page 1311: ...he rear switch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW SWITCH MUX CIRCUIT SHORT TO GROUND All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the rear switch several times to ensure it does not stick If the switch ever sticks replace...

Page 1312: ...between Ground and the Passenger Rear Window Switch Mux circuit Is the resistance below 100 0 ohms All Yes Repair the Passenger Rear Window Switch Mux circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 915 POWER WINDOWS PASSENGER REAR WINDOW SWITCH MUX INPUT SHORT TO GROUND PDM Continued ...

Page 1313: ...ctions with the rear switch and correct if necessary Operate the Rear Window Switch in all positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW SWITCH MUX CIRCUIT STUCK All Yes Go To 2 No The condition that caused this code to set is not present at this time Operate the rear switch several times to ensure it does not stick If the switch ever sticks repl...

Page 1314: ...etween Ground and the Passenger Rear Window Switch Mux circuit Is the resistance below 30 000 30k ohms All Yes Repair the Passenger Rear Window Switch Mux circuit for a partial short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Passenger Door Module Perform BODY VERIFICATION TEST VER 1 917 POWER WINDOWS PASSENGER REAR WINDOW SWITCH MUX INPUT STUCK PDM Continued ...

Page 1315: ...s Cycle the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW SWITCH STUCK DOWN All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to se...

Page 1316: ...Cycle the ignition switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the switch in both the Up and Down positions several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER REAR WINDOW SWITCH STUCK UP All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is...

Page 1317: ...n switch from Off to Run Check for any possible obstructions with the switch and correct if necessary Operate the DDM Window Lockout Switch several times With the DRBIIIt read DTCs Does the DRBIIIt display WINDOW LOCKOUT SWITCH STUCK All Yes Replace the Driver Door Module Perform BODY VERIFICATION TEST VER 1 No The condition that caused this code to set is not present at this time Operate the swit...

Page 1318: ...indow several times from the DDM but do not hold the switch longer than 5 seconds With the DRBIIIt read DTCs Are there any POWER WINDOW related trouble codes present All Yes Refer to POWER WINDOWS for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 This test assumes that the passenger window IS operational from the related door window switch If it is not Refer to symptom li...

Page 1319: ...light connect one lead to the WINDOW DRIVER UP circuit and the other lead to the WINDOW DRIVER DOWN circuit in the connector Turn the ignition on Press the Power Window Switch UP and then DOWN several times while observing the test light Does the test light illuminate brightly when the switch is pressed in both directions All Yes Check and repair any binding conditions If okay replace the inoperat...

Page 1320: ...resistance of the appropriate Window Driver Up circuit between the Door Module connector and the Motor connector Is the resistance below 5 0 ohms All Yes Replace the appropriate Door Module Perform BODY VERIFICATION TEST VER 1 No Repair the Window Driver Up circuit for an open Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the power window motor connector Disconnect the ap...

Page 1321: ...th the DRBIIIt attempt to communicate with the Amplifier Was the DRBIIIt able to I D or communicate with the Amplifier All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Repl...

Page 1322: ... 1 Turn the ignition on Turn the Radio on With the DRBIIIt attempt to communicate with the Radio Was the DRBIIIt able to I D or communicate with the Radio All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read D...

Page 1323: ...t Condition The Hands Free Module detects a fault during an internal diagnostic check FLASH WRITE ERROR When Monitored With the ignition on Set Condition The Hands Free Module detects a fault during an internal diagnostic check PCI BUS INTERNAL ERROR When Monitored With the ignition on Set Condition The Hands Free Module detects a fault during an internal diagnostic check RAM WRITE ERROR When Moni...

Page 1324: ...FM DTCs and then erase the DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the DTCs Did the same DTC return All Yes Replace and program the Hands Free Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Test Complete 927 TELECOMMUNICATION BLUETOOTH ERROR Continued ...

Page 1325: ...municate with the PCM Was the DRBIIIt able to I D or communicate with the PCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIIIt select System Monitors then J1850 Module Scan Is the PCM one of the modules present on the bus All Yes Go To 3 No Refer to the Communication category for the relate...

Page 1326: ...rcuit MICROPHONE 1 CIRCUIT SHORT TO VOLTAGE When Monitored With the ignition on Set Condition The Hands Free Module detects high voltage on the microphone 1 circuit MICROPHONE 2 CIRCUIT OPEN SHORT TO GROUND When Monitored With the ignition on Set Condition The Hands Free Module detects low voltage on the microphone 2 circuit MICROPHONE 2 CIRCUIT SHORT TO VOLTAGE When Monitored With the ignition on...

Page 1327: ...crophone circuit Is the resistance above 1000 0 ohms for each measurement All Yes Go To 4 No Repair the Microphone circuits for a short to ground Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the Rear View Mirror harness connector Disconnect the Hands Free Module harness connectors Turn the ignition on Measure the voltage of each Microphone circuit Is the voltage below 1 ...

Page 1328: ... conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature wiggle the wiring harnesses This is to try and duplicate the failure Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or part...

Page 1329: ...he engine With the DRBIIIt attempt to I D and communicate with the BCM Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All ...

Page 1330: ...ee Module detects a short to Ground on the Left Audio Output circuit LEFT AUDIO OUTPUT 1 SHORT TO VOLTAGE When Monitored With the ignition on Set Condition The Hands Free Module detects a short to voltage on the Left Audio Output circuit POSSIBLE CAUSES HANDS FREE MODULE LEFT AUDIO OUTPUT AND RIGHT AUDIO OUTPUT CIRCUITS SHORTED TOGETHER LEFT AUDIO OUTPUT CIRCUIT OPEN LEFT AUDIO OUTPUT CIRCUIT SHOR...

Page 1331: ...harness connector Disconnect the Hands Free Module harness connectors Turn the ignition on Measure the voltage of the Left Audio Output circuit Is the voltage below 1 0 volt All Yes Go To 5 No Repair the Left Audio Output circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Amplifier C2 harness connector Disconnect the Hands Free Module harness...

Page 1332: ...icate the failure Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 N...

Page 1333: ...le is properly connected and all associated wiring and connectors are properly routed and connected Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Hands Free Module harness connectors Using a 12 volt test light connected to ground back probe the Fused Accessory Relay Output circuit Cycle the ignition key on and off several times while observing the test light NOTE The ...

Page 1334: ...DTCs Does the DRBIIIt display this DTC All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the Rear View Mirror harness connectors automatic day night mirror Disconnect the Hands Free Module harness connectors Measure the resistance of the Fused Accessory Relay Output circuit Is the resistance below 10 0 ohms All Yes Go To 3 No Repair the Fused Accessory Relay Output circuit for an open ...

Page 1335: ...e with the Service Information Turn the ignition on With the DRBIIIt erase the DTC s Attempt to make a phone call using the system With the DRBIIIt read DTCs Does the DRBIIIt display this DTC All Yes Inspect the wiring and connectors for damage or shorted circuits Repair as necessary If ok replace and program the Hands Free Module in accordance with the Service Information Perform BODY VERIFICATIO...

Page 1336: ... Condition The HFM has detected a fault on the PCI Bus circuit PCI BUS CIRCUIT OPEN When Monitored With the ignition on Set Condition The HFM has detected a fault on the PCI Bus circuit PCI BUS CIRCUIT SHORT TO GROUND When Monitored With the ignition on Set Condition The HFM has detected a fault on the PCI Bus circuit PCI BUS CIRCUIT SHORT TO VOLTAGE When Monitored With the ignition on Set Conditi...

Page 1337: ...intermittent condition With the engine running at normal operating temperature wiggle the wiring harnesses This is to try and duplicate the complete bus failure condition Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for...

Page 1338: ...onitored With the ignition on Set Condition The Hands Free Module detects voltage between 3 5 volts and 4 0 volts on the VR Phone Switch Signal circuit for more than 30 seconds VOICE RECOGNITION PHONE SWITCH CIRCUIT RATIONALITY When Monitored With the ignition on Set Condition The Hands Free Module detects an invalid voltage signal on the VR Phone Switch Signal circuit VOICE RECOGNITION PHONE SWIT...

Page 1339: ...he voltage measured All Voltage is above 5 3 volts Go To 2 Voltage is between 4 7 and 5 3 volts Go To 3 Voltage is below 4 7 volt Go To 4 2 Turn the ignition off Disconnect the Rear View Mirror harness connector Disconnect the Hands Free Module harness connectors Turn the ignition on Measure the voltage of the VR Phone Switch Signal circuit Is the voltage below 1 0 volt All Yes Inspect the wiring ...

Page 1340: ...h the Service Information Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the Rear View Mirror harness connector Disconnect the Hands Free Module harness connectors Measure the resistance of the VR Phone Switch Signal circuit Is the resistance below 10 0 ohms All Yes Go To 5 No Repair the VR Phone Switch Signal circuit for an open Perform BODY VERIFICATION TEST VER 1 5 Turn...

Page 1341: ...View Mirror harness connector Is the resistance above 1000 0 ohms All Yes Inspect the wiring and connectors for damage or shorted circuits Repair as necessary If ok replace and program the Hands Free Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the VR Phone Switch Signal circuit for a short to Sensor Ground Perform BODY VERIFICATION TEST VER 1 94...

Page 1342: ...With the DRBIIIt attempt to communicate with the PCM TCM Was the DRBIIIt able to I D or communicate with the PCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Replace th...

Page 1343: ...ee Module detects a short to ground on the Right Audio Output circuit RIGHT AUDIO OUTPUT 1 SHORT TO VOLTAGE When Monitored With the ignition on Set Condition The Hands Free Module detects a short to voltage on the Right Audio Output circuit POSSIBLE CAUSES HANDS FREE MODULE LEFT AUDIO OUTPUT AND RIGHT AUDIO OUTPUT CIRCUITS SHORTED TOGETHER RIGHT AUDIO OUTPUT CIRCUIT OPEN RIGHT AUDIO OUTPUT CIRCUIT...

Page 1344: ...harness connector Disconnect the Hands Free Module harness connectors Turn the ignition on Measure the voltage of the Right Audio Output circuit Is the voltage below 1 0 volt All Yes Go To 5 No Repair the Right Audio Output circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Amplifier C2 harness connector Disconnect the Hands Free Module harne...

Page 1345: ...icate the failure Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 N...

Page 1346: ...he DRBIIIt select Engine and read the Engine RPM Was the DRBIIIt able to I D or communicate with the PCM and read RPM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Repla...

Page 1347: ...o 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIIIt select System Monitors then J1850 Module Scan Is the PCM one of the modules present on the bus All Yes Go To 3 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 3 With the DRBIIIt erase DTC s Cycle the ...

Page 1348: ...TY 1 Turn the ignition on With the DRBIIIt read PCM DTCs Are there any PCM DTC s All Yes Refer to the Driveability category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt erase the HFM DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Replace the Hands Free Module in ac...

Page 1349: ...TIALIZATION FAULT SKREEM When Monitored and Set Condition INITIALIZATION FAULT SKREEM When Monitored Ignition ON Set Condition When the automatic Sensor Transmitter relearn program is not success ful this DTC is set TIRE SENSOR 1 HIGH PRESSURE ALERT SKREEM When Monitored Ignition ON Set Condition When the SKREEM detects a high tire pressure condition from the number 1 Sensor Transmitter TIRE SENSO...

Page 1350: ... a high tire pressure condition from the number 3 Sensor Transmitter TIRE SENSOR 3 LOW PRESSURE ALERT SKREEM When Monitored Ignition ON Set Condition When the SKREEM detects a low tire pressure condition from the number 3 Sensor Transmitter TIRE SENSOR 3 TRANSMIT FAILURE SKREEM When Monitored Ignition ON Set Condition When the SKREEM cannot detect the RF frequency from the number 3 Sensor Transmit...

Page 1351: ...t front wheel deflate the tire down to 25 PSI If the TPMS fault was detected and associated to this Sensor Transmitter it would correspond to the left front Sensor Transmitter If the TPMS fault was detected and not associated to this Sensor Transmitter repeat the process until the faulty Sensor Transmitter has been identified NOTE Once a fault alert has set it will establish the location of the Ti...

Page 1352: ...quency signal Check for RF frequency concerns and aftermarket accessories that would compromise the RF frequency signal before diagnosing Sensor Transmitter or SKREEM being the fault NOTE Review with the customer their environmental driving conditions Are there environmental factors causing the RF frequency issue All Yes Test Complete No Go To 5 5 Turn the ignition off Replace the appropriate Tire...

Page 1353: ...Set Condition When the CMTC detects a low battery condition from the Left Front Sensor Transmitter LF TIRE PRESSURE SENSOR FAILURE CMTC When Monitored Key ON Set Condition When the CMTC detects a no transmit condition from the Left Front Sensor Transmitter LR TIRE PRESSURE SENSOR BATTERY LOW CMTC When Monitored Key ON Set Condition When the CMTC detects a low battery condition from the Left Rear S...

Page 1354: ...USES CMTC INTERNAL FAULT SENSOR TRANSMITTER INTERNAL FAULT TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s Drive the vehicle for 10 minutes at 32 km h 20 mph With the DRBIIIt read DTCs Does the DRBIIIt display a Sensor Failure or Sensor Low Battery message All Yes Replace the indicated Tire Pressure Sensor Transmitter Perform TIRE PRESSURE VERIFICATION TEST VER 1 CMTC No Go To ...

Page 1355: ...ed and Set Condition PRNDL MESSAGE MISSING SKREEM When Monitored Ignition ON Set Condition When the PRNDL message is not received for 5 seconds this DTC is set VEHICLE SPEED MESSAGE MISSING SKREEM When Monitored Ignition ON Set Condition When the vehicle speed message is not received for 5 seconds this DTC is set POSSIBLE CAUSES TCM DTC S INSTRUMENT CLUSTER DTC S BUS COMMUNICATION SKREEM FAULT 958...

Page 1356: ...entified NOTE Once a fault alert has set it will establish the location of the Tire Pressure Sensors Transmitter Repeat steps until the applicable Tire Pres sure Sensor Transmitter has been located Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 Cycle the ignition switch from OFF to ON With the DRBIIIt record and erase DTC s Drive the vehicle With the DRBIIIt read the Tran...

Page 1357: ... condition from the number 1 Sensor Transmitter SENSOR 2 FAULT SKREEM When Monitored Ignition ON Set Condition When the SKREEM detects an internal fault condition from the number 2 Sensor Transmitter SENSOR 3 FAULT SKREEM When Monitored Ignition ON Set Condition When the SKREEM detects an internal fault condition from the number 3 Sensor Transmitter SENSOR 4 FAULT SKREEM When Monitored Ignition ON...

Page 1358: ... Faults are linked to Sensor Transmitter ID s NOTE You must determine which Tire Pressure Sensor Transmitter has set the fault or alert before diagnosing the system correctly NOTE Set ALL tire pressures to recommended specifications and recheck for faults alerts The fault will set within two minutes when at 25 PSI Starting with the left front wheel deflate the tire down to 25 PSI If the TPMS fault...

Page 1359: ...ce and program the Tire Pressure Sensor Transmitter in accordance with the Service Information Perform TIRE PRESSURE VERIFICATION TEST VER 2 SKREEM No Go To 3 3 Drive the vehicle for 10 minutes at 20 mph 32km h Observe the TPMS indicator in the Instrument Cluster Is the TPMS indicator illuminated All Yes Replace and program the SKREEM in accordance with the Service Information Perform TIRE PRESSUR...

Page 1360: ...ion that caused the alarm is not present at this time The following list may help to indentify the cause of the intermittent condition Refer to any Technical Service Bulletins TSB that may apply Visually inspect related wiring harnesses Look for chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for loose connections broken bent pushed out ...

Page 1361: ...e valid the security system must arm and flash the VTSS indicator properly With the DRBIIIt under Driver Door Module read the DOOR STATUS Open the driver door Does the DRBIIIt display Ajar All Yes Replace and program the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom DRIVER DOOR AJAR CKT OPEN in the DOOR AJAR category Perform VTSS VERIFICATION TEST 1A 964 VEHICLE THEFT S...

Page 1362: ...o be valid the security system must arm and flash the VTSS indicator properly With the DRBIIIt read the Left Rear Door Ajar SW status Open the left rear door Does the DRBIIIt display CLOSED All Yes Replace and program the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom LEFT REAR DOOR AJAR CKT OPEN in the DOOR AJAR category Perform VTSS VERIFICATION TEST 1A 965 VEHICLE THE...

Page 1363: ... be valid the security system must arm and flash the VTSS indicator properly With the DRBIIIt under Passenger Door Module read the Door Status Open the passenger door Does the DRBIIIt display Ajar All Yes Replace and program the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom PASSENGER DOOR AJAR CKT OPEN in the DOOR AJAR category Perform VTSS VERIFICATION TEST 1A 966 VEHI...

Page 1364: ...valid the security system must arm and flash the VTSS indicator properly With the DRBIIIt under BCM read the Right Rear Door Ajar SW status Open the right rear door Does the DRBIIIt display CLOSED All Yes Replace and program the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom RIGHT REAR DOOR AJAR CKT OPEN in the DOOR AJAR category Perform VTSS VERIFICATION TEST 1A 967 VEH...

Page 1365: ...S Indicator Driver circuit at the I P Switch Pod connector Turn the ignition on With the DRBIIIt under BCM actuate the VTSS Indicator lamp Is the voltage above 10 0 volts when the VTSS Indicator lamp is actuated All Yes Replace the Instrument Panel Switch Pod assembly Perform VTSS VERIFICATION TEST 1A No Go To 3 3 Disconnect the Instrument Panel Switch Pod connector Disconnect the BCM C4 harness c...

Page 1366: ... the DRBIIIt verify the Ajar Switch operation in the BCM and in both Driver and Passenger Door Modules Did the ajar switches operate properly All Yes Go To 3 No Refer to the Symptom List and diagnose the appropriate symp tom Perform VTSS VERIFICATION TEST 1A 3 With the DRBIIIt read the active DTC s in the IPM BCM and both door modules Are any VTSS related DTC s present All Yes Refer to the Symptom...

Page 1367: ...sing the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circuits Were there any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the Front Washer Pump Motor harness connector NOTE Check connectors Clean repair...

Page 1368: ... of the Front Washer Pump Motor Control Circuit from the IPM C5 connector to the Front Washer Pump Motor harness connector Is the resistance above 5 0 ohms All Yes Repair the Front Washer Pump Motor Control Circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off to the lock position Disconnect the IPM C5 harness connector Disconnect the Front Washer Pump Motor h...

Page 1369: ...VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the IPM C5 harness connector Disconnect the Front Washer Motor harness connector NOTE Check connectors Clean repair as necessary Measure the resistance between ground and the Front Washer Motor Control circuit Is the resistance less than 5 0 ohms All Yes Repair the Front Washer Motor Control Circuit fo...

Page 1370: ...on off Disconnect the Wiper Washer Switch harness connector Disconnect the BCM C5 harness connector Measure the resistance between ground and the Front Wiper Switch MUX circuit Is the resistance below 1000 0 ohms All Yes Repair the Front Wiper Switch MUX circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 4 Turn...

Page 1371: ...R 1 2 Install a substitute relay in place of the Wiper On Off Relay Turn the ignition on Turn the wipers on Does the system operate correctly All Yes Replace the Wiper On Off Relay Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Remove the wiper High Low Relay from the IPM Remove the wiper On Off Relay from the IPM Measure the resistance of the Common Relay circuit between ...

Page 1372: ...cuit at the IPM connector to ground Measure the resistance between ground and the Wiper Hi Low Relay Control circuit Is the resistance below 5 0 ohms All Yes Replace the Integrated Power Module Perform BODY VERIFICATION TEST VER 1 No Repair the Wiper Hi Low Relay Control circuit for an open Perform BODY VERIFICATION TEST VER 1 975 WINDSHIELD WIPER WASHER FRONT WIPER HI LO RELAY OPEN IPM Continued ...

Page 1373: ... ignition on Measure the voltage of the Wiper Hi Low Relay Control circuit at the IPM connector Is the voltage above 1 0 volt All Yes Repair the Wiper Hi Low Relay Control circuit for a short to battery Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Install a substitute relay in place of the Wiper Hi Low Relay Turn the ignition on Turn the wipers on Does the system operate correctly All Yes Rep...

Page 1374: ...FICATION TEST VER 1 2 Install a substitute relay in place of the Wiper On Off Relay Turn the ignition on Turn the wipers on Does the system operate correctly All Yes Replace the Wiper On Off Relay Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Remove the Wiper On Off Relay from the IPM Disconnect the IPM C8 harness connector Connect a jumper wire between the Wiper On Off R...

Page 1375: ...age of the Wiper On Off Relay Control circuit at the IPM connector Is the voltage above 1 0 volt All Yes Repair the Wiper On Off Relay Control circuit for a short to battery Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Install a substitute relay in place of the Wiper On Off Relay Turn the ignition on Turn the wipers on Does the system operate correctly All Yes Replace the Wiper On Off Relay P...

Page 1376: ...ront Wiper On Off Relay Operate the Wiper system in all modes With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 3 No Replace the Front Wiper On Off Relay in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition on With the DRBIIIt erase DTCs Turn the ignition off NOTE Place the Wipers in the parked position Disconnect the Front Wiper Motor harne...

Page 1377: ...sistance between the Front Wiper Park Switch Ground circuit at the Front Wiper Motor harness connector Is the resistance above 5 0 ohms All Yes Repair the Front Wiper Park Switch Ground Circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the Front Wiper Motor Disconnect the IPM C7 harness connector Turn the ignition on Measure the resistance of th...

Page 1378: ...the ignition on Operate the Front Wiper system in all modes With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 3 No Replace the Front Wiper On Off Relay in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition on With the DRBIIIt erase DTCs Turn the ignition off NOTE Place the Wipers in the Parked position Disconnect the Front Wiper Motor harness...

Page 1379: ...IFICATION TEST VER 1 No Replace the Integrated Power Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 5 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circuits Were there any problems found All Y...

Page 1380: ...nnector Measure the resistance of the Front Wiper Switch MUX circuit between the BCM C5 harness connector and the Wiper Washer Switch harness connector Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Front Wiper Switch MUX circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Wiper Washer Switch harness connector Disconnect the BCM C4 harnes...

Page 1381: ... With the DRBIIIt read the Front Wiper Switch volts Is the voltage below 0 5 volt All Yes Replace the Wiper Washer Switch Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition on With the DRBIIIt erase all BCM DTCs Turn the ignition off NOTE Visually inspect the related wiring harness and circuits Look for any chafed pierce...

Page 1382: ...ircuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off Disconnect the Wiper ...

Page 1383: ...witch MUX circuit for a short to the Multi Function Switch MUX Return circuit Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Wiper Washer Switch harness connector Turn the ignition on With the DRBIIIt read the Front Wiper Switch volts Is the voltage above 4 5 volts All Yes Replace the Wiper Washer Switch Perform BODY VERIFICATION TEST VER 1 No Replace the Bo...

Page 1384: ...n on With the DRBIIIt read DTCs Does the DRBIIIt display High Voltage Disable Front and Rear Washer All Yes Repair the vehicle s charging system for a high voltage condition Perform BODY VERIFICATION TEST VER 1 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 wi...

Page 1385: ...le checking for shorts and open circuits Were there any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the Rear Washer Pump Motor harness connector NOTE Check connectors Clean repair as necessary Ignition on engine not running Using a 12 volt test light connected to ground check the Fused Acce...

Page 1386: ...er Pump Motor Control circuit in the Rear Washer Pump Motor harness connector while pressing the Rear Washer Switch NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Replace the Rear Washer Pump Motor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Test...

Page 1387: ...VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the IPM C5 harness connector Disconnect the Rear Washer Motor harness connector NOTE Check connectors Clean repair as necessary Measure the resistance between ground and the Rear Washer Motor Control circuit Is the resistance less than 5 0 ohms All Yes Repair the Rear Washer Motor Control Circuit for a...

Page 1388: ...dule and read the Rear Washer Switch state Does the DRB display switch state as Open All Yes Replace the Rear Washer Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With the DRBIIIt erase all BCM DTCs Turn the ignition off The conditions necessary to set this DTC are not present at this time Using the schematics as a guide in...

Page 1389: ...s DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circuits Were there any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the Rear Wiper Motor harness connector NOTE ...

Page 1390: ... Motor harness connector NOTE Check connectors Clean repair as necessary Measure the resistance of the Rear Wiper Motor Control Circuit from the Body Control Module harness connector to the Rear Wiper Motor harness connector Is the resistance above 5 0 ohms All Yes Repair the Rear Wiper Motor Control Circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off to the...

Page 1391: ... a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circuits Were there any problems found All Yes Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 3 Turn the ignition off to the lock position Disconnect the Body Control Module C2 harness connector Disconnect the Rear Wiper Motor harness connector NOTE Ch...

Page 1392: ...Module connector harness NOTE An internal short in the Wiper Motor may cause the fuse to open Does the Wiper Motor function All Yes Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the Rear Wiper Motor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 995 WINDSHIELD WIPER WASHER REAR WIPER OUTPU...

Page 1393: ...nect the Wiper Washer Switch harness connector Ensure that the Wiper Washer Switch is in the Off position Measure the internal resistance of the Wiper Washer Switch between cavity 5 and cavity 7 Does the Wiper Washer Switch measure more than 5 0 ohms All Yes Replace the Wiper Washer Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignitio...

Page 1394: ...TEST VER 1 2 Turn the ignition off Disconnect the Wiper Washer Switch harness connector Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display Rear Wiper Park Input Short All Yes Replace the Wiper Washer Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Wiper Washer Switch harness connector Dis...

Page 1395: ...tor 9 Road test the vehicle With the DRBIIIt monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 degrees 10 Below 25 MPH make 5 to 8 wide open throttle kickdowns to 1st gear Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown 11 For a specific DTC drive the vehicle to the Sym...

Page 1396: ... Again with the DRBIIIt read DTC s If any DTC s are present return to Symptom list 11 If there are no Diagnostic Trouble Codes DTC s present and the customer s concern can no longer be duplicated the repair is complete Are any DTC s present or is the original concern still present All Yes Repair is not complete refer to appropriate symptom No Repair is complete ADJUSTABLE PEDALS VERIFICATION TEST ...

Page 1397: ...les Are any DTC s present or is the original condition still present All Yes Repair is not complete refer to the appropriate symptom No Repair is complete POWER SEAT SYSTEM VERIFICATION TEST VER 1 APPLICABILITY 1 Reconnect all previously disconnected components and connectors 2 Turn the ignition on and with the DRBIII erase all Diagnostic Trouble Codes from ALL modules 3 If the Memory Heated Seat ...

Page 1398: ...ation Number PIN assigned to it s original SKIM This number can be obtained from the vehicle s invoice or Chrysler s Customer Center 1 800 992 1997 3 NOTE When entering the PIN care should be taken because the SKREEM will only allow 3 consecutive attempts to enter the correct PIN If 3 consecutive incorrect PIN s are entered the SKREEM will Lock Out the DRB III for 1 hour 4 To exit Lock Out mode th...

Page 1399: ...ot Are any DTC s present or is the original complaint still present All Yes Repair is not complete refer to the appropriate symptom Perform VTSS VERIFICATION TEST 1A No Repair is complete __AIRBAG VERIFICATION TEST VER 1 APPLICABILITY 1 Remove any special tools or jumper wires and reconnect all previously disconnected components except the Battery 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN T...

Page 1400: ...8 0 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM C O M P O N E N T L O C A T I O N S 1003 COMPONENT LOCATIONS ...

Page 1401: ...8 2 AUDIO 8 2 1 AMPLIFIER 8 2 2 SUBWOOFER 8 3 BODY CONTROL MODULE 8 3 1 GENERAL LOCATION C O M P O N E N T L O C A T I O N S 1004 COMPONENT LOCATIONS ...

Page 1402: ...8 3 2 CONNECTOR LOCATIONS 8 4 ELECTRICALLY HEATED SYSTEMS 8 4 1 MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE 8 4 2 HEATED SEAT CONNECTORS C O M P O N E N T L O C A T I O N S 1005 COMPONENT LOCATIONS ...

Page 1403: ...POWER SEAT CIRCUIT BREAKER 8 5 HEATING A C 8 5 1 BLEND FRONT MODE ACTUATORS 8 5 2 RECIRCULATION ACTUATOR C O M P O N E N T L O C A T I O N S 1006 COMPONENT LOCATIONS 8 4 ELECTRICALLY HEATED SYSTEMS Continued ...

Page 1404: ...8 5 3 REAR MODE ACTUATOR 8 5 4 EVAPORATOR TEMPERATURE SENSOR 8 5 5 FRONT BLOWER MOTOR C202 CONNECTOR C O M P O N E N T L O C A T I O N S 1007 COMPONENT LOCATIONS ...

Page 1405: ...6 REAR BOOSTER FAN 8 6 INSTRUMENT CLUSTER 8 6 1 FUEL PUMP MODULE HARNESS CONNECTOR 8 7 POWER LIFTGATE 8 7 1 DRIVE UNIT C O M P O N E N T L O C A T I O N S 1008 COMPONENT LOCATIONS 8 5 HEATING A C Continued ...

Page 1406: ...8 7 2 DRIVE UNIT COMPONENTS 8 8 POWER DOOR LOCKS RKE 8 8 1 DRIVER DOOR MODULE 8 8 2 SENTRY KEY REMOTE ENTRY MODULE SKREEM C O M P O N E N T L O C A T I O N S 1009 COMPONENT LOCATIONS ...

Page 1407: ...9 POWER SEATS 8 9 1 MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE AND SEAT BASE MOTORS 8 9 2 SEAT BACK MOTORS 8 9 3 LUMBAR MOTOR INLINE CONNECTOR C O M P O N E N T L O C A T I O N S 1010 COMPONENT LOCATIONS ...

Page 1408: ...8 9 4 RECLINER MOTOR SENSOR CONNECTOR 8 9 5 POWER SEAT CIRCUIT BREAKER 8 10 POWER WINDOWS C O M P O N E N T L O C A T I O N S 1011 COMPONENT LOCATIONS ...

Page 1409: ...8 11 SENTRY KEY REMOTE ENTRY MODULE 8 12 TELECOMMUNICATIONS HANDS FREE SYSTEM C O M P O N E N T L O C A T I O N S 1012 COMPONENT LOCATIONS ...

Page 1410: ...ADJUSTABLE PEDALS MOTOR HALL SENSE 5 G914 22VT GY ADJUSTABLE PEDALS MOTOR HALL SENSE RETURN 6 G14 20VT DB ADJUSTABLE PEDALS MOTOR HALL SIGNAL ADJUSTABLE PEDALS SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 G11 20VT TN ADJUSTABLE PEDALS SENSOR FEED 2 G12 22VT BR ADJUSTABLE PEDALS SENSOR SIGNAL 3 G912 20VT WT ADJUSTABLE PEDALS SENSOR RETURN C O N N E C T O R P I N O U T S 1013 CONNECTOR PINOUTS ...

Page 1411: ...SOR 2 GROUND 21 R20 20WT LG RIGHT SIDE IMPACT SENSOR 2 GROUND 22 R17 20LG LEFT SIDE IMPACT SENSOR 2 SIGNAL 23 R18 20LB RIGHT SIDE IMPACT SENSOR 2 SIGNAL 24 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 25 R1 20DG YL EARLY BUILD LEFT CURTAIN SQUIB LINE 1 25 R1 20LB BR LATE BUILD LEFT CURTAIN SQUIB LINE 1 26 R3 20VT EARLY BUILD LEFT CURTAIN SQUIB LINE 2 26 R3 20LB OR LATE BUILD LEFT CURTAIN SQUIB LI...

Page 1412: ...FT SIDE IMPACT SENSOR 3 GROUND 15 D25 20WT VT PCI BUS 16 F201 20PK LB ORC RUN START DRIVER 17 18 19 R24 20YL LB RIGHT SIDE IMPACT SENSOR 3 GROUND 20 R81 20LB WT LEFT FRONT IMPACT SENSOR GROUND 21 22 Z12 18BK OR GROUND 23 24 F100 20PK VT ORC RUN DRIVER 25 R79 20LB VT LEFT FRONT IMPACT SENSOR SIGNAL 26 R80 20LB TN RIGHT FRONT IMPACT SENSOR SIGNAL 27 28 R21 20LB DG LEFT SIDE IMPACT SENSOR 3 SIGNAL 29...

Page 1413: ...EFT CURTAIN YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R1 20DG YL EARLY BUILD LEFT CURTAIN SQUIB LINE 1 1 R1 20LB BR LATE BUILD LEFT CURTAIN SQUIB LINE 1 2 R3 20VT EARLY BUILD LEFT CURTAIN SQUIB LINE 2 2 R3 20LB OR LATE BUILD LEFT CURTAIN SQUIB LINE 2 AIRBAG SQUIB PASSENGER YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R44 20LB OR PASSENGER SQUIB 1 LINE 2 2 R42 20LB BR PASSENGER SQUIB 1 LINE 1 3 R64 20LB TN PASSEN...

Page 1414: ...UBWOOFER 1 12 X301 18GY WT AMPLIFIED SUBWOOFER 2 13 X296 18DG GY AMPLIFIED RIGHT REAR DOOR SPEAKER 14 X206 18DG LG AMPLIFIED RIGHT REAR DOOR SPEAKER 15 X295 18GY DG AMPLIFIED LEFT REAR DOOR SPEAKER 16 X290 18GY OR AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER 17 X292 18DG YL AMPLIFIED RIGHT FRONT DOOR SPEAKER 18 X201 18GY VT AMPLIFIED LEFT FRONT DOOR SPEAKER AMPLIFIER C2 WHITE 12 WAY CAV CIRCUIT FUNCT...

Page 1415: ... DB RECIRCULATION DOOR DRIVER A 7 C135 20DB GY FRONT MODE DOOR DRIVER B 8 C35 22LB OR FRONT MODE DOOR DRIVER A 9 C153 22DB BR REAR MODE DOOR DRIVER A 10 C53 22LB REAR MODE DOOR DRIVER B 11 G21 22VT WT REAR FAN ON INDICATOR DRIVER 12 C931 22DB TN REAR FAN SENSE RETURN 13 AUTOMATIC DAY NIGHT MIRROR BLACK 7 WAY CAV CIRCUIT FUNCTION 1 F316 20PK OR EARLY BUILD FUSED ACCESSORY RELAY OUTPUT 1 F316 20BK P...

Page 1416: ... GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C133 20DB WT PASSENGER BLEND DOOR DRIVER B 2 C33 20LB BR PASSENGER BLEND DOOR DRIVER A BODY CONTROL MODULE C1 BLACK 6 WAY CAV CIRCUIT FUNCTION 1 A701 14BR RD EARLY BUILD FUSED B 1 A701 18BR RD LATE BUILD FUSED B 2 A101 12VT RD FUSED B 3 Z100 16BK VT GROUND 4 5 A101 12VT RD FUSED B 6 C O N N E C T O R P I N O U T S 1019 CONNECTOR PINOUTS ...

Page 1417: ...TURN SIGNAL LAMP DRIVER 5 F20 20PK GY IGNITION SWITCH OUTPUT RUN START 6 7 8 G77 20VT GY LEFT REAR DOOR AJAR SWITCH SENSE 9 10 W13 18BR WT REAR WIPER MOTOR CONTROL 11 12 13 14 15 16 17 18 A114 20GY RD FUSED B 19 Z10 18BK TN GROUND 20 21 22 23 24 25 26 M22 18YL OR COURTESY LAMPS DRIVER 27 28 29 30 P30 20TN DG LIFTGATE HANDLE SWITCH SENSE 31 32 L1 18WT LG BACK UP LAMP DRIVER 33 34 C O N N E C T O R ...

Page 1418: ...TCH MUX 8 M24 18YL WT FRONT READING COURTESY LAMPS DRIVER 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 N4 20DB YL FUEL LEVEL SENSOR SIGNAL NO 1 24 D25 20WT VT PCI BUS 25 M11 18YL VT LIFTGATE COURTESY LAMP DRIVER 26 27 W17 20BR LG REAR WIPER PARK SWITCH SENSE 28 P31 18TN YL BASE LIFTGATE RELEASE DRIVER 29 G78 20VT OR LIFTGATE AJAR SWITCH SENSE 30 G10 20VT LG DRIVER SEAT BELT SWITCH SENSE 31 32 33 34...

Page 1419: ...ADIO CONTROL MUX RETURN 14 G900 22OR VT IGNITION SWITCH SENSE RETURN 15 16 17 L160 22WT TN RIGHT TURN SIGNAL 18 19 20 21 22 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 23 24 25 26 M28 18YL TN GLOVE BOX LAMP DRIVER 27 28 29 30 31 W35 22BR LG FRONT WIPER HIGH LOW SWITCH SENSE 32 B27 20DG WT TRACTION CONTROL SWITCH SENSE 33 L306 20LB WT RIGHT TURN SWITCH SENSE 34 C O N N E C T O R P I N O U T S 102...

Page 1420: ...17 L900 22WT YL HEADLAMP SWITCH MUX RETURN 18 W52 22BR YL FRONT WIPER SWITCH MUX 19 20 21 22 23 24 25 26 27 E2 22OR BR PANEL LAMPS DIMMER SIGNAL 28 29 30 31 L307 22BR WT HEADLAMP SWITCH MUX SENSE 32 W27 22DB BR REAR WIPER SWITCH DELAY 33 X20 22GY WT RADIO CONTROL MUX 34 C100 BLACK BODY SIDE CAV CIRCUIT 1 R80 20LB TN 2 R82 20WT LB 3 L60 18WT TN 4 R81 20LB WT 5 R79 20LB VT 6 L61 18LG WT C100 BLACK F...

Page 1421: ...PK LB 32 F1 20PK WT 33 T44 20YL DG 34 T5 20DG YL 35 D15 20BR WT 36 37 38 F2 18PK YL 39 40 E12 18OR GY 41 C57 20DB LB 42 C53 20LB 43 C153 20DB BR 44 45 F504 20GY PK 46 G21 22VT WT 47 C31 20LB YL 48 C11 22LB OR 49 C931 22DB TN 50 D20 20WT LG 51 D21 20WT GY 52 D24 20WT YL 53 54 Z111 18BK WT 55 D123 20WT BR 56 57 58 59 60 61 62 63 64 65 66 G400 20VT LB NAVIGATION 67 68 G410 20VT LG NAVIGATION 69 70 G4...

Page 1422: ...9 30 F100 20PK VT 31 F201 20PK LB 32 F1 20PK WT 33 T44 20YL DG 34 T5 20DG YL 35 D15 20BR WT 36 37 38 F2 18PK YL 39 40 E12 18OR GY 41 C57 22DB LB 42 C53 22LB 43 C153 22DB BR 44 45 F504 20GY PK 46 G21 22VT WT 47 C31 22LB YL 48 C11 22LB OR 49 C931 22DB TN 50 D20 20WT LG 51 D21 20WT GY 52 D24 20WT YL 53 54 Z111 18BK WT 55 D123 20WT BR 56 57 58 59 60 61 62 63 64 65 66 G400 20VT LB NAVIGATION 67 68 G410...

Page 1423: ...EL SIDE CAV CIRCUIT 1 Z134 12BK LG 2 C56 20LB DB 3 C32 20TN DB 4 C33 22LB BR 5 C61 22DB LG 6 C35 22LB OR 7 C7 12DB 8 C132 20DB YL 9 C133 22DB WT 10 C161 20LB WT 11 C135 20DB GY 12 C21 20LG DB 13 C121 20DB DG C205 NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 X53 20DG 2 X55 20DG BR 3 X54 20GY 4 X56 20GY BR 5 X200 18GY DB 6 X290 18GY OR 7 8 9 10 11 R22 20LG DG 12 R24 20YL LB 13 14 15 16 17 18 19 20 C ...

Page 1424: ...83 20VT OR 2 X201 18GY VT 3 X291 18GY YL 4 Q211 14TN LB 5 A215 18RD LG 6 P112 20TN OR 7 P114 20TN WT 8 Q1 20OR WT 9 E25 20OR GY 10 Q111 14TN YL 11 12 13 14 C301 BLACK LEFT FRONT DOOR SIDE CAV CIRCUIT 1 G983 20VT OR 2 X201 18GY VT 3 X291 18GY YL 4 Q211 14TN LB 5 A215 18RD LG 6 P112 20TN OR 7 P114 20TN WT 8 Q1 20OR WT 9 E25 20OR GY 10 Q111 14TN YL 11 12 13 14 C O N N E C T O R P I N O U T S 1027 CON...

Page 1425: ...IDE CAV CIRCUIT 1 Z821 12BK BR 2 F515 12PK LB 3 D25 20WT VT 4 D123 20WT BR C303 BLACK BODY SIDE CAV CIRCUIT 1 Q111 14TN YL 2 Q211 14TN LB 3 4 P222 18VT DG 5 P292 18VT LG 6 G77 20VT GY 7 8 9 X205 18GY LG 10 X295 18GY DG 11 Q1 20OR WT 12 E25 20OR GY 13 G983 20VT OR 14 C O N N E C T O R P I N O U T S 1028 CONNECTOR PINOUTS ...

Page 1426: ...BUILD 9 X205 18DG LG LATE BUILD 10 X295 18GY DG EARLY BUILD 10 X295 18DG GY LATE BUILD 11 Q1 20OR WT EARLY BUILD 11 Q1 20WT TN LATE BUILD 12 E25 20OR GY 13 G983 20VT OR EARLY BUILD 13 G983 20VT TN LATE BUILD 14 C304 BLACK BODY SIDE CAV CIRCUIT 1 G982 20VT TN 2 X202 18DG VT 3 X292 18DG YL 4 Q212 14OR VT 5 A214 18RD LB 6 7 8 Q2 20WT TN 9 E26 20OR GY 10 Q112 14OR BR 11 P222 18VT DG 12 P292 18VT LG 13...

Page 1427: ... SIDE CAV CIRCUIT 1 F516 12PK 2 Z822 12BK BR 3 D25 20WT VT 4 D123 20WT BR C305 BLACK RIGHT FRONT DOOR SIDE CAV CIRCUIT 1 F516 12PK 2 Z822 12BK BR 3 D25 20WT VT 4 D123 20WT BR C306 BLACK BODY SIDE CAV CIRCUIT 1 Q112 14OR BR 2 Q212 14OR VT 3 4 P222 18VT DG 5 P292 18VT LG 6 G76 20VT YL 7 8 9 X206 18DG LG 10 X296 18DG GY 11 Q2 20WT TN 12 E26 20OR GY 13 G982 20VT TN 14 C O N N E C T O R P I N O U T S 1...

Page 1428: ...T DG 5 P31 18TN YL 6 M11 18YL VT 7 G78 20VT OR 8 W13 18BR WT 9 P30 20TN DG 10 Z800 12BK C307 BLACK LIFTGATE SIDE CAV CIRCUIT 1 C15 12DB WT 2 W17 20BR LG 3 L3 18WT VT 4 L51 18WT DG 5 P31 18TN YL BASE 6 M11 18YL VT 7 G78 22VT OR 8 W13 18BR WT 9 P30 20TN DG 10 Z800 12BK C308 POWER LIFTGATE BLACK BODY SIDE CAV CIRCUIT 1 Q85 16TN WT 2 Q75 20OR LB 3 Q84 16TN GY 4 Q901 20OR VT 5 Q83 18OR GY 6 Q60 22OR YL...

Page 1429: ...FUNCTION 1 R61 20LG VT DRIVER SQUIB 2 LINE 1 2 R63 20LG WT DRIVER SQUIB 2 LINE 2 3 R43 20LG BR DRIVER SQUIB 1 LINE 1 4 R45 20LG OR DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 X20 20GY WT RADIO CONTROL MUX 1 X20 20GY WT RADIO CONTROL MUX 2 X920 20GY OR RADIO CONTROL MUX RETURN 2 X920 20GY OR RADIO CONTROL MUX RETURN 3 V37 20VT S C SWITCH SIGNAL 3 V37 20VT S C SWITCH SIGN...

Page 1430: ...OR SIGNAL 34 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 37 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 42 B1 18DG DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 43 B2 18DG LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 44 45 B9 18DG LG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPL...

Page 1431: ... 20WT VT PCI BUS 3 4 Z11 18BK LG GROUND 5 Z111 18BK WT GROUND 6 7 D21 20WT GY SCI TRANSMIT PCM 8 9 D123 20WT BR FLASH PROGRAM ENABLE 10 D24 20WT YL FLASH ABS 11 12 D20 20WT LG SCI RECEIVE PCM 13 14 15 D15 20BR WT SCI TRANSMIT TCM 16 A105 20DB RD FUSED B DOOR LOCK MOTOR AJAR SWITCH DRIVER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20VT DRIVER DOOR AJAR SWITCH SENSE 2 Z75 20BK VT GROUND 3 P1 20TN LG DRI...

Page 1432: ...2 18VT DG DOOR LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH PASSENGER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE 2 Z74 20BK WT GROUND 3 P292 20VT LG DOOR UNLOCK DRIVER 4 P222 20VT DG DOOR LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH PASSENGER REAR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G76 20VT YL RIGHT REAR DOOR AJAR SWITCH SENSE 2 G982 20VT TN GROUND 3 P292 18VT LG DOOR UN...

Page 1433: ...SWITCH MUX 8 P309 20LG VT DRIVER SEAT HORIZONTAL LUMBAR IN SWITCH MUX 9 P200 20LG YL DRIVER SEAT FRONT RISER PEDAL FORWARD SWITCH MUX 10 P7 20LG DG DRIVER HEATED SEAT SWITCH MUX 11 G200 20VT BR MEMORY SELECT SWITCH MUX 12 P202 20LG DB DRIVER SEAT REAR RISER PEDAL BACK SWITCH MUX DOOR MODULE DRIVER C3 BLACK 20 WAY CAV CIRCUIT FUNCTION 1 Z75 20BK VT GROUND 2 P65 22VT TN DRIVER MIRROR HORIZONTAL POSI...

Page 1434: ...SWITCH ILLUMINATION DRIVER 7 P308 20LG VT PASSENGER SEAT RECLINER SWITCH MUX 8 P310 20LG OR PASSENGER SEAT HORIZONTAL SWITCH MUX 9 10 P8 20LG WT PASSENGER HEATED SEAT SWITCH MUX 11 12 DOOR MODULE PASSENGER C3 BLACK 20 WAY CAV CIRCUIT FUNCTION 1 Z74 20BK WT GROUND 2 P68 22TN YL PASSENGER MIRROR HORIZONTAL POSITION SIGNAL 3 4 5 Q2 20WT TN PASSENGER REAR WINDOW SWITCH MUX 6 P66 22TN LG PASSENGER MIRR...

Page 1435: ...14 20OR TN PANEL LAMPS DRIVER 4 5 6 7 8 X40 22GY WT AUDIO OUT RIGHT 9 Z530 20GY BK GROUND 10 11 X112 20DG GY IGNITION RUN ACC SIGNAL 12 D25 20WT VT PCI BUS 13 14 15 X140 22GY OR COMMON AUDIO 16 X41 22DG WT AUDIO OUT LEFT DVD CD CHANGER C2 BLACK 12 WAY CAV CIRCUIT FUNCTION 1 X114 20GY TN FUSED B 2 X211 20YL GY IGNITION RUN ACC SIGNAL 3 4 5 X915 22GY LB VIDEO CONTROL 6 X515 22GY OR VIDEO SIGNAL 7 X5...

Page 1436: ... LEFT FRONT FOG LAMP DRIVER B Z349 18BK YL GROUND FRONT BLOWER POWER MODULE C1 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z134 12BK OR GROUND 3 C56 20DB LB FRONT BLOWER MOTOR CONTROL 4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT FRONT BLOWER POWER MODULE C2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C112 12DG BLOWER MOTOR SUPPLY 2 C113 12BK BLOWER MOTOR GROUND C O N N E C T O R P I N O U T S 1039 CONNECTOR PI...

Page 1437: ... LEFT AUDIO OUTPUT 10 11 12 13 14 D25 20WT VT PCI BUS 15 X730 20GY YL VOICE RECOGNITION PHONE SWITCH SIGNAL 16 X712 20DG LB MICROPHONE 1 IN 17 X792 20LB DG MICROPHONE IN 18 19 20 21 X835 20OR GY SENSOR GROUND 22 Z409 18BK WT GROUND HEADLAMP LEFT BLACK 8 WAY CAV CIRCUIT FUNCTION 1 L33 18WT DG LEFT HIGH BEAM LAMP DRIVER 2 Z345 18BK LB GROUND 3 L43 18WT DB LEFT LOW BEAM LAMP DRIVER 4 Z343 18BK LG GRO...

Page 1438: ...ON A BK DRIVER HEATED SEAT DRIVER B BK DRIVER SEAT HEATER GROUND HEATED SEAT BACK PASSENGER GREEN 2 WAY CAV CIRCUIT FUNCTION A P98 18BK PASSENGER HEATED SEAT DRIVER B P97 18BK PASSENGER SEAT HEATER GROUND HEATED SEAT BACK PASSENGER SEAT BACK SIDE GREEN 2 WAY CAV CIRCUIT FUNCTION A BK PASSENGER HEATED SEAT DRIVER B BK PASSENGER SEAT HEATER GROUND C O N N E C T O R P I N O U T S 1041 CONNECTOR PINOU...

Page 1439: ...AT TEMPERATURE SENSOR INPUT 4 BK DRIVER SEAT HEATER GROUND HEATED SEAT CUSHION PASSENGER DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 P95 18LG WT PASSENGER SEAT HEATER B DRIVER 2 P93 20LG VT PASSENGER SEAT TEMPERATURE SENSOR 5 VOLT SUPPLY 3 P99 20LG LB PASSENGER SEAT TEMPERATURE SENSOR INPUT 4 P97 18LG YL PASSENGER SEAT HEATER GROUND HEATED SEAT CUSHION PASSENGER SEAT CUSHION SIDE DK GRAY 4 WAY CAV CIRCUI...

Page 1440: ... 5 WAY CAV CIRCUIT FUNCTION 1 G900 22OR VT IGNITION SWITCH SENSE RETURN 2 G20 22VT BR IGNITION SWITCH SENSE 3 F20 20PK GY IGNITION SWITCH OUTPUT RUN START 4 T751 20YL IGNITION SWITCH OUTPUT START 5 A106 20LB RD FUSED B IMPACT SENSOR LEFT FRONT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R81 20LB WT LEFT FRONT IMPACT SENSOR GROUND 2 R79 20LB VT LEFT FRONT IMPACT SENSOR SIGNAL C O N N E C T O R P I N O U T S...

Page 1441: ...T SIDE IMPACT SENSOR 1 GROUND 2 R13 20LG VT LEFT SIDE IMPACT SENSOR 1 SIGNAL IMPACT SENSOR LEFT SIDE 2 EARLY BUILD BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R19 20LG WT LEFT SIDE IMPACT SENSOR 2 GROUND 2 R17 20LG LEFT SIDE IMPACT SENSOR 2 SIGNAL IMPACT SENSOR LEFT SIDE 2 LATE BUILD DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R19 20LG WT LEFT SIDE IMPACT SENSOR 2 GROUND 2 R17 20LG LEFT SIDE IMPACT SENSOR 2 SIGNA...

Page 1442: ...NSOR GROUND 2 R80 20LB TN RIGHT FRONT IMPACT SENSOR SIGNAL IMPACT SENSOR RIGHT SIDE 1 EARLY BUILD BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 2 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL IMPACT SENSOR RIGHT SIDE 1 LATE BUILD DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 2 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL C O ...

Page 1443: ... SENSOR RIGHT SIDE 2 LATE BUILD DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R20 20WT LG RIGHT SIDE IMPACT SENSOR 2 GROUND 2 R18 20LB RIGHT SIDE IMPACT SENSOR 2 SIGNAL IMPACT SENSOR RIGHT SIDE 3 DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R24 20YL LB RIGHT SIDE IMPACT SENSOR 3 GROUND 2 R22 20LG DG RIGHT SIDE IMPACT SENSOR 3 SIGNAL C O N N E C T O R P I N O U T S 1046 CONNECTOR PINOUTS ...

Page 1444: ...INSTRUMENT CLUSTER C2 NAVIGATION BLACK 12 WAY CAV CIRCUIT FUNCTION 1 G107 22VT YL NAV MUX SIGNAL 2 3 G430 20VT GY SCREEN SYNCHRONIZE 4 G410 20VT LG BLUE SIGNAL 5 G420 20VT BR GREEN SIGNAL 6 G400 20VT LB RED SIGNAL 7 8 G591 22 SHIELD 9 10 11 12 INSTRUMENT PANEL SWITCH POD BLACK 12 WAY CAV CIRCUIT FUNCTION 1 A118 20RD OR FUSED B 2 G106 20VT OR EVIC MUX SIGNAL 3 G107 22VT YL NAVIGA TION NAV MUX SIGNA...

Page 1445: ...C O N N E C T O R P I N O U T S 1048 CONNECTOR PINOUTS ...

Page 1446: ...USED B 85 INTERNAL FUSED B 86 INTERNAL FRONT WIPER HIGH LOW RELAY CONTROL 87 W4 12BR OR FRONT WIPER HIGH LOW RELAY HIGH SPEED OUTPUT 87A W3 12BR WT FRONT WIPER HIGH LOW RELAY LOW SPEED OUTPUT FRONT WIPER ON OFF RELAY CAV CIRCUIT FUNCTION 30 INTERNAL FUSED B 85 INTERNAL FUSED B 86 INTERNAL FRONT WIPER ON OFF RELAY CONTROL 87 INTERNAL FUSED B 87A INTERNAL GROUND HORN RELAY CAV CIRCUIT FUNCTION 30 IN...

Page 1447: ...D B 86 INTERNAL REAR WINDOW DEFOGGER RELAY CONTROL 87 C15 12DB WT REAR WINDOW DEFOGGER RELAY OUTPUT 87A RUN RELAY CAV CIRCUIT FUNCTION 30 INTERNAL B 85 INTERNAL B 86 INTERNAL RUN RELAY CONTROL 87 INTERNAL FUSED RUN RELAY OUTPUT 87A C O N N E C T O R P I N O U T S 1050 CONNECTOR PINOUTS ...

Page 1448: ...7 8 9 10 A107 12TN RD FUSED B 11 12 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 13 K136 18BR MANIFOLD TUNING VALVE RELAY OUTPUT 14 C3 18DB YL A C COMPRESSOR CLUTCH RELAY OUTPUT 15 INTEGRATED POWER MODULE C2 DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 2 3 A101 12VT RD FUSED B 4 F515 12PK LB FUSED DOOR NODE RELAY OUTPUT INTEGRATED POWER MODULE C3 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 2 A112 12OR RD FUSED B C...

Page 1449: ...89 18WT YL FOG LAMPS LEFT FRONT FOG LAMP DRIVER 3 W1 18BR TN WASHER FLUID LEVEL SWITCH SENSE 4 5 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 6 L778 20WT LB RIGHT FRONT SIDE MARKER LAMP DRIVER 7 L777 20WT VT LEFT FRONT SIDE MARKER LAMP DRIVER 8 9 10 11 12 13 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 14 Z118 18BK YL GROUND 15 16 L44 16TN WT RIGHT LOW BEAM LAMP DRIVER 17 L90 18WT OR FOG LAMPS RIGHT FRO...

Page 1450: ...NSMISSION CONTROL RELAY OUTPUT 10 K31 20BR FUEL PUMP RELAY CONTROL INTEGRATED POWER MODULE C8 WHITE 15 WAY CAV CIRCUIT FUNCTION 1 F516 12PK FUSED DOOR NODE RELAY OUTPUT 2 C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 3 W4 12BR OR FRONT WIPER HIGH LOW RELAY HIGH SPEED OUTPUT 4 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 5 A701 14BR RD EARLY BUILD FUSED B 5 A100 16RD VT TRAILER TOW LATE BUILD FUSED ...

Page 1451: ...LICENSE LAMP DRIVER 16 F201 20PK LB ORC RUN START DRIVER 17 18 19 F2 18PK YL IGNITION SWITCH OUTPUT RUN START 20 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 21 22 23 24 N1 16DB OR FUEL PUMP RELAY OUTPUT 25 A105 18DB RD FUSED B 26 F525 16TN PK MIDDLE ROW HEATED SEATS FUSED RUN RELAY OUTPUT LICENSE LAMP RED 6 WAY CAV CIRCUIT FUNCTION 1 L3 18WT VT LICENSE LAMP DRIVER 2 Z367 20BK BR GROUND 3 Q94 22TN LG POWE...

Page 1452: ...DLE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P30 20TN DG LIFTGATE HANDLE SWITCH SENSE 2 Z87 20BK LG BASE GROUND 2 Q901 20OR VT POWER LIFTGATE GROUND LIFTGATE LOCK MOTOR AJAR SWITCH BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK OR GROUND 2 G78 22VT OR LIFTGATE AJAR SWITCH SENSE 3 P31 18TN YL LIFTGATE RELEASE DRIVER 4 Z245 18BK GY GROUND LIFTGATE PINCH SENSOR LEFT POWER LIFTGATE BLACK 2 WAY CAV ...

Page 1453: ... VT PCI BUS 12 P42 14LG GY PASSENGER SEAT RECLINER DOWN DRIVER 13 P206 14LG TN ADJUST ABLE PEDALS ADJUSTABLE PEDALS MOTOR REVERSE 14 P14 14LG OR PASSENGER SEAT HORIZONTAL FORWARD DRIVER 15 P95 18LG WT FRONT ROW HEATED SEATS PASSENGER SEAT HEATER B DRIVER 16 G11 20VT TN ADJUST ABLE PEDALS ADJUSTABLE PEDALS SENSOR FEED 17 18 19 G12 22VT BR ADJUST ABLE PEDALS ADJUSTABLE PEDALS SENSOR SIGNAL 20 G912 2...

Page 1454: ...CAV CIRCUIT FUNCTION 1 P141 14LG BR DRIVER SEAT RECLINER DOWN DRIVER 2 P115 14LG OR DRIVER SEAT HORIZONTAL FORWARD DRIVER 3 P117 14LG LB DRIVER SEAT HORIZONTAL REARWARD DRIVER 4 P111 14LG YL DRIVER SEAT REAR UP DRIVER 5 P119 14LG DG DRIVER SEAT FRONT UP DRIVER 6 P94 18LG TN FRONT ROW HEATED SEATS DRIVER SEAT HEATER GROUND 7 P87 18LG LB FRONT ROW HEATED SEATS DRIVER SEAT HEATER B DRIVER 8 P143 14LG...

Page 1455: ...MP SWITCH MUX SENSE 7 8 L87 20WT OR FRONT FOG SWITCH SENSE 9 Z102 20GY BK GROUND 10 L38 20DB WT OPTICAL HORN SIGNAL 11 L37 20WT BR HIGH BEAM SWITCH SENSE 12 L900 22WT YL HEADLAMP SWITCH MUX RETURN NAVIGATION MODULE BLACK 16 WAY CAV CIRCUIT FUNCTION 1 A114 20GY RD FUSED B 2 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 3 Z495 18BK GY GROUND 4 X400 20GY WT NAVIGATION AUDIO 5 G591 20 EARLY BUILD SHIELD 5...

Page 1456: ...20BK WT LATE BUILD BACK UP LAMP SIGNAL POWER LIFTGATE DRIVE UNIT DK GRAY 10 WAY CAV CIRCUIT FUNCTION 1 Q88 14TN BR LIFTGATE OPEN DRIVER 2 Q203 20OR TN OPTICAL SENSOR SUPPLY 3 Q901 20OR VT GROUND 4 Q201 18OR LG LIFTGATE CLUTCH DRIVER 5 Q901 20OR VT GROUND 6 Q89 14TN OR LIFTGATE CLOSE DRIVER 7 Q204 20OR DG OPTICAL SENSOR SIGNAL 1 8 Q205 20OR DB OPTICAL SENSOR SIGNAL 2 9 Z805 18BK OR GROUND 10 Q51 20...

Page 1457: ...IRROR VERTICAL POSITION SIGNAL 2 P69 22WT TN DRIVER MIRROR SENSOR GROUND 3 P65 22VT TN DRIVER MIRROR HORIZONTAL POSITION SIGNAL 4 P73 22TN VT DRIVER MIRROR COMMON DRIVER 5 P75 22TN LG DRIVER MIRROR HORIZONTAL DRIVER 6 P71 22TN DG DRIVER MIRROR VERTICAL DRIVER 7 8 9 P114 20TN WT AUTO DAY NIGHT MIRROR 10 P112 20TN OR AUTO DAY NIGHT MIRROR 11 P53 20LG OR DRIVER HEATED MIRROR DRIVER 12 C17 20LB WT DRI...

Page 1458: ... DRIVER POWER SEAT MOTOR DRIVER LUMBAR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P107 18DB DRIVER SEAT LUMBAR IN DRIVER 2 P105 18PK DRIVER SEAT LUMBAR OUT DRIVER POWER SEAT MOTOR DRIVER REAR RISER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P113 14LG VT DRIVER SEAT REAR DOWN DRIVER 2 P111 14LG YL DRIVER SEAT REAR UP DRIVER POWER SEAT MOTOR DRIVER RECLINER DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 P141 14LG BR DRIVER S...

Page 1459: ...T FRONT ROW HEATED SEATS DRIVER HEATED SEAT HIGH INDICATOR DRIVER 3 P81 20TN LB FRONT ROW HEATED SEATS DRIVER HEATED SEAT LOW INDICATOR DRIVER 4 P989 20TN LG SEAT SWITCH MUX RETURN 5 Z301 20TN BK ILLUMINATION GROUND 6 P301 20LG OR DRIVER DOOR SWITCH ILLUMINATION DRIVER 7 P311 20LG VT DRIVER SEAT RECLINER LUMBAR OUT SWITCH MUX 8 P309 20LG VT DRIVER SEAT HORIZONTAL LUMBAR IN SWITCH MUX 9 P200 20LG Y...

Page 1460: ...HEATED SEATS PASSENGER HEATED SEAT SWITCH MUX 11 12 POWER WINDOW MOTOR DRIVER LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Q21 14OR WT DRIVER WINDOW DRIVER DOWN 2 Q11 14OR LG DRIVER WINDOW DRIVER UP POWER WINDOW MOTOR DRIVER REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Q211 14TN LB EARLY BUILD DRIVER REAR WINDOW DRIVER DOWN 1 Q211 14OR VT LATE BUILD DRIVER REAR WINDOW DRIVER DOWN 2 Q111 14TN YL EARLY BUILD D...

Page 1461: ...2 Q1 20OR WT EARLY BUILD DRIVER REAR WINDOW SWITCH MUX 2 Q1 20WT TN LATE BUILD DRIVER REAR WINDOW SWITCH MUX 3 G983 20VT OR EARLY BUILD GROUND 3 G983 20VT TN LATE BUILD GROUND 4 E25 20OR GY PANEL LAMPS DRIVER POWER WINDOW SWITCH PASSENGER REAR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Q2 20WT TN PASSENGER REAR WINDOW SWITCH MUX 3 G982 20VT TN GROUND 4 E26 20OR GY PANEL LAMPS DRIVER C O N N E C T O R P ...

Page 1462: ...7 18 Z131 16BK DG GROUND 19 20 G6 16VT GY OIL PRESSURE SIGNAL 21 22 G31 20OR VT AAT SIGNAL 23 24 25 D20 20WT LG SCI RECEIVE PCM 26 D123 20WT BR FLASH PROGRAM ENABLE 27 28 29 A109 18OR RD FUSED B 30 T751 20YL IGNITION SWITCH OUTPUT START 31 K141 20DB YL O2 1 2 SIGNAL 32 K904 20DB DG O2 RETURN DOWN 33 34 35 36 D21 20WT GY SCI TRANSMIT PCM 37 D15 20BR WT SCI TRANSMIT TCM 38 D25 20WT VT PCI BUS C O N ...

Page 1463: ...8GY OR ANTENNA SIGNAL 14 D25 20WT VT PCI BUS 15 16 17 18 19 20 21 22 RADIO C1 EXCEPT BASE DK GRAY 22 WAY CAV CIRCUIT FUNCTION 1 A118 20RD OR FUSED B 2 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 3 E12 18OR GY PANEL LAMPS DRIVER 4 5 6 7 X54 20GY RADIO RIGHT AUDIO 8 X56 20GY BR RADIO RIGHT AUDIO 9 X55 20DG BR RADIO LEFT AUDIO 10 X53 20DG RADIO LEFT AUDIO 11 Z514 18BK LG GROUND 12 13 X60 18GY OR ANTENN...

Page 1464: ...GROUND 3 4 M27 18YL LB RAIL LAMPS DRIVER 5 M24 18YL WT FRONT READING COURTESY LAMPS DRIVER 6 E3 20OR YL OVERHEAD CONSOLE DOME LAMPS DIMMER SIGNAL READING COURTESY LAMP LEFT MIDDLE GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 18YL OR COURTESY LAMPS DRIVER 2 Z327 18BK WT GROUND 3 M27 18YL LB RAIL LAMPS DRIVER REAR BOOSTER FAN POWER MODULE C1 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z135 18BK LB GROUND 3 C57 20...

Page 1465: ...N REAR VIEW MIRROR BLACK 12 WAY CAV CIRCUIT FUNCTION 1 2 3 4 X722 20DG WT EARLY BUILD MICROPHONE 2 IN 4 X722 20BR WT LATE BUILD MICROPHONE 2 IN 5 6 X712 20DG LB EARLY BUILD MICROPHONE 1 IN 6 X712 20BR LATE BUILD MICROPHONE 1 IN 7 8 9 X730 20GY YL EARLY BUILD VOICE RECOGNITION PHONE SWITCH SIGNAL 9 X730 20BR GY LATE BUILD VOICE RECOGNITION PHONE SWITCH SIGNAL 10 11 X835 20OR GY EARLY BUILD SENSOR G...

Page 1466: ...IO SIGNAL RIGHT 9 X607 20 SHIELD 10 X917 22DG AUDIO SIGNAL COMMON 11 X17 22DG OR AUDIO SIGNAL LEFT 12 13 X480 20DG LB AUDIO MUX ENABLE 14 15 Z141 20BK TN GROUND 16 E14 20OR TN PANEL LAMPS DRIVER 17 X160 20GY YL FUSED B 18 D25 20WT VT PCI BUS 19 Z141 20BK TN GROUND 20 21 X160 20GY YL FUSED B 22 SATELLITE RADIO MULTIPLEXER C2 DK GRAY 10 WAY CAV CIRCUIT FUNCTION 1 X40 22GY WT AUDIO OUT RIGHT 2 X140 2...

Page 1467: ...T SEAT BELT SWITCH DRIVER DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G10 20VT LG DRIVER SEAT BELT SWITCH SENSE 2 Z237 20BK YL GROUND SEAT BELT TENSIONER DRIVER YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R53 20LG YL DRIVER SEAT BELT TENSIONER LINE 2 2 R55 20LG DG DRIVER SEAT BELT TENSIONER LINE 1 SEAT BELT TENSIONER PASSENGER YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R54 20LB YL PASSENGER SEAT BELT TENSIONER LINE 2 2...

Page 1468: ...SITION SENSOR DRIVER REAR RISER WHITE 3 WAY CAV CIRCUIT FUNCTION 1 P29 20LG WT DRIVER SEAT POSITION SENSOR 5 VOLT SUPPLY 2 P27 20LG DB DRIVER SEAT REAR RISER POSITION SIGNAL 3 P28 20LG BR DRIVER SEAT POSITION SENSOR GROUND SEAT POSITION SENSOR DRIVER RECLINER BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG BR DRIVER SEAT POSITION SENSOR GROUND B P47 20LG LB DRIVER SEAT RECLINER POSITION SIGNAL C P29 2...

Page 1469: ...01 18GY VT AMPLIFIED LEFT FRONT DOOR SPEAKER 2 3 X291 18GY YL AMPLIFIED LEFT FRONT DOOR SPEAKER SPEAKER LEFT REAR DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X205 18GY LG EARLY BUILD AMPLIFIED LEFT REAR DOOR SPEAKER 1 X205 18DG LG LATE BUILD AMPLIFIED LEFT REAR DOOR SPEAKER 2 3 X295 18GY DG EARLY BUILD AMPLIFIED LEFT REAR DOOR SPEAKER 3 X295 18DG GY LATE BUILD AMPLIFIED LEFT REAR DOOR SPEAKER SPEAKER ...

Page 1470: ...EAKER 2 3 X296 18DG GY AMPLIFIED RIGHT REAR DOOR SPEAKER SPEAKER SUBWOOFER RED 6 WAY CAV CIRCUIT FUNCTION 1 X301 18GY WT AMPLIFIED SUBWOOFER 2 2 3 X300 18GY BR AMPLIFIED SUBWOOFER 1 4 X390 18DG BR AMPLIFIED SUBWOOFER 1 5 6 X391 18DG WT AMPLIFIED SUBWOOFER 2 TRACTION CONTROL SWITCH BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z427 20BK WT GROUND 2 E12 18OR GY PANEL LAMPS DRIVER 3 B27 20DG WT TRACTION CONTROL...

Page 1471: ...2 Z243 18BK GROUND WASHER PUMP MOTOR REAR DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 2 Z243 18BK GROUND WIPER MODULE FRONT BLACK 5 WAY CAV CIRCUIT FUNCTION 1 Z103 12BK WT GROUND 2 W7 20BR GY FRONT WIPER PARK SWITCH SENSE 3 4 W3 12BR WT FRONT WIPER HIGH LOW RELAY LOW SPEED OUTPUT 5 W4 12BR OR FRONT WIPER HIGH LOW RELAY HIGH SPEED OUTPUT C O N N E C T O R P I N O...

Page 1472: ...TE 10 WAY CAV CIRCUIT FUNCTION 1 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 2 3 W33 22BR DG FRONT WASHER SIGNAL 4 5 W26 20BR DB REAR WIPER SWITCH MUX 6 W27 22DB BR REAR WIPER SWITCH DELAY 7 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 8 W52 22BR YL FRONT WIPER SWITCH MUX 9 W35 22BR LG FRONT WIPER HIGH LOW SWITCH SENSE 10 C O N N E C T O R P I N O U T S 1075 CONNECTOR PINOUTS ...

Page 1473: ...NOTES 1076 ...

Page 1474: ...10 0 SCHEMATIC DIAGRAMS 10 1 ADJUSTABLE PEDAL SYSTEM S C H E M A T I C D I A G R A M S 1077 SCHEMATIC DIAGRAMS ...

Page 1475: ...10 2 AIRBAG SYSTEM SCHEMATIC S C H E M A T I C D I A G R A M S 1078 SCHEMATIC DIAGRAMS ...

Page 1476: ...10 3 AUDIO 10 3 1 RADIO AMPLIFIER SPEAKERS S C H E M A T I C D I A G R A M S 1079 SCHEMATIC DIAGRAMS ...

Page 1477: ...10 3 2 CD DVD CHANGER 10 3 3 REMOTE RADIO CONTROLS S C H E M A T I C D I A G R A M S 1080 SCHEMATIC DIAGRAMS 10 3 AUDIO Continued ...

Page 1478: ...10 3 4 SATELLITE DIGITAL AUDIO RECEIVER SDAR SYSTEM S C H E M A T I C D I A G R A M S 1081 SCHEMATIC DIAGRAMS ...

Page 1479: ...10 4 CHIME S C H E M A T I C D I A G R A M S 1082 SCHEMATIC DIAGRAMS ...

Page 1480: ...10 5 COMMUNICATION 10 5 1 VEHICLE COMMUNICATION S C H E M A T I C D I A G R A M S 1083 SCHEMATIC DIAGRAMS ...

Page 1481: ...10 5 2 PCM COMMUNICATION 10 6 DOOR AJAR SYSTEM S C H E M A T I C D I A G R A M S 1084 SCHEMATIC DIAGRAMS 10 5 COMMUNICATION Continued ...

Page 1482: ...10 7 ELECTRICALLY HEATED SYSTEMS 10 7 1 HEATED SEATS FRONT S C H E M A T I C D I A G R A M S 1085 SCHEMATIC DIAGRAMS ...

Page 1483: ...10 7 2 REAR WINDOW DEFOGGER S C H E M A T I C D I A G R A M S 1086 SCHEMATIC DIAGRAMS 10 7 ELECTRICALLY HEATED SYSTEMS Continued ...

Page 1484: ...10 8 EXTERIOR LIGHTS FRONT LIGHTING S C H E M A T I C D I A G R A M S 1087 SCHEMATIC DIAGRAMS ...

Page 1485: ...10 9 HEATING A C 10 9 1 AUTOMATIC TEMPERATURE CONTROL SYSTEM S C H E M A T I C D I A G R A M S 1088 SCHEMATIC DIAGRAMS ...

Page 1486: ...10 10 IGNITION POWER ACCESSORY 10 10 1 IGNITION SWITCH S C H E M A T I C D I A G R A M S 1089 SCHEMATIC DIAGRAMS ...

Page 1487: ...10 11 INSTRUMENT CLUSTER 10 11 1 NAVIGATION BCM SWITCH POD S C H E M A T I C D I A G R A M S 1090 SCHEMATIC DIAGRAMS ...

Page 1488: ...10 11 2 FUEL LEVEL SENSORS S C H E M A T I C D I A G R A M S 1091 SCHEMATIC DIAGRAMS ...

Page 1489: ...10 12 INTERIOR LIGHTING S C H E M A T I C D I A G R A M S 1092 SCHEMATIC DIAGRAMS ...

Page 1490: ...10 13 NAVIGATION SYSTEM S C H E M A T I C D I A G R A M S 1093 SCHEMATIC DIAGRAMS ...

Page 1491: ...10 14 OVERHEAD CONSOLE S C H E M A T I C D I A G R A M S 1094 SCHEMATIC DIAGRAMS ...

Page 1492: ...10 15 POWER DOOR LOCKS RKE S C H E M A T I C D I A G R A M S 1095 SCHEMATIC DIAGRAMS ...

Page 1493: ...10 16 POWER LIFTGATE SYSTEM 10 16 1 LIFTGATE S C H E M A T I C D I A G R A M S 1096 SCHEMATIC DIAGRAMS ...

Page 1494: ...10 16 2 LIFTGATE RELEASE S C H E M A T I C D I A G R A M S 1097 SCHEMATIC DIAGRAMS ...

Page 1495: ...10 17 POWER MIRROR SYSTEM 10 17 1 DRIVER MIRROR 10 17 2 PASSENGER MIRROR S C H E M A T I C D I A G R A M S 1098 SCHEMATIC DIAGRAMS ...

Page 1496: ...10 18 POWER SEAT SYSTEM S C H E M A T I C D I A G R A M S 1099 SCHEMATIC DIAGRAMS ...

Page 1497: ...10 19 POWER WINDOW SYSTEM S C H E M A T I C D I A G R A M S 1100 SCHEMATIC DIAGRAMS ...

Page 1498: ...10 20 TELECOMMUNICATIONS HANDS FREE SYSTEM S C H E M A T I C D I A G R A M S 1101 SCHEMATIC DIAGRAMS ...

Page 1499: ...10 21 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 1102 SCHEMATIC DIAGRAMS ...

Page 1500: ...10 22 WINDSHIELD WIPERS 10 22 1 FRONT WIPER WASHER S C H E M A T I C D I A G R A M S 1103 SCHEMATIC DIAGRAMS ...

Page 1501: ...10 22 2 REAR WIPER WASHER S C H E M A T I C D I A G R A M S 1104 SCHEMATIC DIAGRAMS 10 22 WINDSHIELD WIPERS Continued ...

Page 1502: ...ND BLANK SCREEN 4 3 7 1 DRBIIIT DOES NOT POWER UP 4 3 7 2 DISPLAY IS NOT VISIBLE 4 4 0 DISCLAIMERS SAFETY WARNINGS 5 4 1 DISCLAIMERS 5 4 2 SAFETY 5 4 2 1 TECHNICIAN SAFETY INFORMATION 5 4 2 2 VEHICLE PREPARATION FOR TESTING 5 4 2 3 SERVICING SUB ASSEMBLIES 5 4 2 4 DRBIIIT SAFETY INFORMATION 5 4 3 WARNINGS 6 4 3 1 VEHICLE DAMAGE WARNINGS 6 4 3 2 ROAD TESTING A COMPLAINT VEHICLE 6 4 4 DIAGNOSIS 6 5 ...

Page 1503: ...S VERIFICATION TESTS 46 8 0 COMPONENT LOCATIONS 47 8 1 CONTROLLER ANTILOCK BRAKE CAB 47 8 2 DATA LINK CONNECTOR 47 8 3 FUSES 47 8 4 TRACTION CONTROL SWITCH 48 8 5 INDICATORS 48 8 6 BRAKE LAMP SWITCH 48 9 0 CONNECTOR PINOUTS 49 BRAKE LAMP SWITCH BLACK 6 WAY 49 CONTROLLER ANTILOCK BRAKE BLACK 47 WAY 49 DATA LINK CONNECTOR BLACK 16 WAY 50 FUSES IPM 52 TRACTION CONTROL SWITCH BLACK 3 WAY 53 WHEEL SPEE...

Page 1504: ...ng system ABS and the traction con trol system TCS found on Chrysler Pacifica 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the controller antilock brake module is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem isolation repair of isolated problem verification of proper operation 2 0 IDENTIFICATION OF SYSTEM Vehicles equipped w...

Page 1505: ...tendencies control fluid pressure modulation to the brakes during antilock stop monitor the system for proper operation manage traction control functions provide communication to the DRBIIIt while in diagnostic mode store diagnostic information in non volatile mem ory The CAB continuously monitors the speed of each wheel When a wheel locking tendency is detected the CAB will command the appropriat...

Page 1506: ... of the tooth on the tone wheel to the permanent magnet in the sensor signals the IC of the sensor to toggle a second 7 mA power supply on or off The output of the sensor sent to the CAB is a DC voltage signal with changing voltage and current levels The CAB monitors the changing amperage digital signal from each wheel speed sensor The resulting signal is interpreted by the CAB as the wheel speed ...

Page 1507: ...on control system will become inoperative until a time out period has elapsed When in this thermal protection mode the traction control indicator will illuminate however a fault will not be registered The TCS switch is sensed by the BCM 3 5 DIAGNOSTIC TROUBLE CODES The Controller Antilock Brake may report any of several Diagnostic Trouble Codes DTC s 3 6 FREEZE FRAME Freeze Frame takes a snapshot ...

Page 1508: ...on Only those components with approved repair and installation procedures in the service manual should be serviced 4 2 4 DRBIIIT SAFETY INFORMATION WARNING EXCEEDING THE LIMITS OF THE DRBIIIT MULTIMETER IS DANGEROUS IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS Follow the vehicle manufacturer s service speci fications ...

Page 1509: ...stic trouble code is present it must be repaired prior to addressing any other DTC s If any additional DTC s are present proceed to the appropriate test by locating the matching test in the Table of Contents and begin to diagnose the symptom 5 For ABS if there are no diagnostic trouble codes present identify the customer complaint Select Inputs Outputs and read the brake switch in put as you press...

Page 1510: ...lectronic variable brake proportion ing HCU hydraulic control unit I C integrated circuit ICU integrated control unit IPM integrated power module JBLK junction block mA milli Amp PCI programmable communication inter face P M pump motor TCS traction control system VSS vehicle speed signal WSS wheel speed sensor 7 GENERAL INFORMATION ...

Page 1511: ...NOTES 8 ...

Page 1512: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9 ...

Page 1513: ...n With the DRBIIIt read DTC s With the DRBIIIt erase DTC s Turn the ignition off Start the engine With the DRBIIIt read DTC s Does the DRBIIIt display BATTERY VOLTAGE OUT OF RANGE All Yes Go To 2 No Go To 6 2 Turn the ignition off Perform a battery test and charging system test NOTE Refer to service information for the related test s symptom s Does the battery and charging system pass All Yes Go T...

Page 1514: ...s All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for br...

Page 1515: ...tion on With the DRBIIIt attempt to communicate with the Body Control Module Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC rese...

Page 1516: ...CIRCUIT OPEN CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display CAB INTERNAL FAILURE All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB CAB harness connecto...

Page 1517: ...es Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an...

Page 1518: ...ATION INSTRUMENT CLUSTER SELF TEST INSTRUMENT CLUSTER INTERNAL FAULT CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs Are there any Instrument Cluster or ABS DTCs present All Yes Refer to the appropriate category for the related symptom s Perform ABS VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Perform the Key on Bulb Check Does the ABS B...

Page 1519: ...gnition off Turn the ignition to RUN Perform the Instrument Cluster self test NOTE Refer to Body information for the related test s Did the indicators illuminate during the Instrument Cluster self test All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Turn the ignition to RUN Perform the I...

Page 1520: ...peed sensor signal current is out of range RIGHT FRONT SENSOR CIRCUIT FAILURE When Monitored Ignition On Continuously Set Condition When the CAB detects a wheel speed sensor signal current is out of range RIGHT REAR SENSOR CIRCUIT FAILURE When Monitored Ignition On Continuously Set Condition When the CAB detects a wheel speed sensor signal current is out of range POSSIBLE CAUSES INTERMITTENT CONDI...

Page 1521: ...e connector s damaged All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the affected Wheel Speed Sensor connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and ground Is the voltage above 10 volts All Yes Go To 6 No Go To 4 4 Turn the ...

Page 1522: ...eel Speed Sensor Signal circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Sensor connector Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor Signal circuit Does the test light illuminate All Yes Repair the affected Wheel Speed Sensor Sign...

Page 1523: ... 1 11 Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors Disconnect the affected Wheel Speed Sensor connector Turn the ignition on Measure the voltage of the affected Wheel Speed Sensor 12 Volt Supply circuit in the affected Wheel Speed Sensor connector while reconnecting the sensor connector Did the affected Wheel Speed Sensor 12 Volt Supply circuit drop voltage to...

Page 1524: ... wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were any problems found All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 21 BRAKES CAB LEFT FRONT SENSOR CIRCUIT FAILURE Continued ...

Page 1525: ...al circuit missing signal continuously low wheel speed changes erratically periodic drop out of a wheel speed and too long of pressure reduction during an ABS event RIGHT FRONT WHEEL SPEED SIGNAL FAILURE When Monitored Ignition On Continuously Set Condition When the CAB detects the following on the wheel speed sensor signal circuit missing signal continuously low wheel speed changes erratically pe...

Page 1526: ...4 km h 15 mph Is the affected Wheel Speed Signal showing 0 km h 0 mph All Yes Go To 3 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the related wiring harness Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform ABS VERIFICATION TEST VER 1 3 Turn the ignition off Inspect the ...

Page 1527: ... appropriate service information if necessary for procedures or specifications Is the bearing clearance OK All Yes Go To 7 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 7 Turn the ignition off Visually inspect brakes for locking up due to lining contamination or overheating Inspect all Components for defects which may cause a Signal DTC to set Is any Component Damaged All Yes Repair a...

Page 1528: ...e cluster wakeup circuit Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt erase DTC s With the DRBIIIt read DTC s Did this DTC reset All Yes Go To 3 No The condition that caused this DTC is currently not present Use the wiring diagrams schematic as a guide and inspect the related wiring harness for a possible intermittent Perform BODY VERIFICATION TEST VER 1 ...

Page 1529: ...from off to on and wait approximately 1 minute With the DRBIIIt read DTC s Did this DTC reset All Yes Replace the module which set the DTC in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 26 BRAKES CAB MIC MESSAGES NOT RECEIVED Continued ...

Page 1530: ...I BUS CIRCUIT OPEN CAB INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PCI BUS COMMUNICATION FAULT All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the CAB...

Page 1531: ...es Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the CAB harness connector Turn t...

Page 1532: ...e in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 10 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were a...

Page 1533: ...PUMP FUSED B CIRCUIT OPEN CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PCI BUS LOOPBACK FAILURE All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB CAB...

Page 1534: ... Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an o...

Page 1535: ...US CIRCUIT OPEN CAB INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PCI BUS SHORTED TO GROUND All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the CAB harn...

Page 1536: ...Yes Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the CAB harness connector Turn ...

Page 1537: ...ke in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 10 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were ...

Page 1538: ...BUS CIRCUIT OPEN CAB INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PCI BUS SHORTED TO VOLTAGE All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the CAB ha...

Page 1539: ...es Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the CAB harness connector Turn t...

Page 1540: ...ke in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 10 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were ...

Page 1541: ...BS PUMP FUSED B CIRCUIT OPEN CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PCI HARDWARE FAILURE All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB CAB ...

Page 1542: ...es Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an...

Page 1543: ...gnition on With the DRBIIIt enter Instrument Cluster System Tests then PCM Monitor Does the DRBIIIt display PCM is active on BUS All Yes Erase the DTC if DTC resets measure the resistance of the PCI Bus circuit between the PCM connector and the CAB connector If open repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt attempt to communicate wi...

Page 1544: ...TION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit between the DLC and the PCM connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 41 BRA...

Page 1545: ...UIT FAILURE INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR ABS PUMP FUSED B CIRCUIT OPEN PUMP MOTOR GROUND CIRCUITS OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With the DRBIIIt read DTCs Does the DRBIIIt display PUMP MOTOR CIRCUIT FAILURE All Yes ...

Page 1546: ...oded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the CAB harness connector Check connectors Clean repair as necessary Measure the voltage of the ABS Pump Fused B circuit Is the voltage above 10 volts All Yes Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ...

Page 1547: ...fer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts probe both ground circuits Is the test light illuminated for each circuit All Yes Go To 3 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VE...

Page 1548: ...Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the CAB connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Ye...

Page 1549: ...pair is complete BODY VERIFICATION TEST VER 1 APPLICABILITY 1 Disconnect all jumper wires and reconnect all previously disconnected components and connectors 2 NOTE If the SKREEM or PCM was replaced refer to the service information for proper programming procedures If the IPM was replaced ensure the IOD fuse is in the Normal Run position 3 If the Body Control Module BCM was replaced turn the ignit...

Page 1550: ...8 0 COMPONENT LOCATIONS 8 1 CONTROLLER ANTILOCK BRAKE CAB 8 2 DATA LINK CONNECTOR 8 3 FUSES C O M P O N E N T L O C A T I O N S 47 COMPONENT LOCATIONS ...

Page 1551: ...8 4 TRACTION CONTROL SWITCH 8 5 INDICATORS 8 6 BRAKE LAMP SWITCH C O M P O N E N T L O C A T I O N S 48 COMPONENT LOCATIONS ...

Page 1552: ...6 Z127 12BK DG GROUND 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 A111 12DG RD FUSED B 33 B6 18DG WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 37 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 42 B1 18DG DB RIGHT REAR WHEEL SPEED ...

Page 1553: ...11 18BK LG GROUND 5 Z111 18BK WT GROUND 6 7 D21 20WT GY SCI TRANSMIT PCM 8 9 D123 20WT BR FLASH PROGRAM ENABLE 10 D24 20WT YL FLASH ABS 11 12 D20 20WT LG SCI RECEIVE PCM 13 14 15 D15 20BR WT SCI TRANSMIT TCM 16 A105 20DB RD FUSED B C O N N E C T O R P I N O U T S 50 CONNECTOR PINOUTS ...

Page 1554: ...C O N N E C T O R P I N O U T S 51 CONNECTOR PINOUTS ...

Page 1555: ...ORY RELAY OUTPUT 27 28 25A INTERNAL FUSED B 29 20A A108 18LG RD FUSED B 30 10A A106 20LB RD FUSED B 31 20A A701 18BR RD LATE BUILD FUSED B 31 20A A100 18RD VT TRAILER TOW EARLY BUILD FUSED B 34 10A C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 35 36 20A INTERNAL FUSED B 37 25A INTERNAL FUSED B 38 20A INTERNAL FUSED B 39 20A A109 18OR RD FUSED B 40 40A F515 12PK LB FUSED DOOR NODE RELAY OUTPUT 41...

Page 1556: ... 12 VOLT SUPPLY 2 B8 18DG TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR LEFT REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR RIGHT FRONT LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B6 18DG WT RIGHT FRONT WHEEL SPEED SE...

Page 1557: ...SENSOR RIGHT REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B2 18DG LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B1 18DG DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL C O N N E C T O R P I N O U T S 54 CONNECTOR PINOUTS ...

Page 1558: ...10 0 SCHEMATIC DIAGRAMS 10 1 TEVES MARK 25 CONTROLLER ANTILOCK BRAKE ABS S C H E M A T I C D I A G R A M S 55 SCHEMATIC DIAGRAMS ...

Page 1559: ...NOTES 56 ...

Page 1560: ...INION FACTOR IF APPLICABLE 4 3 4 USING THE DRBIIIT 5 3 5 DRBIIIT ERROR MESSAGES 5 3 5 1 DRBIIIT DOES NOT POWER UP BLANK SCREEN 5 3 5 2 DISPLAY IS NOT VISIBLE 5 3 5 3 SOME DISPLAY ITEMS READ 9 9 5 3 6 TRANSMISSION SIMULATOR MILLER TOOL 8333 AND FWD ADAPTER MILLER TOOL 8333 1A 5 4 0 DISCLAIMERS SAFETY AND WARNINGS 6 4 1 DISCLAIMERS 6 4 2 SAFETY 6 4 2 1 TECHNICIAN SAFETY INFORMATION 6 4 2 2 VEHICLE P...

Page 1561: ...REVERSE 69 P0740 TCC OUT OF RANGE 71 P0750 LR SOLENOID CIRCUIT 73 P0755 2 4 SOLENOID CIRCUIT 77 P0760 OD SOLENOID CIRCUIT 81 P0765 UD SOLENOID CIRCUIT 85 P0841 LR PRESSURE SWITCH SENSE CIRCUIT 88 P0845 2 4 HYDRAULIC PRESSURE TEST FAILURE 92 P0846 2 4 PRESSURE SWITCH SENSE CIRCUIT 97 P0870 OD HYDRAULIC PRESSURE TEST FAILURE 101 P0871 OD PRESSURE SWITCH SENSE CIRCUIT 106 P0884 POWER UP AT SPEED 110 ...

Page 1562: ...T LOCATIONS 163 8 4 POWERTRAIN COMPONENT LOCATION 164 9 0 CONNECTOR PINOUTS 165 AUTOSTICK SWITCH BLACK 4 WAY 165 DATA LINK CONNECTOR BLACK 16 WAY 165 FUSES IPM 167 TRANSMISSION CONTROL RELAY 167 POWERTRAIN CONTROL MODULE C1 BLACK BLACK 38 WAY 168 POWERTRAIN CONTROL MODULE C2 BLACK ORANGE 38 WAY 169 POWERTRAIN CONTROL MODULE C3 BLACK WHITE 38 WAY 170 POWERTRAIN CONTROL MODULE C4 BLACK GREEN 38 WAY ...

Page 1563: ...NOTES iv ...

Page 1564: ...iew the entire manual to become familiar with all new and changed diagnostic procedures This book reflects many suggested changes from readers of past issues After using this book if you have any comments or recommendations please fill out the form at the back of the book and mail it back to us 1 1 SYSTEM COVERAGE The diagnostic procedure manual covers all 2004 CS vehicles equipped with a 41TE tra...

Page 1565: ...omes restricted or if a customer drives aggressively in low gear the calcu lated oil temperature will be inaccurate Conse quently the shift schedule selected may be inappro priate for the current conditions 3 3 DIAGNOSTIC TROUBLE CODES Diagnostic trouble codes DTC s are codes stored by the PCM NGC or TCM EATX depending on application and help diagnose Transmission prob lems They are viewed using t...

Page 1566: ...ined as sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a minimum temperature of 71 C 160 F The Malfunction Indicator Lamp MIL will turn off after 3 good trips or when the DTC s are cleared from the control module 3 3 6 QUICK LEARN A warm up cycle is defined as sufficient vehicle operation such that the coolant tempera...

Page 1567: ... a 2 3 shift The transmission temperature must be above 43 C 110 F The clutch volume should be between 40 and 150 The UD clutch volume is updated when doing a 4 3 or 4 2 shift The transmission temperature must be above 43 C 110 F The clutch volume should be between 24 and 70 Transmission Effects These CVIs that are out of range are usually set with other DTC s which indicates an internal transmiss...

Page 1568: ...ad cable Check the vehicle battery voltage A mini mum of 11 volts is required to adequately power the DRBIIIt If all connections are proper between the DRBI IIt and the vehicle or other devices and the vehicle battery is fully charged an inoperative DRBIIIt may be the result of faulty cable or vehicle wiring For a blank screen refer to the appropriate Body Diagnostic manual 3 5 2 DISPLAY IS NOT VI...

Page 1569: ...r inspection or testing purposes These systems when fully charged contain fluid at high pressure Before disconnecting any hydraulic tubes hoses and fittings be sure that the system is fully depres surized When servicing a vehicle always wear eye protection and remove any metal jewelry such as watchbands or bracelets that might make an inad vertent electrical contact When diagnosing a Transmission ...

Page 1570: ...rating other than indicated may result in a dangerous electrical system over load If a properly rated fuse continues to blow it indicates a problem in the circuit that must be corrected 4 3 2 ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condi...

Page 1571: ...other control modules will be affected that depend on speed information 4 4 4 BULLETINS AND RECALLS Always perform all Safety Recalls and Technical Service Bulletins that are applicable to the prob lem 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIIIt diagnostic read out box Must be at latest release level Transmission Simulator Miller 8333 Adapter harness panel overlay kit for Transmis sion Simulator Mill...

Page 1572: ...re Switch 6 2 DEFINITIONS OBDII EURO STAGE III OBD Trip A vehicle start and drive cycle such that all once per trip diagnostic monitors have run Key Start A vehicle start and run cycle of at least 20 seconds Warm up Cycle A vehicle start and run cycle such that the engine coolant must rise to at least 71 C 160 DRBIIIt F and must rise by at least 4 4 C 40 F from initial start up To count as a warm ...

Page 1573: ...NOTES 10 ...

Page 1574: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 11 ...

Page 1575: ...pri ate symptom Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connect...

Page 1576: ...RANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to 12 volts probe each ground circuit in the appropr...

Page 1577: ... wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Go To 6 ...

Page 1578: ...the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC ...

Page 1579: ... the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set this...

Page 1580: ... the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC...

Page 1581: ...he schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set this D...

Page 1582: ...erforming any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For G...

Page 1583: ...ation Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 NOTE Due to the integration of the Powertrain and Transmission Control Modules communication between the modules is internal Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Repl...

Page 1584: ... symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and ...

Page 1585: ... aid the Technician in diagnosing shift quality complaints This DTC indicates that the transmission has been operating in the 9Overheat9 shift schedule which may generate a customer complaint The customer driving patterns may indicate the need for an additional transmission oil cooler With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set View repair op...

Page 1586: ...use of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission D...

Page 1587: ... SINCE SET counter set at 0 All Yes Go To 4 No Go To 9 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Us...

Page 1588: ... open or high resistance Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Remove the Transmission Control Relay Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNE...

Page 1589: ...particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 9 The conditions necessary to set the DTC are not present at this time Using the schematics as ...

Page 1590: ... ERROR TEST ACTION APPLICABILITY 1 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FAC TOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER ...

Page 1591: ...ing in park or neutral if a problem exists POSSIBLE CAUSES SHIFTER OUT OF ADJUSTMENT TRS T1 SENSE CIRCUIT OPEN TRS T3 SENSE CIRCUIT OPEN TRS T41 SENSE CIRCUIT OPEN TRS T42 SENSE CIRCUIT OPEN TRS T1 SENSE CIRCUIT SHORT TO GROUND TRS T3 SENSE CIRCUIT SHORT TO GROUND TRS T41 SENSE CIRCUIT SHORT TO GROUND TRS T42 SENSE CIRCUIT SHORT TO GROUND TRS T1 SENSE CIRCUIT SHORT TO VOLTAGE TRS T3 SENSE CIRCUIT ...

Page 1592: ...y flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIIIt erase Transmission DTCs Cycle the ignition off then start the vehicle Firmly apply the brakes and shift into Overdrive NOTE...

Page 1593: ...ever Position Test pass All Yes Go To 5 No Go To 6 NOTE After completion of this procedure make sure to disconnect the Transmission Simulator Miller tool 8333 and FWD adaptor cable kit Miller tool 8333 1A and reconnect all connectors 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Range Sensor per the Service Informa tion Perform 41TE NGC TRANSMISSION VE...

Page 1594: ...NECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T1 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T1 Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Turn the ignition off to the lock position Disconnect the TRS harness connector Disconnect the PCM harness co...

Page 1595: ...ING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T3 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T3 Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 12 12 Turn the ignition off to the lock position Disconnect the TRS harness connec...

Page 1596: ...ING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T41 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T41 Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 15 15 Turn the ignition off to the lock position Disconnect the TRS harness conn...

Page 1597: ...NG IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T42 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T42 Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 18 18 Turn the ignition off to the lock position Disconnect the TRS harness conne...

Page 1598: ... Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 21 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits Check the Shift Linkage and cable for proper operation per the Service Information With the ...

Page 1599: ...level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram...

Page 1600: ...h the Transmission Simulator turn the Input Output switch to OFF With the DRBIIIt monitor the TRANS TEMP VOLTS while turning the Thermistor Voltage switch to all three positions on the Transmission Simulator Compare the DRBIIIt readings with the numbers listed on the Transmission Simulator Do the readings on the Transmission Simulator match the DRBIIIt readings 0 2 volts All Yes Go To 5 No Go To 6...

Page 1601: ...s circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 38 TRANSMISSION NGC P0711 TRANSMISSION TEMPERATURE SENSOR PERFORMANCE Continued ...

Page 1602: ...C s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifte...

Page 1603: ...or Do the readings on the Transmission Simulator match the DRBIIIt readings 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission Solenoid TRS assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM C4 harness connector Disconnect...

Page 1604: ...RANSMISSION VERIFICATION TEST VER 1 8 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes R...

Page 1605: ...ys perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring an...

Page 1606: ...nsmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Note Check connectors Clean repair as necessary Ignition on engine not running With the Transmission Simulator turn the Input Output switch to OFF With the DRBIIIt monitor the TRANS TEMP VOLTS while turning the Thermistor Voltage switch to all three positions on the Transmission Simulator Compare the DRBIIIt ...

Page 1607: ...repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Connect a jumper wire between the Fused B circuit and the Transmission Control Relay Output circuit in the Transmission Control Relay connector Ignition on engine not ...

Page 1608: ... this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 45 TRANSMISSION NGC P0713 TRANSMISSION TEMPERATURE SENSOR HIGH Continued ...

Page 1609: ...smission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s ch...

Page 1610: ...IIIt reading 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission Solenoid TRS assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are...

Page 1611: ...n NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect th...

Page 1612: ...es Go To 4 No Go To 5 4 If there are no possible causes remaining view repair All Repair Replace the Input Speed Sensor per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Input Speed Sensor harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT P...

Page 1613: ...O PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Input Speed Sensor Signal circuit Is the resistance Below 5 0 ohms All Yes Repair the Input Speed Sensor Signal circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lock position Disconnect the Input Speed Sens...

Page 1614: ...orm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION F...

Page 1615: ...tion NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect...

Page 1616: ...tion With the DRBIIIt read the Input and Output RPM Does the Input RPM read 3000 and the Output RPM read 1250 within 50 RPM All Yes Go To 4 No Go To 5 4 If there are no possible causes remaining view repair All Repair Replace the Output Speed Sensor per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 Turn the ignition off to the lock position Disconnect the PCM harn...

Page 1617: ...N POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Output Speed Sensor Signal circuit Is the resistance below 5 0 ohms All Yes Repair the Output Speed Sensor Signal circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lock position Disconnect t...

Page 1618: ...C TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perfo...

Page 1619: ... DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some mu...

Page 1620: ...dule per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With th...

Page 1621: ...IIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does n...

Page 1622: ... still sets Gear Ratio DTC check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the wiring and connectors for the Speed Sensors for a good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapte...

Page 1623: ... symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position ...

Page 1624: ...ch Test and still sets Gear Ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adap...

Page 1625: ...r internal transmission per the Service Information Check all of the components related to the UD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 62 TRANSMISSION NGC P0732 GEAR RATIO ERROR IN 2ND Continued ...

Page 1626: ... symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position ...

Page 1627: ...he vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the speed sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the El...

Page 1628: ...ir internal transmission per the Service Information Check all of the components related to the UD and OD clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 65 TRANSMISSION NGC P0733 GEAR RATIO ERROR IN 3RD Continued ...

Page 1629: ... symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position ...

Page 1630: ...rcuits If the vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333...

Page 1631: ...r internal transmission per the Service Information Check all of the components related to the OD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 68 TRANSMISSION NGC P0734 GEAR RATIO ERROR IN 4TH Continued ...

Page 1632: ...DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test do...

Page 1633: ...ch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and Electronic Transmission Adapter kit Miller t...

Page 1634: ...r the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a...

Page 1635: ...nditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits This DTC can also be set under extreme temperature conditions this is usually caused by an internal problem Verify if the problem is only experienced under extreme hot ...

Page 1636: ... then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully mat...

Page 1637: ...id the L R Solenoid LED on the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness conne...

Page 1638: ...ECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the LR Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the LR Solenoid Control circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Turn ...

Page 1639: ...TOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any pr...

Page 1640: ...d adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using...

Page 1641: ...on the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Tran...

Page 1642: ...THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Solenoid Control circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VE...

Page 1643: ...orm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were ther...

Page 1644: ...he fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wirin...

Page 1645: ...Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmissio...

Page 1646: ...THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the OD Solenoid Control circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER ...

Page 1647: ...orm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were ther...

Page 1648: ... Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide...

Page 1649: ...on the Transmission Simulator blink on and off All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid...

Page 1650: ...y Connect a jumper wire between the Fused B circuit and Transmission Control Relay Output circuit in the Transmission Control Relay connector Ignition on engine not running CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the vo...

Page 1651: ...e Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guid...

Page 1652: ...ition off to the lock position Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Install the Transmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Note Check connectors Clean repair as necessary Ignition on engine not running With the Transmission Simulator turn the Pressur...

Page 1653: ...CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is the resistance below 5 0 ohms All Yes Repair the L R Pressure Switch Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Turn...

Page 1654: ...ake sure to check for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QU...

Page 1655: ...rily turns on element pressure to the clutch circuits that don t have pressure to identify the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES LOSS OF PRIME P0944 PRESENT TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN 2 4 PRESSURE SWITCH SENSE CIRCUIT OPEN 2 4 PRESSURE SWITCH CIRCUIT SHORT TO GROUND INTERNAL TRANSMISSION 2 4 PRESSURE SWITCH...

Page 1656: ...riving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIIIt check for other Transmission DTC s Is the DTC P0944...

Page 1657: ...ble and inspect the Valve Body per the Service Informa tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harne...

Page 1658: ...CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Turn the ignition off ...

Page 1659: ...orm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems f...

Page 1660: ... NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the...

Page 1661: ...n the Transmission Simulator Did the state of the 2 4 Pressure Switch change while pressing the Pressure Switch Test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock posit...

Page 1662: ...SS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1...

Page 1663: ...Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were any problems fou...

Page 1664: ...s on element pressure to the clutch circuits that don t have pressure to identify the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES LOSS OF PRIME P0944 PRESENT TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN OD PRESSURE SWITCH SENSE CIRCUIT SHORT TO GROUND OD PRESSURE SWITCH SENSE CIRCUIT OPEN OD PRESSURE SWITCH SENSE CIRCUIT SHORT TO VOLT...

Page 1665: ...set by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIIIt check for other Transmission DTC s Is the D...

Page 1666: ...e Informa tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harness connector Note...

Page 1667: ...ING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Turn...

Page 1668: ...orm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems f...

Page 1669: ...ways perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring ...

Page 1670: ...re Switch test button Did the OD Pressure Switch state change while pressing the Pressure Switch test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harne...

Page 1671: ...g CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TR...

Page 1672: ...E NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any p...

Page 1673: ...oss of power to the Transmission portion of the PCM CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS NOTE Due to the integration of the Powertrain and Transmission Control Modules the transmission part of the PCM has its own specific po...

Page 1674: ...n and Transmission Control Modules the transmission part of the PCM has its own specific power and ground circuits POSSIBLE CAUSES FUSED B CIRCUIT OPEN TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN TRANSMISSION CONTROL RELAY TRANSMISSION CONTROL RELAY CONTROL CIRCUIT OPEN TRANSMISSION CONTROL RELAY GROUND CIRCUIT OPEN TRANSMISSION CONTROL RELAY CONTROL CIRCUIT SHORT TO GROUND TRANSMISSION CONTROL...

Page 1675: ...rocedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIIIt Check the STARTS SINCE SET counter for P0888 Note This counter only applies to the last DTC set Is the STARTS SINCE SET counter equal to 0 All Yes Go To 3 No Go To 13 3 Turn the ignition off to the lock position Remove the Transmission Control Relay Note Check connectors Clean repair as necessary Using a 12 volt test light...

Page 1676: ...oes the test light illuminate brightly All Yes Go To 7 No Repair the Transmission Control Relay Ground circuit for an open Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Remove the Transmission Control Relay Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING...

Page 1677: ...cular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 10 Turn the ignition off to the lock position Remove the Transmission Control Relay Disconnect the P...

Page 1678: ...RIFICATION TEST VER 1 No Go To 12 12 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 13 The condit...

Page 1679: ...vel is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Di...

Page 1680: ...t Is the voltage above 0 5 volt All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harness connector Remove the Transmission Control Relay Note Check connectors Clean ...

Page 1681: ...or a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 6 6 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEAR...

Page 1682: ...ission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DT...

Page 1683: ...put circuit in the Transmission Control Relay connector Is the voltage above 0 5 volts All Yes Repair the Transmission Control Relay Output circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Remove the Transmission Control Relay Note Check connectors Clean repair as necessary Ignition on engine not running NO...

Page 1684: ... 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there an...

Page 1685: ... DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer t...

Page 1686: ...e and adjust the fluid per the Service Information With the DRBIIIt perform a Battery Disconnect NOTE The Battery Disconnect must be done to re enable EMCC during an A C Clutch engagement NOTE The vehicle may exhibit intermittent shudder during the first few hundred miles The new Transmission Fluid will gradually penetrate the Torque Convertor Clutch friction material and the shudder should disap ...

Page 1687: ...ice Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a gu...

Page 1688: ...ring and connectors specific to this circuit Wiggle the wiring while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 5 With the DRBIIIt perform a Shift Lever Position test Follow t...

Page 1689: ...f there are no possible causes remaining view repair All Repair Replace the Transmission Oil Pump per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 126 TRANSMISSION NGC P0944 LOSS OF PRIME Continued ...

Page 1690: ...E INTERMITTENT WIRING AND CONNECTORS TEST ACTION APPLICABILITY 1 With the DRBIIIt Check the STARTS SINCE SET counter for P0951 Note This counter only applies to the last DTC set Is the Starts Since Set counter set at 0 All Yes Go To 2 No Go To 6 2 Turn the ignition off to the lock position Disconnect the AutoStickt Switch harness connector Note Check connectors Clean repair as necessary Ignition o...

Page 1691: ... NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the AutoStickt Upshift Sense circuit Is the resistance below 5 0 ohms All Yes Repair the AutoStickt Upshift Sense circuit for a short to ground Perform 41T...

Page 1692: ...c to this circuit Wiggle the wires while checking for shorts and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 129 TRANSMISSION NGC P0952 AUTOSTICK INPUT CIRCUIT LOW Continued ...

Page 1693: ...rform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and con...

Page 1694: ... diagnostics for both P0870 and P0845 to determine which switch is failing With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set If there are no possible causes remaining view repair All Repair Refer to the Transmission category and perform the symptoms for P0845 and P0870 Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 131 TRANSMISSION NGC P0992...

Page 1695: ...any Engine Communication DTC s present All Yes Refer to the Powertrain category and perform the appropriate symptom Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt erase Transmission DTC s Start the Engine in Park With the DRBIIIt read Transmission DTCs NOTE The Engine must run for at least 20 seconds to reset this DTC Did the DTC reset after the engine was star...

Page 1696: ...ntrollers on the bus on this vehicle If there is a bus problem refer to the Communication Category for diagnosis With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 133 TRANSMISSION NGC P1652 SERIAL COMMUNICATION LINK MALFU...

Page 1697: ...k and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC U...

Page 1698: ...5 5 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to ground check th...

Page 1699: ...brightness to that of a direct connection to the battery Does the test light illuminate brightly for all the ground circuits All Yes Go To 7 No Repair the Ground circuits for an open Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit W...

Page 1700: ...om diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record...

Page 1701: ... the Communications category and perform test for 9MIC MESSAGES NOT RECEIVED9 Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Ignition on engine not running With the DRBIIIt erase Transmission DTC s Start the engine in park With the DRBIIIt read Transmission DTC s Is the DTC 9P1687 NO COMMUNICATION WITH THE MIC9 present All Yes Replace the Powertrain Control Module WITH THE DRBI...

Page 1702: ... To 3 2 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER...

Page 1703: ...ervice Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a...

Page 1704: ...Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Ignition on engine not running With the Transmission Simulator turn the Pressure Switch selector switch to L R With the DRBIIIt monitor the L R Pressure Switch State while pressing the Pressure Switch Test button Did the Pressure Switch state change from open to closed when the test button was pressed All Yes Go To 5 No Go To 6 ...

Page 1705: ...M TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is the resistance below 5 0 ohms All Yes Repair the L R Pressure Switch Sense circuit for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lock...

Page 1706: ... Output circuit for an open Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QU...

Page 1707: ... and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Us...

Page 1708: ...or Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Ignition on engine not running With the Transmission Simulator turn the Pressure Switch selector switch to L R With the DRBIIIt monitor the L R Pressure Switch State while pressing the Pressure Switch Test button on the Transmission Simulator Did the Pressure Switch state change from open to closed when test button was presse...

Page 1709: ...essary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the L R Pressure Switch Sense circuit from the Pinout Box to the Transmission Solenoid Pressure Switch Assembly harness connector Is the resistance above ...

Page 1710: ...ematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions ...

Page 1711: ...ully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE...

Page 1712: ...equent torque reduction messages to the Powertrain Control Module PCM and does not receive a confirmation from the PCM Note Due to the integration of the Powertrain and Transmission Control Modules bus communication between the modules is internal POSSIBLE CAUSES POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 NOTE Due to the integration of the Engine and Transmission controllers into one mo...

Page 1713: ...With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If th...

Page 1714: ...ERIFICATION TEST VER 1 No Test Complete 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Input and Output Speed Sensor harness connectors Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL...

Page 1715: ...y to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift...

Page 1716: ...r the Service Information Make sure it is not overfilled NOTE Aggressive driving or driving in low for extended periods of time in AutoStick mode will set this DTC If there are no possible causes remaining view repair All Repair If the Transmission Fluid is low repair any Transmission Fluid leak as necessary and adjust the Transmission Fluid Level per the Service Information Refer to Service Infor...

Page 1717: ...TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the P N Position Switch Sense circuit from the appropriate terminal of special tool 8815 to the Transmission Range Sensor harness connector Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the P N Position Switch Sense circuit for an open 3 Turn the igni...

Page 1718: ...NNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Did the resistance change from above 10 0 ohms to below 10 0 ohms All Yes Go To 5 No Replace the Transmission Range Sensor per the Service Informa tion 5 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attent...

Page 1719: ...ness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the AutoStickt Ground circuit at the AutoStickt harness connector Is the resistance above 5 0 ohms All Yes Repair the AutoStickt Ground circuit for an open No Go To 3 3 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the AutoStickt Switch harness conne...

Page 1720: ...Switch harness connector Is the resistance above 5 0 ohms All Yes Repair the AutoStickt Downshift Sense circuit for an open No Go To 5 5 Ignition on engine not running With the DRBIIIt monitor the AutoStickt Switch status Firmly apply the brake and shift into AutoStickt Push the shift lever to the right several times to actuate the AutoStickt Upshift Switch and then to the left several times to ac...

Page 1721: ...s least three times pausing momentarily in each gear NOTE If all the PRNDL lights box individually then the error was cleared Shift into park and turn the ignition off to the lock position Ignition on engine not running With the DRBIIIt read Transmission DTCs Does the DTC P0706 reset or do all the PRNDL indicators remain boxed in park or neutral All Yes Return to the symptom list and perform diagn...

Page 1722: ...e engine speed and listen to the noise NOTE THE RADIO MUST BE TURNED OFF Alternator noise can come through the speakers and be misinterpreted as Transmission Pump Whine This can happen even with the volume turned down Does the noise get louder or change pitch while the engine speed is changing All Yes Go To 3 No Go To 4 3 If there are no possible causes remaining view repair All Repair Repair inte...

Page 1723: ...ary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorts and open circuits Although it takes two occurences of a missed TRD link message to set the DTC P1793 one missed message will cause the transmission to short shift until the next start up If the vehicle has any indicati...

Page 1724: ...ion Control Relay can cause the Trans mission Simulator to not Power up NOTE If the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapter kit 8333 1A will not power up make sure to check all connectors and the ground cable for proper installation If there are no possible causes remaining view repair All Repair Check and repair these symptoms before having the Transmission...

Page 1725: ...r 9 Road test the vehicle With the DRBIIIt monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 degrees 10 Below 25 MPH make 5 to 8 wide open throttle kickdowns to 1st gear Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown 11 For a specific DTC drive the vehicle to the Sympt...

Page 1726: ...8 0 COMPONENT LOCATIONS 8 1 AUTO STICK IF EQUIPPED 8 2 PRESSURE PORT LOCATIONS 8 3 TRANSMISSION COMPONENT LOCATIONS C O M P O N E N T L O C A T I O N S 163 COMPONENT LOCATIONS ...

Page 1727: ...8 4 POWERTRAIN COMPONENT LOCATION C O M P O N E N T L O C A T I O N S 164 COMPONENT LOCATIONS ...

Page 1728: ...WT IGNITION UNLOCK RUN START DATA LINK CONNECTOR BLACK 16 WAY CAV CIRCUIT FUNCTION 1 2 D25 20WT VT PCI BUS 3 4 Z11 18BK LG GROUND 5 Z111 18BK WT GROUND 6 7 D21 20WT GY SCI TRANSMIT PCM 8 9 D123 20WT BR FLASH PROGRAM ENABLE 10 D24 20WT YL FLASH ABS 11 12 D20 20WT LG SCI RECEIVE PCM 13 14 15 D15 20BR WT SCI TRANSMIT TCM 16 A105 20DB RD FUSED B C O N N E C T O R P I N O U T S 165 CONNECTOR PINOUTS ...

Page 1729: ...C O N N E C T O R P I N O U T S 166 CONNECTOR PINOUTS ...

Page 1730: ... B 31 20A A701 18BR RD LATE BUILD FUSED B 31 20A A100 18RD VT TRAILER TOW EARLY BUILD FUSED B 34 10A C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 35 36 20A INTERNAL FUSED B 37 25A INTERNAL FUSED B 38 20A INTERNAL FUSED B 39 20A A109 18OR RD FUSED B 40 40A F515 12PK LB FUSED DOOR NODE RELAY OUTPUT 41 40A F516 12PK FUSED DOOR NODE RELAY OUTPUT 42 40A C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT ...

Page 1731: ...17 18 Z131 16BK DG GROUND 19 20 G6 16VT GY OIL PRESSURE SIGNAL 21 22 G31 20OR VT AAT SIGNAL 23 24 25 D20 20WT LG SCI RECEIVE PCM 26 D123 20WT BR FLASH PROGRAM ENABLE 27 28 29 A109 18OR RD FUSED B 30 T751 20YL IGNITION SWITCH OUTPUT START 31 K141 20DB YL O2 1 2 SIGNAL 32 K904 20DB DG O2 RETURN DOWN 33 34 35 36 D21 20WT GY SCI TRANSMIT PCM 37 D15 20BR WT SCI TRANSMIT TCM 38 D25 20WT VT PCI BUS C O N...

Page 1732: ...2 16BR DB INJECTOR CONTROL NO 2 14 K11 16BR YL INJECTOR CONTROL NO 1 15 16 K36 20DB YL MTV CONTROL 17 18 K99 18BR TN O2 1 1 HEATER CONTROL 19 K20 18BR GY GEN FIELD CONTROL 20 K2 18VT OR ECT SIGNAL 21 K22 18BR OR TP SIGNAL 22 K34 20DB LG EGR SIGNAL 23 K1 20VT BR MAP SIGNAL 24 K942 20BR LG KS RETURN 25 K42 20DB OR KS SIGNAL 26 27 K900 20DB DG SENSOR GROUND 28 K961 20BR VT IAC RETURN 29 F855 20PK YL ...

Page 1733: ...342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20DB WT EVAP PURGE CONTROL 21 22 23 B29 20DG WT BRAKE SWITCH SIGNAL 24 25 26 T44 20YL DG AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20DG YL AUTOSTICK UPSHIFT SWITCH SIGNAL 28 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K70 20DB BR EVAP PURGE RETURN 30 31 C18 20LB BR A C PRESSURE TRANSDUCER SIGNAL 32 K91 20DB YL BATTERY TEMP SIGNAL 33 34 V37 20V...

Page 1734: ...PRESSURE SWITCH SENSE 23 24 25 26 27 T41 18YL DB TRS T41 SENSE 28 T16 16YL OR TRANSMISSION CONTROL RELAY OUTPUT 29 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 30 T47 18YL DG 2 4 PRESSURE SWITCH SENSE 31 32 T14 18DG BR OUTPUT SPEED SENSOR SIGNAL 33 T52 18DG WT INPUT SPEED SENSOR SIGNAL 34 T13 18DG VT SPEED SENSOR GROUND 35 T54 18DG OR TRANSMISSION TEMPERATURE SENSOR SIGNAL 36 37 T42 18DG YL TRS T...

Page 1735: ...DB TRS T3 SENSE 9 T42 18DG YL TRS T42 SENSE 10 T41 18YL DB TRS T41 SENSE TRANSMISSION SOLENOID PRESSURE SWITCH ASSEMBLY BLACK 8 WAY CAV CIRCUIT FUNCTION 1 T47 18YL DG 2 4 PRESSURE SWITCH SENSE 2 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 3 T9 18DG TN OVERDRIVE PRESSURE SWITCH SENSE 4 T16 16YL OR TRANSMISSION CONTROL RELAY OUTPUT 5 T59 18YL LB UNDERDRIVE SOLENOID CONTROL 6 T60 18YL GY OVERDRIVE ...

Page 1736: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 173 SCHEMATIC DIAGRAMS ...

Page 1737: ...NOTES 174 ...

Page 1738: ...11 0 CHARTS AND GRAPHS TRANSMISSION RANGE SENSOR STATES PRESSURE SWITCH STATES C H A R T S A N D G R A P H S 175 CHARTS AND GRAPHS ...

Page 1739: ...SOLENOID APPLICATION CHART SHIFT LEVER ERROR CODES TRANSMISSION TEMPERATURE SENSOR C H A R T S A N D G R A P H S 176 CHARTS AND GRAPHS ...

Page 1740: ... Lamps 8M Message Systems 8N Power Systems 8Ns Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8T Navigation Telecommunication 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 14 Fuel System 14s Fuel System 19 Steering 19s Steering 21 Transmission Transaxle 21s Transmission Transaxle 22 Tires Wheels 23 Body 24 Heating Air Conditioning 25 Emissions Cont...

Page 1741: ......

Page 1742: ...formation on the body code plate Lines 4 5 6 and 7 are not used to define service information Information reads from left to right starting with line 3 in the center of the plate to line 1 at the bottom of the plate BODY CODE PLATE LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 THROUGH 17 Open Space DIGITS 18 AND 19 Vehicle Shell Line CS DIGIT 20 Carline Chrysler FWD M Pacifica AWD F Pa...

Page 1743: ...ate will be fol lowed by END When two plates are required the last code space on the first plate will indicate CTD When a second plate is required the first four spaces of each line will not be used due to overlap of the plates FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Identification is d...

Page 1744: ...Fig 2 FASTENER IDENTIFICATION CS INTRODUCTION 3 FASTENER IDENTIFICATION Continued ...

Page 1745: ...Fig 3 FASTENER STRENGTH 4 INTRODUCTION CS FASTENER IDENTIFICATION Continued ...

Page 1746: ... procedures INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart Fig 4 are used to identify various instrument con trols The symbols correspond to the controls and dis plays that are located on the instrument panel Fig 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Hea...

Page 1747: ...s x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M x 1 0936 Yards mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600 Kilometers Hr Km h COMMON METRIC EQUIVALENTS 1 inch 25 Millimeters 1 Cubic ...

Page 1748: ...Fig 5 METRIC CONVERSION CHART CS INTRODUCTION 7 METRIC SYSTEM Continued ...

Page 1749: ...ON Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 6 Fig 6 TORQUE SPECIFICATIONS 8 INTRODUCTION CS ...

Page 1750: ...rmula to use the check digit is not released to the general public VIN CODE BREAKDOWN CHART POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Manufactured by DaimlerChrysler Corporation 2 Manufactured by DaimlerChrysler Canada Inc 2 Make C Chrysler 3 Vehicle Type 4 Multipurpose Passenger Vehicle Less Side Airbags 8 Multipurpose Passenger Vehicle With Side Airbags 4 Gross Vehicle Weigh...

Page 1751: ...so included All communications or inquiries regarding the vehicle should include the Month Day Hour and Vehicle Identification Number VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor mation VECI Label DaimlerChrysler permanently attaches the label in the engine compartment It can not be removed without defacing information and destroying the label The label contains the vehi...

Page 1752: ...lerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations Fig 1 FLUID TYPES DESCRIPTION DESCRIPTION ENGINE OIL AND LUBRICANTS 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 ...

Page 1753: ...oleum Institute API and SAE viscos ity standard Follow the service schedule that describes your driving type ENGINE OIL ADDITIVES SUPPLEMENTS The manufacturer does not recommend the addi tion of any engine oil additives supplements to the specified engine oil Engine oil additives supplements should not be used to enhance engine oil perfor mance Engine oil additives supplements should not be used t...

Page 1754: ...blocks cylinder heads and water pumps requires special corrosion protection Mopart Antifreeze Coolant 5 Year 100 000 Mile Formula MS 9769 or the equiva lent ethylene glycol base coolant with hybrid organic corrosion inhibitors called HOAT for Hybrid Organic Additive Technology is recommended This coolant offers the best engine cooling without corrosion when mixed with 50 Ethylene Glycol and 50 dis...

Page 1755: ...opart ATF 4 Automatic Transmission Fluid is required in the 41TE automatic transaxles Substi tute fluids can induce transmission problems and or failure Mopart ATF 4 Automatic Transmission Fluid when new is red in color The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid c...

Page 1756: ...on standards with Cleaner Burning Cali fornia reformulated gasoline with low sulfur If such fuels are not available in states adopting California emission standards your vehicles will operate satis factorily on fuels meeting federal specifications but emission control system performance may be adversely affected Gasoline sold outside of California is permitted to have higher sulfur levels which ma...

Page 1757: ...VISCOSITY GRADE CAUTION Low viscosity oils must have the proper API quality or the CCMC G5 designation To assure of properly formulated engine oils it is recommended that SAE Grade 10W 40 engine oils that meet Chrysler material standard MS 6395 be used in accordance to ACEA B3 B4 specification European Grade 10W 40 oils are also acceptable Oils of the SAE 5W 40 grade number are preferred when mini...

Page 1758: ...ow the interval that occurs first NOTE Under no circumstances should oil change intervals exceed 6000 miles 10 000 km or 6 months whichever comes first CAUTION Failure to perform the required mainte nance items may result in damage to the vehicle At Each Stop for Fuel Check the engine oil level about 5 minutes after a fully warmed engine is shut off Checking the oil level while the vehicle is on l...

Page 1759: ...ules9 section of this manual Miles 3 000 6 000 9 000 12 000 15 000 18 000 Kilometers 5 000 10 000 14 000 19 000 24 000 29 000 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the engine air cleaner filter X Change the All Wheel Drive AWD power transfer unit fluid See note at the end of thi...

Page 1760: ... 72 000 Kilometers 91 000 96 000 101 000 106 000 110 000 115 000 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the engine air cleaner filter X Inspect the tie rod ends and boot seals Front Rear X Inspect the PCV valve and replace if necessary X Inspect the serpentine drive belt replace ...

Page 1761: ...l Drive AWD overrunning clutch and rear carrier fluid See note at the end of this chart X Replace the air conditioning filter X Miles 93 000 96 000 99 000 100 000 102 000 105 000 Kilometers 149 000 154 000 158 000 160 000 163 000 168 000 Change engine oil and engine oil filter X X X X X Inspect the brake linings X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the eng...

Page 1762: ...e AWD power transfer unit fluid See note at the end of this chart X Replace the air conditioning filter X X This maintenance is recommended by the manu facture to the owner but is not required to maintain the emissions warranty This maintenance is not required if previously replaced Inspection and service should also be performed anytime a malfunction is observed or suspected Retain all receipts T...

Page 1763: ...00 54 000 60 000 66 000 72 000 Kilometers 67 000 77 000 86 000 96 000 106 000 115 000 Months 42 48 54 60 66 72 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the engine air cleaner filter X Inspect the tie rod ends and boot seals Front Rear X Check the PCV valve and replace if necessary ...

Page 1764: ... the engine air cleaner filter replace if necessary X X X Replace the engine air cleaner filter X Inspect the tie rod ends and boot seals Front Rear X Check the PCV valve and replace if necessary X Inspect the serpentine drive belt replace if necessary X X Flush and replace the engine coolant at 120 months if not done at 100 000 miles 160 000 km X Replace the air conditioning filter X X This maint...

Page 1765: ...me and mileage are listed follow the interval that occurs first CAUTION Failure to perform the required mainte nance items may result in damage to the vehicle At Each Stop for Fuel Check the engine oil level about 5 minutes after a fully warmed engine is shut off Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading Add oil only when the lev...

Page 1766: ...00 96 000 108 000 120 000 132 000 144 000 Miles 52 500 60 000 67 500 75 000 82 500 90 000 Months 42 48 54 60 66 72 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X Replace the engine air cleaner filter X X Inspect the tie rod ends and boot seals Front Rear X X Check the PCV valve and replace if nece...

Page 1767: ...necessary X Inspect the serpentine drive belt replace if necessary X X Replace the spark plugs 3 5 liter engines X Flush and replace the engine coolant at 100 000 miles if not done at 60 months X Replace the air conditioning filter X This maintenance is recommended by the manu facture to the owner but is not required to maintain the emissions warranty This maintenance is not required if previously...

Page 1768: ...ce Schedules9 section of this manual Kilometers 5 000 10 000 14 000 19 000 24 000 29 000 Miles 3 000 6 000 9 000 12 000 15 000 18 000 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the engine air cleaner filter X Change the All Wheel Drive AWD power transfer unit fluid See note at the en...

Page 1769: ... 110 000 115 000 Miles 57 000 60 000 63 000 66 000 69 000 72 000 Change engine oil and engine oil filter X X X X X X Inspect the brake linings X X Inspect the engine air cleaner filter replace if necessary X X X X X Replace the engine air cleaner filter X Inspect the tie rod ends and boot seals Front Rear X Inspect the PCV valve and replace if necessary X Change the automatic transmission fluid an...

Page 1770: ... of this chart X X Change the All Wheel Drive AWD overrunning clutch and rear carrier fluid See note at the end of this chart X Replace the air conditioning filter X X Kilometers 149 000 154 000 158 000 160 000 163 000 168 000 Miles 93 000 96 000 99 000 100 000 102 000 105 000 Change engine oil and engine oil filter X X X X X Inspect the brake linings X Inspect the engine air cleaner filter replac...

Page 1771: ...nded by the manu facture to the owner but is not required to maintain the emissions warranty This maintenance is not required if previously replaced Inspection and service should also be performed anytime a malfunction is observed or suspected Retain all receipts NOTE The AWD power transfer unit fluid and the AWD overrunning clutch rear carrier fluid must be changed at the more frequent intervals ...

Page 1772: ...ETALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCI DENTAL ARCING OF BATTERY CURRENT WHEN USING A HIGH OUTPUT BOOSTING DEVICE DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED CAUTION DO NOT ATTEMPT TO PUSH OR TOW THE VEHICLE TO START IT THE VEHICLE CANNOT BE STARTED THIS WAY PUSHING WITH ANOTHER VEHICLE MAY DAMAGE THE TRANSAXLE OR TH...

Page 1773: ...RONT OR REAR BUMPER DO NOT GO UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE USE A SAFETY CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE CAUTION Do not damage brake lines exhaust sys tem shock absorbers sway bars or any other under vehicle components when attaching towing device to vehicle Do not secure vehicle to t...

Page 1774: ...and in the bracket extending inboard of the right bumper extension TOWING FRONT WHEEL DRIVE Your vehicle may be towed under the following con ditions The gear selector must be in NEUTRAL the distance to be traveled must not exceed 100 miles 160 km and the towing speed must not exceed 44 mph 72 km h Exceeding these towing limits may cause a transmission gear train failure If the trans mission is no...

Page 1775: ...r addi tional information refer to RECOMMENDED TOW ING EQUIPMENT in this section TOWING THIS VEHICLE BEHIND ANOTHER VEHICLE WITH A TOW DOLLEY The manufacture does not recommend that you tow an All Wheel Drive AWD or front wheel drive vehicle on a tow dolley Vehicle damage may occur VEHICLE STORAGE STANDARD PROCEDURE If you are leaving your vehicle dormant for more than 21 days you may want to take...

Page 1776: ...ND BEARING 2 REMOVAL 3 INSTALLATION 4 KNUCKLE DESCRIPTION 5 REMOVAL 5 INSPECTION 7 INSTALLATION 7 LOWER BALL JOINT DIAGNOSIS AND TESTING LOWER BALL JOINT 8 LOWER BALL JOINT SEAL BOOT REMOVAL 8 INSTALLATION 9 LOWER CONTROL ARM REMOVAL 9 INSPECTION 9 INSTALLATION 10 STABILIZER BAR REMOVAL 10 INSPECTION 11 INSTALLATION 11 STRUT ASSEMBLY DESCRIPTION 12 DIAGNOSIS AND TESTING STRUT ASSEMBLY 12 REMOVAL 1...

Page 1777: ...NG The condition of the front hub and bearing assem bly is diagnosed using the inspection and testing pro cedure detailed below The bearing contained in the Unit III front hub bearing assembly will produce noise and vibration when worn or damaged The noise will generally change when the bearings are loaded A road test of the vehicle is normally required to determine the location of a worn or damag...

Page 1778: ...rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTOR REMOVAL 6 Disconnect vehicle wiring harness from wheel speed sensor connector Fig 2 7 Unclip wheel speed sensor connector and rout ing clip from frame rail outer reinforcement Fig 2 8 Remove screw fastening wheel speed sensor routing bracket to strut assembly Fig 3 9 Open routing clip at knuckle and remove wheel speed sensor cable Fig 4 10 Push in...

Page 1779: ...reinforcement Fig 2 6 Connect vehicle wiring harness to wheel speed sensor connector Fig 2 7 Install brake rotor then install disc brake cal iper and adapter assembly Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTOR INSTALLATION 8 Verify that wheel speed sensor is not routed improperly allowing cable to come in contact with brake rotor or other moving parts 9 Install washer and hub nut on end of halfs...

Page 1780: ...d of halfshaft stub shaft and hub nut Fig 1 4 With aid of a helper applying brakes to keep front hub from turning remove hub nut Fig 1 5 Access and remove front brake rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTOR REMOVAL 6 Disconnect vehicle wiring harness from wheel speed sensor connector Fig 2 7 Unclip wheel speed sensor connector and rout ing clip from frame rail outer reinforcement Fig 2 ...

Page 1781: ...nd promote tool longevity 17 Place Remover Special Tool C 4150A over ball joint stud and nut as shown Fig 11 Release ball joint stud from steering knuckle by tightening tool screw drive To ease Remover installation and use it may help to rotate knuckle around so inside of knuckle faces outward 18 Remove tool and nut from top of ball joint stud 19 Remove steering knuckle from vehicle 20 If hub and ...

Page 1782: ...hten nut by holding ball joint stud with hex wrench while turning nut with a wrench Fig 12 Using a crowfoot wrench on a torque wrench tighten nut to 81 N m 60 ft lbs torque Then tighten nut an additional 1 4 90 turn after that torque is met 4 Slide halfshaft stub shaft into hub and bearing assembly CAUTION The steering knuckle to strut assembly attaching bolts are serrated and must not be turned d...

Page 1783: ...b nut to 244 N m 180 ft lbs torque 14 Install spring washer and hub nut lock over hub nut and stub shaft Install a NEW cotter pin securing nut lock in place and tightly wrap cotter pin prongs around nut lock 15 Install tire and wheel assembly Refer to 22 TIRES WHEELS INSTALLATION Tighten wheel mounting nuts to a torque of 135 N m 100 ft lbs 16 Lower vehicle 17 Pump brake pedal several times to ens...

Page 1784: ...TION LOWER CONTROL ARM REMOVAL 1 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove wheel and tire assembly 3 Remove steering knuckle Refer to 2 SUS PENSION FRONT KNUCKLE REMOVAL 4 Remove bolts attaching lower control arm to engine cradle Fig 17 5 Remove lower control arm INSPECTION Inspect lower control arm for signs of damage from contact with the gr...

Page 1785: ...gnment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE STABILIZER BAR REMOVAL 1 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove both front wheel and tire assemblies 3 Remove nut attaching outer tie rod to steering knuckle by holding rod end stud stationary while loosening and removing nut with a wrench 4 Remove tie rod end from steering kn...

Page 1786: ... it was removed in Ensure bar gets routed in front of brake tubes on cradle NOTE When installing cushion retainers make sure shielded retainer is installed on right side with shield pointing forward 2 Install cushions on stabilizer bar utilizing slits in cushions Install each cushion so its slit faces for ward and flat side is positioned toward cradle once installed Fig 21 3 Install retainers on c...

Page 1787: ...ach component is serviced by removing the strut assembly from the vehicle and disassembling it Left and right springs must not be interchanged Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service If the coil springs require replacement be sure that the springs are replaced with springs meeting the correct load rating a...

Page 1788: ...OWER SPRING ISOLATOR 10 STRUT DAMPER Fig 23 Strut Assembly Leakage Inspection Typical 1 DUST BOOT 2 STRUT SHAFT 3 STRUT FLUID RESERVOIR 4 INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID LEAKAGE Fig 24 Wheel Speed Sensor Mounting To Strut 1 STRUT ASSEMBLY 2 SCREW 3 WHEEL SPEED SENSOR ROUTING BRACKET CS FRONT SUSPENSION 2 13 STRUT ASSEMBLY Continued ...

Page 1789: ... way Refer to 7 COOLING ENGINE COOLANT RECOVERY PRESS CONTAINER REMOVAL 8 Remove three nuts attaching strut assembly upper mount to strut tower Fig 28 then remove strut assembly from vehicle 9 To disassemble strut assembly Refer to 2 SUSPENSION FRONT STRUT DISASSEMBLY Fig 25 Stabilizer Bar Link To Strut 1 NUT 2 STRUT 3 STABILIZER BAR LINK Fig 26 Left Side Correctly Oriented Mounting Bolts 1 STRUT ...

Page 1790: ... removed from upper mount 3 Install Strut Nut Wrench Special Tool 6864 on strut shaft retaining nut Fig 30 Next install a 10 mm socket onto hex located on end of strut shaft While holding strut shaft from turning remove nut from strut shaft 4 Remove upper mount from strut shaft Fig 22 5 If pivot bearing needs to be serviced remove it from top of upper seat by pulling it up off seat Fig 31 6 If upp...

Page 1791: ...ompressor upper hooks over coil spring following manufacturers instructions 3 Compress coil spring far enough to allow strut installation 4 If separated install isolator onto upper seat Fig 22 Be sure to match master notches built into each up to one another Fig 32 5 Install upper isolator and upper seat on top of coil spring if previously removed Fig 22 6 If pivot bearing has been removed from up...

Page 1792: ...erently on each side Left hand side bolts are to be installed from vehicle rear to front Fig 26 Right side bolts are to be installed from vehicle front to rear Fig 27 3 Align steering knuckle in clevis bracket of strut Install strut clevis to steering knuckle attach ing bolts Fig 26 Fig 27 Install nuts on ends of bolts and tighten to 81 N m 60 ft lbs torque Then tighten nuts an additional 1 4 90 t...

Page 1793: ...IRES WHEELS INSTALLATION Tighten wheel mounting nuts to a torque of 135 N m 100 ft lbs 8 Lower vehicle 9 Perform wheel alignment as necessary Refer to 2 SUSPENSION WHEEL ALIGNMENT STAN DARD PROCEDURE 2 18 FRONT SUSPENSION CS STRUT ASSEMBLY Continued ...

Page 1794: ...R SUSPENSION DESCRIPTION This vehicle utilizes a five link rear suspension including the following major components Fig 1 Camber Link Compression Link Spring Link Tension Link Toe Link Coil Spring Crossmember Hub And Bearing Knuckle Shock Absorber Load Leveling Stabilizer Bar The knuckle camber link compression link and tension link are aluminum castings Extra care needs to be taken when servicing...

Page 1795: ...AL TOOLS REAR SUSPENSION HUB BEARING REMOVAL NOTE Before proceeding Refer to 2 SUSPEN SION REAR WARNING 1 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove tire and wheel assembly 3 If equipped with AWD a Remove cotter pin nut lock and spring washer from half shaft Fig 2 b While a helper applies brakes to keep hub from turning remove hub nut Fig 2 4 R...

Page 1796: ...ugh to hold support in place as hub and bearing is installed 2 Install hub and bearing by first feeding end of wheel speed sensor cable through hole in bottom of parking brake support Fig 5 As this is being done if equipped with AWD slide hub and bearing onto Fig 2 Hub Nut And Lock 1 HUB NUT 2 NUT LOCK 3 COTTER PIN 4 SPRING WASHER Fig 3 Rear Wheel Speed Sensor Cable Routing 1 WIRING HARNESS CONNEC...

Page 1797: ...ecessary Refer to 5 BRAKES PARKING BRAKE SHOES ADJUSTMENT 12 Lower vehicle 13 Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle 14 Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake shoes KNUCKLE REMOVAL 1 Lock out automatic adjuster in parking brake lever Refer to 5 BRAKES PARKING BRAKE STANDARD PROCEDU...

Page 1798: ...ith new upon installation 12 Remove bolt and nut fastening compression link to knuckle Fig 17 13 Remove bolt fastening toe link to knuckle Fig 28 14 Remove nut and bolt fastening stabilizer link to knuckle 15 Remove nut and bolt fastening tension link to knuckle Fig 15 16 Remove nut and bolt fastening camber link to knuckle Fig 15 17 Remove knuckle 18 Remove hub mounting bolts from knuckle INSTALL...

Page 1799: ... s head Fig 11 b Slide Bolt with sleeve through knuckle and spring link ball joint starting from knuckle forward end Fig 13 c Install thrust bearing and nut on end of Bolt Fig 13 d While holding Bolt head stationary rotate Nut using hand tools installing sleeve in knuckle Install sleeve until Nut stops turning Do not overtighten Nut e Remove tool f Install spring link to knuckle bolt and nut as sh...

Page 1800: ...t rack drive on hoist Raise vehicle as necessary to access mounting bolts 20 Tighten fasteners at knuckle vehicle at curb height as follows Camber Link 95 N m 70 ft lbs torque Compression Link 81 N m 60 ft lbs torque Stabilizer Link 61 N m 45 ft lbs torque Tension Link 119 N m 88 ft lbs torque Toe Link 108 N m 80 ft lbs torque 21 Perform wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STAND...

Page 1801: ... tightening it tools in place Fig 16 d Move spring link up or down as necessary aligning shock mounting bolt hole with Curb Height Gage hole then insert pin through both Fig 16 4 Tighten camber link mounting bolts to Bolt at crossmember 68 N m 50 ft lbs torque Bolt at knuckle 95 N m 70 ft lbs torque 5 Remove special tools 6 Install rear shock absorber and components removed to access it Refer to 2...

Page 1802: ...k to knuckle nut and bolt Fig 18 NOTE Prior to using Special Tool 9050 lubricate bolt threads to provide ease of tool and promote tool longevity 4 Remove sleeve retaining spring link ball joint in knuckle using Remover Installer Special Tool 9050 as follows a Using Tap Special Tool 9050 3 on an appro priate handle cut threads approximately halfway through bushing or about six complete threads Fig ...

Page 1803: ...tools installing sleeve in knuckle Install sleeve until Nut stops turning Do not overtighten Nut e Remove tool f Install spring link to knuckle bolt and nut as shown Fig 18 While holding bolt head station ary tighten nut to 129 N m 95 ft lbs torque 3 Install rear spring as well as all components necessary to access it Refer to 2 SUSPENSION REAR HUB BEARING INSTALLATION 4 Lower vehicle 5 Position v...

Page 1804: ... height using following tools a Place Receiver Special Tool 9031 3 cup side down over top of crossmember rear mount bushing Fig 25 b Place Curb Height Gage Special Tool 9094 into shock absorber pocket in spring link and oppo site end of tool over Receiver Special Tool 9031 3 Fig 25 c Install bolt through crossmember rear mount bushing Receiver Special Tool 9031 3 and Curb Height Gage Special Tool ...

Page 1805: ... holding toe adjustment cam bolt from rotating cam facing upward Fig 27 Install nut securing toe link at crossmember Fig 28 Do not tighten nut at this time 4 Clip wheel speed sensor cable along top of toe link at flats machined into link Fig 26 5 Right side link only Install rear exhaust as necessary 6 Install tire and wheel assembly Refer to 22 TIRES WHEELS INSTALLATION Tighten wheel mounting nut...

Page 1806: ...ut AWD or rear driveline module with AWD Fig 31 Raise jack head to contact driveline module suspension crossmember and secure in place 5 Remove two shock absorber upper mounting bolts Fig 29 6 Remove shock absorber lower mounting bolt and nut Fig 30 CAUTION When removing crossmember mounting bolts it is important NOT to loosen or remove crossmember mounting bolts on opposite side of vehicle Doing ...

Page 1807: ...00 ft lbs torque 9 Lower vehicle 10 Position vehicle on alignment rack drive on hoist Raise vehicle as necessary to access mounting bolt 11 Tighten shock absorber lower mounting bolt to 102 N m 75 ft lbs torque SPRING REMOVAL 1 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Position an extr...

Page 1808: ...Do not tighten at this time 7 Continue to raise crossmember with jack until two crossmember mounting bolts can be installed and tightened Fig 32 Tighten bolts to 163 N m 120 ft lbs torque 8 Tighten shock absorber upper mounting bolts to 61 N m 45 ft lbs torque 9 Lower and remove jack 10 Install wheel and tire assembly Refer to 22 TIRES WHEELS INSTALLATION Tighten the wheel nuts in the proper seque...

Page 1809: ...ween shoes and rotor to easily remove caliper from knuckle This can usually be accomplished before guide pin bolts are removed by grasping rear of caliper and pulling outward working with guide pins thus retracting piston Never push on piston directly as it may get damaged 12 Remove each rear caliper from its mount and support as follows a Remove two caliper guide pin bolts Fig 36 b Remove caliper...

Page 1810: ...dy at all four mount bushing locations using a marker or crayon Fig 40 Do not use a scratch awl to mark location 17 Position under hoist utility jack or transmis sion jack under center of rear suspension crossmem Fig 36 Rear Brake Caliper Mounting 1 BRAKE HOSE BANJO FITTING 2 CALIPER GUIDE PIN BOLT 3 CALIPER ADAPTER 4 DISC BRAKE CALIPER 5 COPPER SEAL WASHERS 6 BANJO BOLT Fig 37 Rear Caliper Remova...

Page 1811: ...y 25 Remove coil spring and isolator Fig 33 lower end first 26 Raise right side of crossmember back into mounted position It is not necessary to install mounting bolts 27 Remove both front and rear crossmember mounting bolts previously removed on left side of crossmember Fig 32 28 Slowly lower jack Do not lower jack at a fast rate As jack is lowered remove propeller shaft from alignment pin on end...

Page 1812: ...tallation Do not lower jack any further than necessary 16 Install coil spring and isolator Fig 33 top end first NOTE Verify spring lower end coil is correctly placed against abutment built into spring link 17 Carefully raise jack guiding coil spring and lower end of shock absorber into mounted positions Once shock absorber lower mounting hole lines up with hole in spring link stop jacking 18 Insta...

Page 1813: ... SYSTEM INSTALLATION 32 Install tire and wheel assemblies Refer to 22 TIRES WHEELS INSTALLATION Tighten wheel mounting nuts to 135 N m 100 ft lbs torque 33 Lower vehicle 34 Unlock automatic adjuster in parking brake lever Refer to 5 BRAKES PARKING BRAKE STANDARD PROCEDURE 35 Connect battery negative cable to battery post 36 If vehicle is not equipped with All Wheel Drive AWD Install spare tire und...

Page 1814: ...ner tripod joint of both half shafts is splined into the transaxle side gears The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint 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 HALF SHAFT VEHICLE INSPECTION 1 Check for grease in the vicin...

Page 1815: ... 22 TIRES WHEELS STANDARD PROCEDURE Improper tire and or wheel runout Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING REMOVAL 1 Raise vehicle 2 Remove the cotter pin and nut lock Fig 2 from the end of the half shaft 3 Remove the wheel and tire assembly from the vehicle Refer to 22 TIRES WHEELS REMOVAL Fig 1 Unequal Length Half Shaft System 1 STUB AXLE 8 OUTER C V JOINT 2 OUTER C V JOINT 9 RIGHT HAL...

Page 1816: ...rut assembly Fig 5 Do not allow the brake caliper assembly to hang by the brake flex hose 9 Remove the brake rotor from the hub and bear ing assembly 10 Remove the steering knuckle to strut attach ment bolts Fig 6 from the steering knuckle 11 Pull the steering knuckle from the strut clevis bracket Fig 3 Wave Washer 1 HUB BEARING ASSEMBLY 2 WAVE WASHER 3 STUB AXLE Fig 4 Front Brake Mounting 1 BRAKE...

Page 1817: ...h the tripod joint into side gear of transaxle until snap ring is engaged with trans axle side gear Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand If snap ring is fully engaged with side gear tripod joint will not be removable by hand 4 Clean all debris and moisture out of steering knuckle in the area were outer CV joint will be inst...

Page 1818: ...ing sequence to the full specified torque of 135 N m 100 ft lbs 13 Lower vehicle 14 With the vehicle s brakes applied to keep hub from turning tighten the hub nut to a torque of 244 N m 180 ft lbs Fig 11 15 Install the spring wave washer on the end of the half shaft 16 Install the hub nut lock and a new cotter pin Fig 2 Wrap cotter pin prongs tightly around the hub nut lock as shown in Fig 2 17 Ch...

Page 1819: ... 12 6 Remove snap ring which retains spider assem bly to interconnecting shaft Fig 13 Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft 7 Remove the spider assembly from interconnect ing shaft If spider assembly will not come off inter connecting shaft by hand it can be removed by tapping spider assembly with a brass drift Fig 14 8 Slide sealin...

Page 1820: ...bearings in an attempt to install spider assem bly on interconnecting shaft 3 Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of inter connecting shaft Fig 18 Be sure the snap ring is fully seated into groove on interconnecting shaft Fig 14 Spider Assembly Removal from Interconnecting Shaft 1 SPIDER ASSEMBLY 2 DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN REM...

Page 1821: ...ched or out of shape in any way If seal boot is NOT shaped correctly equalize pressure in seal and shape it by hand 9 Position sealing boot into the tripod housing retaining groove Install seal boot retaining clamp evenly on sealing boot Fig 18 Spider Assembly Retaining Snap Ring Installed 1 INTERCONNECTING SHAFT 2 SPIDER ASSEMBLY 3 RETAINING SNAP RING Fig 19 Installing Tripod Housing on Spider As...

Page 1822: ...k inserted between sealing boot insert and the CV joint housing position the inter connecting shaft so it is at the center of its travel in the tripod joint housing Remove the trim stick from between the sealing boot insert and the CV joint housing This procedure will equalize the air pressure in the CV joint preventing premature sealing boot failure 13 Clamp CV joint sealing boot to CV joint usin...

Page 1823: ...nt and interconnecting shaft 4 Remove outer C V joint from interconnecting shaft using the following procedure Support inter connecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to intercon necting shaft Then using a soft faced hammer sharply hit the end of the C V joint housing to dis lodge housing from internal circlip on interconnecting shaft Fig 28 Then sl...

Page 1824: ...ng shaft by using a soft faced hammer and tapping end of stub axle with hub nut installed until outer C V joint is fully seated on interconnect ing shaft Fig 31 4 Outer C V joint assembly must be installed on interconnecting shaft until cross of outer C V joint assembly is seated against circlip on interconnecting shaft Fig 32 5 Distribute 1 2 the amount of grease provided in seal boot service pac...

Page 1825: ... seal and shape it by hand Fig 31 Outer C V Joint Installation on Interconnecting 1 SOFT FACED HAMMER 2 STUB AXLE 3 OUTER C V JOINT 4 HUB NUT Fig 32 Outer C V Joint Correctly Installed on Interconnecting Shaft 1 INTERCONNECTING SHAFT 2 CROSS 3 OUTER C V JOINT ASSEMBLY Fig 33 Crimping Tool Installed on Sealing Boot Clamp 1 SPECIAL TOOL C 4975A 2 INTERCONNECTING SHAFT 3 CLAMP 4 SEALING BOOT Fig 34 S...

Page 1826: ...ng tool C 4975 A until jaws on tool are closed completely together face to face Fig 36 10 Install the halfshaft requiring boot replace ment back on the vehicle Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLATION Fig 35 Crimping Tool Installed on Sealing Boot Clamp 1 CLAMP 2 TRIPOD JOINT HOUSING 3 SPECIAL TOOL C 4975A 4 SEALING BOOT Fig 36 Sealing Boot Retaining Clamp Installed 1 CLAMP 2 TRI...

Page 1827: ... 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 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 CLICKING POPPING NOISE DURING SHIFT R to D or D to R This noi...

Page 1828: ...being removed from differential Install Tool 9099 to protect seal upon disassembly Fig 3 13 Remove three 3 rear driveline module to crossmember bolts Fig 4 Fig 5 14 Lower driveline module assembly just enough to facilitate removal of shaft from differential Make sure Tool 9099 engages seal 15 Disconnect propeller shaft from driveline mod ule and secure to exhaust system Fig 6 Fig 1 Cotter Pin Nut ...

Page 1829: ...propeller shaft to driveline module flange Install but do not tighten three 3 propeller shaft to driveline module bolts 4 Raise driveline module into position Install and torque module to cradle bolts to 102 N m 75 ft lbs Fig 8 Fig 9 5 Torque propeller shaft to driveline module bolts to 54 N m 40 ft lbs Fig 5 Module Mounting Bolts 1 BOLT 2 2 DRIVELINE MODULE Fig 6 Secure Propeller Shaft to Exhaust...

Page 1830: ... 100 SPECIAL TOOLS CV BOOT INNER REMOVAL 1 Remove the half shaft requiring boot replace ment from the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 2 Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard 3 Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and dis card 4 Remove the sealing boo...

Page 1831: ...e not serviceable INSTALLATION 1 Slide inner CV joint seal boot retaining clamp onto the interconnecting shaft Then slide the replacement inner CV joint sealing boot onto the interconnecting shaft Inner CV joint seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft Fig 14 Fig 11...

Page 1832: ... USE ANY OTHER TYPE OF GREASE into tripod housing Put the remaining amount into the sealing boot 5 Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft Fig 18 6 Install inner CV joint seal boot to interconnect ing shaft clamp evenly on sealing boot 7 Place crimping tool C 4975 A over bridge of clamp Fig 19 Fig 15 Spider Assembly Ins...

Page 1833: ... in any way while being vented the sealing boot can not be used 11 Insert a trim stick between the CV joint hous ing and the sealing boot insert to vent inner CV joint assembly Fig 21 When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing If this is not done damage to the sealing boot can occur 12 With trim stick inser...

Page 1834: ...r until top band of clamp is latched behind the two tabs on lower band of clamp Fig 25 14 Install the half shaft back into the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION Fig 22 Crimping Tool Installed on Sealing Boot Clamp 1 CLAMP 2 TRIPOD JOINT HOUSING 3 SPECIAL TOOL C 4975 A 4 SEALING BOOT Fig 23 Sealing Boot Retaining Clamp Installed 1 CLAMP 2 TRIPOD HOUSING 3 SPECIAL TOO...

Page 1835: ...ft before attempting to remove outer C V joint sealing boot 6 Slide sealing boot off interconnecting shaft 7 Thoroughly clean and inspect outer C V joint assembly and interconnecting joint for any signs of excessive wear If any parts show signs of exces sive wear the halfshaft assembly will require replacement Component parts of these half shaft assemblies are not serviceable INSTALLATION 1 Slide ...

Page 1836: ...ly on sealing boot 7 Clamp sealing boot onto interconnecting shaft using crimper Special Tool C 4975 A and the follow ing procedure Place crimping tool C 4975 A over bridge of clamp Fig 32 Tighten nut on crimping tool C 4975 A until jaws on tool are closed completely together face to face Fig 33 Fig 29 Sealing Boot Installation on Interconnecting Shaft 1 SEALING BOOT 2 RAISED BEAD IN THIS AREA OF ...

Page 1837: ... C 4975 A until jaws on tool are closed completely together face to face Fig 35 10 Install the halfshaft requiring boot replace ment back on the vehicle Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLATION Fig 33 Sealing Boot Retaining Clamp Installed 1 CLAMP 2 JAWS OF SPECIAL TOOL C 4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 INTERCONNECTING SHAFT 4 SEALING BOOT Fig 34 Crimping Tool Ins...

Page 1838: ... CV joint Center support bearings 2 Rubber coupler at driveline module flange The front shaft segment utilizes a plunging CV joint at the power transfer unit connection The cen ter and rear shaft segments utilize a support bear ing bracket assembly The rear shaft segment uses a rubber coupler at the driveline module flange OPERATION The propeller shaft Fig 1 is used to transmit torque from the tra...

Page 1839: ...rt front segment by hand while removing center segment bearing support to body bolts Support front and center segments by hand Fig 3 8 While manually supporting front and center segments have helper support rear segment while removing rear segment bearing support Fig 3 9 Lower propeller shaft assembly to ground using care not to damage fore and aft flanges Fig 3 INSTALLATION CAUTION Propeller shaf...

Page 1840: ...nge to Driveline Module Flange 54 40 Bolt Support Bearing to Body 54 40 Fig 3 Propeller Shaft at Body and Driveline Module 1 FRONT SEGMENT 2 CENTER SUPPORT BEARING 3 CENTER SEGMENT 4 REAR SUPPORT BEARING 5 BOLT 2 6 RUBBER COUPLER 7 REAR DRIVELINE MODULE 8 BOLT 3 9 SUPPORT BRACKET 10 BOLT 4 11 EXHAUST HANGER 12 BOLT 2 CS PROPELLER SHAFT 3 27 PROPELLER SHAFT Continued ...

Page 1841: ...components Differential Assembly serviced only as assem bly Viscous Coupling Bi Directional Overrunning Clutch BOC Overrunning Clutch Housing Seals Input Shaft Output Shaft Overrunning Clutch Housing O rings Input Flange Shield Vents Fasteners OPERATION The primary benefits of All Wheel Drive are Superior straight line acceleration and corner ing on all surfaces Better traction and handling under ...

Page 1842: ...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 Tires Road surfaces Wheel bearings Engine...

Page 1843: ...re of the following drive conditions 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 objec tionable gear noise occurs note the driving condi tions and the speed range BEARING NOISE DRIVE PINION AND DIFFERENTIAL Defective bearings p...

Page 1844: ...clutch housing fluid as well Refer to 3 DIF FERENTIAL DRIVELINE REAR DRIVELINE MODULE FLUID STANDARD PROCEDURE 3 Place vehicle on drive on hoist in Park 4 Remove exhaust system center hanger at pro peller shaft bearing support 5 Disconnect exhaust system at rear most hanger and lower 6 Lower exhaust system at least 254 mm 10 in Support system with suitable wire or rope 7 Index propeller shaft and ...

Page 1845: ...HAFT 2 SEAL PROTECTOR Fig 4 Module Mounting Bolt 1 BOLT 2 DRIVELINE MODULE Fig 5 Module Mounting Bolts 1 BOLT 2 2 DRIVELINE MODULE Fig 6 Secure Propeller Shaft to Exhaust 1 PROPELLER SHAFT 2 EXHAUST SYSTEM 3 STRAP 3 32 REAR DRIVELINE MODULE CS REAR DRIVELINE MODULE Continued ...

Page 1846: ... and a breaker bar Fig 7 2 Remove input flange nut Fig 8 3 Remove input flange and washer Fig 9 Fig 10 Fig 7 Input Flange Nut 1 INPUT FLANGE 2 TOOL 6958 Fig 8 Input Flange Nut Removal Installation 1 NUT Fig 9 Input Flange Washer 1 WASHER Fig 10 Input Flange Removal Installation 1 INPUT FLANGE CS REAR DRIVELINE MODULE 3 33 REAR DRIVELINE MODULE Continued ...

Page 1847: ...ront bearing snap ring Fig 20 7 Remove front bearing Fig 20 8 Remove o ring and washer from overrunning clutch assembly Fig 14 Fig 15 Fig 11 Input Flange Seal Removal 1 SEAL 2 SCREWDRIVER Fig 12 Overrunning Clutch Housing Bolts 1 BOLT 4 2 HOUSING Fig 13 Overrunning Clutch Housing 1 HOUSING 2 O RING 3 RELIEF Fig 14 Input Flange O ring Seal 1 O RING 3 34 REAR DRIVELINE MODULE CS REAR DRIVELINE MODUL...

Page 1848: ... of same thickness 12 Remove overrunning clutch housing large o ring from differential assembly Fig 20 13 Remove output flange seals Fig 19 Fig 15 Input Flange Washer 1 WASHER Fig 16 Overrunning Clutch Assembly 1 VISCOUS COUPLER 2 OVERRUNNING CLUTCH ASSEMBLY Fig 17 Viscous Coupler Removal Installation 1 VISCOUS COUPLER 2 SHIM SELECT Fig 18 Shim Select 1 SHIM SELECT 2 DIFFERENTIAL PINION CS REAR DR...

Page 1849: ...COUS COUPLER 2 WASHER INPUT FLANGE NUT 7 SNAP RING BEARING RETAINER 12 O RING OVERRUNNING CLUTCH HOUSING 3 INPUT FLANGE SHIELD 8 O RING 13 SHIM SELECT 4 SEAL INPUT FLANGE 9 WASHER 14 DIFFERENTIAL ASSEMBLY 5 OVERRUNNING CLUTCH HOUSING 10 BI DIRECTIONAL OVERRUNNING CLUTCH Fig 19 Axle Seal Removal 1 SEAL 2 SCREWDRIVER Fig 21 Axle Seal Installation 1 TOOL C 4171 2 TOOL 8493 3 36 REAR DRIVELINE MODULE ...

Page 1850: ...unning clutch assembly to viscous coupler Fig 25 Fig 22 ORC Housing to Differential O Ring Seal 1 O RING Fig 23 Shim Select 1 SHIM SELECT 2 DIFFERENTIAL PINION Fig 24 Viscous Coupler Removal Installation 1 VISCOUS COUPLER 2 SHIM SELECT Fig 25 Overrunning Clutch Assembly 1 VISCOUS COUPLER 2 OVERRUNNING CLUTCH ASSEMBLY CS REAR DRIVELINE MODULE 3 37 REAR DRIVELINE MODULE Continued ...

Page 1851: ...ing clutch housing into posi tion making sure ground tab engages with notch in housing Fig 30 Fig 26 Flange Bottoming Washer 1 WASHER Fig 27 Input Flange O ring Seal 1 O RING Fig 28 Proper O ring and Washer Installation 1 O RING 2 WASHER Fig 29 Overrunning Clutch Orientation 1 OVERRUNNING CLUTCH ASSEMBLY 2 TAB AT 3 O CLOCK 3 38 REAR DRIVELINE MODULE CS REAR DRIVELINE MODULE Continued ...

Page 1852: ...ool 8802 Fig 32 12 Install flange shield assembly Fig 33 Fig 30 Overrunning Clutch Housing 1 HOUSING 2 O RING 3 RELIEF Fig 31 Overrunning Clutch Housing Bolts 1 BOLT 4 2 HOUSING Fig 32 Input Seal Installation 1 HAMMER 2 TOOL 8802 Fig 33 Input Flange Removal Installation 1 INPUT FLANGE CS REAR DRIVELINE MODULE 3 39 REAR DRIVELINE MODULE Continued ...

Page 1853: ... a time Fig 37 3 Index and install propeller shaft to driveline module flange Install but do not tighten three 3 propeller shaft to driveline module bolts 4 Raise driveline module into position Fig 38 Fig 34 Input Flange Washer 1 WASHER Fig 35 Input Flange Nut Removal Installation 1 NUT Fig 36 Input Flange Nut 1 INPUT FLANGE 2 TOOL 6958 Fig 37 Install Seal Protector 1 HALFSHAFT 2 SEAL PROTECTOR 3 ...

Page 1854: ...nt 75W 90 Refer to 3 DIF FERENTIAL DRIVELINE REAR DRIVELINE MODULE FLUID STANDARD PROCEDURE 9 Fill overrunning clutch housing with 0 58L 0 61 qts of Mopart ATF 4 Refer to 3 DIFFER ENTIAL DRIVELINE REAR DRIVELINE MOD ULE FLUID STANDARD PROCEDURE Fig 38 Support Module with Jack 1 DRIVELINE MODULE 2 TRANSMISSION JACK Fig 39 Module Mounting Bolt 1 BOLT 2 DRIVELINE MODULE Fig 40 Module Mounting Bolts 1...

Page 1855: ...benefits regard ing braking stability handling and driveline durabil ity Disconnecting the front and the rear driveline during braking helps to maintain the braking stabil ity of an AWD vehicle In an ABS braking event the locking of the rear wheels must be avoided for stabil ity reasons Therefore brake systems are designed to lock the front wheels first Any torque transfer from the rear axle to th...

Page 1856: ...to the overrunning mode most of the time This allows BOC to significantly reduce the rolling resistance of the vehicle which improves fuel consumption allows the downsizing of the driveline components and prevents the PTU and propshaft joints from overheating 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SH...

Page 1857: ...s running under these conditions at low vehicle speeds the drag shoes and the cage keep the rollers up on the left side forward side of the inner shaft flats This is what is known as overrunning mode Notice that when the clutch is in overrunning mode the rollers are spinning clockwise and with the outer race thus no torque is being transferred NOTE Low speed forward and reverse operation is identi...

Page 1858: ...ion ground due to centrifugal forces at higher rotational speeds To keep the rollers in the overrunning position and avoid undesired 9high speed lockup9 a high speed latch Fig 46 positions the cage before the ground shoes lift off A further explanation of the high speed effects follows as well Utilizing only the friction shoes approach means that at high speed the required ground shoe drag torque ...

Page 1859: ... device and does not prevent high speed lockup in the reverse direction At high speeds the BOC provides the same function as low speeds transferring torque to the viscous coupler only when front wheel slip overcomes the axle ratio offset At high speed the rollers are forced outward to the outer race because of centrifugal force At high speeds the friction shoes can no longer prevent lock up When t...

Page 1860: ...ows The pinion gear 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 pin ion gears do not rotate on the pinion mate shaft This occurs because input torque appli...

Page 1861: ... unit The fill plug Fig 54 for the differential assembly is located on the rear 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 cor rect fill level 1 Raise the vehicle on a hoist 2 Position a drain pan under the differential drain plug Fig 53 3 Remove the drain plug a...

Page 1862: ...ning clutch housing fill plug 6 Remove fill plug Fig 57 7 Using a suction gun Fig 58 add 0 58 L 1 22 pts of Mopart ATF 4 Automatic Transmission Flu id Type 9602 8 Install fill plug and torque to 30 N m 22 ft lbs Fig 55 Filling Differential 1 DIFFERENTIAL ASSEMBLY 2 SUCTION GUN Fig 56 Overrunning Clutch Case Drain Plug 1 OVERRUNNING CLUTCH HOUSING DRAIN PLUG Fig 57 Overrunning Clutch Housing Fill P...

Page 1863: ...nput flange nut Fig 59 4 Remove input flange nut and washer Fig 60 Fig 61 5 Remove input flange Fig 62 6 Using suitable screwdriver remove input flange seal from overrunning clutch housing Fig 63 Fig 59 Input Flange Nut 1 INPUT FLANGE 2 TOOL 6958 Fig 60 Input Flange Nut Removal Installation 1 NUT Fig 61 Input Flange Washer 1 WASHER 3 50 REAR DRIVELINE MODULE CS ...

Page 1864: ...all input flange Fig 65 Fig 62 Input Flange Removal Installation 1 INPUT FLANGE Fig 63 Input Flange Seal Removal 1 SEAL 2 SCREWDRIVER Fig 64 Input Seal Installation 1 HAMMER 2 TOOL 8802 Fig 65 Input Flange Removal Installation 1 INPUT FLANGE CS REAR DRIVELINE MODULE 3 51 INPUT FLANGE SEAL Continued ...

Page 1865: ...ig 68 5 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 6 Lower vehicle Fig 66 Input Flange Washer 1 WASHER Fig 67 Input Flange Nut Removal Installation 1 NUT Fig 68 Input Flange Nut 1 INPUT FLANGE 2 TOOL 6958 3 52 REAR DRIVELINE MODULE CS INPUT FLANGE SEAL Continued ...

Page 1866: ...ely splined to an inner and outer drum The viscous coupler provides torque in the following modes Shear mode normal operation Hump mode locked mode The inner plates are slotted around the radius and the outer plates have holes in them In the shear mode normal operation the plates are evenly spaced and the torque is created by the shearing of the plates through the fluid and 90 100 of the torque is...

Page 1867: ...scous Coupler Powerflow 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SHOES 9 INPUT FLANGE 5 BOC ROLLERS 3 54 REAR DRIVELINE MODULE CS VISCOUS COUPLER Continued ...

Page 1868: ...TION CALIPER 20 ASSEMBLY ASSEMBLY CALIPER GUIDE PIN BUSHINGS 20 ASSEMBLY CALIPER PISTON AND SEAL 21 INSTALLATION 22 DISC BRAKE CALIPER ADAPTER FRONT REMOVAL 23 INSTALLATION 24 DISC BRAKE CALIPER GUIDE PINS FRONT REMOVAL 24 INSTALLATION 25 FLUID DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION 26 STANDARD PROCEDURE BRAKE FLUID LEVEL CHECKING 26 SPECIFICATIONS BRAKE FLUID 26 MASTER CYLINDER STANDARD ...

Page 1869: ...INING UNLESS EQUIPMENT USED IS DESIGNED TO CON TAIN THE DUST RESIDUE DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN ING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL FOL LO...

Page 1870: ...CATION 1 Brake lamp switch 1 Replace switch 2 Brake Transmission Shift Interlock Linkage 2 Lubricate BTSI linkage 3 Pedal pivot bushings 3 Lubricate pivot bushings Replace if necessary DISC BRAKE CHIRP 1 Excessive brake rotor runout 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lack of lubricant on brake caliper slides 2 Lubricate brake caliper slides 3 Caliper shoes not fully ...

Page 1871: ...rake shoes BRAKES GRAB 1 Contaminated brake shoe linings 1 Inspect and clean or replace shoes Repair source of contamination 2 Improper power brake booster assist 2 Refer to power brake booster diagnosis and testing EXCESSIVE PEDAL EFFORT 1 Obstruction of brake pedal 1 Inspect remove or move obstruction 2 Low power brake booster assist vacuum leak 2 Refer to power brake booster diagnosis and testi...

Page 1872: ...liper piston 1 Replace frozen piston or caliper Bleed brakes 2 Contaminated brake shoe lining 2 Inspect and clean or replace shoes Repair source of contamination 3 Pinched brake lines 3 Replace pinched line 4 Leaking piston seal 4 Replace piston seal or brake caliper 5 Suspension problem 5 Refer to the Suspension group PARKING BRAKE EXCESSIVE LEVER TRAVEL 1 Rear disc brake parking brake shoes out ...

Page 1873: ...apped air from the brake system Be sure to monitor the fluid level in the master cylinder so it stays at a proper level so air will not enter the brake system through the master cylinder 5 Check pedal travel If pedal travel is excessive or has not been improved enough fluid has not passed through the system to expel all the trapped air Continue to bleed system as necessary 6 Perform a final adjust...

Page 1874: ...acket To Cradle Bolts 28 21 250 ABS ICU Mounting Bracket To Frame Bolts 14 18 216 ABS CAB To HCU Mounting Screws 2 17 ABS Wheel Speed Sensor Head Mounting Bolt 20 15 180 Adjustable Pedal Position Sensor Mounting Screws 7 5 66 Adjustable Pedal Mounting Nuts 28 21 250 Brake Tube Nuts 14 120 Brake Hose Bracket Bolt 18 160 Brake Hose Caliper Banjo Bolt 47 35 Disc Brake Caliper Adapter Mounting Bolts F...

Page 1875: ...tabs lock it to brake fluid reservoir 2 Connect vehicle wiring harness connector to brake fluid level switch Fig 3 PEDAL POSITION SENSOR BRAKE REMOVAL 1 Remove battery ground cable from battery negative post and isolate 2 Remove two mounting screws securing pedal position sensor in place Fig 4 3 Remove pedal position sensor from pedals bracket 4 Disconnect wiring connector and remove pedal positio...

Page 1876: ...ry 7 500 miles or 12 months which ever comes first every engine oil change Inspect hydraulic brake hoses for surface cracking scuffing or worn spots If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover the hose should be replaced imme diately Eventual deterioration of the hose can take place with possible burst failure Faulty installation can ...

Page 1877: ...cap INSTALLATION NOTE Perform Step 1 through Step 6 on each side of vehicle 1 Place brake shoes in anti rattle clips on adapter Fig 7 Make sure clips are properly installed Fig 8 2 If applied remove protective paper from noise suppression gasket on rear of both inner and outer brake shoes 3 Completely retract caliper piston back into bore of caliper CAUTION Use care when installing caliper onto di...

Page 1878: ...etween shoes and rotor to easily remove caliper from knuckle This can usually be accomplished before guide pin bolts are removed by grasping rear of caliper and pulling outward working with guide pins thus retracting piston Never push on piston directly as it may get damaged 3 Remove two caliper guide pin bolts Fig 9 4 Remove caliper assembly from brake adapter by first rotating bottom of caliper ...

Page 1879: ... hand until retainer clip seats itself in piston cav ity groove Be sure inboard brake shoe backing plate is flush against caliper piston CAUTION Outboard brake shoes are side oriented Make sure spring clip on each shoe is installed so it is positioned downward once caliper is installed Fig 10 Rear Caliper Removal Fig 11 Supporting Caliper 1 BRAKE HOSE 2 SUSPENSION 3 WIRE HANGER HANG TO VEHICLE SUS...

Page 1880: ...n wheel mounting nuts to a torque of 135 N m 100 ft lbs 9 Lower vehicle 10 Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle 11 Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake shoes DISC BRAKE CALIPER FRONT REMOVAL NOTE Before proceeding Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION 1 Disconnect...

Page 1881: ...G UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PIS TON FROM A CALIPER BORE PERSONAL INJURY COULD RESULT FROM SUCH PRACTICE 1 Drain brake fluid from caliper CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distortion 2 Mount caliper in vise equipped with protective jaws 3 C clamp a block of wood over one piston Fig 17 ...

Page 1882: ...TION Use an appropriate tool to remove piston seals to avoid scratching piston bore Do not use a screwdriver or other metal tool to remove seals 11 Remove piston seals from caliper Fig 20 12 Remove caliper bleeder screw 13 Clean piston bore and drilled passage ways with alcohol or a suitable solvent Wipe it dry using only a lint free cloth 14 Inspect both piston and bore for scoring or pit ting Bo...

Page 1883: ...the caliper These flu ids will damage rubber cups and seals INSPECTION DISC BRAKE CALIPER Inspect the disc brake caliper for the following Brake fluid leaks in and around piston boot area Ruptures brittleness or damage to the piston dust boot If caliper fails inspection disassemble and recondi tion caliper replacing the seals and dust boots ASSEMBLY CAUTION Dirt oil and solvents can damage cali pe...

Page 1884: ...move brake pedal holding tool 7 Connect battery negative cable to battery post 8 Bleed base brake hydraulic system as neces sary Refer to 5 BRAKES STANDARD PROCE DURE 9 Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes DISC BRAKE CALIPER REAR REMOVAL NOTE Before proceeding Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION 1 Disconnect and i...

Page 1885: ... out rear of caliper and bushing Fig 27 2 Using fingers collapse one side of rubber guide pin bushing Pull guide pin bushing out other side of brake caliper mounting boss Fig 28 Fig 24 Rear Brake Caliper Mounting 1 BRAKE HOSE BANJO FITTING 2 CALIPER GUIDE PIN BOLT 3 CALIPER ADAPTER 4 DISC BRAKE CALIPER 5 COPPER SEAL WASHERS 6 BANJO BOLT Fig 25 Rear Caliper Removal Fig 26 Outboard Shoe Removal 1 LO...

Page 1886: ...n to push out of bore far enough to be removed by hand after being loosened by air pressure yet large enough keep pis ton from coming completely out utilizing air pres sure WARNING DO NOT PLACE FACE OR HANDS NEAR CALIPER AND PISTON IF USING COMPRESSED AIR PRESSURE TO REMOVE PISTON DO NOT USE HIGH PRESSURE 3 Apply low pressure compressed air to caliper fluid inlet in short spurts to ease piston out...

Page 1887: ...CESSING AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS To clean or flush the internal passages of the brake caliper use fresh brake fluid or Mopart Non Chlori nated Brake Parts Cleaner Never use gasoline ker osene alcohol oil transmission fluid or any fluid containing mineral oil to clean the caliper These flu ids will damage rubber cups and seals INSPECTION CALIPER Inspect the d...

Page 1888: ...ve ASSEMBLY CALIPER PISTON AND SEAL CAUTION Dirt oil and solvents can damage cali per seals Ensure assembly area is clean and dry NOTE Always use new clean MoparT DOT 3 Motor Vehicle Brake Fluid when assembling brake caliper NOTE Never use old piston seals or boots 1 Lubricate caliper pistons piston seals and pis ton bores with clean fresh brake fluid Fig 33 Installing Caliper Guide Pin Bushing 1 ...

Page 1889: ... bot toms Do not over seat dust boot or damage will occur 6 Install bleeder screw 7 Install caliper on vehicle Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER INSTALLATION INSTALLATION 1 Completely retract caliper piston back into bore of caliper Use hand pressure or a C clamp may be used to retract piston first placing a wood block over piston before installing C clamp to avoid damaging...

Page 1890: ... installed 7 Carefully install caliper guide pin bolts Fig 24 Tighten bolts to 23 N m 200 in lbs torque 8 Install banjo bolt attaching brake hose to cali per Fig 24 Install NEW washers on each side of hose fitting as banjo bolt is placed through fitting Thread banjo bolt into caliper and tighten to 47 N m 35 ft lbs torque 9 Install tire and wheel assembly Tighten wheel mounting nuts to 135 N m 100...

Page 1891: ...NS FRONT REMOVAL NOTE Before proceeding Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION 1 Remove master cylinder fluid reservoir cap 2 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 3 Remove tire and wheel assembly 4 Place an appropriately sized C Clamp over brake caliper as shown Fig 44 placing screw drive head against outboard shoe and hook against re...

Page 1892: ... Fig 46 The boots have grooves built into their inner lips to fit onto pins and adapter CAUTION If adhesive is missing from noise sup pression gasket on rear of either inner and outer brake shoes or if gasket is damaged replace brake shoes Refer to 5 BRAKES HYDRAULIC MECHAN ICAL BRAKE PADS SHOES REMOVAL CAUTION Use care when installing caliper onto disc brake adapter to avoid damaging boots on cal...

Page 1893: ...eal damage will result Petroleum based fluids would be items such as engine oil transmission fluid power steering fluid etc SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications DOT 4 and DOT 4 are acceptable and SAE J1703 standards No other type of brake fluid is recommended or approved for usage in the vehicle brake system Use only Mopart Brake Flui...

Page 1894: ... tubes in reservoir while bleeding 5 Remove bleeder tubes from master cylinder outlet ports then plug outlet ports and install fill cap on reservoir 6 Remove master cylinder from vise 7 Install master cylinder on vehicle Refer to 5 BRAKES BASE HYDRAULIC MECHANICAL MAS TER CYLINDER INSTALLATION REMOVAL CAUTION Vacuum in power brake booster must be pumped down removed before removing master cylinder...

Page 1895: ...nly a solvent such as Mopar Brake Parts Cleaner or an equivalent 2 Remove brake fluid reservoir cap Using a syringe or equivalent type tool empty as much brake fluid as possible from the reservoir CAUTION When removing fluid reservoir from the master cylinder do not pry off using any type of tool This can damage the fluid reservoir or master cylinder housing 3 Remove the master cylinder assembly f...

Page 1896: ...of tubes This is required due to movement between ABS ICU and master cylinder while vehicle is in motion 5 Thread primary and secondary brake tubes into master cylinder primary and secondary ports Fig 49 Brake tubes must be held securely when tightened to control orientation of flex section Tighten tube nuts to 14 N m 120 in lbs torque 6 Connect wiring harness connector to brake fluid level switch...

Page 1897: ...ing push rod to brake pedal 7 Install and adjust NEW brake lamp switch Fig 53 Refer to 8 ELECTRICAL LAMPS LIGHT ING EXTERIOR BRAKE LAMP SWITCH INSTALLATION 8 Connect steering column coupling to intermedi ate shaft To do so a Match intermediate shaft to coupling pinch loop b Install coupling pinch bolt Tighten to 28 N m 21 ft lbs torque c Install hair pin at end of pinch bolt 9 Install instrument p...

Page 1898: ...uid reservoir Fig 48 8 Disconnect primary and secondary brake tubes coming from master cylinder at ABS ICU Fig 54 Cap off brake tubes and install sealing plugs in open brake tube outlet ports of ICU 9 Remove two nuts attaching master cylinder to power brake booster Fig 49 10 Slide master cylinder straight out of power brake booster Fig 53 Adjustable Pedals And Booster Mounting 1 BRAKE LAMP SWITCH ...

Page 1899: ...ower brake booster forward and remove through engine compartment INSTALLATION NOTE Before installing booster make sure there is a NEW booster seal placed over push rod and mounting studs on rear of booster 1 Install power brake booster through engine compartment guiding push rod and mounting studs through dash panel 2 Install four power brake booster mounting nuts Fig 53 Tighten nuts to 28 N m 21 ...

Page 1900: ...tor 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 lin ings are replaced If cracks or burned spots are evi dent the rotor must be replaced ROTOR MINIMUM THICKNES...

Page 1901: ...place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken This way the original mounting spot of the rotor on the hub is indexed Fig 59 Remove the rotor from the hub NOTE Clean the hub face surface before checking runout This provides a clean surface to get an accurate indicator reading Mount Dial Indicator Special Tool C 3339 and Mounti...

Page 1902: ... the rotor within service tolerances to ensure proper brake action 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 Fig 62 or replaced The use of a hub mounted on car brake lathe is highly recommended to eliminate the possibility of excessive runout It trues the bra...

Page 1903: ...CA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove tire and wheel assembly NOTE In some cases it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle This can usually be accomplished before mounting bolts are removed by grasping rear of caliper and pulling outward working w...

Page 1904: ... 6 Remove any clips retaining brake rotor to wheel mounting studs Fig 69 7 Remove brake rotor from hub Fig 69 INSTALLATION INSTALLATION FRONT NOTE Inspect brake shoes before installation Refer to 5 BRAKES HYDRAULIC MECHANICAL BRAKE PADS SHOES INSPECTION 1 Clean hub face to remove any dirt or corrosion where rotor mounts 2 Install brake rotor over studs on hub and bear ing Fig 65 3 Install disc bra...

Page 1905: ... Install brake caliper in opposite way it was removed Starting with upper end carefully position caliper and brake shoes over brake rotor and align outboard shoe s upper edge with caliper slide abut ment Rotate lower end of caliper into mounting posi tion on adapter CAUTION Extreme caution should be taken not to crossthread caliper guide pin bolts when they are installed 6 Carefully install calipe...

Page 1906: ...ke cable at cable connector front to right rear cable Fig 70 and pull outward on front cable Pull on cable until it stops and hold it in this position 5 Have assistant inside passenger compartment insert pin punch locking pin or drill bit into hole in lever and foot pedal past tang on adjuster mecha nism and through hole in backing plate of lever Fig 71 Fig 72 Hold pin in place This pin will lock ...

Page 1907: ...icle PARKING BRAKE CABLE FRONT REMOVAL 1 Disconnect and isolate battery negative cable from battery post 2 Lock out automatic adjuster in parking brake lever Refer to 5 BRAKES PARKING BRAKE STANDARD PROCEDURE 3 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE NOTE It may be necessary to back off parking brake shoe adjustment to allow sufficient slack to disen...

Page 1908: ...on from lever take up reel Fig 77 3 Pull button on end of cable strand out of hous ing and route around lever cam up to take up reel 4 Install front cable button into lever take up reel as shown Fig 79 5 Slide any extra cable back into housing 6 Position lever against left lower cowl and install 2 mounting bolts and one nut Fig 76 Tighten all three fasteners to 28 N m 21 ft lbs torque 7 Install bo...

Page 1909: ...ith a pair of pliers at the front cable button Place right rear cable button into cable con nector Fig 70 Release cables allowing button to seat It may take some hand pressure to completely seat button Fig 74 Front Cable Routing Through Interior 1 GROMMET 2 FRONT PARKING BRAKE CABLE 3 ROUTING CLIP STUDS 4 CABLE ACCESS HOLE 5 FLOOR PAN Fig 75 Indicator Switch Wiring Connection 1 WIRING CONNECTOR 2 ...

Page 1910: ...ack to disengage cable buttons from connectors in follow ing step 3 Slide left rear cable button inboard and remove from equalizer Fig 70 4 Access and remove rear hub and bearing Refer to 2 SUSPENSION REAR HUB BEARING REMOVAL 5 Remove parking brake cable bolt at knuckle Fig 80 6 Remove parking brake shoes from support Refer to 5 BRAKES PARKING BRAKE SHOES REMOVAL 7 Remove shoe actuator from end of...

Page 1911: ...th wheel speed sen sor as well as all components necessary to access it Refer to 2 SUSPENSION REAR HUB BEARING INSTALLATION 7 Place left rear parking brake cable button into equalizer Fig 70 Release cables allowing button to seat It may take some hand pressure to completely seat button 8 Lower vehicle 9 Unlock automatic adjuster in parking brake lever Refer to 5 BRAKES PARKING BRAKE STANDARD PROCE...

Page 1912: ...rt Refer to 5 BRAKES PARKING BRAKE SHOES INSTALLATION 5 Install bolt securing parking brake cable to knuckle Fig 80 Tighten bolt to 28 N m 21 ft lbs torque 6 Install hub and bearing with wheel speed sen sor as well as all components necessary to access it Refer to 2 SUSPENSION REAR HUB BEARING INSTALLATION 7 While holding cable connector on end of front cable secure with a pair of pliers at the fr...

Page 1913: ...orque 8 Install body control module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES BODY CONTROL CENTRAL TIMER MODUL INSTALLATION 9 Connect wiring connector at parking brake indicator lamp switch Fig 75 10 Connect parking brake release rod at parking brake lever 11 Position carpet into place 12 Install lower cowl trim 13 Install left front door weather strip 14 Install left front door opening si...

Page 1914: ...ar wheel upward 6 Install parking brake shoe adjuster spring Fig 84 7 Install bolt securing parking brake cable to knuckle Fig 80 Tighten bolt to 28 N m 21 ft lbs torque 8 Using Brake Shoe Gauge Special Tool C 3919 or equivalent measure inside diameter of parking brake drum portion of rotor Fig 85 9 Place Gauge over parking brake shoes at wid est point Fig 86 10 Using adjuster star wheel Fig 86 ad...

Page 1915: ...es outward against the drum Left brake Rotate star wheel toward rear of vehicle Right brake Rotate star wheel toward front of vehicle 4 Using an appropriate tool turn adjuster star wheel until wheel will not rotate dead lock 5 Back off adjuster six detents teeth 6 Rotate wheel checking for light drag If drag is too heavy continue to back off adjuster one detent at a time until light drag is presen...

Page 1916: ... The cooling system uses spring type hose clamps If a spring type clamp replacement is necessary replace with the original Mopart equipment spring type clamp CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only a original equipment clamp with matching number or letter Fig 1 OPERATION COOLING SYSTEM The engine cooling systems primary ...

Page 1917: ...es If an abnormal amount of coolant or steam emits from the tailpipe it may indicate a coolant leak caused by a faulty head gas ket cracked engine block or cracked cylinder head There may be internal leaks that can be deter mined by removing the oil dipstick If water globules appear intermixed with the oil it will indicate an internal leak in the engine If there is an internal leak the engine must...

Page 1918: ...nt on drive belts or the generator For cooling system capacity Refer to LUBRICATION MAINTENANCE FLUID TYPES SPECIFICA TIONS Fill coolant pressure container to at least the MAX mark with 50 50 solution It may be necessary to add coolant to the coolant pressure container after three or four warm up cool down cycles to maintain coolant level between the MAX and MIN mark This will allow trapped air to...

Page 1919: ...let Connector Thermostat Housing Bolts 28 250 Water Pump 12 105 Water Pump Inlet Tube Bolts 12 105 Water Pump Inlet Tube Bolts 28 250 Water Pump Pulley Bolts 28 250 Radiator to A C Condenser Screws 5 45 Radiator Fan Screws 5 45 Radiator Mounting Upper Bracket Nuts 12 105 SPECIAL TOOLS COOLING SYSTEM Pliers 6094 Hose Clamp Pliers 8495 Cooling System Tester 7700 Coolant Refractometer 8286 7 4 COOLIN...

Page 1920: ...Raise vehicle on hoist 2 Remove the drive belt shield 3 Remove the drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove the belt tensioner Fig 1 INSTALLATION 1 Install the belt tensioner and bolt Tighten bolt to 28 N m 250 in lbs 2 Install the drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLA TION 3 Install the drive belt shield 4 Lower the vehicle Fig 1 BELT...

Page 1921: ... ROLLED OVER IN GROOVE OR BELT JUMPS OFF 1 Broken cord in belt 1 Replace belt 2 Belt too loose or too tight 2 Replace tensioner 3 Misaligned pulleys 3 Align accessories 4 Non uniform groove or eccentric pulley 4 Replace pulley REMOVAL 1 Raise vehicle on hoist 2 Remove the drive belt shield Fig 2 WARNING DO NOT ALLOW DRIVE BELT TEN SIONER TO SNAP BACK AS DAMAGE TO TEN SIONER AND OR PERSONAL INJURY ...

Page 1922: ...or restorer on Poly V Belts INSTALLATION 1 Route and position the drive belt onto all pul leys except for the crankshaft Fig 5 2 Rotate belt tensioner counterclockwise until belt can be installed onto the crankshaft pulley Fig 3 Slowly release belt tensioner 3 Verify belt is properly routed and engaged on all pulleys 4 Install drive belt shield and lower vehicle Fig 4 Drive Belt Inspection 1 NORMA...

Page 1923: ...t and the upper idler pulley 3 Remove the bolt and the lower idler pulley Fig 6 INSTALLATION 1 Install bolt and loweridler pulley 2 Install bolt and upper idler pulley 3 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION Fig 6 Idler Pulleys 1 BOLT 2 IDLER PULLEY 7 8 ACCESSORY DRIVE CS ...

Page 1924: ...G SYSTEM PRESSURE CAP TESTING 23 DIAGNOSIS AND TESTING PRESSURE CAP TO FILLER NECK SEAL 24 CLEANING 24 INSPECTION 24 RADIATOR FAN RELAY DESCRIPTION 24 OPERATION 25 REMOVAL 25 INSTALLATION 25 WATER PUMP DESCRIPTION 25 REMOVAL 26 INSPECTION 26 INSTALLATION 26 ENGINE DIAGNOSIS AND TESTING ENGINE COOLING SYSTEM Establish what driving condition caused the cooling system complaint The problem may be cau...

Page 1925: ...ap as necessary 2 Incorrect cap was installed 2 Replace cap as necessary 3 Incorrect coolant mixture 3 Check concentration level of the coolant Refer to 7 COOLING ENGINE COOLANT DIAGNOSIS AND TESTING Adjust the ethylene glycol to water ratio as required COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF GAUGE IS READING HIGH OR HOT 1 Coolant leaks in radiator cooling system hoses water pump o...

Page 1926: ...tor and or A C condenser If these seals are missing or damaged not enough air flow will be pulled through the radiator and A C condenser 4 Check for missing or damaged air seals and repair as necessary INADEQUATE HEATER PERFORMANCE 1 Check for a Diagnostic trouble code DTC 1 For procedures Refer to appropriate Diagnostic Information Repair as necessary 2 Coolant level low 2 Refer to 7 COOLING STAN...

Page 1927: ...VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET ENGINE WARMED UP AND RUNNING WITH VEHICLE STATIONARY OR JUST SHUT OFF TEMPERATURE GAUGE IS NORMAL 1 During wet weather moisture snow ice rain or condensation on the radiator will evaporate when the thermostat opens The thermostat opening allows heated coolant into the radiator When the moisture contacts the hot radiator steam may be emitted This usually ...

Page 1928: ...ondition No correction is necessary The gauge should return to normal range Fig 1 Example A after a few minutes of engine operation 4 Temperature gauge or engine coolant temperature sensor defective or shorted Also corroded or loose wiring in the electrical circuit 4 Check operation of gauge or engine coolant temperature sensor and repair if necessary CLEANING Drain cooling system and refill with ...

Page 1929: ...Fig 1 Temperature Gauge Indications 7 14 ENGINE CS ENGINE Continued ...

Page 1930: ...oolant solu tion The green coolant MUST NOT BE MIXED with the orange or magenta coolants When replacing cool ant the complete system flush must be performed before using the replacement coolant CAUTION MoparT Antifreeze Coolant 5 Year 100 000 Mile Formula MS 9769 may not be mixed with any other type of antifreeze Doing so will reduce the corrosion protection and may result in premature water pump ...

Page 1931: ...oration or boiling losses REMOVAL 1 Disconnect two recovery hoses from the coolant recovery container Fig 2 2 Remove the lower attaching nuts Fig 2 3 Remove the upper attaching nut Fig 2 4 Remove the recovery container INSTALLATION 1 Connect the recovery hose to container 2 Position the recovery container on the frame rail Fig 2 3 Install the upper attaching screw and tighten to 7 N m 60 in lbs 4 ...

Page 1932: ...ADIATOR FAN REMOVAL 2 Fan blade striking a surrounding object 2 Locate point of fan blade contact and repair as necessary 3 Air obstructions at radiator or A C condenser 3 Remove obstructions and or clean debris 4 Electric fan motor defective 4 Replace fan assembly Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL ELECTRIC FAN MOTOR DOES NOT OPERATE 1 Fan relay powertrain control module PCM coolant t...

Page 1933: ...al accessory on all models The heater is operated by ordinary house current 110 Volt A C through a power cord located behind the radiator grille This provides easier engine starting and faster warm up when vehicle is operated in areas having extremely low temperatures The heater is mounted in a core hole in place of a core hole plug in the engine block with the heating element immersed in coolant ...

Page 1934: ...PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 1 Disconnect negative cable from remote jumper terminal 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Raise vehicle on hoist 4 Disconnect electrical connectors from engine oil and power steering pressure switches 5 Disconnect radiator and heater hoses from thermostat housing 6 Remove thermostat housing bolts Fig 6 7 Remove hous...

Page 1935: ... sealing surfaces 2 Inspect heater tube O ring Replace as neces sary 3 Lubricate O ring with a silicone type grease such as Mopart Dielectric Grease Fig 7 4 Install O ring on heater tube 5 Install heater tube on manifold 6 Install retaining bolts and tighten to 12 N m 105 in lbs 7 Install lower and upper intake manifolds Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 8 Refill cooling sys...

Page 1936: ... OCCUR 4 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 5 Disconnect the radiator fan electrical connec tors 6 Disconnect coolant reserve recovery hose 7 Remove A C lines Refer to 24 HEATING AIR CONDITIONING PLUMBING A C CON DENSER REMOVAL 8 Remove the auxiliary transmission cooler hoses 9 Remove the pushpins and the upper radiator seal 10 Remove the pushpins and the LH and RH rad...

Page 1937: ...ransmission coole hoses 11 Connect the coolant reserve recovery hose 12 Install the front fascia Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA INSTAL LATION 13 Fill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 14 Connect negative cable to battery RADIATOR DRAINCOCK REMOVAL WARNING DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE B...

Page 1938: ...apsed on cool down Clean the vent valve Fig 14 and inspect cool ant recovery hose routing to ensure proper sealing when boiling point is reached The gasket in the cap seals the filler neck so that vacuum can be maintained allowing coolant to be drawn back into the radiator from the reserve tank If the gasket is dirty or damaged a vacuum may not be achieved resulting is loss of coolant and eventual...

Page 1939: ...ING DOWN ROTATE COUNTERCLOCK WISE TO THE FIRST STOP ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COM PLETELY SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL TO CHECK PRESSURE BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED CLEANING Use only a mild soap to clean th...

Page 1940: ...y remove the front fascia to gain access to the radiator fan relay Refer to 23 BODY EXTERIOR GRILLE REMOVAL 4 Disconnect the relay electrical connector Fig 18 5 Remove the rivet attaching the relay to the front bumper beam Fig 18 6 Remove the relay INSTALLATION CAUTION The relay mounting location is designed to dissipate heat Ensure the relay is securely attached to prevent relay thermal shutdown ...

Page 1941: ...ng this will be evident by traces of thick deposits of dried glycol run ning down the pump body and components below A thin black stain below pump weep hole passage is considered normal operation 3 Impeller rubs inside of the rear timing belt cover 4 Excessively loose or rough turning bearing NOTE It is normal for the water pump to weep a small amount of coolant from the weep hole black stain on w...

Page 1942: ...leaks cracks or damage Replace as necessary Use only approved transmission oil cooler hoses that are molded to fit the space available Inspect the air to oil cooler for leaks loose mounts or damage Replace as necessary TRANS COOLER REMOVAL 1 Remove the cowl plenum grille Refer to 23 BODY EXTERIOR COWL GRILLE REMOVAL 2 Disconnect lines from oil cooler Fig 1 3 Remove oil cooler attaching screws 4 Re...

Page 1943: ......

Page 1944: ... INSTALLATION 15 VIDEO SCREEN DESCRIPTION 15 REMOVAL 15 INSTALLATION 15 AUDIO VIDEO DESCRIPTION An audio system is standard equipment A rear seat video system is an available option Two radio receivers are offered The audio video 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 ACCESSORY DELAY positi...

Page 1945: ...IO CONNECTOR FAULTY 2 CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR REPAIR IF REQUIRED 3 WIRING FAULTY 3 CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR REPAIR WIRING IF REQUIRED 4 GROUND FAULTY 4 CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND THERE SHOULD BE CONTINUITY REPAIR GROUND IF REQUIRED 5 RADIO FAULTY 5 EXCHANGE OR REPLACE RADIO IF REQUIRED 6 SPEAKERS FAULTY 6 PERFORM DIAGN...

Page 1946: ...N 2 FOREIGN OBJECTS BEHIND TAPE DOOR 2 REMOVE FOREIGN OBJECTS AND TEST OPERATION 3 DIRTY CASSETTE TAPE HEAD 3 CLEAN HEAD WITH MOPAR CASSETTE HEAD CLEANER 4 FAULTY TAPE DECK 4 EXCHANGE OR REPLACE RADIO IF REQUIRED NO COMPACT DISC OPERATION 1 FAULTY CD 1 INSERT KNOWN GOOD CD AND TEST OPERATION 2 FOREIGN MATERIAL ON CD 2 CLEAN CD AND TEST OPERATION 3 CONDENSATION ON CD OR OPTICS 3 ALLOW TEMPERATURE O...

Page 1947: ... OPERATION 4 DVD PLAYER FAULTY 4 WITH DVD PLAYER CONNECTED TO WIRE HARNESS CHECK FOR 100mv 2 VOLTS AT DVD PLAYER CONNECTOR BETWEEN PINS 5 AND 6 IF BATTERY VOLTAGE AND GROUND IS PRESENT BUT 1 2 VOLTS ARE NOT AT PINS 5 AND 6 REPLACE THE DVD PLAYER 5 CONTRAST CONTROL IS SET TOO LOW 5 ADJUST CONTRAST CONTROL TO PROPER LEVELS DOTS APPEAR ON SCREEN MAY BE ANY COLOR 1 CONDITION IS NORMAL 1 NO ACTION REQU...

Page 1948: ...g information The power amplifier unit should be checked if there is no sound output noted from the speakers For diagnosis of the speakers Refer to 8 ELEC TRICAL AUDIO SPEAKER DIAGNOSIS AND TESTING REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the rear floor stowage tray Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY REMOVAL 3 Remove the three mounting fasteners Fig 1 4 D...

Page 1949: ...oax cable connector OPERATION The antenna module receives both AM and FM radio signals supplied by the side window integral radio antenna system and selectively amplifies them The amplified signal is then sent through the body length coax cable to the radio input DIAGNOSIS AND TESTING ANTENNA MODULE CONDITION POSSIBLE CAUSES CORRECTION NO AM RECEPTION WEAK FM RECEPTION 1 Antenna module to antenna ...

Page 1950: ...at the same time Each operation happens sequentially The radio unit provides control over all features of the CD DVD changer with the exception of the CD DVD load and eject functions which are con trolled by buttons located on the front of the CD DVD changer All features you would expect such as Disc Up Down Track Up Down Random and Scan are controlled by the radio which also displays all rele van...

Page 1951: ...x 3 Disconnect instrument panel antenna cable from antenna cable 4 Disconnect cable hanger clip from HVAC unit 5 Remove radio Refer to 8 ELECTRICAL AU DIO RADIO REMOVAL CAUTION Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio 6 Disconnect the antenna cable by pulling the locking antenna connector away from the radi...

Page 1952: ...eceivers for this model include AM FM CD with CD DVD changer control RAH sales code AM FM cassette CD equalizer with CD DVD changer control feature RBP sales code OPERATION The radio receiver operates on ignition switched battery current that is available only when the igni tion switch is in the On or Accessory Accessory Delay positions REMOVAL 1 Disconnect and isolate the battery negative cable 2...

Page 1953: ...etween the spark plug terminal and the center elec trode to help reduce the production of electromag netic radiation that can result in radio noise OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference RFI and ElectroMagnetic Interference EMI radio noise The first suppression strategy involves preventing the production of RFI and EMI electromagnetic si...

Page 1954: ...the proper Diagnostic Procedures manual are recommended For more information on the operation of the remote radio switch controls refer to the owner s manual in the vehicle glove box DIAGNOSIS AND TESTING REMOTE SWITCHES WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE F...

Page 1955: ...K repair the open circuit as required REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove th...

Page 1956: ...e 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 and or amplifier may result 1 If all speakers are inoperative check the fuses in the Integrated Power Module IPM If OK go to Step 2 If not OK repair the shorted circuit or com ponent as required and replace the faulty fuse 2 Check the amplifier fuse if equipped in the I...

Page 1957: ...ve speaker SUBWOOFER 1 Disconnect and isolate the battery negative cable 2 Using a trim stick Special tool C 4755 or equivalent carefully pry at the rear of the speaker grille and remove 3 Remove mounting fasteners 4 Disconnect wire harness connectors and remove speaker TWEETER 1 Disconnect and isolate the battery negative cable 2 Remove the front door trim panel Refer to 23 BODY DOOR FRONT TRIM P...

Page 1958: ...fasteners Tighten to 3 N m 28 in lbs 3 Install front door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 4 Connect battery negative cable VIDEO SCREEN DESCRIPTION WARNING THIS VEHICLE CONTAINS MERCURY ADDED DEVICES ADDED BY THE MANUFAC TURER NAVIGATION DISPLAY REMOVE DEVICES BEFORE VEHICLE DISPOSAL UPON REMOVAL OF DEVICES PLEASE REUSE RECYCLE OR DISPOSE OF AS HAZARDOUS WASTE The v...

Page 1959: ......

Page 1960: ...elt Lamp after turning the ignition to the run start position if the driver seat belt is unbuckled After 6 seconds the chime will stop but the Seat Belt Lamp will stay illuminated If the ignition is in the run position for a period greater than 60 seconds and the driver seat belt is unbuckled and the vehicle s speed is greater than 5 mph 8 km h in a forward gear the Enhanced Fasten Seat Belt Remin...

Page 1961: ...the driver seat belt is unbuckled After 6 seconds the chime will stop but the Seat Belt Lamp will stay illuminated If the ignition is in the run position for a period greater than 60 seconds and the driver seat belt is unbuckled and the vehicle s speed is greater than 5 mph 8 km h in a forward gear the Enhanced Fasten Seat Belt Reminder will activate This will cause the Seat Belt Lamp to blink and...

Page 1962: ...ftgate actua tion with the Overhead console or RKE and the doors are locked Overhead console and the vehicle is not in park Overhead console or RKE and the temperature is too cold for actuation Overhead console or RKE and the temperature is too hot for actuation TIRE PRESSURE MONITOR SYSTEM The tire pressure monitoring system will request A chime illuminate an amber TPM lamp and display an EVIC me...

Page 1963: ......

Page 1964: ... not serviced separately from the instrument panel switch pod If found defective the entire switch assembly must be replaced Refer to 8 ELECTRICAL INSTRUMENT CLUSTER INSTRU MENT PANEL SWITCH POD REMOVAL OPERATION To set the analog clock at the top center of the instrument panel press and hold the button Fig 2 until the setting is correct Fig 2 CLOCK SETTING BUTTON 1 NAVIGATION CONTROLS 4 CLOCK SET...

Page 1965: ...v battery power and ground at the instrument panel connector end of the instrument panel switch pod If both are present replace instrument panel switch pod Refer to 8 ELECTRICAL INSTRUMENT CLUSTER IN STRUMENT PANEL SWITCH POD REMOVAL If one or both are not present repair short open wire 8C 2 CLOCK CS CLOCK Continued ...

Page 1966: ... 12 DIAGNOSIS AND TESTING MEMORY HEATED SEAT ADJUSTABLE PEDAL MODULE 13 REMOVAL 13 INSTALLATION 13 BODY CONTROL MODULE DESCRIPTION CAUTION Do not swap BCM s between vehicles or with BCM s off the shelf The Body Control Module BCM is located on the bulkhead left side underneath the instrument panel Fig 1 The BCM utilizes integrated circuitry and information carried on the Programmable Communi catio...

Page 1967: ...oes not receive any new input that would cause the interior lamps to remain on Pulse Width Modulated PWM instrument panel dimming Power liftgate switch input The BCM has 1 Liftgate switch input located in the overhead console All stalk switch inputs including wipers and light switches Seat belt position input indicating a buckled or unbuckled seat belt Turn signal operation Fuel Level inputs Monit...

Page 1968: ...e preferred method is to use the DRBIIIt scan tool The 12v square wave selection on the 20 volt scale provides a good view of the bus activity Voltage on the bus should pulse between zero and about seven and a half volts The PCI Bus failure modes are broken down into two categories Complete PCI Bus Communication Failure and individual module no response Causes of complete PCI Bus Communication Fai...

Page 1969: ...The normal base braking system will remain opera tional NOTE If the vehicle is equipped with traction con trol the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates The CAB 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 detecte...

Page 1970: ...ector at CAB Fig 5 6 Remove CAB INSTALLATION 1 Connect 47 way wiring connector at CAB Fig 5 2 Align CAB solenoids and pump motor wiring connector with HCU valves and connector passage Fig 6 Slide CAB onto HCU 3 Install 3 screws mounting CAB to HCU Fig 4 Tighten CAB mounting screws to 2 N m 17 in lbs torque 4 Lower vehicle 5 Connect negative battery cable to battery post 6 Hook up DRBIIIt to initia...

Page 1971: ...l them to set store a memory location or to recall a memory location Power door lock Switch learning features Window lockout feature for all passenger power windows The functions and features of the PDM include the following Power door locks Passenger front and rear window including express down for both Passenger memory mirror Passenger power mirror Passenger heated mirror The door modules are se...

Page 1972: ...e Intake Air Temperature Sensor Knock Sensor NVLD Assembly Manifold Absolute Pressure MAP Sensor Park Neutral PCI Bus Power Steering Pressure Switch EVAP Purge Return SCI Receive Speed Control Throttle Position Sensor Transmission Control Relay Switched B Transmission Pressure Switches Transmission Temperature Sensor Transmission Input Shaft Speed Sensor Transmission Output Shaft Speed Sensor Tran...

Page 1973: ... the PCM is replaced after 320 km 200 miles of usage update the mileage in new PCM Use the DRBIIIt scan tool to change the mileage in the PCM Refer to the appropriate Powertrain Diagnostic Manual and the DRBIIIt scan tool TRANSMISSION CONTROL CLUTCH VOLUME INDEX CVI An important function of the PCM is to monitor Clutch Volume Index CVI CVIs represent the vol ume of fluid needed to compress a clutc...

Page 1974: ...iety of shift schedules Shift schedule selection is dependent on the follow ing Shift lever position Throttle position Engine load Fluid temperature Software level As driving conditions change the PCM appropri ately adjusts the shift schedule Refer to the follow ing chart to determine the appropriate operation expected depending on driving conditions Schedule Condition Expected Operation Extreme C...

Page 1975: ... there is noise suppression on the sensor ground For EMI and RFI protection the housing and cover are also grounded separately from the ground pins OPERATION 5 VOLT SUPPLY PCM OUTPUT The PCM supplies 5 volts to the following sensors A C pressure transducer Ambient Temperature sensor Battery temperature Camshaft Position Sensor NGC Crankshaft Position Sensor NGC Electronic Throttle Control 1 6L Eng...

Page 1976: ...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 follow ing conditions must be met 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 t...

Page 1977: ...hardwired resistor multi plexed signal to the corresponding door module The door module then sends a PCI data bus message to the Memory Heated Seat Adjustable Pedal Module MHSAPM The module detects the heated seat switch status via the PCI data bus cir cuit and energizes the appropriate heated seat ele ment The programmed software in the MHSAPM allows it to know the temperature of the seat cushion...

Page 1978: ...blem is corrected erase the stored fault code using the DRB IIIt scan tool and verify correct heated seat system operation If the heated seat sys tem appears to be functioning correctly verify that there are no other stored codes in the module and return the vehicle to service If the fault code could not be verified such as not finding anything wrong when following the diagnos tic flow chart in th...

Page 1979: ......

Page 1980: ... INSTALLATION 15 BATTERY TRAY DESCRIPTION 15 OPERATION 15 REMOVAL 15 INSTALLATION 15 THERMOWRAP DESCRIPTION 16 OPERATION 16 REMOVAL 16 INSTALLATION 16 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on this model All of the compo nents of the battery system are located within the engine compartment of the vehicle The battery sys tem is comprised of the ...

Page 1981: ...ed 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 thor oughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal bat tery discharge overcharging or ...

Page 1982: ...connections are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Check and clean and tighten the battery terminal connections as required 5 The battery has an incorrect size or rating for this vehicle 5 Refer to Battery System Specifications for the proper size and rating Replace an incorrect battery as required 6 The battery is faulty 6 Tes...

Page 1983: ...d testing procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads 8 Slow driving or prolonged idling with high amperage draw loads in use 8 Advise the vehicle operator as required THE BATTERY WILL NOT ACCEPT A CHARGE 1 The battery is f...

Page 1984: ...ith a sodium bicarbonate baking soda and warm water cleaning solution using a soft bristle parts cleaning brush to remove any acid film 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 Fig 3 INSPECTION The following information details the recommended inspection procedures fo...

Page 1985: ... sized replace ment Cold Cranking Amperage The Cold Crank ing Amperage CCA rating specifies how much cur rent 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 requirement...

Page 1986: ...de positive plate or sponge lead negative plate Insu lators or plate separators made of a non conductive material are inserted between the positive and nega tive plates to prevent them from contacting or short ing against one another These dissimilar metal plates are submerged in a sulfuric acid and water solution called electrolyte The chemical composition of the metal coated plates within the lo...

Page 1987: ...ttery System Cleaning for the proper cleaning pro cedures and Battery System Inspection for the proper battery inspection procedures Refer to Stan dard Procedures for the proper battery charging pro cedures MICRO 420 BATTERY TESTER The Micro 420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery Follow the instruc tion manual supplied...

Page 1988: ...ce Refer to Battery System Cleaning for the proper battery cleaning procedures and Battery Sys tem Inspection for the proper battery inspection pro cedures CHARGING A COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery Unless this proce dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the batte...

Page 1989: ...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 STANDARD PROCEDURE OPEN CIRCUIT VOLTAGE TEST A battery open circuit voltage test will show the approximate state of charge of a battery This te...

Page 1990: ...ontinuity 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 4 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 th...

Page 1991: ...t battery movement during the most extreme vehicle operation conditions Periodic removal and lubrica tion of the battery holddown hardware is recom mended to prevent hardware seizure at a later date NOTE Never operate a vehicle without a battery holddown device properly installed Damage to the vehicle components and battery could result REMOVAL 1 Turn the ignition switch to the Off position Be cer...

Page 1992: ...re has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw in the engine compartment DIAGNOSIS AND TESTING BATTERY CABLE A voltage drop test will determine if there is exces sive resistance in the battery cable terminal connec tions or the battery cable If excessive resistance is found in the battery cable connections the connec tion point should ...

Page 1993: ...oid B terminal stud Repeat the test If the reading is still above 0 2 volt replace the faulty battery positive cable 4 Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block Fig 11 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 nega...

Page 1994: ...ttery tray and support unit is secured with three fasteners Two are located directly under the battery and the other is located on the right side of the tray The battery tray and support unit also includes a drainage hose located in the front of the unit OPERATION The battery tray provides a secure mounting loca tion and supports the battery The battery tray also provides the anchor point for the ...

Page 1995: ...ial of the thermowrap creates a dead air space which helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment REMOVAL 1 Disconnect and isolate the negative battery cable 2 Disconnect the positive battery cable 3 Lift the battery thermowrap straight up to remove from the battery INSTALLATION 1 Position the thermowrap on the battery 2 Conne...

Page 1996: ...mps 4 5 40 Battery Hold Down 20 3 180 BATTERY TEMPERATURE SENSOR REMOVAL 1 Disconnect and isolate the battery negative cable then the positive cable 2 Remove battery from battery tray 3 Disconnect the Battery Temperature Sensor electrical connector Fig 1 4 Unsnap the Battery Temperature Sensor from the battery tray and remove the sensor by pushing in the snap fits and pushing up out of tray Fig 2 ...

Page 1997: ...ted in series with the second rotor field terminal and ground An Ambient air temperature sensor is used to cal culate the temperature near the battery This tem perature data along with data from monitored line voltage battery voltage sense circuit is used by the PCM to vary the battery charging rate This is done by cycling the ground path to control the strength of the rotor magnetic field The PCM...

Page 1998: ...ting bolts Fig 5 8 Remove generator INSTALLATION 1 Install generator 2 Install the 2 lower mounting bolts Fig 5 3 Install the upper mounting bracket Fig 4 4 Tighten the 2 lower bolts first then tighten the 2 upper bolts Refer to the torque chart for torque values 5 Connect the generator field circuit wiring con nector Fig 3 Push the RED locking tab to lock connector 6 Install the B terminal nut an...

Page 1999: ...decoupler pulley cover Fig 7 5 Using a 10mm and 17mm wrench with Special Tool 8433A move wrenches in the direction of the arrows to remove decoupler Fig 8 INSTALLATION 1 Using a 10mm and 17mm wrench with Special Tool 8433A move wrenches in the direction of the arrows to Install decoupler Fig 9 Refer to the torque chart for torque value Fig 6 DECOUPLER PULLEY Fig 7 DECOUPLER PULLEY COVER Fig 8 DECO...

Page 2000: ... Fig 6 Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Install the air cleaner box Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 5 Connect the negative battery cable Fig 10 DECOUPLER PULLEY COVER INSTALLED CS CHARGING 8F 21 GENERATOR DECOUPLER Continued ...

Page 2001: ...g Bolts 47 4 35 10 Starter B Nut 11 3 100 10 Battery Clamp 4 5 40 STARTER MOTOR REMOVAL 1 Disconnect the negative battery cable 2 Remove Fig 1 and relocate Fig 2 the upper radiator crossmember Refer to 23 BODY EXTERI OR RADIATOR CROSSMEMBER REMOVAL 3 Remove the radiator fan module Fig 3 Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 4 Remove the wiring harness clip from front mount 5 Remove the co...

Page 2002: ...Fig 2 UPPER RADIATOR CROSS MEMBER REMOVED Fig 3 FAN MODULE IN VEHICLE Fig 4 COOLANT LINE BRACKET Fig 5 FRONT RUBBER MOUNT UPPER NUT CS STARTING 8F 23 STARTER MOTOR Continued ...

Page 2003: ...arter bolt Fig 7 9 Raise vehicle and support 10 Remove the lower front mount nut Fig 8 11 Raise and support engine Fig 9 Fig 6 UPPER STARTER BOLT Fig 7 MIDDLE STARTER BOLT Fig 8 FRONT RUBBER MOUNT IN POSITION Fig 9 SUPPORT ENGINE 8F 24 STARTING CS STARTER MOTOR Continued ...

Page 2004: ...rter bolt Fig 12 3 Connect the solenoid connector to starter 4 Connect the positive battery cable to starter 5 Relocate the front mount and bracket NOTE The front mount has an alignment pin Fig 14 make sure that the mount and bracket line up together The alignment pin goes toward the front of vehicle NOTE Make sure that the wire harness is in front of the front mount 6 Start the middle starter bol...

Page 2005: ...cle 15 Install the upper nut to the front mount and tighten Fig 5 16 Install the coolant line clamp bolt Fig 4 17 Install the wiring harness clip to front mount 18 Install the radiator fan module Fig 3 Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 19 Relocate and install Fig 1 and Fig 2 the upper radiator crossmember Refer to 23 BODY EXTERIOR RADIATOR CROSSMEMBER INSTAL LATION 20 Connect the...

Page 2006: ...r window The electrical circuit consists of the rear defogger switch in the heater A C control and a relay with timer switch to turn OFF the system after ten min utes The main feed circuit is protected by fuse 13 40 amp in the Power Distribution Center PDC which is connected directly to the front control mod ule FCM to form an integrated unit called an Inte grated Power Module IPM The rear defogge...

Page 2007: ...ed 3 The rear window defogger or the heated wind shield wiper deicer operation can be checked by feel ing the glass A distinct difference in temperature between the grid lines and adjacent clear glass can be detected in 3 to 4 minutes of operation 4 Using a DC voltmeter Fig 3 contact terminal B with the negative lead and terminal A with the positive lead The voltmeter should read 10 14 volts 5 Ind...

Page 2008: ...or terminal by gently rubbing area with steel wool 2 Wipe area with clean cloth soaked in alcohol or similar solvent It is necessary that all contaminants be removed from repair area 3 Remove package separator clamp and mix plas tic conductive epoxy thoroughly 4 For grid line mark off area to be repaired with masking tape Fig 4 5 Apply conductive epoxy through slit in masking tape Overlap both end...

Page 2009: ...Power Distribution Center PDC part of the Integrated Power Module IPM in the engine compartment 3 Test voltage at rear window defogger switch If no voltage repair wire Remove mirror glass and test the wires for con tinuity If no continuity repair wires If wires are OK test and replace mirror assem bly To test defogger switch refer to the appropriate section in Electrical MIRROR SWITCH DESCRIPTION ...

Page 2010: ...ecessary if the grid is damaged and diagnostics have been performed Refer to 23 BODY EXTERIOR SIDE VIEW MIR ROR REMOVAL RELAY DESCRIPTION There is no heated mirror relay it is integrated into the E B L relay that is located in the IPM in the engine compartment CS HEATED MIRRORS 8G 5 ...

Page 2011: ...hicles with the heated seat option can be visu ally identified by the two heated seat switches located in the front door trim panels A second set of heated seat switches are located in the rear seat cen ter console The front door trim panel mounted switches control the front seats while the rear con sole mounted switches control the second row seats The heated seat system allows the driver front s...

Page 2012: ...the Integrated Power Module IPM Fused ignition switch output run acc circuits are used so that the systems will only operate when the ignition switch is in the On or Accessory positions The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except On or Accessory Also the heated seat system will not operate when the surface temperature of the seat...

Page 2013: ...witch The module will automatically turn off the heating elements if it detects an OPEN or HI LOW short in the sensor circuit or an OPEN or LOW short in the heating element circuit See the owner s manual in the vehicle glove box for more information on the features use and operation of the front seat heated seat system DIAGNOSIS AND TESTING HEATED SEAT SYSTEM FRONT SEAT HEATED SEAT SYSTEM DIAGNOSI...

Page 2014: ...seat switch indicator lamps will flash if a failure occurs in the left rear heated seat and the right side heated seat switch indicator lamps will flash for a right rear heated seat failure If a monitored heated seat system fault occurs the switch indicator lamps will flash at a pulse rate of one half second on fol lowed by one half second off for a duration of one minute after the switch for the ...

Page 2015: ...ends a PCI Data Bus message to the Memory Heated Seat Adjustable Pedal Module MHSAPM to indicate the selected switch position The module responds to the heated seat switch messages by controlling the 12v output to the front seat heating elements The Low heat position set point is about 36 C 97 F and the High heat position set point is about 41 C 105 F DIAGNOSIS AND TESTING DRIVER HEATED SEAT SWITC...

Page 2016: ...ty or damaged the heated seat element assembly must be replaced Refer to the procedure later in this section OPERATION The heated seat elements resist the flow of electri cal current When battery current is passed through the elements the energy lost by the resistance of the elements is released in the form of heat The heated seat temperature sensor is a NTC ther mistor When the temperature of the...

Page 2017: ...the cush ion foam and the rear carpet flap of the trim cover HEATED SEAT SENSOR FRONT SEATS DESCRIPTION Four heated seat sensors are used per vehicle One sensor is located in each heated seat cushion The heated seat temperature sensors are Negative Tem perature Coefficient NTC thermistors Each front seat sensor is hardwired to the memory heated seat adjustable pedal module located under the driver...

Page 2018: ...ircuits If OK refer to Diagnosis and Testing the Heated Seat Element for the proper heated seat element diagnosis and testing procedures If not OK repair the shorted or open heated seat wire harness as required HEATED SEAT MODULE FRONT SEATS DESCRIPTION A Memory Heated Seat Adjustable Pedal Module MHSAPM is used on vehicles that are equipped with the heated seat system option A Memory Seat Adjusta...

Page 2019: ...ver the PCI data bus circuit also DIAGNOSIS AND TESTING HEATED SEAT MODULE FRONT SEATS In order to obtain conclusive testing of the memory heated seat adjustable pedal module the Program mable Communications Interface PCI data bus cir cuit and any components that provide inputs to the module must be checked The most reliable efficient and accurate means to diagnose the module requires the use of a...

Page 2020: ...the heated seat module is damaged or faulty the entire module must be replaced OPERATION When a 2nd row heated seat switch is depressed a resistance ohms signal is sent to the heated seat mod ule the module energizes the proper indicator LED Low or High in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating At the same time the heated seat module...

Page 2021: ...at module with a known good unit and retest system if Not OK Repair the open or shorted ground circuit as required REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the 2nd row seat center console Refer to the Body section for the procedure 3 Disconnect the wire harness connector from the heated seat module Depress the connector retaining tab and pull straight apart 4 Remove the...

Page 2022: ...at System Diagnosis and Testing for more information DIAGNOSIS AND TESTING HEATED SEAT SWITCHES 2ND ROW SEATS Refer to Wiring for connector pin outs and the loca tion of complete heated seat system wiring diagrams 1 Disconnect and isolate the battery negative cable Remove the 2nd row seat center console to access the heated seat switch Disconnect the heated seat switch to be tested Check for conti...

Page 2023: ...si tion is selected and the high position LED indicator illuminates If the switch is depressed a second time in the same direction Off is selected and both LED indicators are extinguished Both heated seat switch assemblies provide sepa rate resistive multiplexed inputs to the appropriate door module The Door Module then sends a PCI Data Bus message to the Memory Heated Seat Adjustable Pedal Module...

Page 2024: ...GNOSIS AND TESTING REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the front door trim panel Refer to Front Door Trim Panel Removal in the Body section for the procedure 3 Disconnect the harness from the door module 4 Remove the heated seat switch assembly by pressing in the four clips INSTALLATION 1 Install the heated seat switch assembly 2 Connect the harness to the door mod...

Page 2025: ......

Page 2026: ...se of the DRB IIIt refer to the appropriate Diagnostic Service Manual For complete circuit diagrams refer to the appro priate wiring information In most cases any problem involving continually sounding horns can be quickly alleviated by removing the horn fuse from the Integrated Power Module IPM WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIO...

Page 2027: ...DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COM PONENTS DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A SOLID SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN PERSONAL INJURY WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTIN...

Page 2028: ...gnition timing is not adjustable All spark advance is determined by the Powertrain Control Module PCM The ignition system used on these engines is referred to as the Direct Ignition System DIS The system s three main components are the coils crank shaft position sensor and camshaft position sensor If equipped with the coil on plug ignition system it uti lizes an ignition coil for every cylinder it...

Page 2029: ... each cylin der by the pulses generated by the notches on the camshaft sprocket When metal aligns with the sensor voltage goes low less than 0 3 volts When a notch aligns with the sensor voltage spikes high 5 0 volts As a group of notches pass under the sensor the voltage switches from low metal to high notch then back to low The number of notches determine the amount of pulses If available an osc...

Page 2030: ...round the coil area and spark plug On 3 5L engines it is necessary to loosen the screws by alternating back and forth Do not lose the spacers under the coil when loosening the screws 5 Remove the ignition coil Fig 5 REMOVAL REAR 3 5L 1 Disconnect the negative battery cable 2 Remove the electrical connector from the igni tion coil Fig 6 3 Prior to removing the ignition coils spray com pressed air a...

Page 2031: ... coil Fig 5 2 Hand tighten coil screws 3 Refer to the torque chart for torque specifica tion 4 Install and lock the electrical connector to the ignition coil Fig 4 5 Connect the negative battery cable IGNITION COIL CAPACITOR DESCRIPTION The coil capacitor is used for radio noise suppres sion REMOVAL 1 Disconnect the negative battery cable 2 Remove the electrical connector from capacitor 3 Remove t...

Page 2032: ... timing to reduce engine knock If the knock sensor voltage exceeds a preset value the PCM retards ignition timing for all cylinders It is not a selective cylinder retard The PCM ignores knock sensor input during engine idle conditions Once the engine speed exceeds a specified value knock retard is allowed Knock retard uses its own short term and long term memory program Long term memory stores pre...

Page 2033: ...dentification and specifications Refer to the Specifications section Do not use an ohm meter to check the resis tance of the spark plugs This will give an inac curate reading When the spark plugs use a single or double plat inum tips and they have a recommended service life of 100 000 miles for normal driving conditions per schedule A in this manual The spark plugs have a recommended service life ...

Page 2034: ...e cylinder head by hand 2 Tighten spark plugs 3 Install ignition coil assembly onto spark plug 4 Hand tighten coil screws 5 Refer to the torque chart for torque specifica tion 6 Connect and lock the electrical connector 7 Front Plugs Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANI FOLD INSTALLATION 8 Connect the negative battery cable IGNITION SWITCH REMOVAL The ignition switch...

Page 2035: ...nnect the electrical connector from the ignition Switch and SKREEM Module Fig 18 8 Remove the interlock cable by depressing the locking tab and pulling straight out Fig 19 Fig 16 SWITCH IN DASH Fig 17 IGNITION SWITCH ASSEMBLY 1 Switch Assembly 2 Rear Mounting Nut 3 Interlock Cable Fig 18 SKREEM MODULE 1 SKREAM Module 2 Ignition Switch Fig 19 INTERLOCK CABLE 1 Retaining Tab for Cable 8I 8 IGNITION ...

Page 2036: ...er to the torque chart for specification 3 Attach electrical connector to SKREEM Mod ule 4 Attach electrical connector to ignition switch 5 Install the interlock cable into the switch assembly Fig 19 6 Install switch assembly into Instrument Panel Fig 22 Make sure that the rear mounting nut is in the correct position Fig 16 and Fig 17 7 Tighten the 3 mounting nuts refer to the torque chart for tor...

Page 2037: ...2 The shaft at the end of the lock cylinder aligns with the socket in the end of the housing To align the socket with the lock cylinder ensure the socket is in the ON position 3 Align the lock cylinder with the grooves in the housing Slide the lock cylinder into the housing until the tab sticks through the opening in the hous ing 4 Turn key to Off position Remove key 5 Install center console bezel...

Page 2038: ...ing Amber LED EVIC Display Left VF Display The cluster Thin Filmed Transistor TFT screen if so equipped shall have the capability to display vehi cle navigation information such as maps and turn by turn direction as input by the navigation module ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center EVIC is part of the instrument cluster The EVIC display screen is located...

Page 2039: ...med Transistor TFT screen if equipped The Instrument Panel Switch Pod is the secondary part of the CIS The switch pod will contain an Ana log Clock w time adjust button Hazard Switch EVIC and NAV optional controls and Vehicle Theft Security System VTSS LED The Instrument Cluster has four gauges Speedom eter tachometer fuel and temperature The gauges and the LED s are not individually replaceable t...

Page 2040: ...re is indicated immediate repair is necessary Vehi cles equipped with Anti Lock brakes ABS are also equipped with Electronic Brake Force Distribution EBD In the event of an EBD failure the Brake Warning Indicator will turn on along with the ABS Indicator Immediate repair to the ABS system is required The operation of the Brake Warning Indica tor can be checked by turning the ignition switch from t...

Page 2041: ...e ON position as a reminder to buckle up The LED will remain on until the driv er s seat belt is buckled The chime will sound for 6 seconds or until the seat belt is buckled TIRE PRESSURE MONITOR SYSTEM INDI CATOR Fig 13 This Light Emitting Diode LED will turn on when there is a low tire pressure condi tion The LED will also turn on if a problem exist with any tire sensor The LED will remain on un...

Page 2042: ... CENTER EVIC DISPLAY Fig 1 When the appropriate conditions exist this Vacuum Fluores cent VF display shows the Electronic Vehicle Infor mation Center EVIC messages ELECTRONIC VEHICLE INFORMATION CENTER The EVIC has access to 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 ...

Page 2043: ...scratch the cluster face INSTALLATION 1 Place cluster straight into cluster opening in instrument panel Fig 18 Be careful not to scratch the cluster face 2 Install the four retaining screws to the cluster Fig 17 3 Install the two electrical connectors to the bot tom of the cluster accessed from underneath instru ment panel Fig 16 4 Raise the column and install four nuts 5 Install the cluster bezel...

Page 2044: ...odule NAV and Instrument Cluster IC The EVIC function buttons are labeled US M MENU STEP and RESET The Navigation function buttons are labeled NAV CANCEL ENTER scroll left scroll up scroll right and scroll down The Vehi cle Theft Security System VTSS Light Emitting Diode LED is a red oval located under the EVIC reset button The Analog Clock consists of an hour and minute hand with one time adjust ...

Page 2045: ...NEL SWITCH POD ELECTRONIC VEHICLE INFORMATION CENTER AND NAVIGATION CONTROLS Refer to the appropriate wiring information for connector views and pin outs Check fuses first that supply power to the switch pod IOD fuse If OK continue If not OK repair as necessary to continue Remove the instrument panel switch pod for test ing First of all check for 12v battery power at termi nal 1 of the instrument ...

Page 2046: ...ound at the instrument panel connector end of the instrument panel switch pod terminal 1 12v and terminal 12 ground If power and ground are present and the clock doesn t work replace switch pod If the set button is inoperative the complete switch pod must be replaced HAZARD SWITCH A low side ground signal will be provided from the Instrument Panel Switch Pod to the BCM to indi cate that the Hazard...

Page 2047: ...e three retaining screws holding the switch pod to the cluster bezel 2 Install the cluster bezel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL INSTALLATION WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE Refer to 8 ELECTRICAL RE STRAINTS DIAGNOSIS AND TESTING AIRBAG SYSTEM FIRST 3 Verify vehicle and system operation Fig 22 INSTRUMENT PANEL SWITCH POD REMOVE INSTALL 1 INSTRUMENT PANEL SWITCH P...

Page 2048: ...RD PROCEDURE FOG LAMP UNIT ALIGNMENT 9 REMOVAL 9 INSTALLATION 9 FRONT SIDE MARKER LAMP REMOVAL 10 INSTALLATION 10 HAZARD SWITCH DESCRIPTION 10 OPERATION 11 HEADLAMP DESCRIPTION 11 OPERATION 11 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HEADLAMP 12 DIAGNOSIS AND TESTING HIGH INTENSITY DISCHARGE HEADLAMPS 14 REMOVAL 15 INSTALLATION 16 HEADLAMP UNIT STANDARD PROCEDURE HEADLAMP UNIT ALIGNMENT 17 REMO...

Page 2049: ...is a dedicated signal return ground wire The fourth wire provides power to the front fog lamp indicator The fifth wire contains infor mation regarding the Optical Horn The sixth wire contains information regarding the High Beam Sig nal The seventh wire contains information regarding the Right Turn Input The eighth wire contains infor mation regarding the Left Turn Input HEADLAMP TIME DELAY SYSTEM ...

Page 2050: ...er through a high side driver HEADLAMP TIME DELAY SYSTEM The headlamp time delay system is activated by turning the headlamps ON high or low beam while the engine is running turning the ignition switch OFF and then turning the headlamp switch OFF within 45 seconds The system will not activate if more than 45 seconds elapse between ignition switch OFF and headlamp switch OFF The BCM will allow the ...

Page 2051: ...lbs with fingers or other possibly oily surface reduced bulb life will result Do not use bulbs other than those indicated in the Bulb Application table Dam age to lamp and or Daytime Running Lamp Module can result Do not use fuses circuit breakers or relays having greater amperage value than indi cated on the fuse panel or in the Owners Manual CAUTION Do not use bulbs other than those listed in th...

Page 2052: ...mp into tail lamp unit and then twist clockwise until lamp stops about 1 4 turn 3 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION BRAKE LAMP SWITCH DESCRIPTION The brake lamp switch is located under the instru ment panel at the brake pedal arm Fig 4 It has three internal switches controlling various functions of the vehicle It s main function i...

Page 2053: ...er is rotated to the adjusted position as indicated Fig 5 This action locks the plunger to the internal switches Once in this posi tion the switch is permanently adjusted or locked and cannot be readjusted or released even if the lever is moved back DIAGNOSIS AND TESTING BRAKE LAMP SWITCH NOTE Before proceeding with this diagnostic test verify the adjustment lever on the back of the switch is in t...

Page 2054: ...b and disconnect the wir ing connector from the switch 4 Discard the brake lamp switch It must not be reused INSTALLATION CAUTION Do not reuse the original brake lamp switch The switch can only be adjusted once That is during initial installation of the switch If the switch is not adjusted properly or has been removed for some service a new switch must be installed and adjusted 1 Mount and adjust ...

Page 2055: ...replace the entire unit 1 Remove the liftgate spoiler Refer to 23 BODY EXTERIOR SPOILER REMOVAL 2 Separate the CHMSL from the spoiler by removing the fasteners INSTALLATION 1 Place the CHMSL into position and install the fasteners 2 Install the liftgate spoiler Refer to 23 BODY EXTERIOR SPOILER INSTALLATION 3 Verify vehicle and system operation FOG LAMP REMOVAL 1 Open hood disconnect and isolate t...

Page 2056: ...L 1 Disconnect and isolate the battery negative cable 2 Remove the one retaining screw from the under side of the fascia in the fog lamp opening Fig 8 3 Pull fog lamp unit straight out of front fascia 4 Disconnect the electrical connection to the fog lamp and separate from vehicle If replacing fog lamp unit with new the fog lamp must be transferred to the new unit INSTALLATION If replacing fog lam...

Page 2057: ...the lamp socket 2 Place the front side marker lamp into head lamp unit and twist clockwise Fig 17 3 Install the headlamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT INSTALLATION 4 Verify vehicle and system operation HAZARD SWITCH DESCRIPTION The Hazard Switch is part to the instrument panel switch pod located in the instrument cluster bezel just to the right of the cluster F...

Page 2058: ...r in operation to common vapor filled street headlamps Instead of using a filament to produce light the gas inside the lamp is ignited by creating an arc between two electrodes The color of the light source is classified as its color temperature As the color temperature increases the color of the light moves from yellow to blue white to white The light produced by the HID lamps appears as a white ...

Page 2059: ...ehicle is equipped with various lamp assem blies A good ground is necessary for proper lighting operation Grounding is provided by the lamp socket when it comes in contact with the metal body or through a separate ground wire When changing lamp bulbs check the socket for corrosion If corrosion is present clean it with a wire brush When it is necessary to remove components to ser vice another it sh...

Page 2060: ...ltage 1 Test and repair Integrated Power Module 2 Loose or corroded terminals or splices in circuit 2 Inspect and repair all connectors and splices Refer to Electrical Wiring Diagrams HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Electrical Wiring Diagrams 2 Poor lighting circuit Z343 Z344 ground 2 Test for voltage drop...

Page 2061: ...dule damage in case of an open or shorted circuit The module has overcharge and undercharge circuit protection If either is sensed the module will not illuminate the headlamps for that key cycle or until the fault is corrected Recycle the ignition and headlamp switch if both headlamps do not illumi nate Before determining the headlamp assembly is faulty check the connector at the headlamp and chec...

Page 2062: ... the elements 3 Grab the igniter and twist counterclockwise approximately 1 4 turn There is an arrow pointing which direction to turn Fig 17 The igniter electri cal connector will disengage when this happens unlocking the igniter from the HID lamp 4 Pull the igniter straight out of the headlamp unit 5 Pull lamp straight out of igniter Fig 15 HALOGEN HEADLAMP UNIT 1 HEADLAMP HIGH BEAM 2 HEADLAMP LO...

Page 2063: ...g Fig 15 3 Connect the lamp electrical connector Fig 16 4 Install the rubber boots seals protecting the lamp from the elements 5 Install the headlamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT INSTALLATION HIGH INTENSITY DISCHARGE HID HEADLAMPS IF EQUIPPED LOW BEAM HEADLAMP 1 Place the headlamp into the lamp opening of headlamp unit being careful to align the lamp to the in...

Page 2064: ...l the headlamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT INSTALLATION HEADLAMP UNIT STANDARD PROCEDURE HEADLAMP UNIT ALIGNMENT HEADLAMP UNIT ALIGNMENT PREPARATION 1 Verify headlamp dimmer switch and high beam indicator operation 2 Inspect and correct damaged or defective com ponents that could interfere with proper headlamp alignment 3 Verify proper tire inflation 4 Clean ...

Page 2065: ...lignment screen with tape Use this line for up down adjustment reference HEADLAMP UNIT ADJUSTMENT The low beam headlamp will project on the screen upper edge of the beam cut off at the horizontal lamp centerline 50 mm 2 in Horizontal aim is preset and can not be adjusted The high beam pat tern should be correct when the low beams are aligned properly To adjust headlamp vertical align ment rotate a...

Page 2066: ... unit forward unsnap ping it from the lower retaining clip Fig 24 Be careful not to damage lower retaining clip upon removal Fig 23 HEADLAMP UNIT MOUNTING REMOVE INSTALL 1 HEADLAMP UNTI RETAINING SCREW 3 LOWER HEADLAMP UNIT RETAINING CLIP 2 HEADLAMP UNIT 4 VERTICAL HEADLAMP ADJUSTMENT SCREW CS LAMPS LIGHTING EXTERIOR 8L 19 HEADLAMP UNIT Continued ...

Page 2067: ...of the multi function switch mounting housing at the top of the steering column just below the steering wheel Fig 25 The only visible compo nent of the left multi function switch is the control stalk that extends through a dedicated opening in the left side of the steering column shrouds The remainder of the left multi function switch is con cealed beneath the steering column shrouds The switch is...

Page 2068: ...or extinguish the headlamps Headlamp Beam Selection The Body Control Module BCM monitors the left multi function switch then based upon that switched ground input provides a message to the IPM to activate the selected headlamp beam Headlamp Optical Horn The Body Control Module BCM monitors the left multi function switch then based upon that switched ground input provides a message to the IPM to ac...

Page 2069: ...H SWITCH POSITION CONTINUITY BETWEEN RESISTANCE BETWEEN RESISTANCE Off Pins 4 11 3743 3824 V Park Lamps On Pins 4 11 901 926 V Head Lamps On Pins 4 11 345 358 V Auto Headlamps On Pins 4 11 74 81 V Fog Lamps Pins 1 4 Optical Horn Pins 2 5 High Beam Pins 2 6 INTERIOR LIGHTING SWITCH Dome Lamp Disable On Pins 4 10 63 70 V Panel Lamps Dimming Position 1 Pins 4 10 198 208 V Dimming Position 2 Pins 4 10...

Page 2070: ...ecures the multi func tion switch mounting housing to the steering column housing Fig 26 6 Remove the multi function switch mounting housing Fig 27 and Fig 28 INSTALLATION LEFT MULTI FUNCTION SWITCH 1 Position the left multi function switch onto the housing 2 Install the two screws to the left multi function switch Torque the screws to 2 5 N m 22 in lbs 3 Reconnect the instrument panel wire harnes...

Page 2071: ...LATION 5 Install the left multi function switch onto the multi function switch housing refer to above proce dure 6 Install the clock spring onto the multi function switch housing Refer to 8 ELECTRICAL RE STRAINTS CLOCK SPRING INSTALLATION 7 Connect the battery negative cable 8 Verify vehicle and system operation Fig 28 MULTI FUNCTION SWITCH REMOVE INSTALL 1 RIGHT MULTI FUNCTION SWITCH CONNECTOR 4 ...

Page 2072: ...t counterclockwise and pull out lamp from tail lamp unit 3 Pull lamp straight out of lamp socket INSTALLATION 1 Push lamp straight into lamp socket 2 Place lamp into tail lamp unit and then twist clockwise until lamp stops about 1 4 turn 3 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION TAIL LAMP REMOVAL 1 Remove the tail lamp unit Refer to 8 E...

Page 2073: ...unit transfer lamps to new unit INSTALLATION 1 If replacing the tail lamp unit transfer lamps to new unit 2 Connect electrical connector 3 Place tail lamp unit over retaining clip and push to seat in clip until you hear a snap Fig 32 4 Install the hex head nut into the D Pillar Fig 32 5 Connect the battery negative cable 6 Verify vehicle and system operation 7 Close liftgate Fig 32 TAIL LAMP UNIT ...

Page 2074: ...e dome OFF posi tion The courtesy lamp switch on the headlamp switch is in the dome ON position A Remote Keyless Entry unlock message is received The operator unlocks the driver door with the key with VTSS only ILLUMINATED ENTRY Illuminated entry will be initiated when the cus tomer enters the vehicle by unlocking the doors with the key fob or with the key if the vehicle is equipped with vehicle t...

Page 2075: ...g pins making sure that they are lined up and them firmly snap into place Fig 1 3 Close door 4 Connect the battery negative cable 5 Verify vehicle and system operation DOOR COURTESY LAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the front door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL and Fig 3 3 With the trim panel on the bench push in on the side r...

Page 2076: ...cial tool C 4755 or equivalent gently pry out glove box lamp switch from glove box opening surround Fig 5 6 If replacing the lamp pull straight out of glove box lamp switch Fig 3 DOOR COURTESY LAMP UNIT FRONT REMOVE INSTALL 1 FRONT DOOR TRIM PANEL 3 DOOR COURTESY LAMP UNIT CONNECTOR 2 FRONT DOOR PANEL 4 DOOR COURTESY LAMP UNIT Fig 4 DOOR COURTESY LAMP UNIT REMOVE INSTALL 1 DOOR COURTESY LAMP UNIT ...

Page 2077: ...itting Diode LED into lamp opening in instrument panel switch pod 2 Turn 1 4 turn clockwise 3 Install Cluster bezel Refer to 23 BODY IN STRUMENT PANEL CLUSTER BEZEL INSTAL LATION 4 Verify vehicle and system operation LIFTGATE LAMP REMOVAL 1 Open hood disconnect and isolate the battery negative cable 2 Open liftgate 3 Using a trim stick special tool C 4755 or equivalent gently pry out on door court...

Page 2078: ...unit in the liftgate door trim panel opening and firmly snap into place Fig 10 2 Install the liftgate trim panel Refer to 23 BODY INTERIOR INTERIOR TRIM PANELS INSTALLATION and Fig 9 3 Connect the battery negative cable 4 Verify vehicle and system operation READING LAMPS REMOVAL FRONT READING LAMP 1 Open hood disconnect and isolate the battery negative cable 2 Open door 3 Using a trim stick specia...

Page 2079: ...mp unit retaining clips and firmly snap into place Fig 13 2 Place the rear reading lamp lens over the retaining pins making sure that they are lined up and them firmly snap into place Fig 12 3 Connect the battery negative cable 4 Close hood 5 Verify vehicle and system operation 6 Close front door VANITY LAMP REMOVAL 1 Open hood disconnect and isolate the battery negative cable 2 Open door 3 Using ...

Page 2080: ...nity lamp lens over the retaining slots making sure that they are lined up and them firmly snap into place Fig 14 3 Connect the battery negative cable 4 Close hood 5 Verify vehicle and system operation 6 Close door Fig 14 VANITY LAMP LENS REMOVAL Fig 15 VANITY LAMP REMOVAL CS LAMPS LIGHTING INTERIOR 8L 33 VANITY LAMP Continued ...

Page 2081: ......

Page 2082: ...torage bin The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner The overhead console CMTC module display and Electronic Vehicle Information Center EVIC is built in to the instrument cluster on this model The instrument panel switch pod contains the US M MENU STEP and RESET push buttons used to con trol the CMTC and EVIC ...

Page 2083: ... is a good indication that a INTERMIT TENT problem may be present You must than attempt to find the intermittent problem such as running a tire pressure monitoring system self test Refer to the Tires Wheels section for more informa tion Always eliminate all other potential problems before attempting to replace the module TESTING VOLTAGE AND GROUND SUPPLY TO OVERHEAD CONSOLE 1 Remove the overhead c...

Page 2084: ...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 calibration procedure in another location STANDARD PROCEDURE COMPASS DEMAGNETIZING A degaussing tool Special Tool 6029 is used to demagnetize or degauss the overhead console for ward mounting screw and the roof panel above the overhead conso...

Page 2085: ... current vari ance zone setting 5 Momentarily depress and release the STEP push button to step through the zone numbers until the zone number for your geographic location appears in the display 6 Momentarily depress and release the RESET push button to enter the displayed zone number into the module memory 7 Confirm that the correct directions are now indicated by the compass REMOVAL OVERHEAD CONS...

Page 2086: ...t The FCM receives a hard wired input from the ambient temperature sensor The ambient temperature sensor Fig 6 is a variable resistor mounted to a bracket that is secured with a screw to the left side of the cooling module behind the front grille For more information on the Front Control Module refer to the Electronic Control Modules section The ambient temperature sensor cannot be adjusted or Fig...

Page 2087: ...ng tab and pull the con nector straight off the ambient temperature sensor 4 Remove the sensor retaining screw and remove the sensor from the vehicle INSTALLATION 1 Install the sensor and connect the sensor elec trical connector 2 Install the front grille assembly on the vehicle Refer to the Body section for the procedure 3 Connect the battery negative cable COMPASS MINI TRIP COMPUTER DESCRIPTION ...

Page 2088: ... being replaced the tire pressure monitoring system must be retrained Refer to the Tires Wheels section for detailed instructions INSTALLATION 1 Position the CMTC module in the overhead console and connect the electrical connector 2 Install the screws holding the CMTC module in the overhead console 3 Install the overhead console Refer to 8 ELECTRICAL OVERHEAD CONSOLE INSTALLA TION 4 Connect the ba...

Page 2089: ...niversal transmitter and press any of the transmitters buttons 3 The red signal detection LEDs will light and the tool will beep if a radio signal is detected Repeat this test three times STANDARD PROCEDURE STANDARD PROCEDURE SETTING TRANSMITTER CODES 1 Turn off the engine 2 Erase the codes by pressing the two outside buttons labeled with one and three dots Release the buttons when the display con...

Page 2090: ...DESCRIPTION 8 OPERATION 9 REMOVAL 9 INSTALLATION 9 EXTERIOR HANDLE SWITCH DESCRIPTION 9 OPERATION 9 REMOVAL 10 INSTALLATION 10 FULL OPEN SWITCH DESCRIPTION 10 OPERATION 10 DIAGNOSIS AND TESTING FULL OPEN SWITCH 10 REMOVAL 10 INSTALLATION 11 LIFTGATE DRIVE UNIT MOTOR DESCRIPTION 11 OPERATION 11 DIAGNOSIS AND TESTING LIFTGATE MOTOR 11 REMOVAL 12 INSTALLATION 12 LINK ROD DESCRIPTION 12 OPERATION 12 R...

Page 2091: ...r to the Wiring section of this man ual For system operation instructions refer to the vehicles owner manual Refer to the Body Section of this manual for additional information on liftgate components such as the prop rods hinges door align ment and striker alignment The power liftgate system is designed with a num ber of system inhibitors These inhibitors are neces sary for safety and or feasibili...

Page 2092: ...ed instruc tions DIAGNOSIS AND TESTING POWER LIFTGATE SYSTEM The power liftgate system is a complex system con taining many components involving at least two elec tronic control modules In order to perform conclusive testing the Programmable Communications Interface PCI data bus circuit and the electronic modules that provide inputs to or receive outputs from the power liftgate control module must...

Page 2093: ...k for diagnostic trouble codes with DRB III Failure of motor assembly Test motor assembly No automatic latching in primary and or secondary positions Failure of latch assembly Check wire connections and for blown fuse Check for diagnostic trouble codes and cycle with DRB III Troubleshoot using Body Diagnostic Manual Replace latch assembly if necessary Binding or sticking of components Establish lo...

Page 2094: ...RB III Troubleshoot using body diagnostic manual Wiring problems system or vehicle Troubleshoot using electrical schematics Refer to wiring diagrams Failure of Body Control Module BCM Check for diagnostic trouble codes and cycle with DRB III Troubleshoot using body diagnostic manual Replace BCM if necessary Failure of key fob Reprogram key fob Replace key fob if necessary Failure of Power Liftgate...

Page 2095: ...ck for continuous drive condition Wiring problems system or vehicle Troubleshoot using electrical schematics Refer to Wiring Diagrams Liftgate opens very slowly Low battery voltage Check battery electrical system voltage Failure of liftgate prop rods Replace prop rods if necessary Binding or sticking of components Establish location of binding and replace necessary components Grade of vehicle too ...

Page 2096: ...e the plug from the trim panel by gently prying out 3 Insert the screwdriver through the access hole and find the slot in the beige release lever Rotate the release lever up and to the right when facing rearward Hold the release lever until the latch has cleared the striker SPECIFICATIONS TORQUE SPECIFICATIONS TABLE COMPONENT TORQUE SPECIFICATIONS DESCRIPTION N m In Lbs Drive Unit to D pillar 28 2...

Page 2097: ...ttery cable DRIVE UNIT DESCRIPTION Vehicles equipped with a power liftgate utilize a power liftgate drive unit The drive unit assembly Fig 1 consists of a DC motor optical sensor clutch full open switch rack housing bracket assembly and wire harness The clutch and motor portion Fig 2 of the assembly provides the power and torque required to open or close the liftgate under the worst case con ditio...

Page 2098: ...50 in lbs 28 N m 3 Connect the wire harness connector on the power liftgate drive unit assembly 4 Install the link rod assembly on the drive unit attachment point Refer to the Link Rod installation procedure in this section 5 Install the left rear D pillar trim panel on the vehicle Refer to the Body section for the procedure 6 Install the link rod assembly on the liftgate attachment point Refer to...

Page 2099: ...witch to the drive unit s main electrical connector The full open switch cannot be adjusted or repaired and if found to be faulty must be replaced Consult your Mopar parts catalog for a specific part number OPERATION When the power liftgate is approaching the full open position the full open switch s contact arm leaves contact with the moving rack assembly This releases the switch and opens the ci...

Page 2100: ...entire drive unit assembly and components The power liftgate motor cannot be repaired or adjusted and if found to be defective the motor must be replaced Refer to the procedure in this section for detailed instructions OPERATION LIFTGATE IS CLOSED Depressing either of the power liftgate open close command switches sends a PCI data bus signal to the power liftgate control module The control module ...

Page 2101: ...sing an appropriate scan tool check any erase any power liftgate control module diagnostic trouble codes related to the drive unit assembly 8 Verify power liftgate system operation Cycle the power liftgate through one complete open and close cycle this will allow the power liftgate control module to relearn its cycle with the new components LINK ROD DESCRIPTION Vehicles equipped with a power liftg...

Page 2102: ...cannot be adjusted or repaired The power latch assembly can be replaced as a com plete assembly latch without actuator or just the actuator Consult your Mopar parts catalog for spe cific part numbers OPERATION Operating on hardwired inputs from the power lift gate control module the latch mounted actuator cinch release motor provides the torque required to close the liftgate from the secondary to ...

Page 2103: ...assembly from the liftgate 6 Place the latch assembly on a bench and locate the three wires leading from the actuator portion of the latch assembly 7 Disengage the main connector retaining push pins from the latch actuator housing CAUTION Locate the wires coming from the actua tor portion of the latch assembly On a piece of paper note the wire color and cavity the wires are currently installed in ...

Page 2104: ...trol module The speed signal is generated from a trigger wheel located inside the clutch housing of the drive unit assembly When the optical sensor is installed in the clutch housing prop erly the trigger wheel is positioned in the optical sensor Hard wired inputs to and from the liftgate control module are used to monitor the speed time of the liftgate motor and clutch assembly REMOVAL 1 Open the...

Page 2105: ...ition The conduc tive rubber strips incorporated into the sensors pro vide the mechanical means for this sensor function DIAGNOSIS AND TESTING PINCH SENSOR To verify power liftgate system and pinch sensor operation 1 Cycle the power liftgate through two complete open and close cycles during each of the final close cycles with the liftgate in mid travel depress each of the pinch sensors to verify t...

Page 2106: ... available Remote Key less Entry RKE system radio frequency transmit ters if equipped AUTOMATIC DOOR LOCKS When enabled this feature will lock all of the door locks if all of the doors are closed and the vehicle speed goes above 25 7 km h 15 mph If a door unlock has occurred then the DDM PDM will per form another auto lock if the doors did not electri cally unlock another auto lock will not occur ...

Page 2107: ...er to be linked to the memory system The RKE transmitter can be linked to either position 1 or position 2 This allows the operator to have the vehi cle move the mirrors seat pedals and radio stations upon a depress of the unlock switch on the transmit ter Sound Horn on Lock Allows the option of having the horn sound a short chirp as an audible verification that the RKE system received a valid Lock...

Page 2108: ...round wire to the other pin To unlock the door reverse the wire con nections at the motor pin terminals If these results are not obtained replace the door latch DRIVER CYLINDER LOCK SWITCH DESCRIPTION The Door Cylinder Lock Switch is used to Unlock Lock all the doors via the Central Lock ing feature Arm Disarm the Vehicle Theft Security System Trigger the Illuminated Entry feature The door cylinde...

Page 2109: ...Asian transmit ters and 30 5 centimeters 12 inches for all others To test position the transmitter as shown Fig 1 Press any transmitter button then test each button individually The tool will beep if a radio signal strength that lights five or more LED s is detected Repeat this test three times If transmitter fails any of the test refer to the Diagnostic Procedures manu al STANDARD PROCEDURE STAND...

Page 2110: ...K buttons on the transmitter at the same time Then press and release any button on the same transmitter and a chime will sound after successfully programming the transmit ter 7 Repeat steps 5 and 6 for all transmitters that will be used with this vehicle up to 4 total 8 Turn ignition to the OFF position Transmitter programming mode will discontinue after 60 seconds All transmitter programming must...

Page 2111: ...ith the use of the DRB IIIt diag nostic tool For information on the use of the DRB IIIt refer to the appropriate Diagnostic Service Manual For complete circuit diagrams refer to the appro priate wiring information AUTOMATIC DAY NIGHT MIRROR DESCRIPTION An automatic dimming inside day night rear view mirror and an automatic dimming driver side outside rear view mirror is an available option The aut...

Page 2112: ...day night mirror switch in the On LED in the switch is lighted position Cover the forward facing ambient photocell sensor to keep out any ambient light NOTE The ambient photocell sensor must be cov ered completely so that no light reaches the sen sor Use a finger pressed tightly against the sensor or cover the sensor completely with electrical tape 7 Shine a light into the rearward facing head lam...

Page 2113: ...R MOTOR DESCRIPTION 35 OPERATION 35 DIAGNOSIS AND TESTING RECLINER MOTOR 35 REMOVAL 36 INSTALLATION 36 POWER SEAT SYSTEM DESCRIPTION DESCRIPTION The power seat system option allows the driver and front seat passenger to electrically adjust their seating positions for optimum control and comfort Power seat switches are used to position the seats in the desired location and are located on each of th...

Page 2114: ...c modules in the vehicle over the Programmable Communications Interface PCI data bus network The PCI data bus network allows the sharing of sensor information This system provides increased reliability enhanced diagnostics and allows the addition of new feature capabilities For diagnosis of the electronic modules or of the PCI data bus network the use of a DRB IIIt scan tool and the proper Diagnos...

Page 2115: ...c Vehicle Information Center EVIC module serves as the user interface for the memory system It displays memory system messages in the cluster display and provides the vehicle operator with a means for enabling and disabling the customer pro grammable features available in the system Refer to Electronic Vehicle Information Center in Overhead Console for more information on the EVIC module See the o...

Page 2116: ... out in the proper diagnostic proce dures manual to resolve if codes are present 4 To check the memory heated seat adjustable pedal module for proper output obtain a DRB IIIt scan tool energize each seat track motor axis one at a time If any axis stops without hitting the end of travel the potentiometer signal for that axis may have an open short or be mis wired Check the wir ing to that axis modu...

Page 2117: ...rcuit as required 4 Using an ohmmeter verify the Seat Switch resistance values using the seat switch connector receptacle If the values are not within spec replace the driver seat switch MEMORY SWITCH TESTING SWITCH RESISTANCE 4 PIN s 11 4 1 8000 Ohms 8 Kohms SET 4815 Ohms 4 815 Kohms SET 1 3420 Ohms 3 420 Kohms 2 2410 Ohms 2 410 Kohms SET 2 1730 Ohms 1 730 Kohms HEATED SEAT SWITCH TESTING PIN s 1...

Page 2118: ...ich moves the seat track in the forward and rearward directions The forth motor is the recliner adjustment motor which moves the seat back in the forward and rear ward directions The power seat track unit cannot be repaired and is serviced only as a complete unit If any component in this unit is faulty or damaged the entire power seat track unit must be replaced OPERATION When a power seat switch ...

Page 2119: ...justable pedal module retaining screws 9 Install the seat assembly in the vehicle Refer to 23 BODY SEATS SEAT INSTALLATION LUMBAR MOTOR DESCRIPTION The power seat system includes an electrically operated lumbar support mechanism The power lumbar adjuster and motor are concealed beneath the seat back trim cover and padding where they are secured to the seat back frame The power lumbar adjuster mech...

Page 2120: ...circuit diagrams LUMBAR CONTROL SWITCH DESCRIPTION The lumbar control switch is one of eight separate switches ganged together in driver seat switch assembly The switch is located on the drivers front door trim panel Fig 2 The driver seat switch assembly can provide up to six resistive multiplexed inputs into the driver door module The inputs can include memory heated seat power seat and foot peda...

Page 2121: ... switch used on CS vehicles is incorporated into the driver seat switch assembly For diagnostic routine Refer to 8 ELECTRICAL POWER SEATS DRIVER SEAT SWITCH DIAGNO SIS AND TESTING PASSENGER SEAT SWITCH DESCRIPTION The passenger seat switch assembly includes up to three switches ganged together in one compact switch assembly The switch is located on the passen gers front door trim panel This seat s...

Page 2122: ...air the open voltage supply circuit as required 4 Using an ohmmeter check the Seat Switch resistance values If the values are not within spec replace the seat switch HEATED SEAT SWITCH TESTING SWITCH RESISTANCE 4 PINS 10 4 LO 8010 Ohms 8 010 Kohms HI 2415 Ohms 2 415 Kohms POWER SEAT SWITCH TESTING PINS 8 4 SEAT CUSHION REARWARD 8020 Ohms 8 020 Kohms SEAT CUSHION FORWARD 2420 Ohms 2 420 Kohms POWER...

Page 2123: ...ever these tests may not prove conclu sive In order to obtain conclusive testing of the power seat system the Programmable Communica tions Interface PCI data bus network and all of the electronic modules that provide inputs to or receive outputs from the system components must be checked PRELIMINARY TESTS 1 Obtain a DRB IIIt scan tool and check for any stored diagnostic trouble codes recorded in t...

Page 2124: ...s The door module then sends the request to the Memory Heated Seat Adjustable Pedal Module MHSAPM via the PCI data bus circuit The MHSAPM is responsible for the 12v battery feed and ground path to the power seat recliner adjuster motor The adjuster motor operates to move the recliner mechanism through its drive unit in the selected direction until the switch is released or until the travel limit o...

Page 2125: ...B IIIt scan tool and energize the recliner motor If the motor stops without hitting the end of travel the potentiometer signal for that axis may have an open short or be mis wired Check the wiring to that axis module to motor Fix any wiring problems and retry that axis If the recliner motor is inoperational apply 12v and a good ground source to the inop motor If the motor does not operate in eithe...

Page 2126: ...DDM will still be able to actuate all of the windows When the window lockout is disabled the window lockout switch will illuminate emerald green and again allow the passenger window lift switches to activate their corresponding window and return illumination to the passenger window switches WINDOW MOTOR Window motors use permanent type magnets The B and ground applied at the motor terminal pins wi...

Page 2127: ...ch power window switch including the lockout switch is illuminated by a Light Emitting Diode LED when the ignition switch is turned to the On position However when the lockout switch is placed in the Lock position the LED for the locked out front and rear passenger door power window switches is turned off When the lockout switch is enabled lit red the window switches on the DDM still operate their...

Page 2128: ...the battery negative cable 2 Remove the rear door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 3 Remove the rear door speaker Refer to 8 ELECTRICAL AUDIO SPEAKER REMOVAL 4 Remove the watershield 5 Disconnect electrical harness wire connector from the motor 6 Loosen window regulator mounting fasteners do not remove 7 Remove mounting fasteners and motor INSTALLATION FRONT DOOR 1 Install...

Page 2129: ......

Page 2130: ...RATION 8 REMOVAL 9 INSTALLATION 9 EXTERIOR HANDLE SWITCH DESCRIPTION 9 OPERATION 9 REMOVAL 9 INSTALLATION 9 FULL OPEN SWITCH DESCRIPTION 10 OPERATION 10 DIAGNOSIS AND TESTING FULL OPEN SWITCH 10 REMOVAL 10 INSTALLATION 10 LIFTGATE DRIVE UNIT MOTOR DESCRIPTION 11 OPERATION 11 DIAGNOSIS AND TESTING LIFTGATE MOTOR 11 REMOVAL 11 INSTALLATION 11 LINK ROD DESCRIPTION 12 OPERATION 12 REMOVAL 12 INSTALLAT...

Page 2131: ...Body Section of this manual for additional information on liftgate components such as the prop rods hinges door align ment and striker alignment The power liftgate system is designed with a num ber of system inhibitors These inhibitors are neces sary for safety and or feasibility of the power liftgate system Refer to power liftgate system inhibitors noted below POWER LIFTGATE SYSTEM INHIBITORS The...

Page 2132: ...to Standard Procedures in this section for detailed instructions DIAGNOSIS AND TESTING POWER LIFTGATE SYSTEM The power liftgate system is a complex system con taining many components involving at least two elec tronic control modules In order to perform conclusive testing the Programmable Communications Interface PCI data bus circuit and the electronic modules that provide inputs to or receive out...

Page 2133: ... electrical schematics Refer to wiring diagrams Low battery voltage Charge battery Failure of Power Liftgate or Body Control Module Check for diagnostic trouble codes with DRB III Failure of motor assembly Test motor assembly No automatic latching in primary and or secondary positions Failure of latch assembly Check wire connections and for blown fuse Check for diagnostic trouble codes and cycle w...

Page 2134: ... prop rods Excessive cold or weight on liftgate Check for added weight or extreme cold climate High opening effort Failure of liftgate prop rods Replace prop rods Check for broken attachments Drive unit jamed or did not disengage Troubleshoot using Body Diagnostic Information Replace components if necessary Binding or sticking of components Establish location of binding and replace necessary compo...

Page 2135: ...liftgate component is removed replaced or a liftgate adjustment is performed a learn cycle must be performed This learn cycle enables the power liftgate control module to learn or relearn information travel limits resistance to door travel etc which allows it to perform properly and safely To perform a learn cycle do the following 1 Obtain a DRB IIIt scan tool 2 Connect the DRB IIIt to the vehicle...

Page 2136: ... 1 Open the liftgate 2 Disconnect and isolate the negative battery cable 3 Remove the rear light bar assembly from the vehicle Refer to the Body section for the procedure 4 Using your hands grasp the light bar at its sides next to chime thermistor assembly and gently pull the two sides of the light bar apart until the chime thermistor can be removed CAUTION Locate the wires coming from the chime t...

Page 2137: ...ts cannot be adjusted or repaired and if damaged they must be replaced Consult your Mopar parts catalog for a specific part number OPERATION LIFTGATE IS CLOSED Depressing either of the power liftgate open close command switches sends a PCI data bus signal to the power liftgate control module The control module will then signal the door mounted latch assembly to release the door from its primary cl...

Page 2138: ...tivation of the handle switch during a automatic power close cycle will cause the liftgate to reverse direction Activation of the handle switch during an power open cycle will cause the power lift gate to disengage allowing full manual operation The exterior handle switch cannot be adjusted or repaired and if damaged it must be replaced Consult your Mopar parts catalog for a specific part num ber ...

Page 2139: ...ct and isolate the negative battery cable 3 Remove the left rear D pillar trim panel from the vehicle Refer to the Body section of this manual for the procedure CAUTION Locate the two wires coming from the full open switch On a piece of paper note the wire color and cavity the wires are currently installed in on both the switch and connector side of the har ness This will prove helpful later 4 Cut...

Page 2140: ... cycle the power liftgate control module will automatically reverse direction of the liftgate to pre vent vehicle damage or personal injury Refer to Power Liftgate System description operation for addi tional information DIAGNOSIS AND TESTING LIFTGATE MOTOR 1 Open liftgate and remove D pillar trim to access the power liftgate motor Refer to the Body section for the procedure 2 Using a DRB IIIt sca...

Page 2141: ...d attaches the liftgate to the power liftgate drive unit assembly The link rod consists of a steel shaft equipped with two spherical rod end receptacles at each end The weight of the liftgate is not supported by the link rod the liftgate prop rods are designed to support the liftgate The link rod cannot be adjusted or repaired and if damaged must be replaced Consult your Mopar parts catalog for a ...

Page 2142: ...ator or just the actuator Consult your Mopar parts catalog for spe cific part numbers OPERATION Operating on hardwired inputs from the power lift gate control module the latch mounted actuator cinch release motor provides the torque required to close the liftgate from the secondary to the primary closed and latched position The actuator also releases the liftgate from the primary closed and latche...

Page 2143: ...he three wires out of the main latch elec trical connector Refer to the wiring section for detailed instructions 9 Flip the latch assembly over and remove the latch actuator retaining screw s 10 Remove the latch actuator from the latch assembly INSTALLATION 1 Install the latch actuator on the latch assem bly 2 Install the latch actuator retaining screws Torque the screws to 4 in lbs 3 Install the ...

Page 2144: ...at bladed tool depress one of the optical sensor s plastic retaining tabs Fig 10 to unhook the optical sensor from the clutch housing assembly INSTALLATION NOTE Be certain the optical sensor wires are rein stalled in the correct wire cavities Failure to do so could result in damage to components Refer to Wiring Diagrams if previous notes were not made 1 Perform a wiring repair on the optical senso...

Page 2145: ... to the open position If OK pinch sensors and module are OK at this time If NOT OK go to Step 2 2 Remove the liftgate trim panel to access the inoperable pinch sensor s electrical connector Using an ohmmeter check for continuity on the two wires leading from the pinch sensor While depressing the pinch sensor continuity should be 300 ohms max While NOT depressing the pinch sensor continuity should ...

Page 2146: ... available Remote Key less Entry RKE system radio frequency transmit ters if equipped AUTOMATIC DOOR LOCKS When enabled this feature will lock all of the door locks if all of the doors are closed and the vehicle speed goes above 25 7 km h 15 mph If a door unlock has occurred then the DDM PDM will per form another auto lock if the doors did not electri cally unlock another auto lock will not occur ...

Page 2147: ...utton RKE Linked to Memory Allows the RKE transmitter to be linked to the memory system The RKE transmitter can be linked to either position 1 or position 2 This allows the operator to have the vehi cle move the mirrors seat pedals and radio stations upon a depress of the unlock switch on the transmit ter Sound Horn on Lock Allows the option of having the horn sound a short chirp as an audible ver...

Page 2148: ...o the pos itive pin of the lock motor and a ground wire to the other pin To unlock the door reverse the wire con nections at the motor pin terminals If these results are not obtained replace the door latch DRIVER CYLINDER LOCK SWITCH DESCRIPTION The Door Cylinder Lock Switch if equipped is used to Unlock Lock all the doors via the Central Lock ing feature Arm Disarm the Vehicle Theft Security Syst...

Page 2149: ...s 12 inches for all others To test position the transmitter as shown Fig 1 Press any transmitter button then test each button individually The tool will beep if a radio signal strength that lights five or more LED s is detected Repeat this test three times If transmitter fails any of the test refer to the Diagnostic Procedures manual STANDARD PROCEDURE STANDARD PROCEDURE HORN CHIRP PREFERENCE DISA...

Page 2150: ...eters 23 ft of the vehicle Range may be better or worse depending on the environment around the vehicle SPECIFICATIONS BATTERY The batteries can be removed without special tools and are readily available at local retail stores The recommended battery is Duracell DL 2016 or equiva lent TWO cells are required Battery life is about three years minimum CAUTION Do not touch the battery terminals or han...

Page 2151: ...TALLATION 33 RECLINER MOTOR DESCRIPTION 33 OPERATION 33 DIAGNOSIS AND TESTING RECLINER MOTOR 34 REMOVAL 34 INSTALLATION 34 POWER SEAT SYSTEM DESCRIPTION DESCRIPTION The power seat system option allows the driver and front seat passenger to electrically adjust their seating positions for optimum control and comfort Power seat switches are used to position the seats in the desired location and are l...

Page 2152: ...le Communications Interface PCI data bus network The PCI data bus network allows the sharing of sensor information This system provides increased reliability enhanced diagnostics and allows the addition of new feature capabilities For diagnosis of the electronic modules or of the PCI data bus network the use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual are recommended Electr...

Page 2153: ...EVIC module serves as the user interface for the memory system It displays memory system messages in the cluster display and provides the vehicle operator with a means for enabling and disabling the customer pro grammable features available in the system Refer to Electronic Vehicle Information Center in Overhead Console for more information on the EVIC module See the owner s manual in the vehicle ...

Page 2154: ...sting instructions 3 Obtain a DRB IIIt scan tool and check for any stored diagnostic trouble codes recorded in the mem ory heated seat adjustable pedal module Follow the procedures called out in the proper diagnostic proce dures manual to resolve if codes are present 4 To check the memory heated seat adjustable pedal module for proper output obtain a DRB IIIt scan tool energize each seat track mot...

Page 2155: ... 3 If NOT OK repair the open ground circuit as required 3 Using an voltmeter check the appropriate 12v circuit cavity of the power seat switch connector for approx 12v It should be present If OK go to Step 4 If NOT OK repair the open voltage supply circuit as required 4 Using an ohmmeter verify the Seat Switch resistance values using the seat switch connector receptacle If the values are not withi...

Page 2156: ...the motor position This enables the memory system to function by referenc ing the motor positions programmed into the module The front and rear of the seat are operated by two separate vertical adjustment motors These motors can be operated independently of each other tilting the entire seat assembly forward or rearward or they can be operated in unison by selecting the proper power seat switch fu...

Page 2157: ...g the power seat track to the seat assembly 7 Pull the seat back trim cover up slightly to access and remove the two seat back frame mounting bolts and also remove two seat back recliner bolts 8 Remove four seat track mounting bolts from the seat cushion pan 9 Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat track retainin...

Page 2158: ...System and or Charging Sys tem section for testing instructions 3 Obtain a DRB IIIt scan tool and energize each seat track motor axis one at a time If any axis stops without hitting the end of travel the potentiometer signal for that axis may have an open short or be mis wired Check the wiring to that axis module to motor Fix any wiring problems and retry that axis If a lumbar motor is inoperation...

Page 2159: ...out The driver seat switch assem bly can provide up to six major resistive multiplexed inputs into the driver door module The inputs can include memory heated seat seat front up down and foot pedal forward seat rear up down and pedal backwards seat forward backward and lumbar aft recline forward backward and lumbar backwards All inputs are hardwired resistive mux to the driver door module to decod...

Page 2160: ...e switch assembly cannot be adjusted or repaired If one switch is damaged or faulty the entire seat switch assembly must be replaced OPERATION The passenger seat switch has up to three momen tary switch buttons The heated seat switch portion of the switch is back lit with Light Emitting Diodes LED for easy visibility When any of the switch but tons are depressed a resistance signal is sent to the ...

Page 2161: ...it The power seat track unit includes two reversible electric motors that are secured to the upper half of the track unit Each motor moves the seat adjuster through a combination of worm drive gearboxes and screw type drive units The CS passenger seat base and seat back recliner can be adjusted forward and backward One motor is the horizontal adjustment motor which moves the seat track in the forw...

Page 2162: ...ectrical connectors connecting the power seat track to the seat assembly 5 Pull the seat back trim cover up slightly to access and remove the two seat back frame mounting bolts and seat back recliner bolts 6 Remove four seat track mounting bolts from the seat cushion pan 7 Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat t...

Page 2163: ...aker diagnosis and testing procedure 2 Check for proper battery or electrical system voltage The CS is equipped with a low voltage cut off feature If the electrical system voltage drops below a predetermined set point approx 11 5v the power seat system will not function until the proper system voltage has been restored If OK go to Step 4 Refer to the Battery System and or Charging Sys tem section ...

Page 2164: ...NSTALLATION 35 SEAT BELT HEIGHT ADJUSTER REMOVAL 35 INSTALLATION 35 SEAT BELT HEIGHT ADJUSTER KNOB COVER REMOVAL 36 INSTALLATION 36 SEAT BELT SWITCH DESCRIPTION 36 OPERATION 37 SEAT BELT TENSIONER DESCRIPTION 37 OPERATION 37 RESTRAINTS DESCRIPTION The occupant restraints for this model include both active and passive types Active restraints are those which require the vehicle occupants to take som...

Page 2165: ...his system is designed to protect occu pants in the event of a front impact collision These airbags and seat belt tensioners are all serviceable parts If these pyrotechnics are deployed or defective they must be replaced as well as the Occupant Restraint Controller ORC must be diagnosed follow ing procedures outlined in the service diagnostic manuals The Driver and Passenger Airbag System was desi...

Page 2166: ...em utilize a curtain airbag side impact sensors and the ORC to determine if the airbag should be deployed Following a side impact event where the side airbag was deployed the headliner as well as the curtain airbag must be replaced OPERATION The primary passenger restraints in this are the seat belts and child restraint anchors Seat belts and child restraint anchors are referred to as an Active Re...

Page 2167: ...by the forces of gravity G force upon the impact sensors When an impact is severe enough the microprocessor in the ORC signals the inflator of the appropriate airbag units to deploy their airbag cushions The front seat belt tensioners are provided with a deployment signal by the ORC in conjunction with the front airbags and driver knee blocker air bag During a frontal vehicle impact the knee block...

Page 2168: ...hicles equipped with power door locks will unlock automat ically In addition approximately 5 seconds after the vehicle has stopped moving the interior lights will illuminate until the ignition switch is turned off WARNING WARNINGS WARNING THIS SYSTEM IS A SENSITIVE COM PLEX UNIT DISCONNECT AND ISOLATE THE BAT TERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCE DURES ALLOW SY...

Page 2169: ...Steering Wheel Complete Steering Column Assembly w Lower Steering Column Coupler All other airbag and vehicle components should be closely inspected following any airbag deployment and should be replaced when visible damage is incurred PASSENGER AIRBAG After a Passenger Airbag has been deployed due to a collision the following MUST be replaced Passenger Airbag Instrument Panel and Pad Assembly All...

Page 2170: ...anchors are welded to the seat cushion frame They are each accessed from the front of their respective seats at each side where the seat back meets the seat cush ion These lower anchors cannot be adjusted or repaired and if faulty or damaged the seat must be replaced as a unit Each second row seating position has a child restraint upper tether anchor as well It is located in the middle of the seat...

Page 2171: ...the lap portion tight around the child restraint so that it is not necessary to use a locking clip Pulling up on the shoulder portion of the lap shoulder belt will tighten the belt The cinching latch plate will keep the belt tight however any seat belt system will loosen with time so check the belt occasionally and pull it tight if necessary CLOCK SPRING DESCRIPTION The clock spring assembly is se...

Page 2172: ... two connector receptacles on the upper surface of the clock spring rotor to the horn switch the two speed control switches and if the vehicle is so equipped to the optional remote radio switches on the steering wheel Like the clock spring in a timepiece the clock spring tape has travel limits and can be damaged by being wound too tightly during full stop to stop steer ing wheel rotation To preven...

Page 2173: ... the steering wheel until the front wheels are in the straight ahead position 1 Place the front wheels in the straight ahead position 2 Remove the driver airbag from the steering wheel Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Remove the steering wheel from the steering column Refer to 19 STEERING COLUMN STEER ING WHEEL REMOVAL 4 Remove the upper and lower steering column shrouds Re...

Page 2174: ... clock spring to the two connector receptacles below the steering column on the back of the clock spring housing 6 Install the upper and lower steering column shrouds Refer to 19 STEERING COLUMN UPPER SHROUD INSTALLATION and Refer to 19 STEERING COLUMN LOWER SHROUD INSTAL LATION and Fig 9 7 Install and tighten the screw that secures the lower tilting steering column shroud to the multi function sw...

Page 2175: ...ake out and connector of the body wire harness The curtain airbag cannot be adjusted or repaired and must be replaced if deployed faulty or in any way damaged Once a curtain airbag has been deployed the complete airbag unit the headliner the upper A B C and D pillar trim and all other visibly damaged components must be replaced Refer to the proper Body Diagnostic Procedures manual for diag nosis a...

Page 2176: ...rvice 3 Remove the headliner from the vehicle Refer to 23 BODY INTERIOR HEADLINER REMOVAL 4 Remove the screws that secure the curtain air bag to the spring nuts in the roof side rail Fig 13 and Fig 14 5 Disconnect the curtain airbag squib connector Fig 13 6 Disengage the side curtain airbag front tether plastic retainer from the hole in the upper A pillar Fig 15 7 Grasp the extruded curtain airbag...

Page 2177: ...NER REMOVAL 4 Remove the curtain airbag Refer to above pro cedure Refer to 8 ELECTRICAL RESTRAINTS CURTAIN AIRBAG REMOVAL 5 Using a trim stick special tool C 4755 or equivalent gently pry out on the counter measure rail to be removed Fig 16 6 Remove head impact counter measure rail from vehicle Fig 16 Fig 14 CURTAIN AIRBAG D PILLAR REMOVE INSTALL 1 COAT HOOK ASSEMBLY BRACKET 3 HEAD IMPACT COUNTER ...

Page 2178: ...BAG SYSTEM FIRST FAILURE TO DO SO COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH 6 Verify vehicle and system operation 7 Close hood HEAD IMPACT COUNTER MEASURES 1 Position the head impact counter measure rail over retaining slots and firmly snap into place Fig 16 2 Install the curtain airbag Refer to above pro cedure Refer to 8 ELECTRICAL RESTRAINTS CURTAIN AIRBAG INSTALLATION 3 Install the hea...

Page 2179: ...bag is a multistage Next Generation type that deploys with less force than those used in some prior models A radial deploying fabric airbag cushion with internal tethers is used The airbag inflator is a dual initiator non azide pyrotechnic type unit Two color coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two y...

Page 2180: ...ckly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back steering wheel side panel of the airbag cushion Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned but they are securely sealed within the airbag inflator Typically both ini tiators are used...

Page 2181: ...tes for the system reserve capac itor to discharge before servicing any airbag compo nents 4 Remove the driver airbag Refer to 8 ELEC TRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 5 With driver airbag removed pick a corner and push down on the inflator or latch hook mounting plate until the latch hooks push out of the driver air bag cover Fig 18 and Fig 19 6 Remove driver airbag from driver airbag cover...

Page 2182: ...O DO SO COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH KNEE BLOCKER AIRBAG DESCRIPTION The Knee Blocker Airbag Fig 23 and Fig 24 is located on the driver side of the vehicle beneath the instrument panel steering column outer cover Fig 25 Fig 20 DRIVER AIRBAG TRIM COVER Fig 21 HORN WIRE ROUTING Fig 22 SECURE AIRBAG TRIM COVER LATCH HOOKS Fig 23 KNEE BLOCKER AIRBAG REAR CS RESTRAINTS 8O 19 DRIVER...

Page 2183: ...nitiate a small pyrotechnic charge which in turn ignites chemical pellets within the inflator Once ignited these chemical pellets burn rapidly and produce a large quantity of inert gas The inflator is sealed to the back of the airbag hous ing and a diffuser in the inflator directs all of the inert gas into the airbag cushion causing the cushion to inflate As the cushion inflates the knee blocker a...

Page 2184: ...ns contact a physician REMOVAL 1 Open hood disconnect and isolate the battery negative cable 2 Wait two minutes for the system reserve capac itor to discharge before beginning any system or com ponent service 3 Remove the steering column opening cover two retaining screws Fig 26 and unsnap cover from instrument panel 4 Remove four knee blocker airbag retaining bolts from airbag Fig 27 5 Pull down ...

Page 2185: ...er tightening torque of the screws that secure the sensor to the bracket cannot be achieved the sensor and bracket unit must be replaced Refer to the proper Body Diagnostic Proce dures manual for diagnosis and testing SIDE IMPACT SENSORS Three side impact sensors are used on each side of the vehicle These sensors are mounted remotely from the bi directional safing sensor that is internal to the Oc...

Page 2186: ...or from the impact sensor and remove from vehicle Fig 29 C PILLAR MOUNTED 1 Open hood disconnect and isolate the battery negative cable 2 Wait two minutes for the system reserve capac itor to discharge before beginning any system or com ponent service 3 Remove the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor Refer to 23 BODY INTERIOR QUARTER TRIM PAN...

Page 2187: ...aining screws to the impact sensor Fig 29 Torque screws to 7 N m 62 in lbs 4 Install the B pillar lower trim for the side of the vehicle that you are replacing the side impact sensor Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INSTALLATION WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE Refer to 8 ELECTRICAL RE STRAINTS DIAGNOSIS AND TESTING AIRBAG SYSTEM FIRST FAILURE TO DO SO COULD RESULT I...

Page 2188: ... the internal electronic circuitry and compo nents An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit and should always be pointed toward the front of the vehicle Two molded plastic electrical connector receptacles exit the right side of the ORC housing These two receptacles con nect the ORC to the vehicle electrical sys...

Page 2189: ...ter sensor within the ORC that provides an additional logic input to the ORC microprocessor The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors and must exceed a safing threshold in order for the airbags to deploy Because of the side curtain airbags feature a second ...

Page 2190: ...NG 7 FRONT FLOOR CONSOLE 4 FLOOR CONSOLE BASE Fig 34 ORC CONNECTORS 1 OCCUPANT RESTRAINT CONTROLLER ORC 2 BODY HARNESS ORC CONNECTOR 3 INSTRUMENT PANEL HARNESS ORC CONNECTOR Fig 35 ORC REMOVE INSTALL 1 OCCUPANT RESTRAINT CONTROLLER ORC 2 ORC RETAINING SCREWS 3 3 INSTRUMENT PANEL HARNESS ORC CONNECTOR 4 BODY HARNESS ORC CONNECTOR 5 FLOOR TUNNEL CS RESTRAINTS 8O 27 OCCUPANT RESTRAINT CONTROLLER Cont...

Page 2191: ...nel structural duct and two screws to the crosscar beam A short four wire pigtail harness with a keyed yellow connector insulator connects the two inflator initiators to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness The passenger airbag is a multistage airbag It consists of a magnesium housing the rectangular fabric airbag cushion and...

Page 2192: ... hazardous chem icals are burned during an airbag deployment event The inert gas that is produced when the chemicals are burned is harmless However a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin eyes or breathing passages If skin or eye irritation is noted rinse the affected area with plenty of cool clean water If breathing passages ...

Page 2193: ...e retractor electrical connector Fig 38 6 Remove the two B pillar seat belt retaining ring mounting screws and then retaining ring from seat belt webbing Fig 38 7 Remove the two seat belt retractor mounting bolts Fig 38 8 Grasp the height adjuster knob cover and gen tly pull inward separating it from the seat belt height adjuster 9 Remove the turning loop retaining bolt from the seat belt height a...

Page 2194: ...c itor to discharge before beginning any system or com ponent service 3 Remove the second and third row seats from side of vehicle that the seat belt and retractor are being serviced 4 Remove second and third row lower seat belt anchor bolt covers and lower seat belt anchor bolts from the lower quarter trim panel at the C Fig 39 and D pillars Fig 40 5 Remove lower quarter trim panel Refer to 23 BO...

Page 2195: ...seat belt retaining ring onto the seat belt webbing and then install the two B pil lar seat belt retaining ring mounting screws Fig 38 6 Connect the retractor electrical connector Fig 38 7 Install the lower B pillar trim Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INSTALLATION 8 Install the lower seat belt anchor bolt and lower seat belt anchor bolt cover through lower B pil lar Fig 38 Torque bo...

Page 2196: ... turning loop cover 3 Install the two seat belt retractor mounting bolts Fig 38 Torque bolts to 40 N m 30 ft lbs 4 Install the B pillar seat belt retaining ring onto the seat belt webbing and then the retaining ring screws to the D pillar Fig 40 5 Install the upper D pillar trim Refer to 23 BODY INTERIOR D PILLAR TRIM INSTALLA TION 6 Install the lower quarter trim panel Refer to 23 BODY INTERIOR Q...

Page 2197: ...d row seat belt buckle is placed in between the seat riser and the cushion SEAT BELT BUCKLE THIRD ROW 1 Remove one screw to trim cover and remove cover 2 Reach down between seats and remove the buckle half retaining nut from the seat cushion frame Fig 43 3 Slide the seat belt buckle off the mounting stud and remove from vehicle Fig 44 Fig 42 SEAT BELT BUCKLE FRONT 1 SEAT ADJUSTER TRIM 2 SEAT BELT ...

Page 2198: ...ng compound is applied to the threads at the factory Once the retaining nut is removed a thread locking compound should be reapplied during installation 2 Reach down between seats and install the buckle half retaining nut onto the seat cushion frame Fig 43 Torque nut to 40 N m 30 ft lbs 3 Install trim cover and retaining screw SEAT BELT HEIGHT ADJUSTER REMOVAL 1 Gently pull inward on height adjust...

Page 2199: ...e seat belt switch is connected to the vehi cle electrical system through a two lead pigtail wire and connector on the driver side front seat belt buck le half which is connected to a wire harness connec tor and take out of the body wire harness on vehicles with manual seat adjusters or to a connector and take out of the power seat wire harness on vehicles with power seat adjusters A radio noise s...

Page 2200: ...oncealed beneath the lower B pillar trim The seat belt tensioner consists prima rily of a sprocket pinion a steel tube a cast metal housing numerous steel balls a stamped metal ball trap a torsion bar a small pyrotechnically activated gas generator and a short pigtail wire All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the ...

Page 2201: ...actor spool rides upon is designed to deform in order to control the loading being applied to the occu pants by the seat belts during a frontal impact fur ther reducing the potential for occupant injuries The ORC monitors the condition of the seat belt tensioners through circuit resistance and will illumi nate the airbag indicator in the instrument cluster and store a Diagnostic Trouble Code DTC f...

Page 2202: ...ION N m Ft Lbs In Lbs Servo Mounting Bolt 5 6 50 Servo Bracket Nuts 6 8 60 CABLE REMOVAL 1 Disconnect the negative battery cable 2 Remove the servo bracket bolt 3 Remove speed control cable from throttle cam by sliding clasp out hole used for throttle cable Fig 1 4 Remove the throttle cable with retaining tab and then slide cable speed control cable out from bracket 5 Disconnect electrical connect...

Page 2203: ...torque chart for torque specifications 6 Connect electrical connectors and vacuum hose 7 Install speed control cable to throttle cam by sliding clasp into hole Fig 1 8 Install the servo bracket bolt Refer to the torque chart for torque specifications 9 Connect the negative battery cable SERVO REMOVAL 1 Disconnect the negative battery cable 2 Remove the servo bracket bolt 3 Remove speed control cab...

Page 2204: ...orque chart for torque specifications 3 Connect electrical connectors and vacuum hose 4 Install speed control cable to throttle cam by sliding clasp into hole Fig 4 5 Install the servo bracket bolt Refer to the torque chart for torque specifications 6 Connect the negative battery cable SWITCH REMOVAL 1 Disconnect the negative battery cable 2 Remove the Driver side Airbag Fig 7 Refer to 8 ELECTRICA...

Page 2205: ...OVAL 1 Disconnect the negative and then the positive battery cable 2 Remove battery 3 Disconnect the wiring harness from battery tray 4 Remove the battery tray Fig 9 5 Disconnect the vacuum line from battery tray vacuum reservoir Fig 10 INSTALLATION 1 Connect the vacuum line to battery tray vac uum reservoir Fig 10 2 Install the battery tray Fig 9 3 Connect the wiring harness to battery tray 4 Ins...

Page 2206: ... tion housing The indicator light is located instru ment panel switch pod just to the right of the instrument cluster OPERATION VEHICLE THEFT SECURITY SYSTEM Upon failure of proper SKREEM communication to the Next Generation Controller NGC the NGC will shut off fuel after two seconds of run time The engine will not re crank on the key cycle that the failure occurred a full key down sequence must b...

Page 2207: ... the VTSS is armed the following actions will trigger the alarm Opening any door excluding liftgate Turning the ignition to the RUN position NOTE When the VTSS is ARMED the interior power door lock switch UNLOCK will be disabled until the vehicle is disarmed CAUTION The VTSS indicator LED will trigger and engine will continue to run if the vehicle is equipped with SKIS and the proper key is used t...

Page 2208: ...m via the Programmable Com munication Interface PCI data bus A VALID KEY message must be sent to the Powertrain Control Module PCM within two seconds of ignition ON to free the engine from immobilization REMOTE KEYLESS ENTRY RKE The RKE transmitter uses radio frequency signals to communicate with the SKREEM module The SKREEM is on the PCI bus When the operator presses a button on the transmitter i...

Page 2209: ... locks will lock the illuminated entry will turn off providing all doors are closed and the VTSS if equipped will arm After pressing the unlock button on the RKE transmitter one time the driver door lock will unlock the illuminated entry will turn on the courtesy lamps and the VTSS if equipped will disarm After pressing the unlock button a second time the remaining door locks will unlock The Elect...

Page 2210: ...L BUILD vehicles the SKREEM controls the functions of the SKIM RKE module and TPM system If diagnosing the TPM use the DRBIIIT scan tool to determine if the SKREEM includes TPM system functionality 1 Open hood disconnect and isolate the battery negative cable 2 Wait two minutes for the system reserve capac itor to discharge before beginning any system or com ponent service 3 Remove knee blocker ai...

Page 2211: ...instrument panel Fig 5 4 From underneath the ignition switch lock assembly tighten the lower retaining screw Fig 5 5 Reach up behind the left side of the center stack and connect the ignition switch and SKREEM electrical connectors Fig 4 6 Position the instrument panel center stack left bezel over retaining slots and firmly snap into place Fig 3 7 Install the knee blocker airbag Refer to 8 ELECTRI...

Page 2212: ...se the SKREEM has a unique 9Secret Key9 code programmed into it by the manu facturer as well When a Sentry Key is programmed into the memory of the SKREEM the SKREEM stores the transponder identification code from the Sentry Key and the Sentry Key learns the 9Secret Key9 code from the SKREEM Once the Sentry Key Fig 5 SKREEM IGNITION CYLINDER MOUNTING 1 IGNITION SWITCH LOCK ASSEMBLY MOUNTING NUTS 3...

Page 2213: ...IIt scan tool select 9Theft Alarm 9 9SKREEM 9 9Miscellaneous 9 and then 9Pro gram New Key 9 3 Enter the four digit PIN code using the DRB IIIt scan tool When programming is completed the SKREEM will exit Secured Access Mode and the DRB IIIt scan tool will display the results of your attempt to program the key One of five distinct results may be displayed All five are listed below Programming Succe...

Page 2214: ...d NOTE Once a Sentry Key has been programmed to a particular vehicle it cannot be used on any other vehicle VTSS SKIS INDICATOR LAMP DESCRIPTION The Sentry Key Immobilizer System SKIS uses an indicator light to convey information on the status of the system to the customer This light is shared with the Vehicle Theft Security System VTSS The light is located in the instrument panel switch pod just ...

Page 2215: ......

Page 2216: ...ODULE DESCRIP TION 9 Integrated Power Module The Integrated Power Module IPM is located in the engine com partment on the driver side next to the battery The IPM receives messages over the Progammable Com munication Interface PCI bus from the BCM and uses the information to appropriately control the front wiper functions and both the front and rear washer motors The IPM does not control the rear w...

Page 2217: ...n on automatically only after the wipers complete three automatic wipe cycles within about thirty seconds and they will turn off automatically after three min utes elapse without any automatic wipe cycles Refer to 8 ELECTRICAL OVERHEAD CONSOLE ELEC TRONIC VEHICLE INFO CENTER STANDARD PROCEDURE ELECTRONIC VEHICLE INFOR MATION CENTER PROGRAMMING Mist Wipe Mode The control stalk of the right wiper mu...

Page 2218: ... of the reservoir and it is accessed from the left front corner of the engine compartment OPERATING MODES The components of the rear wiper and washer sys tem are designed to work in concert to provide the following operating modes Continuous Wipe Mode When the right multi function switch control sleeve is moved to the On position the rear wiper will be operated at a fixed speed continual wipe cycl...

Page 2219: ... wiper motor through the wiper park switch sense cir cuit This causes the wiper motor to continue run ning at low speed until the wiper blades are in the down position on the windshield and the park switch is again closed to 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 BCM ...

Page 2220: ...uts to the rear wiper motor and the rear washer pump motor for all rear wiper and washer system functions The rear wiper and washer system will only oper ate when the ignition switch is in the Accessory or On positions When the ignition switch is in the Accessory or On positions battery current from a fuse in the IPM is provided to the right multi func tion switch through a fused ignition switch o...

Page 2221: ... the element is laying on the wind shield while holding the wrench closest to the pivot stationary 4 Repeat Step 1 and align as necessary until wiper stops chattering and wipes the windshield clear REMOVAL 1 Using a trim stick special tool C 4755 or equivalent gently pry the arm retaining nut cap off 2 Remove the nut holding wiper arm to the wiper pivot 3 Using a suitable two jaw puller separate t...

Page 2222: ...ove wiper module from vehicle INSTALLATION 1 Place wiper module into position in vehicle 2 Install the four retaining bolts to the wiper module Fig 3 3 Connect the wiper motor electrical connector Fig 3 4 Install the cowl plenum grille Refer to 23 BODY EXTERIOR COWL GRILLE INSTALLA TION 5 Connect the battery negative cable 6 Verify vehicle and system operation Fig 3 FRONT WIPER MODULE REMOVE INSTA...

Page 2223: ...R TERMINAL 1 IF NOT OK REPAIR CIRCUIT 5 DEFECTIVE MOTOR 5 APPLY BATTERY JUMPER OVER TO WIPER TERMINAL 1 AND GROUND TERMINAL 5 IF NOT OK REPLACE MOTOR WIPER OPERATES IN INTERMITTENT MODE ONLY 1 DEFECTIVE WIPER SWITCH 1 REFER TO WIPER SWITCH DIAGNOSTIC PROCEDURES WIPER OPERATES IN HIGH SPEED ONLY 1 DEFECTIVE HI LO RELAY 1 CHECK WIPER HI LO RELAY WITH KNOWN GOOD RELAY REPLACE IF NOT OK 2 DEFECTIVE CO...

Page 2224: ...WINDSHIELD 1 DEFECTIVE ON OFF RELAY 1 CHECK WIPER ON OFF RELAY WITH KNOWN GOOD RELAY IF NOT OK REPLACE RELAY 2 OPEN ON OFF RELAY GROUND CIRCUIT 2 OPEN OR DEFECTIVE CIRCUIT BETWEEN ON OFF RELAY CAVITY 9E9 AND LEFT HEADLAMP GROUND 5 OR ENGINE GROUND 1 OR 2 WIPER RUNS CONTINUOUSLY OR INTERMITTENTLY IN LOW SPEED WITH IGNITION OR ACCESSORY ON AND WIPER SWITCH OFF 1 DEFECTIVE ON OFF RELAY 1 CHECK WIPER ...

Page 2225: ... OFF RELAY OR REPAIR CIRCUIT S 6 BCM CONNECTORS 9B9 AND 9C9 LOOSE BENT OR CORRODED 6 CHECK BCM CONNECTORS 9B9 AND 9C9 FOR BENT LOOSE OR CORRODED CONNECTORS 7 OPEN OR DEFECTIVE CONTROL CIRCUIT TO BCM 7 OPEN OR DEFECTIVE CIRCUIT BETWEEN ON OFF RELAY CAVITY 9C9 AND BCM CONNECTOR TERMINAL 4C OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER SWITCH TERMINAL 5 AND BCM CONNECTOR TERMINAL 5B DEFECTIVE BCM IF NOT OK...

Page 2226: ...GED ARM 3 INSPECT ARM IF NOT OK REPLACE ARM DRIVER AND OR PASSENGER ARM WILL NOT CYCLE OPERATE 1 LOOSE ARM TO PIVOT SHAFT 1 CHECK ARM TO PIVOT SHAFT CONNECTION FOR LOOSENESS TORQUE NUT TO SPECIFICATION 2 STRIPPED ARM TO PIVOT SHAFT 2 CHECK ARM TO PIVOT SHAFT FOR STRIPPING TORQUE NUT TO SPECIFICATION IF NOT OK REPLACE ARM DRIVER AND OR PASSENGER ARM OR BLADE HITS COWL SCREEN OR WINDSHIELD MOLDINGS ...

Page 2227: ...N 1 Position the wiper motor into wiper module and install the three front wiper motor mounting bolts Fig 5 2 Press the socket and ball joint together on end of bell crank Fig 5 3 Install the wiper module Refer to 8 ELEC TRICAL WIPERS WASHERS WIPER MODULE INSTALLATION and Fig 4 4 Connect the battery negative cable 5 Verify vehicle and system operation 6 Close hood REAR WIPER ARM REMOVAL 1 Lift up ...

Page 2228: ...TRI CAL WIPERS WASHERS REAR WIPER ARM REMOVAL 3 Open liftgate remove liftgate trim panel Refer to 23 BODY INTERIOR LIFTGATE TRIM PANEL REMOVAL 4 Disconnect the rear wiper motor electrical con nector Fig 7 5 Remove the three rear wiper motor mounting screws Fig 8 6 Remove rear wiper motor from liftgate vehicle Fig 6 REAR WIPER ARM REMOVE INSTALL 1 REAR WIPER ARM 3 REAR WIPER ARM RETAINING NUT COVER...

Page 2229: ...d control sleeve The right multi function switch is the primary control for the front and rear wiper and washer sys tems and contains switches and circuitry to provide signals to the Body Control Module BCM and the rear wiper motor The right wiper multi function switch cannot be adjusted or repaired If any function of the switch is faulty or if the switch is damaged the entire switch unit must be ...

Page 2230: ...ntinuous Rear Wipe Mode The control ring on the right wiper multi function switch con trol stalk is rotated to the most forward clockwise detent to select the continuous rear wiper mode The multi function switch provides a battery current out put to the rear wiper motor on a rear wiper motor control circuit to signal the rear wiper module to operate the rear wiper motor in the continuous wipe mode...

Page 2231: ...H CONTINUITY RESISTANCE FRONT WIPER WASHER SWITCH SWITCH POSITION CONTINUITY BETWEEN RESISTANCE BETWEEN RESISTANCE Off Pins 7 8 4286 4379 V Intermittent Wipe 1 Pins 7 8 1445 1480 V Intermittent Wipe 2 Pins 7 8 847 870 V Intermittent Wipe 3 Pins 7 8 556 573 V Intermittent Wipe 4 Pins 7 8 367 380 V Intermittent Wipe 5 Pins 7 8 218 229 V Low Speed Pins 7 8 99 106 V High Speed Pins 7 9 Pins 7 8 99 106...

Page 2232: ...or to the washer fluid level switch 6 Pull the washer fluid level switch from the res ervoir Fig 17 NOTE Make sure to use a new grommet when installing a new switch or even reinstalling the old switch back into the reservoir INSTALLATION NOTE Make sure to use a new grommet when installing a new switch or even reinstalling the old switch back into the reservoir 1 With grommet installed position the...

Page 2233: ...components that were necessary to remove to access washer hose Refer to Fig 12 Fig 13 Fig 14 Fig 15 and Fig 16 2 Verify vehicle and system operation Fig 12 HOOD HOSE ROUTING WASHER NOZZLES 1 FRONT WASHER NOZZLE 4 INNER HOOD PANEL HOSE RETAINING CLIPS 2 FRONT WASHER NOZZLE INSTALLED POSITION 5 WINDSHIELD WASHER HOSE 3 INNER HOOD PANEL 8R 18 WIPERS WASHERS CS ...

Page 2234: ...Fig 13 ENGINE COMPARTMENT HOSE ROUTING Fig 14 BULKHEAD TO B PILLAR HOSE ROUTING CS WIPERS WASHERS 8R 19 WASHER HOSES Continued ...

Page 2235: ...BODY TO LIFTGATE HOSE ROUTING 1 LIFTGATE SPOILER 4 LIFTGATE GROMMET CHECK VALVE 2 LIFTGATE INNER PANEL 5 REAR HOSE BODY GROMMET 3 LIFTGATE GROMMET AND HOSE ASSEMBLY 6 LIFTGATE OPENING REINFORCEMENT 8R 20 WIPERS WASHERS CS WASHER HOSES Continued ...

Page 2236: ...ield 4 Remove the lower fascia push pins 5 Remove upper bolts at ends ears 6 Disengage lower fascia to grille clips 7 Pull away fascia as necessary to access reser voir 8 Disconnect the hoses and electrical connectors from the reservoir 9 Remove three retaining bolts Fig 18 10 Pull reservoir from filler tube 11 Transfer pumps Make sure to use a new grommet 12 Transfer sensor Make sure to use a new...

Page 2237: ...etaining bolt at upper filler tube Fig 18 3 Slip reservoir up into filler tube 4 Install the three reservoir mounting bolts Fig 18 5 Engage lower fascia to grille clips 6 Install the upper bolts at ends ears 7 Install the lower fascia push pins 8 Install the screws at the left wheel opening splash shield 9 Remove vehicle off of hoist 10 Connect the battery negative cable 11 Verify vehicle and syst...

Page 2238: ...verriding all other audio outputs except hands free cellular sys tem to the front speakers that are active at the same time Spoken prompts are recordings of a human voice For diagnostic information on the instrument panel switch pod Refer to 8 ELECTRICAL INSTRU MENT CLUSTER INSTRUMENT PANEL SWITCH POD DIAGNOSIS AND TESTING TELECOMMUNICATIONS A hands free cellular system is an available option on t...

Page 2239: ...rbal 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 d...

Page 2240: ...r to 23 BODY INTERIOR QUARTER TRIM PANEL REMOVAL 5 Remove liftgate scuff plate Refer to 23 BODY INTERIOR LIFTGATE SCUFF PLATE REMOVAL 6 Remove navigation unit Refer to 8 ELECTRI CAL NAVIGATION TELECOMMUNICATION NAVI GATION UNIT REMOVAL 7 Disconnect antenna cable at instrument panel Remove cable from retainers on floor Disconnect antenna cable from navigation unit INSTALLATION 1 Connect antenna cab...

Page 2241: ...L 1 Disconnect and isolate the battery negative cable 2 Remove rear floor stowage tray Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY REMOVAL 3 Remove mounting fasteners Fig 4 4 Disconnect electrical harness connector and antenna cable from navigation unit 5 Remove navigation unit from mounting bracket INSTALLATION 1 Install navigation unit to mounting bracket 2 Connect electrical harness conne...

Page 2242: ... HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 OCCUPANT RESTRAINT SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 BODY CONTROL MODULE 8W 45 1 AUDIO VIDEO SYSTEM 8W 47 1 REAR WINDOW DEFOGGER 8W 48 1 OVERHEAD CONSOLE 8W 49 1 FRONT LIGHTING 8W 50 1 REAR LIGHTING 8W 51 1 TURN SIGNALS 8W 52 1 WIPERS 8W 53 1 NAVIGATION TELECOMMUNICATIONS 8W 55 1 POWER WINDOWS 8W 60 1 POWER DOOR LOCKS ...

Page 2243: ......

Page 2244: ...wiring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page Fig 1 All switches components ...

Page 2245: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION CS WIRING DIAGRAM INFORMATION Continued ...

Page 2246: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 CS 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued ...

Page 2247: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION CS WIRING DIAGRAM INFORMATION Continued ...

Page 2248: ...rt Vehicles Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and color Fig 4 WIRE COLOR CODE CHART COLOR CODE COLOR BL BLUE BK BLACK BR BROWN DB DARK BLUE DG DARK GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN OR ORANGE PK PINK RD RED TN TAN VT VIOLET WT WHITE YL YELLO...

Page 2249: ...ar group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can however be shown partially in another group if it contains some associated wiring Splice diagrams in Section 8W 70 show the entire splice and provide references to other sections the splices serves Sectio...

Page 2250: ...f general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER A VEHICLE WARNING BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION UNLESS THE PROCEDURE REQUIRES IT TO BE ON WARNING SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRAN...

Page 2251: ... for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify the problem 2 Verify any related symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia ...

Page 2252: ...er lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with the fuse 2 Connect a test light or a voltmeter across the terminals of the fuse 3 Starting at the fuse block wiggle the wiring harness about six to eight inches apart and watch the voltmeter test la...

Page 2253: ...ground has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of the voltmeter to the other side of the switch component or circuit 3 Operate the item 4 The voltmeter will show the difference in volt age between the two points SPECIAL TOOLS WIRING TERMINAL Fig 9 TE...

Page 2254: ...emoved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pin out identification refer to the wiring diagrams 3 When the connector is re assembled the sec ondary terminal lock must be placed in the locked position to prevent terminal push out 4 Replace dress ...

Page 2255: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION CS CONNECTOR Continued ...

Page 2256: ...3 APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPECIAL TOOL 8638 CS 8W 01 WIRING DIAGRAM INFORMATION 8W 01 13 CONNECTOR Continued ...

Page 2257: ...fected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired 2 Cut the repair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wi...

Page 2258: ...e of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION DO NOT USE ACID CORE SOLDER 6 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing...

Page 2259: ......

Page 2260: ...er Power Module 8W 42 Front Wiper High Low Relay 8W 53 Front Wiper On Off Relay 8W 53 Fuel Injectors 8W 30 Fuel Pump Module 8W 30 Component Page Fuel Pump Relay 8W 30 Fuses 8W 10 Fusible Link 8W 20 Generator 8W 20 Glove Box Lamp 8W 44 Grounds 8W 15 Hands Free Module 8W 55 Headlamps 8W 50 Heated Seat Backs 8W 63 Heated Seat Cushions 8W 63 Heated Seat Switches 8W 63 Heated Seats Middle Row 8W 63 Hor...

Page 2261: ...at Belt Tensioners 8W 43 Seat Heater Interface Module 8W 63 Seat Position Sensors 8W 63 Short Runner Valve Solenoid 8W 30 Component Page SKREEM Module 8W 39 Speakers 8W 47 Speed Control Servo 8W 33 Speed Control Switches 8W 33 Speed Sensors 8W 31 Splices 8W 70 Starter Motor 8W 21 Starter Motor Relay 8W 21 Tail Lamps 8W 51 Throttle Position Sensor 8W 30 Traction Control Switch 8W 35 Trailer Tow Con...

Page 2262: ...17 30 Fuse 37 8W 10 17 18 30 Fuse 38 8W 10 17 18 33 Component Page Fuse 39 8W 10 18 19 33 Fuse 40 8W 10 19 35 Fuse 41 8W 10 19 35 Fuse 42 8W 10 16 29 Fuse 44 8W 10 11 20 Fuse 45 8W 10 11 20 Fuse 46 8W 10 11 12 21 Fuse 47 8W 10 12 21 Fuse 48 8W 10 12 21 Fuse 49 8W 10 12 21 Fuse 50 8W 10 12 21 Fusible Link 8W 10 10 G101 8W 10 30 G102 8W 10 37 G103 8W 10 37 Generator 8W 10 10 Hands Free Module 8W 10 ...

Page 2263: ......

Page 2264: ......

Page 2265: ......

Page 2266: ......

Page 2267: ......

Page 2268: ......

Page 2269: ......

Page 2270: ......

Page 2271: ......

Page 2272: ......

Page 2273: ......

Page 2274: ......

Page 2275: ......

Page 2276: ......

Page 2277: ......

Page 2278: ......

Page 2279: ......

Page 2280: ......

Page 2281: ......

Page 2282: ......

Page 2283: ......

Page 2284: ......

Page 2285: ......

Page 2286: ......

Page 2287: ......

Page 2288: ......

Page 2289: ......

Page 2290: ......

Page 2291: ......

Page 2292: ......

Page 2293: ......

Page 2294: ......

Page 2295: ......

Page 2296: ......

Page 2297: ......

Page 2298: ......

Page 2299: ......

Page 2300: ......

Page 2301: ......

Page 2302: ......

Page 2303: ......

Page 2304: ... 15 6 Integrated Power Module 8W 15 2 3 4 License Lamp 8W 15 13 Liftgate Cinch Release Motor 8W 15 13 Liftgate Flood Lamp 8W 15 12 Liftgate Handle Switch 8W 15 13 Liftgate Lock Motor Ajar Switch 8W 15 13 Manifold Tuning Valve Solenoid 8W 15 2 Memory Heated Seat Adjustable Pedals Module 8W 15 11 Multi Function Switch 8W 15 6 Natural Vacuum Leak Detection Assembly 8W 15 11 Navigation Module 8W 15 16...

Page 2305: ......

Page 2306: ......

Page 2307: ......

Page 2308: ......

Page 2309: ......

Page 2310: ......

Page 2311: ......

Page 2312: ......

Page 2313: ......

Page 2314: ......

Page 2315: ......

Page 2316: ......

Page 2317: ......

Page 2318: ......

Page 2319: ......

Page 2320: ... Cd Changer 8W 18 4 G101 8W 18 2 G102 8W 18 2 G202 8W 18 2 Hands Free Module 8W 18 6 Component Page Instrument Cluster 8W 18 2 3 Integrated Power Module 8W 18 2 5 7 Memory Heated Seat Adjustable Pedals Module 8W 18 6 Navigation Module 8W 18 5 Overhead Console 8W 18 5 Power Liftgate Module 8W 18 5 Powertrain Control Module 8W 18 2 5 7 PTC 1 8W 18 2 Radio 8W 18 3 4 Satellite Radio Multiplexer 8W 18 ...

Page 2321: ......

Page 2322: ......

Page 2323: ......

Page 2324: ......

Page 2325: ......

Page 2326: ......

Page 2327: ......

Page 2328: ...20 2 3 Battery Temperature Sensor 8W 20 3 Fuse 37 8W 20 3 Fuse 39 8W 20 3 Fusible Link 8W 20 2 Component Page G101 8W 20 2 G102 8W 20 2 Generator 8W 20 2 Integrated Power Module 8W 20 2 3 Powertrain Control Module 8W 20 2 3 Starter Motor 8W 20 2 CS 8W 20 CHARGING SYSTEM 8W 20 1 ...

Page 2329: ......

Page 2330: ......

Page 2331: ......

Page 2332: ...Fuse 7 8W 21 2 Fusible Link 8W 21 2 G101 8W 21 2 Generator 8W 21 2 Component Page Ignition Switch 8W 21 2 Integrated Power Module 8W 21 2 Powertrain Control Module 8W 21 2 Starter Motor 8W 21 2 Starter Motor Relay 8W 21 2 CS 8W 21 STARTING SYSTEM 8W 21 1 ...

Page 2333: ......

Page 2334: ...8W 30 9 Fuse 8 8W 30 18 Fuse 29 8W 30 15 Fuse 36 8W 30 16 Fuse 37 8W 30 4 Fuse 38 8W 30 11 Component Page Fuse 39 8W 30 2 9 G100 8W 30 8 11 12 G101 8W 30 2 16 G102 8W 30 2 8 G103 8W 30 15 G301 8W 30 9 10 18 G305 8W 30 9 15 Generator 8W 30 4 Idle Air Control Motor 8W 30 11 Intake Air Temperature Sensor 8W 30 14 Integrated Power Module 8W 30 2 3 4 9 11 15 16 18 Knock Sensor 8W 30 11 Manifold Absolut...

Page 2335: ......

Page 2336: ......

Page 2337: ......

Page 2338: ......

Page 2339: ......

Page 2340: ......

Page 2341: ......

Page 2342: ......

Page 2343: ......

Page 2344: ......

Page 2345: ......

Page 2346: ......

Page 2347: ......

Page 2348: ......

Page 2349: ......

Page 2350: ......

Page 2351: ......

Page 2352: ... 8W 31 2 G101 8W 31 3 G102 8W 31 3 G201 8W 31 4 9 Component Page Ignition Switch 8W 31 2 Integrated Power Module 8W 31 2 3 4 6 7 8 9 Powertrain Control Module 8W 31 2 3 4 5 6 7 8 9 Speed Sensor Input 8W 31 5 Speed Sensor Output 8W 31 5 Transmission Control Relay 8W 31 3 6 7 Transmission Range Sensor 8W 31 4 5 Transmission Solenoid Pressure Switch Assembly 8W 31 3 6 7 CS 8W 31 TRANSMISSION CONTROL ...

Page 2353: ......

Page 2354: ......

Page 2355: ......

Page 2356: ......

Page 2357: ......

Page 2358: ......

Page 2359: ......

Page 2360: ......

Page 2361: ......

Page 2362: ...G103 8W 33 3 Powertrain Control Module 8W 33 2 3 4 Speed Control Servo 8W 33 3 Component Page Speed Control Switch Left 8W 33 2 Speed Control Switch Right 8W 33 2 Speed Sensor Input 8W 33 4 Speed Sensor Output 8W 33 4 Transmission Range Sensor 8W 33 4 CS 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

Page 2363: ......

Page 2364: ......

Page 2365: ......

Page 2366: ...15 8W 35 2 Fuse 29 8W 35 3 Fuse 45 8W 35 2 G102 8W 35 2 Component Page G201 8W 35 3 Instrument Cluster 8W 35 3 Integrated Power Module 8W 35 2 3 Run Relay 8W 35 2 Traction Control Switch 8W 35 3 Wheel Speed Sensor Left Front 8W 35 4 Wheel Speed Sensor Left Rear 8W 35 4 Wheel Speed Sensor Right Front 8W 35 4 Wheel Speed Sensor Right Rear 8W 35 4 CS 8W 35 ANTILOCK BRAKES 8W 35 1 ...

Page 2367: ......

Page 2368: ......

Page 2369: ......

Page 2370: ...28 8W 39 3 Fuse 46 8W 39 4 5 Fuse 47 8W 39 4 5 Fuse 50 8W 39 2 G104 8W 39 3 Component Page G201 8W 39 2 3 6 G300 8W 39 4 G301 8W 39 4 G302 8W 39 7 Horn Relay 8W 39 3 Horn Switch 8W 39 3 Horn High Note 8W 39 3 Horn Low Note 8W 39 3 Instrument Panel Switch Pod 8W 39 6 Integrated Power Module 8W 39 2 3 4 5 6 7 8 Liftgate Cinch Release Motor 8W 39 8 Liftgate Handle Switch 8W 39 6 7 8 Liftgate Lock Mot...

Page 2371: ......

Page 2372: ......

Page 2373: ......

Page 2374: ......

Page 2375: ......

Page 2376: ......

Page 2377: ......

Page 2378: ...nnector 8W 40 3 4 Fuse 3 8W 40 4 5 Fuse 25 8W 40 4 Fuse 29 8W 40 2 Fuse 48 8W 40 4 Component Page Fuse 50 8W 40 5 G201 8W 40 2 5 G305 8W 40 2 4 Instrument Cluster 8W 40 2 3 4 5 Instrument Panel Switch POD 8W 40 3 5 Integrated Power Module 8W 40 2 4 5 Navigation Module 8W 40 4 Park Brake Switch 8W 40 2 Run Relay 8W 40 4 5 CS 8W 40 INSTRUMENT CLUSTER 8W 40 1 ...

Page 2379: ......

Page 2380: ......

Page 2381: ......

Page 2382: ......

Page 2383: ......

Page 2384: ... 8W 41 2 G104 8W 41 2 G201 8W 41 2 G202 8W 41 3 4 G303 8W 41 3 Component Page Horn Relay 8W 41 2 Horn Switch 8W 41 2 Horn High Note 8W 41 2 Horn Low Note 8W 41 2 Integrated Power Module 8W 41 2 3 4 Power Outlet Front Console 8W 41 4 Power Outlet Instrument Panel 8W 41 4 Power Outlet Rear 8W 41 3 PTC 1 8W 41 4 CS 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

Page 2385: ......

Page 2386: ......

Page 2387: ......

Page 2388: ...W 42 7 Fuse 34 8W 42 4 Fuse 38 8W 42 6 Fuse 42 8W 42 2 Fuse 45 8W 42 2 Fuse 50 8W 42 4 Component Page G102 8W 42 6 G104 8W 42 7 G201 8W 42 2 G204 8W 42 2 G301 8W 42 4 5 Instrument Cluster 8W 42 5 Integrated Power Module 8W 42 2 4 6 7 Mode Door Actuator Front 8W 42 3 Mode Door Actuator Rear 8W 42 3 Powertrain Control Module 8W 42 6 7 Radiator Fan Motor No 1 8W 42 7 Radiator Fan Motor No 2 8W 42 7 R...

Page 2389: ......

Page 2390: ......

Page 2391: ......

Page 2392: ......

Page 2393: ......

Page 2394: ......

Page 2395: ......

Page 2396: ... 8W 43 4 G203 8W 43 2 G305 8W 43 3 Impact Sensor Left Front 8W 43 6 Component Page Impact Sensor Left Side 1 8W 43 7 Impact Sensor Left Side 2 8W 43 6 Impact Sensor Left Side 3 8W 43 7 Impact Sensor Right Front 8W 43 8 Impact Sensor Right Side 1 8W 43 7 Impact Sensor Right Side 2 8W 43 7 Impact Sensor Right Side 3 8W 43 8 Instrument Cluster 8W 43 2 Integrated Power Module 8W 43 2 Seat Belt Switch ...

Page 2397: ......

Page 2398: ......

Page 2399: ......

Page 2400: ......

Page 2401: ......

Page 2402: ......

Page 2403: ......

Page 2404: ... 2 7 10 Component Page Liftgate Flood Lamp 8W 44 3 Multi Function Switch 8W 44 3 Overhead Console 8W 44 6 Power Seat Switch Driver 8W 44 9 Power Seat Switch Passenger 8W 44 9 Power Window Switch Driver Rear 8W 44 2 Power Window Switch Passenger Rear 8W 44 2 Radio 8W 44 7 Reading Lamp Front 8W 44 4 6 Reading Courtesy Lamp Left Middle 8W 44 4 5 Reading Courtesy Lamp Left Rear 8W 44 4 Reading Courtes...

Page 2405: ......

Page 2406: ......

Page 2407: ......

Page 2408: ......

Page 2409: ......

Page 2410: ......

Page 2411: ......

Page 2412: ......

Page 2413: ......

Page 2414: ...8W 45 3 Instrument Cluster 8W 45 5 Component Page Instrument Panel Switch Pod 8W 45 5 Integrated Power Module 8W 45 2 3 8 Liftgate Flood Lamp 8W 45 7 Liftgate Handle Switch 8W 45 7 Liftgate Lock Motor Ajar Switch 8W 45 7 8 Multi Function Switch 8W 45 4 5 Overhead Console 8W 45 7 Power Liftgate Module 8W 45 6 8 Reading Lamp Front 8W 45 7 Reading Courtesy Lamp Left Rear 8W 45 7 Run Relay 8W 45 3 Sea...

Page 2415: ......

Page 2416: ......

Page 2417: ......

Page 2418: ......

Page 2419: ......

Page 2420: ......

Page 2421: ......

Page 2422: ......

Page 2423: ......

Page 2424: ...t Cluster 8W 47 2 4 Component Page Integrated Power Module 8W 47 2 3 4 5 9 11 Navigation Module 8W 47 13 Powertrain Control Module 8W 47 8 Radio 8W 47 2 3 4 5 9 12 Remote Radio Switch Left 8W 47 8 Remote Radio Switch Right 8W 47 8 Run Relay 8W 47 2 3 4 5 9 11 Satellite Radio Multiplexer 8W 47 11 12 Satellite Radio Receiver 8W 47 12 Speaker Center Instrument Panel 8W 47 7 Speaker Left Front Door Tw...

Page 2425: ......

Page 2426: ......

Page 2427: ......

Page 2428: ......

Page 2429: ......

Page 2430: ......

Page 2431: ......

Page 2432: ......

Page 2433: ......

Page 2434: ......

Page 2435: ......

Page 2436: ......

Page 2437: ......

Page 2438: ...AR WINDOW DEFOGGER Component Page Fuse 5 8W 48 2 G302 8W 48 2 Integrated Power Module 8W 48 2 Component Page Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 CS 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

Page 2439: ......

Page 2440: ...ody Control Module 8W 49 3 Fuse 3 8W 49 2 Fuse 25 8W 49 2 Fuse 48 8W 49 2 G305 8W 49 2 4 Component Page Integrated Power Module 8W 49 2 3 Overhead Console 8W 49 2 3 4 Power Mirror Driver 8W 49 4 Power Sunroof Module 8W 49 3 Reading Lamp Front 8W 49 2 Run Relay 8W 49 2 CS 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

Page 2441: ......

Page 2442: ......

Page 2443: ......

Page 2444: ... 2 3 4 5 Fog Lamp Left 8W 50 6 Fog Lamp Right 8W 50 6 G103 8W 50 4 5 6 G104 8W 50 4 5 6 Component Page G201 8W 50 3 Headlamp Left 8W 50 4 Headlamp Right 8W 50 5 Integrated Power Module 8W 50 3 4 5 6 Multi Function Switch 8W 50 2 3 CS 8W 50 FRONT LIGHTING 8W 50 1 ...

Page 2445: ......

Page 2446: ......

Page 2447: ......

Page 2448: ......

Page 2449: ......

Page 2450: ...51 2 G302 8W 51 5 6 G303 8W 51 4 G304 8W 51 4 Integrated Power Module 8W 51 2 3 4 5 6 Component Page License Lamp 8W 51 5 6 Multi Function Switch 8W 51 2 Power Liftgate Module 8W 51 6 Powertrain Control Module 8W 51 4 Tail Lamp Left 8W 51 3 4 Tail Lamp Right 8W 51 3 4 Transmission Solenoid Pressure Switch Assembly 8W 51 4 CS 8W 51 REAR LIGHTING 8W 51 1 ...

Page 2451: ......

Page 2452: ......

Page 2453: ......

Page 2454: ......

Page 2455: ......

Page 2456: ...104 8W 52 2 G201 8W 52 2 G303 8W 52 3 G304 8W 52 3 Component Page Headlamp Left 8W 52 2 Headlamp Right 8W 52 2 Instrument Cluster 8W 52 3 Instrument Panel Switch Pod 8W 52 2 Integrated Power Module 8W 52 2 Multi Function Switch 8W 52 2 Tail Lamp Left 8W 52 3 Tail Lamp Right 8W 52 3 CS 8W 52 TURN SIGNALS 8W 52 1 ...

Page 2457: ......

Page 2458: ......

Page 2459: ......

Page 2460: ...3 2 Fuse 6 8W 53 2 G103 8W 53 3 G104 8W 53 3 G300 8W 53 2 G302 8W 53 3 Component Page Integrated Power Module 8W 53 2 3 4 Washer Fluid Level Switch 8W 53 3 Washer Pump Motor Front 8W 53 3 Washer Pump Motor Rear 8W 53 3 Wiper Module Front 8W 53 2 Wiper Module Rear 8W 53 3 Wiper Washer Switch 8W 53 4 CS 8W 53 WIPERS 8W 53 1 ...

Page 2461: ......

Page 2462: ......

Page 2463: ......

Page 2464: ... Fuse 3 8W 55 2 4 Fuse 25 8W 55 2 4 Fuse 48 8W 55 2 4 G305 8W 55 2 4 Component Page Hands Free Module 8W 55 4 5 Instrument Cluster 8W 55 3 Instrument Panel Switch Pod 8W 55 3 Integrated Power Module 8W 55 2 4 Navigation Module 8W 55 2 3 Rear View Mirror 8W 55 5 Run Relay 8W 55 2 4 CS 8W 55 NAVIGATION TELECOMMUNICATIONS 8W 55 1 ...

Page 2465: ......

Page 2466: ......

Page 2467: ......

Page 2468: ......

Page 2469: ......

Page 2470: ...60 4 Fuse 46 8W 60 4 Fuse 47 8W 60 2 G300 8W 60 2 Component Page G301 8W 60 4 Integrated Power Module 8W 60 2 4 Power Window Motor Driver 8W 60 3 Power Window Motor Driver Rear 8W 60 3 Power Window Motor Passenger 8W 60 5 Power Window Motor Passenger Rear 8W 60 5 Power Window Switch Driver Rear 8W 60 3 Power Window Switch Passenger Rear 8W 60 5 Run Relay 8W 60 2 4 CS 8W 60 POWER WINDOWS 8W 60 1 ...

Page 2471: ......

Page 2472: ......

Page 2473: ......

Page 2474: ......

Page 2475: ......

Page 2476: ... 6 8 Fuse 46 8W 61 2 Fuse 47 8W 61 2 G300 8W 61 3 G301 8W 61 4 Component Page G302 8W 61 5 6 G303 8W 61 6 8 G306 8W 61 6 Integrated Power Module 8W 61 2 5 6 8 License Lamp 8W 61 6 7 Liftgate Cinch Release Motor 8W 61 6 7 Liftgate Handle Switch 8W 61 5 7 Liftgate Lock Motor Ajar Switch 8W 61 5 Liftgate Pinch Sensor Left 8W 61 7 Liftgate Pinch Sensor Right 8W 61 7 Power Liftgate Drive Unit 8W 61 8 P...

Page 2477: ......

Page 2478: ......

Page 2479: ......

Page 2480: ......

Page 2481: ......

Page 2482: ......

Page 2483: ......

Page 2484: ... Passenger 8W 62 3 Door Node Relay 8W 62 2 3 Fuse 3 8W 62 2 3 Fuse 40 8W 62 2 Fuse 41 8W 62 3 Fuse 46 8W 62 3 Component Page Fuse 47 8W 62 2 G300 8W 62 2 G301 8W 62 3 Integrated Power Module 8W 62 2 3 Power Mirror Driver 8W 62 2 Power Mirror Passenger 8W 62 3 Run Relay 8W 62 2 3 CS 8W 62 POWER MIRRORS 8W 62 1 ...

Page 2485: ......

Page 2486: ......

Page 2487: ......

Page 2488: ...3 Heated Seat Right Middle Row 8W 63 13 Instrument Cluster 8W 63 11 Integrated Power Module 8W 63 2 4 7 11 Memory Heated Seat Adjustable Pedals Module 8W 63 2 4 5 6 7 8 10 Power Seat Motor Driver Front Riser 8W 63 4 Power Seat Motor Driver Horizontal 8W 63 5 Power Seat Motor Driver Lumbar 8W 63 5 Power Seat Motor Driver Rear Riser 8W 63 5 Power Seat Motor Driver Recliner 8W 63 4 Power Seat Motor P...

Page 2489: ......

Page 2490: ......

Page 2491: ......

Page 2492: ......

Page 2493: ......

Page 2494: ......

Page 2495: ......

Page 2496: ......

Page 2497: ......

Page 2498: ......

Page 2499: ......

Page 2500: ......

Page 2501: ......

Page 2502: ...F Component Page Accessory Relay 8W 64 2 Fuse 9 8W 64 2 Fuse 25 8W 64 2 G303 8W 64 3 Component Page Integrated Power Module 8W 64 2 3 Overhead Console 8W 64 3 Power Sunroof Module 8W 64 2 3 CS 8W 64 POWER SUNROOF 8W 64 1 ...

Page 2503: ......

Page 2504: ......

Page 2505: ......

Page 2506: ...3 8W 18 3 S301 8W 10 28 S302 8W 10 21 S303 8W 10 22 S305 8W 18 7 S306 8W 44 8 S307 8W 10 34 S312 8W 10 20 Component Page S313 8W 61 7 S314 8W 51 4 S315 8W 10 42 S320 8W 10 27 S322 8W 63 13 S323 8W 61 3 S324 8W 61 2 S325 8W 61 3 S326 8W 61 2 S327 8W 47 6 S328 8W 47 6 S329 8W 47 6 S330 8W 47 6 S333 8W 15 9 S334 8W 61 4 S336 8W 61 3 S337 8W 61 8 S338 8W 61 7 S339 8W 15 10 S340 8W 15 10 S342 8W 10 27 ...

Page 2507: ......

Page 2508: ......

Page 2509: ......

Page 2510: ......

Page 2511: ......

Page 2512: ... C201 8W 80 19 C201 8W 80 20 C202 8W 80 22 C202 8W 80 22 C204 DVD 8W 80 22 C204 DVD 8W 80 23 C205 8W 80 23 C205 8W 80 24 C300 8W 80 24 Component Page C300 8W 80 25 C301 8W 80 25 C301 8W 80 26 C302 8W 80 26 C302 8W 80 26 C303 8W 80 26 C303 8W 80 27 C304 8W 80 27 C304 8W 80 28 C305 8W 80 28 C305 8W 80 28 C306 8W 80 28 C306 8W 80 29 C307 8W 80 29 C307 8W 80 29 C308 Power Liftgate 8W 80 30 C308 Power ...

Page 2513: ...act Sensor Right Front 8W 80 53 Component Page Impact Sensor Right Side 1 Late Build 8W 80 53 Impact Sensor Right Side 1 Early Build 8W 80 53 Impact Sensor Right Side 2 Early Build 8W 80 54 Impact Sensor Right Side 2 Late Build 8W 80 54 Impact Sensor Right Side 3 8W 80 54 Instrument Cluster C1 8W 80 54 Instrument Cluster C2 Navigation 8W 80 55 Instrument Panel Switch POD 8W 80 55 Intake Air Temper...

Page 2514: ...81 Satellite Radio Multiplexer C1 8W 80 81 Satellite Radio Multiplexer C2 8W 80 82 Satellite Radio Receiver 8W 80 82 Seat Belt Switch Driver 8W 80 82 Seat Belt Tensioner Driver 8W 80 82 Component Page Seat Belt Tensioner Passenger 8W 80 83 Seat Heater Interface Module 8W 80 83 Seat Position Sensor Driver Front Riser 8W 80 83 Seat Position Sensor Driver Horizontal 8W 80 84 Seat Position Sensor Driv...

Page 2515: ...HITE 6 WAY CAV CIRCUIT FUNCTION 1 P205 14LG DB ADJUSTABLE PEDALS MOTOR FORWARD 2 P206 14LG TN ADJUSTABLE PEDALS MOTOR REVERSE 3 4 G13 20VT LB ADJUSTABLE PEDALS MOTOR HALL SENSE 5 G914 22VT GY ADJUSTABLE PEDALS MOTOR HALL SENSE RETURN 6 G14 20VT DB ADJUSTABLE PEDALS MOTOR HALL SIGNAL ADJUSTABLE PEDALS SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 G11 20VT TN ADJUSTABLE PEDALS SENSOR FEED 2 G12 22VT BR ...

Page 2516: ...MPACT SENSOR 2 GROUND 21 R20 20WT LG RIGHT SIDE IMPACT SENSOR 2 GROUND 22 R17 20LG LEFT SIDE IMPACT SENSOR 2 SIGNAL 23 R18 20LB RIGHT SIDE IMPACT SENSOR 2 SIGNAL 24 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 25 R1 20DG YL EARLY BUILD LEFT CURTAIN SQUIB LINE 1 25 R1 20LB BR LATE BUILD LEFT CURTAIN SQUIB LINE 1 26 R3 20VT EARLY BUILD LEFT CURTAIN SQUIB LINE 2 26 R3 20LB OR LATE BUILD LEFT CURTAIN...

Page 2517: ...20LG TN LEFT SIDE IMPACT SENSOR 3 GROUND 15 D25 20WT VT PCI BUS 16 F201 20PK LB ORC RUN START DRIVER 17 18 19 R24 20YL LB RIGHT SIDE IMPACT SENSOR 3 GROUND 20 R81 20LB WT LEFT FRONT IMPACT SENSOR GROUND 21 22 Z12 18BK OR GROUND 23 24 F100 20PK VT ORC RUN DRIVER 25 R79 20LB VT LEFT FRONT IMPACT SENSOR SIGNAL 26 R80 20LB TN RIGHT FRONT IMPACT SENSOR SIGNAL 27 28 R21 20LB DG LEFT SIDE IMPACT SENSOR 3...

Page 2518: ...G SQUIB LEFT CURTAIN YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R1 20DG YL EARLY BUILD LEFT CURTAIN SQUIB LINE 1 1 R1 20LB BR LATE BUILD LEFT CURTAIN SQUIB LINE 1 2 R3 20VT EARLY BUILD LEFT CURTAIN SQUIB LINE 2 2 R3 20LB OR LATE BUILD LEFT CURTAIN SQUIB LINE 2 AIRBAG SQUIB PASSENGER YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R44 20LB OR PASSENGER SQUIB 1 LINE 2 2 R42 20LB BR PASSENGER SQUIB 1 LINE 1 3 R64 20LB ...

Page 2519: ...4 X391 18DG WT AMPLIFIED SUBWOOFER 2 5 X205 18GY LG AMPLIFIED LEFT REAR DOOR SPEAKER 6 X200 18GY DB AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER 7 X202 18DG VT AMPLIFIED RIGHT FRONT DOOR SPEAKER 8 X291 18GY YL AMPLIFIED LEFT FRONT DOOR SPEAKER 9 A116 16YL RD FUSED B 10 11 X390 18DG BR AMPLIFIED SUBWOOFER 1 12 X301 18GY WT AMPLIFIED SUBWOOFER 2 13 X296 18DG GY AMPLIFIED RIGHT REAR DOOR SPEAKER 14 X206...

Page 2520: ...OR FUSED B 5 F504 20GY PK FUSED RUN RELAY OUTPUT 6 D25 20WT VT PCI BUS 7 C56 20LB DB FRONT BLOWER MOTOR CONTROL 8 C57 22DB LB REAR BOOSTER FAN CONTROL 9 C31 22LB YL REAR FAN SENSE 10 C11 22LB OR REAR FAN SENSE SUPPLY 11 Z24 18BK OR GROUND 12 13 AUTO TEMP CONTROL C2 NATURAL 13 WAY CAV CIRCUIT FUNCTION 1 C161 20LB WT DRIVER BLEND DOOR DRIVER B 2 C61 22DB LG DRIVER BLEND DOOR DRIVER A 3 C133 22DB WT ...

Page 2521: ...B LATE BUILD AUTO DAY NIGHT MIRROR 6 7 L24 20WT DB EARLY BUILD AUTOMATIC HEADLAMP SIGNAL 7 L24 20BK GY LATE BUILD AUTOMATIC HEADLAMP SIGNAL AUTOSTICK SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 T44 20YL DG AUTOSTICK DOWNSHIFT SWITCH SIGNAL 2 T5 20DG YL AUTOSTICK UPSHIFT SWITCH SIGNAL 3 Z65 20BK YL GROUND 4 F1 20PK WT IGNITION UNLOCK RUN START BATTERY TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTI...

Page 2522: ...T FUNCTION 1 L61 18LG WT LEFT FRONT TURN SIGNAL LAMP DRIVER 2 L63 18DG WT LEFT REAR TURN SIGNAL LAMP DRIVER 3 L60 18WT TN RIGHT FRONT TURN SIGNAL LAMP DRIVER 4 L62 18WT DB RIGHT REAR TURN SIGNAL LAMP DRIVER 5 F20 20PK GY IGNITION SWITCH OUTPUT RUN START 6 7 8 G77 20VT GY LEFT REAR DOOR AJAR SWITCH SENSE 9 10 W13 18BR WT REAR WIPER MOTOR CONTROL 11 12 13 14 15 16 17 18 A114 20GY RD FUSED B 19 Z10 1...

Page 2523: ...TGATE SWITCH MUX 8 M24 18YL WT FRONT READING COURTESY LAMPS DRIVER 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 N4 20DB YL FUEL LEVEL SENSOR SIGNAL NO 1 24 D25 20WT VT PCI BUS 25 M11 18YL VT LIFTGATE COURTESY LAMP DRIVER 26 27 W17 20BR LG REAR WIPER PARK SWITCH SENSE 28 P31 18TN YL BASE LIFTGATE RELEASE DRIVER 29 G78 20VT OR LIFTGATE AJAR SWITCH SENSE 30 G10 20VT LG DRIVER SEAT BELT SWITCH SENSE 31...

Page 2524: ...22GY OR RADIO CONTROL MUX RETURN 14 G900 22OR VT IGNITION SWITCH SENSE RETURN 15 16 17 L160 22WT TN RIGHT TURN SIGNAL 18 19 20 21 22 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 23 24 25 26 M28 18YL TN GLOVE BOX LAMP DRIVER 27 28 29 30 31 W35 22BR LG FRONT WIPER HIGH LOW SWITCH SENSE 32 B27 20DG WT TRACTION CONTROL SWITCH SENSE 33 L306 20LB WT RIGHT TURN SWITCH SENSE 34 CS 8W 80 CONNECTOR PIN OUT...

Page 2525: ...CAL HORN SIGNAL 10 G20 22VT BR IGNITION SWITCH SENSE 11 12 13 14 15 16 17 L900 22WT YL HEADLAMP SWITCH MUX RETURN 18 W52 22BR YL FRONT WIPER SWITCH MUX 19 20 21 22 23 24 25 26 27 E2 22OR BR PANEL LAMPS DIMMER SIGNAL 28 29 30 31 L307 22BR WT HEADLAMP SWITCH MUX SENSE 32 W27 22DB BR REAR WIPER SWITCH DELAY 33 X20 22GY WT RADIO CONTROL MUX 34 BRAKE FLUID LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION ...

Page 2526: ...SIGNAL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID WHITE 2 WAY CAV CIRCUIT FUNCTION 1 Z101 18BK VT GROUND 2 F2 18PK YL IGNITION SWITCH OUTPUT RUN START C100 BLACK BODY SIDE CAV CIRCUIT 1 R80 20LB TN 2 R82 20WT LB 3 L60 18WT TN 4 R81 20LB WT 5 R79 20LB VT 6 L61 18LG WT C100 BLACK FRONT END LIGHTING SIDE CAV CIRCUIT 1 R80 20LB TN 2 R82 20WT LB 3 L60 18WT TN 4 R81 20LB WT 5 R79 20LB VT 6 L61 18LG WT ...

Page 2527: ... LB C101 BLACK POWERTRAIN SIDE CAV CIRCUIT 1 D21 20WT GY 2 D123 20WT BR 3 D20 20WT LG 4 D15 20BR WT 5 K900 20DB DG 6 F1 20PK WT 7 8 V32 20VT YL 9 B29 20DG WT 10 V37 20VT 11 V30 20VT WT 12 T5 20DG YL 13 B1 18DG DB 14 B2 18DG LB C102 BLACK BODY SIDE CAV CIRCUIT 1 L51 18WT DG 2 D24 20WT YL 3 K106 20VT LB 4 K107 20VT WT 5 B4 18DG GY 6 B3 18DG YL 7 8 T44 20YL DG 9 Z111 18BK WT 10 8W 80 16 8W 80 CONNECT...

Page 2528: ...10 C104 LT GRAY ENGINE SIDE CAV CIRCUIT 1 2 K36 20DB YL 3 K24 20BR LB 4 K900 20DB DG 5 K342 16BR WT 6 7 F855 20PK YL 8 K20 18BR GY 9 K236 18DB LG 10 K136 18BR C104 LT GRAY POWERTRAIN SIDE CAV CIRCUIT 1 2 K36 20DB YL 3 K24 20BR LB 4 K900 20DB DG 5 K342 16BR WT 6 7 F855 20PK YL 8 K20 18BR GY 9 K236 16DB LG 10 K136 18BR CS 8W 80 CONNECTOR PIN OUTS 8W 80 17 ...

Page 2529: ...55 20PK YL C105 LT GRAY POWERTRAIN SIDE CAV CIRCUIT 1 G31 20OR VT 2 K900 20DB DG 3 B6 18DG WT 4 K173 20BR VT 5 V30 20VT WT 6 B7 18DG VT 7 V35 20VT OR 8 V36 20YL VT 9 C18 20LB BR 10 F855 20PK YL C200 LT GRAY FRONT CONSOLE SIDE CAV CIRCUIT 1 A105 18DB RD 2 Z746 18BK DB C200 LT GRAY INSTRUMENT PANEL SIDE CAV CIRCUIT 1 A105 18DB RD 2 Z746 18BK DB 8W 80 18 8W 80 CONNECTOR PIN OUTS CS ...

Page 2530: ...21 R81 20LB WT 22 R80 20LB TN 23 R82 20WT LB 24 R21 20LB DG 25 R23 20LG TN 26 27 D25 20WT VT 28 29 30 F100 20PK VT 31 F201 20PK LB 32 F1 20PK WT 33 T44 20YL DG 34 T5 20DG YL 35 D15 20BR WT 36 37 38 F2 18PK YL 39 40 E12 18OR GY 41 C57 20DB LB 42 C53 20LB 43 C153 20DB BR 44 45 F504 20GY PK 46 G21 22VT WT 47 C31 20LB YL 48 C11 22LB OR 49 C931 22DB TN 50 D20 20WT LG 51 D21 20WT GY 52 D24 20WT YL 53 54...

Page 2531: ...91 22 NAVIGATION LATE BUILD C201 GRAY INSTRUMENT PANEL SIDE CAV CIRCUIT 1 B25 20DG WT 2 A106 20LB RD 3 A108 18LG RD 4 K900 20DB DG 5 F316 20PK OR 6 7 T751 20YL 8 9 10 11 C7 12DB 12 13 14 A105 18DB RD 15 A118 20RD OR 16 F306 16DB PK 17 V37 20VT 18 X3 20DG VT 19 F20 20PK GY 20 R79 20LB VT 21 R81 20LB WT 22 R80 20LB TN 23 R82 20WT LB 24 R21 20LB DG 25 R23 20LG TN 26 27 D25 20WT VT 28 29 30 F100 20PK ...

Page 2532: ...43 C153 22DB BR 44 45 F504 20GY PK 46 G21 22VT WT 47 C31 22LB YL 48 C11 22LB OR 49 C931 22DB TN 50 D20 20WT LG 51 D21 20WT GY 52 D24 20WT YL 53 54 Z111 18BK WT 55 D123 20WT BR 56 57 58 59 60 61 62 63 64 65 66 G400 20VT LB NAVIGATION 67 68 G410 20VT LG NAVIGATION 69 70 G420 20VT BR NAVIGATION 71 72 G430 20VT GY NAVIGATION 73 74 G591 22 NAVIGATION CS 8W 80 CONNECTOR PIN OUTS 8W 80 21 ...

Page 2533: ... DG C202 DK GRAY INSTRUMENT PANEL SIDE CAV CIRCUIT 1 Z134 12BK LG 2 C56 20LB DB 3 C32 20TN DB 4 C33 22LB BR 5 C61 22DB LG 6 C35 22LB OR 7 C7 12DB 8 C132 20DB YL 9 C133 22DB WT 10 C161 20LB WT 11 C135 20DB GY 12 C21 20LG DB 13 C121 20DB DG C204 DVD BLACK DVD SCREEN SIDE CAV CIRCUIT 1 X515 22GY OR 2 X915 22GY LB 3 X955 22 4 X555 22VT OR 5 X114 20GY TN 6 X530 20GY DB 7 X211 20YL GY 8 8W 80 22 8W 80 C...

Page 2534: ... 4 X555 22VT OR 5 X114 20GY TN 6 X530 20GY DB 7 X211 20YL GY 8 C205 NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 X53 20DG 2 X55 20DG BR 3 X54 20GY 4 X56 20GY BR 5 X200 18GY DB 6 X290 18GY OR 7 8 9 10 11 R22 20LG DG 12 R24 20YL LB 13 14 15 16 17 18 19 20 CS 8W 80 CONNECTOR PIN OUTS 8W 80 23 ...

Page 2535: ...Y BODY SIDE CAV CIRCUIT 1 C31 20LB YL 2 C11 22LB OR 3 C931 22DB TN 4 E12 18OR GY 5 Z870 20BK YL 6 G21 22VT WT 7 P189 20LG WT MIDDLE ROW HEATED SEATS 8 P188 16LG VT MIDDLE ROW HEATED SEATS 9 P187 16LG BR MIDDLE ROW HEATED SEATS 10 P196 20LG LB MIDDLE ROW HEATED SEATS 11 P197 20LG DG MIDDLE ROW HEATED SEATS 12 F525 16TN PK MIDDLE ROW HEATED SEATS 13 14 8W 80 24 8W 80 CONNECTOR PIN OUTS CS ...

Page 2536: ...TS 8 P188 16LG VT MIDDLE ROW HEATED SEATS 9 P187 16LG BR MIDDLE ROW HEATED SEATS 10 P196 20LG LB MIDDLE ROW HEATED SEATS 11 P197 20LG DG MIDDLE ROW HEATED SEATS 12 F525 16TN PK MIDDLE ROW HEATED SEATS 13 14 C301 BLACK BODY SIDE CAV CIRCUIT 1 G983 20VT OR 2 X201 18GY VT 3 X291 18GY YL 4 Q211 14TN LB 5 A215 18RD LG 6 P112 20TN OR 7 P114 20TN WT 8 Q1 20OR WT 9 E25 20OR GY 10 Q111 14TN YL 11 12 13 14 ...

Page 2537: ...K BODY SIDE CAV CIRCUIT 1 Z821 12BK BR 2 F515 12PK LB 3 D25 20WT VT 4 D123 20WT BR C302 BLACK LEFT FRONT DOOR SIDE CAV CIRCUIT 1 Z821 12BK BR 2 F515 12PK LB 3 D25 20WT VT 4 D123 20WT BR C303 BLACK BODY SIDE CAV CIRCUIT 1 Q111 14TN YL 2 Q211 14TN LB 3 4 P222 18VT DG 5 P292 18VT LG 6 G77 20VT GY 7 8 9 X205 18GY LG 10 X295 18GY DG 11 Q1 20OR WT 12 E25 20OR GY 13 G983 20VT OR 14 8W 80 26 8W 80 CONNECT...

Page 2538: ...LG EARLY BUILD 9 X205 18DG LG LATE BUILD 10 X295 18GY DG EARLY BUILD 10 X295 18DG GY LATE BUILD 11 Q1 20OR WT EARLY BUILD 11 Q1 20WT TN LATE BUILD 12 E25 20OR GY 13 G983 20VT OR EARLY BUILD 13 G983 20VT TN LATE BUILD 14 C304 BLACK BODY SIDE CAV CIRCUIT 1 G982 20VT TN 2 X202 18DG VT 3 X292 18DG YL 4 Q212 14OR VT 5 A214 18RD LB 6 7 8 Q2 20WT TN 9 E26 20OR GY 10 Q112 14OR BR 11 P222 18VT DG 12 P292 1...

Page 2539: ...LACK BODY SIDE CAV CIRCUIT 1 F516 12PK 2 Z822 12BK BR 3 D25 20WT VT 4 D123 20WT BR C305 BLACK RIGHT FRONT DOOR SIDE CAV CIRCUIT 1 F516 12PK 2 Z822 12BK BR 3 D25 20WT VT 4 D123 20WT BR C306 BLACK BODY SIDE CAV CIRCUIT 1 Q112 14OR BR 2 Q212 14OR VT 3 4 P222 18VT DG 5 P292 18VT LG 6 G76 20VT YL 7 8 9 X206 18DG LG 10 X296 18DG GY 11 Q2 20WT TN 12 E26 20OR GY 13 G982 20VT TN 14 8W 80 28 8W 80 CONNECTOR...

Page 2540: ...VT TN 14 C307 BLACK BODY SIDE CAV CIRCUIT 1 C15 12DB WT 2 W17 20BR LG 3 L3 18WT VT 4 L51 18WT DG 5 P31 18TN YL 6 M11 18YL VT 7 G78 20VT OR 8 W13 18BR WT 9 P30 20TN DG 10 Z800 12BK C307 BLACK LIFTGATE SIDE CAV CIRCUIT 1 C15 12DB WT 2 W17 20BR LG 3 L3 18WT VT 4 L51 18WT DG 5 P31 18TN YL BASE 6 M11 18YL VT 7 G78 22VT OR 8 W13 18BR WT 9 P30 20TN DG 10 Z800 12BK CS 8W 80 CONNECTOR PIN OUTS 8W 80 29 ...

Page 2541: ...RCUIT 1 Q85 16TN WT 2 Q75 20OR LB 3 Q84 16TN GY 4 Q901 20OR VT 5 Q83 18OR GY 6 Q60 22OR YL 7 Q94 22TN LG 8 9 10 G32 22VT LB C310 DK GRAY BODY SIDE CAV CIRCUIT 1 2 P44 14LG DG 3 P93 22LG VT FRONT ROW HEATED SEATS 4 P99 22LG LB FRONT ROW HEATED SEATS 5 P95 18LG WT FRONT ROW HEATED SEATS 6 P97 18LG YL FRONT ROW HEATED SEATS 7 8 9 10 P14 14LG OR 11 P16 14LG BR 12 P42 14LG GY 13 8W 80 30 8W 80 CONNECTO...

Page 2542: ...DG HANDS FREE 6 X835 20OR GY HANDS FREE 7 X722 20DG WT HANDS FREE 8 Q4 20OR WT POWER SUNROOF C312 EXCEPT BASE BLACK DOME SIDE CAV CIRCUIT 1 X730 20GY YL HANDS FREE EARLY BUILD 1 X730 20BR GY HANDS FREE LATE BUILD 2 Q3 22OR TN POWER SUNROOF 3 Q5 22OR LB POWER SUNROOF 4 X712 20DG LB HANDS FREE EARLY BUILD 4 X712 20BR HANDS FREE LATE BUILD 5 X792 20LB DG HANDS FREE EARLY BUILD 5 X792 20BR BK HANDS FR...

Page 2543: ...L WT 4 G25 22VT TN EXCEPT BASE 5 D25 20WT VT EXCEPT BASE 6 F316 20PK OR EXCEPT BASE EARLY BUILD 6 F316 20BK PK EXCEPT BASE LATE BUILD 7 P112 20BK OR EXCEPT BASE 8 P114 20BK LB EXCEPT BASE 9 A114 20GY RD EXCEPT BASE 10 Z327 18BK WT 11 Z137 20BK YL 12 Z113 18BK DB EXCEPT BASE C315 SATELLITE RADIO WHITE BODY SIDE CAV CIRCUIT 1 X17 22DG OR 2 X16 22DG YL 3 X917 22DG 4 D25 20WT VT 5 X112 20DG GY 6 X480 ...

Page 2544: ... 9 Z141 20BK TN 10 C316 LUMBAR SEAT ADJUSTER WHITE DRIVER SEAT SIDE CAV CIRCUIT 1 P107 18LG WT 2 P105 18LG C316 LUMBAR SEAT ADJUSTER WHITE LUMBAR JUMPER SIDE CAV CIRCUIT 1 P107 18DB 2 P105 18PK CAMSHAFT POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F855 20PK YL 5 VOLT SUPPLY 2 K900 20DB DG SENSOR GROUND 3 K44 20DB GY CMP SIGNAL CS 8W 80 CONNECTOR PIN OUTS 8W 80 33 ...

Page 2545: ...UIT FUNCTION 1 F306 16DB PK FUSED ACCESSORY RELAY OUTPUT 2 3 Z736 16BK YL GROUND CIRCUIT BREAKER POWER SEAT EARLY BUILD 25A GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A110 12DG RD FUSED B 2 A210 14OR RD FUSED B CIRCUIT BREAKER POWER SEAT LATE BUILD 30A GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A110 12DG RD FUSED B 2 A210 14OR RD FUSED B 8W 80 34 8W 80 CONNECTOR PIN OUTS CS ...

Page 2546: ...B 1 LINE 2 CLOCKSPRING C3 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 X20 20GY WT RADIO CONTROL MUX 1 X20 20GY WT RADIO CONTROL MUX 2 X920 20GY OR RADIO CONTROL MUX RETURN 2 X920 20GY OR RADIO CONTROL MUX RETURN 3 V37 20VT S C SWITCH SIGNAL 3 V37 20VT S C SWITCH SIGNAL 4 Z23 20BK VT SPEED CONTROL SWITCH GROUND 4 Z23 20BK VT SPEED CONTROL SWITCH GROUND CLOCKSPRING C4 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X3 20...

Page 2547: ...ION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K18 16DB OR COIL CONTROL NO 3 COIL ON PLUG NO 4 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K15 16DB COIL CONTROL NO 4 COIL ON PLUG NO 5 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K16 16DB YL COIL CONTROL NO 5 8W 80 36 8W 80 CONNECTOR PIN OUTS CS ...

Page 2548: ... 29 30 31 32 A111 12DG RD FUSED B 33 B6 18DG WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 37 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 42 B1 18DG DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 43 B2 18DG LB RIGHT REAR WHEEL SPEED SENSOR...

Page 2549: ...Y 2 K900 20DB DG SENSOR GROUND 3 K24 20BR LB CKP SIGNAL CYLINDER LOCK SWITCH DRIVER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z75 20BK VT GROUND 2 G163 20VT LB DRIVER CYLINDER LOCK SWITCH MUX DATA LINK CONNECTOR BLACK 16 WAY CAV CIRCUIT FUNCTION 1 2 D25 20WT VT PCI BUS 3 4 Z11 18BK LG GROUND 5 Z111 18BK WT GROUND 6 7 D21 20WT GY SCI TRANSMIT PCM 8 9 D123 20WT BR FLASH PROGRAM ENABLE 10 D24 20WT YL FLASH ...

Page 2550: ...SENSE 2 G983 20VT OR EARLY BUILD GROUND 2 G983 20VT TN LATE BUILD GROUND 3 P292 18VT LG DOOR UNLOCK DRIVER 4 P222 18VT DG DOOR LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH PASSENGER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE 2 Z74 20BK WT GROUND 3 P292 20VT LG DOOR UNLOCK DRIVER 4 P222 20VT DG DOOR LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH PASSENGER REAR BLACK 4 WAY C...

Page 2551: ...MBAR OUT SWITCH MUX 8 P309 20LG VT DRIVER SEAT HORIZONTAL LUMBAR IN SWITCH MUX 9 P200 20LG YL DRIVER SEAT FRONT RISER PEDAL FORWARD SWITCH MUX 10 P7 20LG DG DRIVER HEATED SEAT SWITCH MUX 11 G200 20VT BR MEMORY SELECT SWITCH MUX 12 P202 20LG DB DRIVER SEAT REAR RISER PEDAL BACK SWITCH MUX DOOR MODULE DRIVER C3 BLACK 20 WAY CAV CIRCUIT FUNCTION 1 Z75 20BK VT GROUND 2 P65 22VT TN DRIVER MIRROR HORIZO...

Page 2552: ...ER DOOR SWITCH ILLUMINATION DRIVER 7 P308 20LG VT PASSENGER SEAT RECLINER SWITCH MUX 8 P310 20LG OR PASSENGER SEAT HORIZONTAL SWITCH MUX 9 10 P8 20LG WT PASSENGER HEATED SEAT SWITCH MUX 11 12 DOOR MODULE PASSENGER C3 BLACK 20 WAY CAV CIRCUIT FUNCTION 1 Z74 20BK WT GROUND 2 P68 22TN YL PASSENGER MIRROR HORIZONTAL POSITION SIG NAL 3 4 5 Q2 20WT TN PASSENGER REAR WINDOW SWITCH MUX 6 P66 22TN LG PASSE...

Page 2553: ...D B 2 3 E14 20OR TN PANEL LAMPS DRIVER 4 5 6 7 8 X40 22GY WT AUDIO OUT RIGHT 9 Z530 20GY BK GROUND 10 11 X112 20DG GY IGNITION RUN ACC SIGNAL 12 D25 20WT VT PCI BUS 13 14 15 X140 22GY OR COMMON AUDIO 16 X41 22DG WT AUDIO OUT LEFT DVD CD CHANGER C2 BLACK 12 WAY CAV CIRCUIT FUNCTION 1 X114 20GY TN FUSED B 2 X211 20YL GY IGNITION RUN ACC SIGNAL 3 4 5 X915 22GY LB VIDEO CONTROL 6 X515 22GY OR VIDEO SI...

Page 2554: ...CONTROL ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K2 18VT OR ECT SIGNAL ENGINE OIL PRESSURE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G6 16VT GY OIL PRESSURE SIGNAL 2 EVAP PURGE SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K52 20DB WT EVAP PURGE CONTROL 2 K70 20DB BR EVAP PURGE RETURN CS 8W 80 CONNECTOR PIN OUTS 8W 80 43 ...

Page 2555: ...ON A L89 18WT YL LEFT FRONT FOG LAMP DRIVER B Z349 18BK YL GROUND FOG LAMP RIGHT BLACK 2 WAY CAV CIRCUIT FUNCTION A L90 18WT OR RIGHT FRONT FOG LAMP DRIVER B Z348 18BK OR GROUND FRONT BLOWER POWER MODULE C1 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z134 12BK OR GROUND 3 C56 20DB LB FRONT BLOWER MOTOR CONTROL 4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT 8W 80 44 8W 80 CONNECTOR PIN OUTS CS ...

Page 2556: ... 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 16BR YL INJECTOR CONTROL NO 1 FUEL INJECTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 16BR DB INJECTOR CONTROL NO 2 FUEL INJECTOR NO 3 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 16BR LB INJECTOR CONTROL NO 3 CS 8W 80 CONNECTOR PIN OUTS 8W 80 45 ...

Page 2557: ...OUTPUT 2 K38 16BR OR INJECTOR CONTROL NO 5 FUEL INJECTOR NO 6 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K58 16BR VT INJECTOR CONTROL NO 6 FUEL PUMP MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 N1 16DB OR FUEL PUMP RELAY OUTPUT 2 N4 20DB YL FUEL LEVEL SENSOR SIGNAL NO 1 3 N5 20DB WT FUEL LEVEL SENSOR SIGNAL NO 2 4 5 Z210 20BK LB GROUND 6 Z201 16BK GROUND 8W 80 ...

Page 2558: ...IRCUIT FUNCTION 1 A114 20GY RD FUSED B 2 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 3 4 5 X722 20DG WT MICROPHONE 2 IN 6 7 8 X704 20DG YL RIGHT AUDIO OUTPUT 9 X703 20DG OR LEFT AUDIO OUTPUT 10 11 12 13 14 D25 20WT VT PCI BUS 15 X730 20GY YL VOICE RECOGNITION PHONE SWITCH SIGNAL 16 X712 20DG LB MICROPHONE 1 IN 17 X792 20LB DG MICROPHONE IN 18 19 20 21 X835 20OR GY SENSOR GROUND 22 Z409 18BK WT GROUN...

Page 2559: ...WT GY RIGHT HIGH BEAM LAMP DRIVER 2 Z346 16BK LG GROUND 3 L44 16TN WT RIGHT LOW BEAM LAMP DRIVER 4 Z344 16BK TN GROUND 5 Z378 20BK OR GROUND 6 L78 20OR WT RIGHT FRONT PARK LAMP DRIVER 7 L60 18WT TN RIGHT FRONT TURN SIGNAL LAMP DRIVER 8 L778 20WT LB RIGHT FRONT SIDE MARKER LAMP DRIVER HEATED SEAT BACK DRIVER GREEN 2 WAY CAV CIRCUIT FUNCTION A P88 18BK DRIVER HEATED SEAT DRIVER B P94 18BK DRIVER SEA...

Page 2560: ...ER SEAT HEATER GROUND HEATED SEAT SWITCH LEFT MIDDLE ROW BLACK 6 WAY CAV CIRCUIT FUNCTION 1 P181 20LG DB LEFT MIDDLE ROW SEAT LOW INDICATOR DRIVER 2 E12 18OR GY PANEL LAMPS DRIVER 3 Z870 20BK YL GROUND 4 F525 16TN PK FUSED RUN RELAY OUTPUT 5 P183 20LG YL LEFT MIDDLE ROW SEAT HIGH INDICATOR DRIVER 6 P77 20LG LEFT MIDDLE ROW SEAT SWITCH MUX HEATED SEAT SWITCH RIGHT MIDDLE ROW GREEN 6 WAY CAV CIRCUIT...

Page 2561: ... SEAT TEMPERATURE SENSOR INPUT HEATED SEAT RIGHT MIDDLE ROW DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 P188 16LG VT RIGHT MIDDLE ROW SEAT HEATER B DRIVER 2 Z870 18BK YL GROUND 3 P189 20LG WT MIDDLE ROW SEAT TEMPERATURE SENSOR 5 VOLT SUPPLY 4 P196 20LG LB RIGHT MIDDLE ROW SEAT TEMPERATURE SENSOR INPUT HORN HIGH NOTE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z299 16BK OR GROUND 2 X2 16DG OR HORN RELAY OUTPUT 8W ...

Page 2562: ...ION SWITCH BLACK 5 WAY CAV CIRCUIT FUNCTION 1 G900 22OR VT IGNITION SWITCH SENSE RETURN 2 G20 22VT BR IGNITION SWITCH SENSE 3 F20 20PK GY IGNITION SWITCH OUTPUT RUN START 4 T751 20YL IGNITION SWITCH OUTPUT START 5 A106 20LB RD FUSED B IMPACT SENSOR LEFT FRONT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R81 20LB WT LEFT FRONT IMPACT SENSOR GROUND 2 R79 20LB VT LEFT FRONT IMPACT SENSOR SIGNAL CS 8W 80 CONNEC...

Page 2563: ...LG BR LEFT SIDE IMPACT SENSOR 1 GROUND 2 R13 20LG VT LEFT SIDE IMPACT SENSOR 1 SIGNAL IMPACT SENSOR LEFT SIDE 2 EARLY BUILD BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R19 20LG WT LEFT SIDE IMPACT SENSOR 2 GROUND 2 R17 20LG LEFT SIDE IMPACT SENSOR 2 SIGNAL IMPACT SENSOR LEFT SIDE 2 LATE BUILD DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R19 20LG WT LEFT SIDE IMPACT SENSOR 2 GROUND 2 R17 20LG LEFT SIDE IMPACT SENSO...

Page 2564: ...IMPACT SENSOR GROUND 2 R80 20LB TN RIGHT FRONT IMPACT SENSOR SIGNAL IMPACT SENSOR RIGHT SIDE 1 EARLY BUILD BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 2 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL IMPACT SENSOR RIGHT SIDE 1 LATE BUILD DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 2 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SI...

Page 2565: ...AV CIRCUIT FUNCTION 1 R24 20YL LB RIGHT SIDE IMPACT SENSOR 3 GROUND 2 R22 20LG DG RIGHT SIDE IMPACT SENSOR 3 SIGNAL INSTRUMENT CLUSTER C1 BLACK 16 WAY CAV CIRCUIT FUNCTION 1 A108 18LG RD FUSED B 2 3 4 5 G150 22VT BR INSTRUMENT CLUSTER WAKE UP SIGNAL 6 D25 20WT VT PCI BUS 7 8 G106 20VT OR EVIC MUX SIGNAL 9 E12 20OR GY PANEL LAMPS DRIVER 10 L160 22WT TN RIGHT TURN SIGNAL 11 L161 20WT LG LEFT TURN SI...

Page 2566: ... SWITCH POD BLACK 12 WAY CAV CIRCUIT FUNCTION 1 A118 20RD OR FUSED B 2 G106 20VT OR EVIC MUX SIGNAL 3 G107 22VT YL NAVIGATION NAV MUX SIGNAL 4 G69 22VT WT VTSS INDICATOR DRIVER 5 6 L91 20WT DB HAZARD SWITCH SENSE 7 E12 20OR GY PANEL LAMPS DRIVER 8 9 10 11 G907 20VT EVIC NAV MUX RETURN 12 Z108 20BK LG GROUND INTAKE AIR TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND...

Page 2567: ...L GROUND 7 8 9 10 A107 12TN RD FUSED B 11 12 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 13 K136 18BR MANIFOLD TUNING VALVE RELAY OUTPUT 14 C3 18DB YL A C COMPRESSOR CLUTCH RELAY OUTPUT 15 INTEGRATED POWER MODULE C2 DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 2 3 A101 12VT RD FUSED B 4 F515 12PK LB FUSED DOOR NODE RELAY OUTPUT INTEGRATED POWER MODULE C3 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 2 A112 12OR RD ...

Page 2568: ...ION 1 2 L89 18WT YL FOG LAMPS LEFT FRONT FOG LAMP DRIVER 3 W1 18BR TN WASHER FLUID LEVEL SWITCH SENSE 4 5 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 6 L778 20WT LB RIGHT FRONT SIDE MARKER LAMP DRIVER 7 L777 20WT VT LEFT FRONT SIDE MARKER LAMP DRIVER 8 9 10 11 12 13 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 14 Z118 18BK YL GROUND 15 16 L44 16TN WT RIGHT LOW BEAM LAMP DRIVER 17 L90 18WT OR FOG LAMPS ...

Page 2569: ...L OR TRANSMISSION CONTROL RELAY OUTPUT 10 K31 20BR FUEL PUMP RELAY CONTROL INTEGRATED POWER MODULE C8 WHITE 15 WAY CAV CIRCUIT FUNCTION 1 F516 12PK FUSED DOOR NODE RELAY OUTPUT 2 C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT 3 W4 12BR OR FRONT WIPER HIGH LOW RELAY HIGH SPEED OUT PUT 4 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 5 A701 14BR RD EARLY BUILD FUSED B 5 A100 16RD VT TRAILER TOW LATE BUI...

Page 2570: ...C RUN START DRIVER 17 18 19 F2 18PK YL IGNITION SWITCH OUTPUT RUN START 20 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 21 22 23 24 N1 16DB OR FUEL PUMP RELAY OUTPUT 25 A105 18DB RD FUSED B 26 F525 16TN PK MIDDLE ROW HEATED SEATS FUSED RUN RELAY OUTPUT KNOCK SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K42 20DB OR KS SIGNAL 2 K942 20BR LG KS RETURN LICENSE LAMP RED 6 WAY CAV CIRCUIT FUNCTION 1 L3 18WT VT LIC...

Page 2571: ...TCH DRIVER LIFTGATE FLOOD LAMP GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z311 20BK VT GROUND 2 3 M11 18YL VT LIFTGATE COURTESY LAMP DRIVER LIFTGATE HANDLE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P30 20TN DG LIFTGATE HANDLE SWITCH SENSE 2 Z87 20BK LG BASE GROUND 2 Q901 20OR VT POWER LIFTGATE GROUND LIFTGATE LOCK MOTOR AJAR SWITCH BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK OR GROUND 2 G78 22VT OR LI...

Page 2572: ...Y CAV CIRCUIT FUNCTION 1 Q77 20OR DB RIGHT PINCH SENSOR SIGNAL 2 Q901 20OR VT GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K1 20VT BR MAP SIGNAL 2 K900 20DB DG SENSOR GROUND 3 F855 20PK YL 5 VOLT SUPPLY MANIFOLD TUNING VALVE SOLENOID DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z110 20BK LG GROUND 2 K136 18BR MANIFOLD TUNING VALVE RELAY OUTPUT CS 8W 80 CONNECTOR PIN OUTS 8W 8...

Page 2573: ...BLE PEDALS ADJUSTABLE PEDALS SENSOR SIGNAL 20 G912 20VT WT ADJUSTABLE PED ALS ADJUSTABLE PEDALS SENSOR RETURN 21 G914 22VT GY ADJUSTABLE PEDALS ADJUSTABLE PEDALS MOTOR HALL SENSE RETURN 22 G14 20VT DB ADJUSTABLE PEDALS ADJUSTABLE PEDALS MOTOR HALL SIGNAL 23 24 P97 18LG YL FRONT ROW HEATED SEATS PASSENGER SEAT HEATER GROUND 25 26 P16 14LG BR PASSENGER SEAT HORIZONTAL REARWARD DRIVER MEMORY HEATED S...

Page 2574: ...SEAT RECLINER UP DRIVER 9 P105 18LG LUMBAR SEAT ADJUSTER DRIVER SEAT LUMBAR OUT DRIVER 10 P107 18LG WT LUMBAR SEAT ADJUSTER DRIVER SEAT LUMBAR IN DRIVER 11 P113 14LG VT DRIVER SEAT REAR DOWN DRIVER 12 P121 14LG DB DRIVER SEAT FRONT DOWN DRIVER MEMORY HEATED SEAT ADJUSTABLE PEDALS MODULE C4 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A210 14OR RD FUSED B 2 Z849 14BK OR GROUND MODE DOOR ACTUATOR FRONT GRAY 2 ...

Page 2575: ...VACUUM LEAK DETECTION ASSEMBLY BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z166 18BK WT GROUND 2 K107 20VT WT NVLD SWITCH SIGNAL 3 K106 20VT LB NVLD SOL CONTROL NAVIGATION MODULE BLACK 16 WAY CAV CIRCUIT FUNCTION 1 A114 20GY RD FUSED B 2 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 3 Z495 18BK GY GROUND 4 X400 20GY WT NAVIGATION AUDIO 5 G591 20 EARLY BUILD SHIELD 5 G591 22 LATE BUILD SHIELD 6 G400 20VT LB RED...

Page 2576: ...NROOF SUNROOF CLOSE 11 L24 20WT DB EARLY BUILD AUTOMATIC HEADLAMP SIGNAL 11 L24 20BK GY LATE BUILD AUTOMATIC HEADLAMP SIGNAL 12 L11 20WT OR EARLY BUILD BACK UP LAMP SIGNAL 12 L11 20BK WT LATE BUILD BACK UP LAMP SIGNAL OXYGEN SENSOR 1 1 UPSTREAM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z42 18BK LG GROUND 2 K99 18BR TN O2 1 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K41 18DB LB O2 1 1 SIGNAL OXYGEN SE...

Page 2577: ... B 6 7 8 Z125 14BK OR EXCEPT NAVIGATION LATE BUILD GROUND 8 Z125 12BK OR NAVIGATION LATE BUILD GROUND POWER LIFTGATE MODULE C2 BLACK 20 WAY CAV CIRCUIT FUNCTION 1 Q203 20OR TN OPTICAL SENSOR SUPPLY 2 3 4 5 Q75 20OR LB PINCH SENSOR SIGNAL 6 7 Q201 18OR LG LIFTGATE CLUTCH DRIVER 8 Q84 16TN GY LIFTGATE LATCH CINCH DRIVER 9 Q85 16TN WT LIFTGATE LATCH RELEASE DRIVER 10 11 D25 20WT VT PCI BUS 12 G78 20V...

Page 2578: ...ROR DRIVER 12 C17 20LB WT DRIVER HEATED MIRROR FEED POWER MIRROR PASSENGER BLACK 12 WAY CAV CIRCUIT FUNCTION 1 P64 22TN PASSENGER MIRROR VERTICAL POSITION SIGNAL 2 P66 22TN LG PASSENGER MIRROR SENSOR GROUND 3 P68 22TN YL PASSENGER MIRROR HORIZONTAL POSITION SIG NAL 4 P70 22TN LB PASSENGER MIRROR COMMON DRIVER 5 P74 22TN OR PASSENGER MIRROR HORIZONTAL DRIVER 6 P72 20TN GY PASSENGER MIRROR VERTICAL ...

Page 2579: ... WAY CAV CIRCUIT FUNCTION 1 P121 14LG DB DRIVER SEAT FRONT DOWN DRIVER 2 P119 14LG DG DRIVER SEAT FRONT UP DRIVER POWER SEAT MOTOR DRIVER HORIZONTAL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P117 14LG LB DRIVER SEAT HORIZONTAL REARWARD DRIVER 2 P115 14LG OR DRIVER SEAT HORIZONTAL FORWARD DRIVER POWER SEAT MOTOR DRIVER LUMBAR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P107 18DB DRIVER SEAT LUMBAR IN DRIVER 2 P105...

Page 2580: ...CLINER DOWN DRIVER 2 P143 14LG GY DRIVER SEAT RECLINER UP DRIVER POWER SEAT MOTOR PASSENGER HORIZONTAL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P16 14LG BR PASSENGER SEAT HORIZONTAL REARWARD DRIVER 2 P14 14LG OR PASSENGER SEAT HORIZONTAL FORWARD DRIVER POWER SEAT MOTOR PASSENGER RECLINER DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 P42 14LG GY PASSENGER SEAT RECLINER DOWN DRIVER 2 P44 14LG DG PASSENGER SEAT REC...

Page 2581: ...H MUX 12 P202 20LG DB DRIVER SEAT REAR RISER PEDAL BACK SWITCH MUX POWER SEAT SWITCH PASSENGER BLACK 12 WAY CAV CIRCUIT FUNCTION 1 2 P84 20TN VT FRONT ROW HEATED SEATS PASSENGER HEATED SEAT HIGH INDICATOR DRIVER 3 P82 20TN DG FRONT ROW HEATED SEATS PASSENGER HEATED SEAT LOW INDICATOR DRIVER 4 P988 20LG TN SEAT SWITCH MUX RETURN 5 Z302 20LG BK ILLUMINATION GROUND 6 P302 20TN OR PASSENGER DOOR SWITC...

Page 2582: ... UP POWER WINDOW MOTOR PASSENGER LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Q22 14VT OR PASSENGER WINDOW DRIVER DOWN 2 Q12 14BR OR PASSENGER WINDOW DRIVER UP POWER WINDOW MOTOR PASSENGER REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Q212 14OR VT PASSENGER REAR WINDOW DRIVER DOWN 2 Q112 14OR BR PASSENGER REAR WINDOW DRIVER UP POWER WINDOW SWITCH DRIVER REAR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Q1 20OR WT EAR...

Page 2583: ...UT RUN START 12 F1 20PK WT IGNITION UNLOCK RUN START 13 14 15 16 K236 16DB LG SRV SOL CONTROL 17 18 Z131 16BK DG GROUND 19 20 G6 16VT GY OIL PRESSURE SIGNAL 21 22 G31 20OR VT AAT SIGNAL 23 24 25 D20 20WT LG SCI RECEIVE PCM 26 D123 20WT BR FLASH PROGRAM ENABLE 27 28 29 A109 18OR RD FUSED B 30 T751 20YL IGNITION SWITCH OUTPUT START 31 K141 20DB YL O2 1 2 SIGNAL 32 K904 20DB DG O2 RETURN DOWN 33 34 3...

Page 2584: ... 3 13 K12 16BR DB INJECTOR CONTROL NO 2 14 K11 16BR YL INJECTOR CONTROL NO 1 15 16 K36 20DB YL MTV CONTROL 17 18 K99 18BR TN O2 1 1 HEATER CONTROL 19 K20 18BR GY GEN FIELD CONTROL 20 K2 18VT OR ECT SIGNAL 21 K22 18BR OR TP SIGNAL 22 K34 20DB LG EGR SIGNAL 23 K1 20VT BR MAP SIGNAL 24 K942 20BR LG KS RETURN 25 K42 20DB OR KS SIGNAL 26 27 K900 20DB DG SENSOR GROUND 28 K961 20BR VT IAC RETURN 29 F855 ...

Page 2585: ...7 18 19 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20DB WT EVAP PURGE CONTROL 21 22 23 B29 20DG WT BRAKE SWITCH SIGNAL 24 25 26 T44 20YL DG AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20DG YL AUTOSTICK UPSHIFT SWITCH SIGNAL 28 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K70 20DB BR EVAP PURGE RETURN 30 31 C18 20LB BR A C PRESSURE TRANSDUCER SIGNAL 32 K91 20DB YL BATTERY TEMP SIGNAL 33 3...

Page 2586: ...BR TRANSMISSION CONTROL RELAY CONTROL 19 20 21 22 T9 18DG TN OVERDRIVE PRESSURE SWITCH SENSE 23 24 25 26 27 T41 18YL DB TRS T41 SENSE 28 T16 16YL OR TRANSMISSION CONTROL RELAY OUTPUT 29 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 30 T47 18YL DG 2 4 PRESSURE SWITCH SENSE 31 32 T14 18DG BR OUTPUT SPEED SENSOR SIGNAL 33 T52 18DG WT INPUT SPEED SENSOR SIGNAL 34 T13 18DG VT SPEED SENSOR GROUND 35 T54...

Page 2587: ...ATOR FAN MOTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N23 12DB DG RADIATOR FAN RELAY OUTPUT 2 Z223 12BK DG GROUND RADIATOR FAN RELAY BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A112 12OR RD FUSED B 2 N23 12DB DG RADIATOR FAN RELAY OUTPUT 3 Z723 18BK DG GROUND 4 K173 18BR VT RAD FAN RELAY CONTROL 8W 80 76 8W 80 CONNECTOR PIN OUTS CS ...

Page 2588: ... 13 X60 18GY OR ANTENNA SIGNAL 14 D25 20WT VT PCI BUS 15 16 17 18 19 20 21 22 RADIO C1 EXCEPT BASE DK GRAY 22 WAY CAV CIRCUIT FUNCTION 1 A118 20RD OR FUSED B 2 F316 20PK OR FUSED ACCESSORY RELAY OUTPUT 3 E12 18OR GY PANEL LAMPS DRIVER 4 5 6 7 X54 20GY RADIO RIGHT AUDIO 8 X56 20GY BR RADIO RIGHT AUDIO 9 X55 20DG BR RADIO LEFT AUDIO 10 X53 20DG RADIO LEFT AUDIO 11 Z514 18BK LG GROUND 12 13 X60 18GY ...

Page 2589: ...7 22 SHIELD 4 D25 20WT VT PCI BUS 5 X112 20DG GY IGNITION RUN ACC SIGNAL 6 X417 22DG WT AUDIO MUX LEFT 7 Z141 20BK TN GROUND 8 9 E14 20OR TN PANEL LAMPS DRIVER 10 X160 20GY YL FUSED B READING LAMP FRONT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 Z137 20BK YL GROUND 3 4 M27 18YL LB RAIL LAMPS DRIVER 5 M24 18YL WT FRONT READING COURTESY LAMPS DRIVER 6 E3 20OR YL OVERHEAD CONSOLE DOME LAMPS DIMMER SIGNAL R...

Page 2590: ... LAMPS DRIVER READING COURTESY LAMP RIGHT REAR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 18YL OR COURTESY LAMPS DRIVER 2 Z327 18BK WT GROUND 3 M27 18YL LB RAIL LAMPS DRIVER REAR BOOSTER FAN POWER MODULE C1 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z135 18BK LB GROUND 3 C57 20DB LB REAR BOOSTER FAN CONTROL 4 C51 18LB BR FUSED REAR BOOSTER FAN RELAY OUTPUT REAR BOOSTER FAN POWER MODULE C2 BLACK 2 WAY CAV CIR...

Page 2591: ...IN 6 X712 20BR LATE BUILD MICROPHONE 1 IN 7 8 9 X730 20GY YL EARLY BUILD VOICE RECOGNITION PHONE SWITCH SIGNAL 9 X730 20BR GY LATE BUILD VOICE RECOGNITION PHONE SWITCH SIGNAL 10 11 X835 20OR GY EARLY BUILD SENSOR GROUND 11 X835 20BR OR LATE BUILD SENSOR GROUND 12 X792 20LB DG EARLY BUILD MICROPHONE IN 12 X792 20BR BK LATE BUILD MICROPHONE IN RECIRCULATION DOOR ACTUATOR GRAY 2 WAY CAV CIRCUIT FUNCT...

Page 2592: ...GY OR AUDIO RETURN 4 5 D25 20WT VT PCI BUS 6 X112 20DG GY IGNITION RUN ACC SIGNAL 7 X112 20DG GY IGNITION RUN ACC SIGNAL 8 X16 22DG YL AUDIO SIGNAL RIGHT 9 X607 20 SHIELD 10 X917 22DG AUDIO SIGNAL COMMON 11 X17 22DG OR AUDIO SIGNAL LEFT 12 13 X480 20DG LB AUDIO MUX ENABLE 14 15 Z141 20BK TN GROUND 16 E14 20OR TN PANEL LAMPS DRIVER 17 X160 20GY YL FUSED B 18 D25 20WT VT PCI BUS 19 Z141 20BK TN GROU...

Page 2593: ...USED B 2 X112 20DG GY IGNITION RUN ACC SIGNAL 3 Z141 20BK TN GROUND 4 X480 20DG LB AUDIO MUX ENABLE 5 6 X17 22DG OR AUDIO SIGNAL LEFT 7 D25 20WT VT PCI BUS 8 9 10 11 X917 22DG AUDIO SIGNAL COMMON 12 X16 22DG YL AUDIO SIGNAL RIGHT SEAT BELT SWITCH DRIVER DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G10 20VT LG DRIVER SEAT BELT SWITCH SENSE 2 Z237 20BK YL GROUND SEAT BELT TENSIONER DRIVER YELLOW 2 WAY CAV C...

Page 2594: ...ELAY OUTPUT 7 P196 20LG LB RIGHT MIDDLE ROW SEAT TEMPERATURE SENSOR INPUT 8 P197 20LG DG LEFT MIDDLE ROW SEAT TEMPERATURE SENSOR INPUT 9 P96 20LB LG RIGHT MIDDLE ROW SEAT SWITCH MUX 10 P182 20LG OR RIGHT MIDDLE ROW SEAT LOW INDICATOR DRIVER 11 P184 20LG GY RIGHT MIDDLE ROW SEAT HIGH INDICATOR DRIVER 12 P181 20LG DB LEFT MIDDLE ROW SEAT LOW INDICATOR DRIVER 13 Z870 20BK YL GROUND 14 P183 20LG YL LE...

Page 2595: ... P28 20LG BR DRIVER SEAT POSITION SENSOR GROUND SEAT POSITION SENSOR DRIVER RECLINER BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG BR DRIVER SEAT POSITION SENSOR GROUND B P47 20LG LB DRIVER SEAT RECLINER POSITION SIGNAL C P29 20LG WT DRIVER SEAT POSITION SENSOR 5 VOLT SUPPLY SHORT RUNNER VALVE SOLENOID GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K236 18DB LG SRV SOL CONTROL 2 K342 16BR WT AUTOMATIC SHUT DOWN ...

Page 2596: ... LEFT FRONT DOOR SPEAKER SPEAKER LEFT FRONT DOOR WOOFER WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X201 18GY VT AMPLIFIED LEFT FRONT DOOR SPEAKER 2 3 X291 18GY YL AMPLIFIED LEFT FRONT DOOR SPEAKER SPEAKER LEFT REAR DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X205 18GY LG EARLY BUILD AMPLIFIED LEFT REAR DOOR SPEAKER 1 X205 18DG LG LATE BUILD AMPLIFIED LEFT REAR DOOR SPEAKER 2 3 X295 18GY DG EARLY BUILD AMPLIFI...

Page 2597: ...FRONT DOOR SPEAKER 2 3 X292 18DG YL AMPLIFIED RIGHT FRONT DOOR SPEAKER SPEAKER RIGHT REAR DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X206 18DG LG AMPLIFIED RIGHT REAR DOOR SPEAKER 2 3 X296 18DG GY AMPLIFIED RIGHT REAR DOOR SPEAKER SPEAKER SUBWOOFER RED 6 WAY CAV CIRCUIT FUNCTION 1 X301 18GY WT AMPLIFIED SUBWOOFER 2 2 3 X300 18GY BR AMPLIFIED SUBWOOFER 1 4 X390 18DG BR AMPLIFIED SUBWOOFER 1 5 6 X391 1...

Page 2598: ...H LEFT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z23 20BK VT SPEED CONTROL SWITCH GROUND 2 3 V37 20VT S C SWITCH SIGNAL SPEED CONTROL SWITCH RIGHT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z23 20BK VT SPEED CONTROL SWITCH GROUND 2 3 V37 20VT S C SWITCH SIGNAL SPEED SENSOR INPUT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 18DG VT SPEED SENSOR GROUND 2 T52 18DG WT INPUT SPEED SENSOR SIGNAL CS 8W 80 CONNECTOR PIN OUTS 8...

Page 2599: ...L LAMP RIGHT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 L72 20WT OR RIGHT TAIL LAMP DRIVER 2 L1 18WT LG BACK UP LAMP DRIVER 3 L72 20WT OR RIGHT TAIL LAMP DRIVER 4 Z362 18BK BR GROUND 5 L51 18WT DG BRAKE LAMP SWITCH OUTPUT 6 L62 18WT DB RIGHT REAR TURN SIGNAL LAMP DRIVER THROTTLE POSITION SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K22 18BR OR TP SIGNAL 3 F855 20PK YL 5 VOLT SUPPL...

Page 2600: ...RS T41 SENSE 6 7 T1 18LB DG TRS T1 SENSE 8 T3 18DG DB TRS T3 SENSE 9 T42 18DG YL TRS T42 SENSE 10 T41 18YL DB TRS T41 SENSE TRANSMISSION SOLENOID PRESSURE SWITCH ASSEMBLY BLACK 8 WAY CAV CIRCUIT FUNCTION 1 T47 18YL DG 2 4 PRESSURE SWITCH SENSE 2 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 3 T9 18DG TN OVERDRIVE PRESSURE SWITCH SENSE 4 T16 16YL OR TRANSMISSION CONTROL RELAY OUTPUT 5 T59 18YL LB U...

Page 2601: ...T GROUND WASHER FLUID LEVEL SWITCH GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z401 18BK TN GROUND 2 W1 18BR TN WASHER FLUID LEVEL SWITCH SENSE WASHER PUMP MOTOR FRONT NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 2 Z243 18BK GROUND WASHER PUMP MOTOR REAR DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 2 Z243 18BK GROUND 8W 80 90 8W 80 CONNECTO...

Page 2602: ...L SPEED SENSOR 12 VOLT SUP PLY 2 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR RIGHT FRONT LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B6 18DG WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR RIGHT REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B2 18DG LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 2 B1 18DG DB RIGHT R...

Page 2603: ...1 Z213 18BK OR GROUND 2 W17 20BR LG REAR WIPER PARK SWITCH SENSE 3 W13 18BR WT REAR WIPER MOTOR CONTROL WIPER WASHER SWITCH WHITE 10 WAY CAV CIRCUIT FUNCTION 1 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 2 3 W33 22BR DG FRONT WASHER SIGNAL 4 5 W26 20BR DB REAR WIPER SWITCH MUX 6 W27 22DB BR REAR WIPER SWITCH DELAY 7 G902 20VT OR MULTI FUNCTION SWITCH MUX RETURN 8 W52 22BR YL FRONT WIPER SWITCH M...

Page 2604: ... Body by Console 26 Airbag Control Module C2 ORC YL Center Body by Console 15 18 Airbag Squib Driver 1 YL BK Steering Wheel 22 Airbag Squib Driver 2 YL TN Steering Wheel 22 Airbag Squib Driver Knee Blocker YL Left Side of Dash 15 16 21 Airbag Squib Left Curtain YL Left Upper B Pillar 27 Airbag Squib Passenger YL Right Side of Dash 15 16 Airbag Squib Right Curtain YL Right Upper B Pillar 31 Ambient...

Page 2605: ...nt of Engine Compartment 3 4 5 C200 LT GY Front Console 15 23 C201 GY BK Left Side of Dash 15 19 21 25 C202 DK GY Right Side of Dash 14 15 16 C204 DVD BK Right Side of Dash 15 19 44 C205 NAT WT Right Side of Dash 15 16 19 30 C300 LT GY Rear Console 23 24 26 30 C301 BK Left Side A Pillar 25 37 C302 BK Left Side A Pillar 25 37 C303 BK Left Side B Pillar 27 39 C304 BK Right Side A Pillar 30 37 C305 B...

Page 2606: ...tch Passenger BK In Door 37 Door Lock Motor Ajar Switch Passenger Rear BK In Door 39 Door Module Driver C1 GY In Door 37 Door Module Driver C2 BK In Door 38 Door Module Driver C3 BK In Door 37 Door Module Passenger C1 GY In Door 37 Door Module Passenger C2 BK In Door 38 Door Module Passenger C3 BK In Door 37 DVD Screen BK Upper Console Headliner 44 DVD CD Changer C1 BK Center of Dash 15 17 DVD CD ...

Page 2607: ...t Side of Body 27 43 Heated Seat Right Middle Row DK GY Right Side of Body 31 43 Horn High Note BK Right Front Frame Rail 2 7 Horn Low Note BK Right Front Frame Rail 2 7 Idle Air Control Motor BK Right Rear Engine 10 Ignition Switch BK Left Side of Dash 15 16 20 Impact Sensor Left Front BK Left Front of Engine Compartment 5 Impact Sensor Left Side 1 Early Build DK GY Left Side B Pillar 27 Impact S...

Page 2608: ...BK Left of Engine 12 License Lamp RD Rear Liftgate 45 46 Liftgate Cinch Release Motor Power Liftgate BL Rear Liftgate 45 Liftgate Flood Lamp GY Rear Liftgate 45 Liftgate Handle Switch BK Rear Liftgate 45 Liftgate Lock Motor Ajar Switch Base BK Rear Liftgate 45 Liftgate Pinch Sensor Left Power Liftgate BK Rear Liftgate 45 Liftgate Pinch Sensor Right Power Liftgate BK Rear Liftgate 45 Manifold Absol...

Page 2609: ...n Driver Seat 40 Power Seat Motor Driver Recliner DK GY In Driver Seat 41 Power Seat Motor Passenger Horizontal BK In Passenger Seat 40 Power Seat Motor Passenger Recliner DK GY In Passenger Seat 41 Power Seat Switch Driver BK Driver Door 38 Power Seat Switch Passenger BK Passenger Door 38 Power Sunroof Module BK Left Upper Body 27 Power Window Motor Driver LT GY Middle of Driver Door 37 Power Win...

Page 2610: ... Ground Left Side Liftgate 45 Rear View Mirror BK On Windshield Glass 44 Recirculation Door Actuator GY On the HVAC Assembly 14 Remote Radio Switch Left BK Steering Wheel 22 Remote Radio Switch Right BK Steering Wheel 22 Satellite Radio Multiplexer C1 DK GY Center of Dash 16 Satellite Radio Multiplexer C2 DK GY Center of Dash 15 17 Satellite Radio Receiver BK Right Rear Body 35 Seat Belt Switch Dr...

Page 2611: ...ont Console 15 23 Trailer Tow Connector BK Left Rear Body 28 Transmission Range Indicator Illumination DK GY Under Front Console 15 23 Transmission Range Sensor DK GY Left Front of Engine 3 9 Transmission Solenoid Pressure Switch Assembly BK Left Side of Engine 3 9 Visor Vanity Lamp Left BK Left Front Headliner 44 Visor Vanity Lamp Right BK Right Front Headliner 44 Washer Fluid Level Switch GY Lef...

Page 2612: ...21 SPLICES SPLICE NUMBER LOCATION FIG S100 Left Side of Engine Compartment 3 8 S101 Left Front of Engine Compartment 3 9 S102 On Engine near MAP sensor T O 12 S103 Center Front Side of Engine 9 S104 On Engine near G104 T O 12 S105 Left Front of Engine Compartment 3 S106 On Engine near EGR Solenoid T O 12 S107 Left Front of Engine Compartment 5 S108 Early Build Left Front of Engine Compartment N S ...

Page 2613: ...enter Side of Body 27 S303 Right Rear Body 31 S305 Left Center Side of Body 25 S306 Middle Row Heated Seats In Rear Center Console 24 S307 Left Side of Engine Compartment 3 S312 Middle Row Heated Seats In Rear Center Console 24 S313 Left Rear Body 27 S314 Left Center Body near Console 26 S315 Left Center Side of Body 27 S320 Right Center Body near Console 26 S322 Middle Center of Body 26 S323 Righ...

Page 2614: ... Headliner 44 S345 Front Headliner 44 S346 Left Front Headliner 44 S347 Left Side Body near A Pillar 25 S348 Right Rear Body 35 S349 Center Instrument Panel 16 S351 Left Rear Body 28 S352 Right Rear Part of Body 31 S353 Left Center Side of Body 26 S354 Left Center Side of Body 25 S355 Below Driver Seat Cushion 40 S356 Below Driver Seat Cushion 40 CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 11 ...

Page 2615: ...Fig 1 FRONT LIGHTING 8W 91 12 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2616: ...Fig 2 HORN CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2617: ...Fig 3 ENGINE COMPARTMENT LEFT FRONT 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2618: ...Fig 4 ENGINE COMPARTMENT LEFT CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2619: ...Fig 5 ENGINE COMPARTMENT FRONT 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2620: ...Fig 6 ENGINE COMPARTMENT LEFT FRONT AND REAR CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2621: ...Fig 7 ENGINE COMPARTMENT RIGHT 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2622: ...Fig 8 BATTERY CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2623: ...Fig 9 ENGINE 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2624: ...Fig 10 ENGINE REAR CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2625: ...Fig 11 ENGINE RIGHT 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2626: ...Fig 12 ENGINE LEFT REAR CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2627: ...Fig 13 ENGINE TOP 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2628: ...Fig 14 HVAC CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2629: ...Fig 15 INSTRUMENT PANEL HARNESS 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2630: ...Fig 16 INSTRUMENT PANEL CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2631: ...Fig 17 INSTRUMENT PANEL CENTER AND RIGHT 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2632: ...Fig 18 INSTRUMENT PANEL CENTER CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2633: ...Fig 19 INSTRUMENT PANEL SIDES 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2634: ...Fig 20 INSTRUMENT PANEL CENTER STACK CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2635: ...Fig 21 INSTRUMENT PANEL STEERING COLUMN 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2636: ...Fig 22 STEERING WHEEL CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2637: ...Fig 23 BODY CENTER 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2638: ...Fig 24 BODY CENTER CONSOLE CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2639: ...Fig 25 BODY LEFT KICK PANEL 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2640: ...Fig 26 BODY CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2641: ...Fig 27 BODY LEFT 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2642: ...Fig 28 BODY LEFT REAR CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2643: ...Fig 29 BODY REAR 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2644: ...Fig 30 BODY LEFT SIDE CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2645: ...Fig 31 BODY RIGHT SIDE 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2646: ...Fig 32 BODY ANTENNA CABLE CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2647: ...Fig 33 BODY REAR FLOOR 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2648: ...Fig 34 REAR SIDE GLASS CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2649: ...Fig 35 BODY RIGHT REAR 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2650: ...Fig 36 FUEL TANK CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2651: ...Fig 37 DOOR FRONT 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2652: ...Fig 38 FRONT DOOR PANEL CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 49 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2653: ...Fig 39 DOOR REAR 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2654: ...Fig 40 SEATS FRONT CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 51 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2655: ...Fig 41 DRIVER SEAT SIDES 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2656: ...Fig 42 PASSENGER SEAT LEFT SIDE CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 53 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2657: ...Fig 43 SEAT MIDDLE ROW 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2658: ...Fig 44 HEADLINER CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 55 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2659: ...Fig 45 LIFTGATE 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCATION CS CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2660: ...Fig 46 LICENSE LAMP Fig 47 TAIL LAMP RIGHT CS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 57 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 2661: ......

Page 2662: ... relay Front and rear blower relay Front wiper HI LOW relay Front wiper ON relay Horn relay Run relay Fuel pump relay REMOVAL NOTE When a replacement IPM is installed in the vehicle the IOD fuse must be rotated to the cus tomer position 1 Disconnect and isolate the battery negative cable 2 Remove the hood cable retaining clip near the Integrated Power Module IPM 3 Using a flat bladed tool depress ...

Page 2663: ... the Off position including the clock The only reason the IOD fuse is reversed in its holder 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 opera tion so that the vehicle can be loaded unloaded and moved as needed by both vehicle transportation com pany and dealer perso...

Page 2664: ...e Refer to Fig 3 5 Disconnect the base wires 6 Set base aside and remove base mount ring INSTALLATION 1 Install base mount ring 2 Connect the base wires 3 Firmly snap base into position inside of instru ment panel 4 Connect the battery negative cable Fig 3 TOOL FOR CIGAR LIGHTER POWER OUTLET REMOVAL 1 2 5MM 3 32 INS 2 WELD 3 100MM 4 INS 4 22 25 TO 22 45MM 7 8 TO 57 64 INS CS 8W 97 POWER DISTRIBUTI...

Page 2665: ......

Page 2666: ...27 INSTALLATION 27 AIR CLEANER HOUSING REMOVAL 27 INSTALLATION 27 CYLINDER HEAD S DESCRIPTION 28 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 28 REMOVAL CYLINDER HEAD S 28 CLEANING 31 INSPECTION 31 INSTALLATION CYLINDER HEAD S 32 CAMSHAFT OIL SEAL S REMOVAL 34 INSTALLATION 35 CAMSHAFT S DESCRIPTION 37 OPERATION 37 REMOVAL 37 INSPECTION 37 INSTALLATION 38 CYLINDER HEAD COVER LEFT REMOVAL 38 INSTALLAT...

Page 2667: ... 64 REMOVAL 65 INSTALLATION 65 PISTON RINGS DESCRIPTION 67 STANDARD PROCEDURE PISTON RING FITTING 67 REMOVAL 68 INSTALLATION 68 STRUCTURAL COVER REMOVAL 69 INSTALLATION 69 VIBRATION DAMPER REMOVAL 70 INSTALLATION 70 ENGINE MOUNTING DESCRIPTION 70 UPPER MOUNT REMOVAL 70 INSTALLATION 70 LEFT MOUNT REMOVAL 71 INSTALLATION 72 RIGHT MOUNT REMOVAL 72 INSTALLATION 72 LUBRICATION DESCRIPTION 73 OPERATION ...

Page 2668: ...ION TIMING BELT 90 INSTALLATION INSTALLATION CRANKSHAFT SPROCKET 91 INSTALLATION CAMSHAFT SPROCKETS 91 INSTALLATION TIMING BELT 92 TIMING BELT TENSIONER PULLEY REMOVAL REMOVAL TENSIONER 93 REMOVAL TENSIONER PULLEY ASSEMBLY 93 INSPECTION INSPECTION TENSIONER 93 INSPECTION TENSIONER PULLEY ASSEMBLY 93 INSTALLATION INSTALLATION TENSIONER PULLEY ASSEMBLY 94 INSTALLATION TENSIONER 94 ENGINE 3 5L DESCRI...

Page 2669: ...Fig 1 3 5L ENGINE Fig 2 Cylinder Numbering and Firing Order Fig 3 ENGINE IDENTIFICATION 1 REAR OF LEFT CYLINDER HEAD 2 ENGINE IDENTIFICATION NUMBER 9 4 ENGINE CS ENGINE 3 5L Continued ...

Page 2670: ...OSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 1 Test battery Charge or replace as necessary Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY DESCRIPTION 2 Corroded or loose battery connections 2 Clean and tighten battery connections Apply a coat of light mineral grease to terminals 3 Faulty starter 3 Test starting system Refer to 8 ELECTRICAL STARTING DIAGNOSIS AND TESTING 4 Faulty coi...

Page 2671: ...ry 9 Faulty coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Set gap as needed or replace plug s 2 Contamination in Fuel System 2 Clean fuel system and replace fuel filter 3 Burned warped or pitted valves 3 Replace valves 4 Faulty coil s 4 Test and replace as necessary Refer to Appropriate D...

Page 2672: ...juster assembly 8 Worn valve guides 8 Replace cylinder head s 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves 10 Missing adjuster pivot 10 Replace rocker arm hydraulic lash adjuster assembly CONNECTING ROD NOISE 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 Thick Thin or dilu...

Page 2673: ...oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low oil pressure 3 Check sending unit and main bearing oil clearance 4 Clogged oil filter 4 Install new oil filter 5 Worn parts in oil pump 5 Replace worn parts or pump 6 Thin or diluted oil 6 Change oil to correct viscosity 7 Oil pump relief valve stuck 7 Remove valve and inspect clean or replace 8 ...

Page 2674: ...in cylinder head Connect the 0 500 psi Blue pressure transducer Special Tool CH7059 with cable adap tors to the DRBIIIt For Special Tool identification Refer to 9 ENGINE SPECIAL TOOLS 7 Crank engine until maximum pressure is reached on gauge Record this pressure as 1 cylin der pressure 8 Repeat the previous step for all remaining cyl inders 9 Compression should not be less than 689 kPa 100 psi and...

Page 2675: ...plying soapy water at the sus pected 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 manual procedures If the leakage occurs at the crankshaft rear oil seal area refer to the section Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air...

Page 2676: ...al 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 MOPARt BED PLATE SEALANT is a unique green in color anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without distu...

Page 2677: ...d holes maintain the original center line Heli Coil tools and inserts are readily available from automotive parts jobbers STANDARD PROCEDURE 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 ind...

Page 2678: ...ANT STANDARD PROCE DURE 12 Disconnect the throttle and cruise control cables from the throttle body Fig 7 13 Disconnect the cruise control and power brake booster vacuum hoses at the engine 14 Disconnect the transmission wiring harness from the solenoid pack input and output sensors and the range sensor connectors Fig 8 15 Disconnect the engine wiring harness grounds at the left inner frame rail 1...

Page 2679: ...emove right drive axle nut Fig 10 46 Remove right steering knuckle pinch bolts Fig 10 47 Separate the right steering knuckle from the strut and suitably support the steering knuckle Fig 10 48 Unplug fascia driving lamps if equipped 49 Remove front fascia 50 Raise the vehicle 51 Disconnect the starter wiring connectors and harness retainers 52 Disconnect the exhaust manifold Oxygen sen sor electric...

Page 2680: ...h cradle Fig 14 65 Carefully lower the vehicle onto the cradle support fixture 66 Remove the upper engine mount Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT REMOVAL CAUTION While slowly separating the body from the cradle assembly constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation 67 Carefully remove the fro...

Page 2681: ...en bolt to right rail 68 N m 50 lbs ft 7 Slowly raise the vehicle off of the engine cradle support 8 Insert drive axles into steering knuckles Tighten nut to 244 N m 180 lbs ft Refer to 2 SUSPENSION FRONT HUB BEARING INSTAL LATION 9 Align front steering knuckles with struts and install bolts Tighten bolts to 244 N m 180 lbs ft Fig 10 Refer to 2 SUSPENSION FRONT KNUCKLE INSTALLATION 10 Install fron...

Page 2682: ... shaft Refer to 3 DIFFERENTIAL DRIVELINE PRO PELLER SHAFT INSTALLATION 27 Install exhaust system Refer to 11 EXHAUST SYSTEM INSTALLATION 28 Connect exhaust manifold and catalytic con verter oxygen sensor electrical connectors Fig 11 29 Connect starter wiring and properly position harness wiring 30 Install front wheels 31 Lower the vehicle 32 Connect both front brake lines to the brake system H C U...

Page 2683: ...t the fuel line to the fuel rail 48 Install cooling fan assembly Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 49 Install radiator core support 50 Install radiator close out panel 51 Connect upper radiator hose Fig 9 52 Install the cruise control servo 53 Install air cleaner housing Fig 6 54 Install the engine cover Fig 6 55 Install new oil filter Fill engine crankcase with proper oil to co...

Page 2684: ...IGHT LOWER ENGINE MOUNT 2 RIGHT LOWER ENGINE MOUNT NUT 3 ALIGNMENT DOWEL ACCESS HOLES 4 CRADLE SUPPORT FIXTURE Fig 14 CRADLE SUPPORT FIXTURE FRONT 1 LEFT LOWER ENGINE MOUNT NUT 2 CRADLE SUPPORT FIXTURE ARMS 3 CRADLE SUPPORT FIXTURE ENGINE STABILIZER Fig 15 ENGINE LIFTING BRACKET 1 SUITABLE LIFTING CHAIN 2 8537 7 PART OF KIT 8537 12 3 8537 15 PART OF KIT 8537 12 CS ENGINE 9 19 ENGINE 3 5L Continued...

Page 2685: ...ams 15 45 15 62 oz Piston Weight B 433 438 grams 15 27 15 45 oz Piston Ring Groove Diameter 1 87 4 87 6 mm 3 441 3 449 in Piston Ring Groove Diameter 2 86 3 86 5 mm 3 397 3 4055 in Piston Ring Groove Diameter 3 85 8 86 0 mm 3 378 3 385 in PISTON PINS DESCRIPTION SPECIFICATIONS Metric Standard Type Full Floating Clearance in Piston 0 005 0 015 mm 0 002 0 0006 in Clearance in Rod 0 007 0 018 mm 0 00...

Page 2686: ... of Round MAX 0 015 mm 0 0006 in Taper MAX 0 015 0 0006 in End Play 0 10 0 30 mm 0 004 0 012 in End Play MAX 0 43 mm 0 017 in CONNECTING ROD JOURNALS DESCRIPTION SPECIFICATIONS Metric Standard Diameter 57 982 58 002 mm 2 282 2 283 in Bearing Diametrical Clearance 0 048 0 084 mm 0 001 0 003 in Out of Round MAX 0 005 mm 0 0001 in Taper MAX 0 007 0 0002 in CAMSHAFT DESCRIPTION SPECIFICATIONS Metric S...

Page 2687: ...Method 0 29 mm 0 0114 in Stem to Guide Clearance Exhaust 0 051 0 094 mm 0 002 0 0037 in Stem to Guide Clearance Intake MAX Rocking Method 0 370 mm 0 0146 in Valve Lift Intake Zero Lash 8 55 mm 0 3367 in Valve Lift Exhaust Zero Lash 6 53 mm 0 2571 in Valve Margin Intake 0 835 1 165 mm 0 0329 0 0459 in Valve Margin Exhaust 1 44 1 77 mm 0 0567 0 0697 in Valve Stem Tip Height Intake 42 366 43 665 mm 1...

Page 2688: ...m 3 149 in Tip Clearance Between Rotors MAX 0 20 mm 0 008 in OIL PRESSURE DESCRIPTION SPECIFICATIONS NOTE At Normal Operating Temperatures Pressure Curb Idle Speed 34 47 kPa Min 5 PSI MIN Pressure 3000 RPM 300 724 kPa 45 105 PSI CAUTION If pressure is zero at curb idle DO NOT run engine at 3000 RPM SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Camshaft Sprocket Bolt Right Side 102 1 4 Turn 7...

Page 2689: ... Up Tube Bolt 28 250 Crankshaft Rear Seal Retainer 12 105 Right Engine Mount to Cradle 75 55 Rocker Shaft Pedestal Retaining Bolts 31 275 Spark Plugs 28 20 Structural Collar Refer to 9 ENGINE ENGINE BLOCK STRUCTURAL COVER INSTALLATION Timing Belt Tensioner Bolts 28 250 Timing Belt Tensioner Pulley Assembly Bolt 61 45 Timing Belt Cover M6 Bolts 12 105 M8 Bolts 28 250 M10 Bolts 54 40 Upper Engine Mo...

Page 2690: ...C 4685 C1 Crankshaft Damper Installer 6792 1 Gear Puller L 4407A Front Crankshaft Seal Remover 6341A Driver 6342 Crankshaft Seal Protector 6780 2 DIAL INDICATOR C 3339 Valve Spring Compressor C 3422 D Spring Compressor Adapter 6526 CS ENGINE 9 25 ENGINE 3 5L Continued ...

Page 2691: ... Indicator Cylinder Bore C 119 Crankshaft Main Bearing Remover C 3059 Rear Crankshaft Oil Seal Installer 6926 Crankshaft Real Seal Retainer Alignment Fixture 8225 Release Probe 8351 Cylinder Compression Pressure Adaptor 8116 Pressure Tester Kit 7700 9 26 ENGINE CS ENGINE 3 5L Continued ...

Page 2692: ...NER HOUSING REMOVAL 1 Disconnect the intake air temperature IAT sensor wiring harness connector 2 Remove the air inlet hose at the throttle body 3 Disconnect the air circulation hose at the ele ment housing 4 Remove the housing retaining bolt 5 Pull housing up and off of the locating pin 6 Remove element housing from vehicle INSTALLATION 1 Install housing into vehicle and the locating pin 2 Instal...

Page 2693: ...n 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 FAST EXCES SIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRES SURE TO EXCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start...

Page 2694: ... 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER PULLEY REMOVAL Fig 17 33 Remove the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 34 Remove the right valve cover to cylinder head ground strap Fig 20 35 Remove the EGR valve and tube assembly Fig 20 36 Remove the right cylinder head cover Fig 20 37 Remove the right rocker arm assembly Fig 21 38 Remove the right ...

Page 2695: ...OVAL 11 Remove the left exhaust manifold Refer to 9 ENGINE MANIFOLDS EXHAUST MANIFOLD REMOVAL 12 Remove the outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 13 Rotate the engine to TDC and align the tim ing marks Fig 19 14 Remove the timing belt tensioner timing belt then reset tensioner Fig 19 15 Remove the left cylinder head cover to cylin der head ground ...

Page 2696: ...gaskets require a scratch free sealing surface Remove all gasket material from cylinder head and block Refer to 9 ENGINE STANDARD PROCE DURE Be careful not to gouge or scratch the alumi num head sealing surface Clean all engine oil passages INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean cylinder head and oil passages Fig 20 EGR VALVE AND TUBE 1 EGR TUBE 2 IGNITION COIL 3 CY...

Page 2697: ...NE GAS KET SURFACE PREPARATION 1 Clean sealing surfaces of cylinder head and block CAUTION Ensure that the correct head gaskets are used and are oriented correctly on cylinder block 2 Install head gasket over locating dowels Ensure the gasket is installed on the correct side of engine NOTE Before installing the cylinder head bolts lubricate the threads with engine oil 3 Insert the front four cylin...

Page 2698: ...nstall the fuel rail 27 Install the upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 28 Install the air cleaner element housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 29 Install the engine cover 30 Fill the coolant system 31 Connect the negative battery cable LEFT CYLINDER HEAD CAUTION THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BET...

Page 2699: ... ENGINE MANIFOLDS EXHAUST MANIFOLD INSTALLATION 18 Install the left rocker arm assembly 19 Install the left cylinder head cover and ground strap 20 Install lower intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 21 Install the fuel rail 22 Install the upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 23 Install the radiator cooling fan assembly R...

Page 2700: ...mshaft journal surfaces when removing the camshaft seal 9 Using an appropriate driver carefully remove camshaft oil seal Fig 29 INSTALLATION RIGHT CYLINDER HEAD 1 Position the camshaft seal into the cylinder head Fig 30 2 Using special tool MD 998306 tap the seal into place Fig 30 3 Apply light coat of clean engine oil to the cam shaft oil seal lip and Special Tool 6788 Seal Protector Sleeve 4 Ins...

Page 2701: ...r of the cylinder head 8 Install rear timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install the camshaft gear and align the timing marks 10 Install the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 11 Install the rocker arm assembly 12 Install the cylinder head cover 13 Install the front timing belt cover Refer t...

Page 2702: ...ecisely machined lobes to provide accurate valve timing and duration REMOVAL NOTE Camshafts are removed from the rear of each cylinder head 1 Remove the cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL CAUTION Care must be taken not to nick or scratch the journals when removing the camshaft 2 Carefully remove the camshaft from the rear of the cylinder head Fig 34 INSPECTION 1 Inspect camshaft...

Page 2703: ...e cylinder head cover retaining bolts and remove the cylinder head cover Fig 38 9 Remove the PCV valve from the valve cover assembly if required INSTALLATION 1 Clean cylinder head and cover mating surfaces Inspect and replace gasket and seals as necessary Fig 39 2 To replace spark plug tube seals a Using a suitable pry tool carefully remove tube seals b Position new seal with the part number on se...

Page 2704: ...ECTORS 3 CYLINDER HEAD COVER 2 IGNITION COILS 4 BRACKET Fig 37 WIRING HARNESS RETAINING TABS 1 PUSH TABS 2 WIRING HARNESS Fig 38 Cylinder Head Covers 1 CYLINDER HEAD COVER LEFT SIDE 2 BOLTS 8 CS ENGINE 9 39 CYLINDER HEAD COVER LEFT Continued ...

Page 2705: ...ecessary Fig 42 2 To replace spark plug tube seals a Using a suitable pry tool carefully remove tube seals b Position new seal with the part number on seal facing cylinder head cover c Install seals using Special Tool MD 998306 Fig 43 3 Install cylinder head cover bolts and tighten to 12 N m 105 in lbs 4 Install the ground strap retaining bolt to the cylinder head cover 5 Install the wire harness ...

Page 2706: ... COILS Fig 42 Cylinder Head Cover Gasket and Spark Plug Tube Seals 1 CYLINDER HEAD COVER GASKET 2 SPARK PLUG TUBE SEALS Fig 43 Spark Plug Tube Seal Installation 1 SPECIAL TOOL MD 998306 2 SPARK PLUG TUBE SEAL CS ENGINE 9 41 CYLINDER HEAD COVER RIGHT Continued ...

Page 2707: ...ve in place Rotate the valve with light pressure If the blue is transferred to the center of valve face contact is satisfactory If the blue is trans ferred to top edge of valve face then lower valve seat with a 15 degree stone If the blue is transferred to the bottom edge of valve face then raise valve seat with a 65 degree stone NOTE Valve seats which are worn or burned can be reworked provided t...

Page 2708: ...insure installation in original location 5 Remove valve s from cylinder head CLEANING 1 Clean all valves thoroughly and discard burned warped and cracked valves INSPECTION INSPECTION VALVES 1 Measure valve stems for wear Fig 49 approx imately 60 mm 2 36 in below the valve lock grooves 2 Compare measurement to specifications Refer to 9 ENGINE SPECIFICATIONS NOTE Valve stems are chrome plated and sh...

Page 2709: ...9 ENGINE CYLINDER HEAD INSTALLATION ROCKER ARM SHAFT ROCKER ARM LASH ADJUSTER DESCRIPTION DESCRIPTION ROCKER ARM Rocker arms are made of light weight permanent mold aluminum alloy with a roller type follower oper ating against the camshaft Fig 52 The valve actu ating end of the rocker arms are machined to retain hydraulic lash adjusters eliminating the need for manual valve lash adjustment DESCRIP...

Page 2710: ...er Tappet Noise Chart for Possible Causes and Correction of a lash adjuster tappet type noise POSSIBLE NOISE SOURCES POSSIBLE NOISE MISDIAGNOSIS SOURCES Spongy soft aerated lash adjusters Exhaust leak Missing lash adjuster swivel contact pads Exhaust rocker arm to cylinder head cover contact Intake rocker to camshaft bearing journal contact Piston pin bore fit Rocker arm bind up Timing drive hydra...

Page 2711: ...der head gasket restrictor for blockage Clean or replace as necessary 6 Worn valve guide s 6 Ream guide s and replace valve s with oversize valves and seal s 7 Air injested into oil due to broken or cracked oil pump pickup tube 7 Inspect pickup tube and replace as necessary 8 Collapsed lash adjuster due to debris injestion 8 Clean debris from engine and replace lash adjuster rocker assembly 9 Inta...

Page 2712: ... one second or longer d Slowly release the rocker arm thereby allow ing the lash adjuster to extend which in turn refills the high pressure chamber with non aerated oil e Remove probes to allow check balls to seat f Recheck for sponginess If the lash adjuster sponginess is not completely or nearly eliminated then repeat procedure g If the spongy condition cannot be removed replace effected rocker ...

Page 2713: ...third rocker shaft support pedestal The rocker arm and shaft assembly on the left side of the engine has an oil passage hole from the cylinder head located at the second rocker shaft support pedestal NOTE To prevent air ingestion into lash adjusters avoid turning rocker arm assembly upside down CAUTION Do not allow rocker arm assembly to rest on lash adjusters as damage may occur to lash adjuster ...

Page 2714: ... in these positions the lobes are in a neutral position no load to the valve This will allow the rocker arm shaft assembly to be tight ened into position with little or no valve spring load on it 2 Install the rocker arm and shaft assembly making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head 3 Tighten rocker arm sh...

Page 2715: ...ll cylinder head cover s Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION VALVE STEM SEALS REMOVAL 1 Remove valve spring Refer to 9 ENGINE CYLINDER HEAD VALVE SPRINGS REMOVAL 2 Remove valve stem seals by using a valve stem seal tool Fig 64 INSTALLATION 1 The valve stem seal valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide D...

Page 2716: ...o 9 ENGINE SPECIAL TOOLS 2 Remove valve retaining locks Release valve spring compressor Remove valve spring retainer and valve spring 3 Remove valve stem seal assembly Refer to 9 ENGINE CYLINDER HEAD VALVE STEM SEALS REMOVAL REMOVAL CYLINDER HEAD ON 1 Disconnect negative battery cable 2 Remove upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 3 Remove cylinder head cover s ...

Page 2717: ... Fractional measure ments are indicated on the table for finer adjust ments Refer to Engine Specifications to obtain specified height and allowable tensions Refer to 9 ENGINE SPECIFICATIONS Replace springs that do not meet specifications INSTALLATION INSTALLATION CYLINDER HEAD OFF 1 Install valves if removed 2 Install valve stem seal spring seat assembly over valve guides on all valve stems Fig 69...

Page 2718: ...deck design with the right bank forward To provide high rigidity and improved noise vibration and harshness NVH the block has cast in contours and ribs along with powdered metal 6 bolt main caps 4 vertical 2 horizontal with a die cast alumi num structural beam windage tray mounted to the main caps CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent INSPECTION ENGINE BLOCK 1 ...

Page 2719: ...ntil complete Limits of taper or out of round on any crankshaft journals should be held to 0 005 mm 0 0001 in Bearings are available in standard 0 025 mm 0 001 in and 0 254 mm 0 010 in undersizes Install the bearings in pairs Do not use a new bearing half with an old bearing half Do not file the rods or bearing caps Fig 71 Cylinder Block and Crankshaft 1 MAIN CAP BOLT VERTICAL 5 CYLINDER BLOCK 2 M...

Page 2720: ...r nately torque each bolt to assemble the cap properly 4 Tighten the connecting rod cap bolts to specifi cation Refer to 9 ENGINE SPECIFICATIONS CONNECTING ROD SIDE CLEARANCE 1 Mount a dial indicator to a stationary point on engine Locate probe perpendicular to and resting against the connecting rod cap being checked Move connecting rod all the way to rear of its travel Zero the dial indicator Mov...

Page 2721: ...TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove crankshaft sprocket Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 7 Tap dowel pin out of crankshaft 8 Remove oil pump assembly Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 9 Remove crankshaft rear oil seal retainer Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL WARNING DO NOT use a metal st...

Page 2722: ...MAIN BEARINGS STANDARD PROCEDURE for proper bearing size selection 1 Install crankshaft upper main bearings in cyl inder block Ensure oil holes in bearings line up with oil holes in cylinder block Fig 79 Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE 2 Install the crankshaft to cylinder block Fig 78 3 Move crankshaft forward to limit of travel Lubricate and install the ...

Page 2723: ...bolts and tighten to 28 N m 250 in lbs 13 Install rear crankshaft oil seal retainer and oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT REAR OIL SEAL RETAINER INSTALLATION and Refer to 9 ENGINE EN GINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION 14 Install oil pump assembly Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 15 Install dowel pin in crankshaft Refer to 9 ENGINE ENGINE BLOCK CRA...

Page 2724: ...5 marked in ink on the bearing surface Fig 83 For verification refer to the MAIN BEARING SELEC TION CHART for number to size identification The upper main bearing has a oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block MAIN BEARING SELECTION CHART Main Bearing Bore Grade Marks 1 2 3 A 3 Standard 2 005 mm 0 0001 in 1 0 006 mm 0 0...

Page 2725: ...OCK CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE NOTE Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened Fig 83 Main Bearing Grade Marks 1 LOWER MAIN BEARING 2 UPPER MAIN BEARING 3 OIL FEED HOLE AND GROOVE 4 GRADE SELECTION INK MARKS Fig 84 Main Bearing Cap Identification Fig 85 Removing and Installing Upper Main Bearing With Special Tool C 3...

Page 2726: ... cap bolts secondly the windage tray bolts lastly the main cap tie horizontal bolts 6 Install each main bearing cap and tighten inner bolts finger tight 7 Tighten inner main bearing cap bolts to 20 N m 1 4 turn 15 ft lbs 1 4 turn 8 Measure crankshaft end play Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT STAN DARD PROCEDURE 9 Install windage tray Lubricate bolts with engine oil and tighten to 27 N m 1...

Page 2727: ...er is permitted INSTALLATION CAUTION If a burr or scratch is present on the crankshaft edge chamfer clean surface using 400 grit sand paper to prevent seal damage during installation 1 Place Special Tool 6926 1 Guide on crankshaft Fig 92 This is a pilot tool with a magnetic base 2 Position seal over pilot tool Assure that lip of seal is facing towards the crankshaft during installa tion The pilot ...

Page 2728: ... 2 Install seal retainer to block but do not tighten attaching screws at this time NOTE The following steps must be performed to prevent oil leaks at sealing joints 3 Attach Special Tools 8225 to pan rail using the oil pan fasteners Fig 94 NOTE Make sure the marking 3 5L on Special Tools 8225 is facing towards the cylinder block pan rail surface notch on tool is towards the seal retainer 4 While a...

Page 2729: ...uirt hole and attaches to the piston with a full floating pin retained by lock rings OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft STANDARD PROCEDURE FITTING PISTONS The pistons are machined to two different weight specifications and matched to rods based on weight All piston and rod assemblies weigh the same to maintain engine balance Piston an...

Page 2730: ...ings Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS INSTALLA TION NOTE The connecting rod bearing cap bolts must be examined before reuse If the threads are necked down the bolts must be replaced 2 Check connecting rod bolts for necking by hold ing a scale or straight edge against the threads If all threads do not contact the scale the bolt must be replaced Fig 98 3 Before installing pistons and conn...

Page 2731: ...ht side of the cylinder bore Fig 102 8 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 9 Install rod caps Install cleaned and inspected connecting rod bolts and tighten to 27 N m 20 ft lbs Plus 1 4 turn 10 Install the cylinder head s Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 11 Install the oil pan Refer to ...

Page 2732: ...ng and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of cylinder bore Check gap with feeler gauge Fig 104 For clearance specifications Refer to 9 ENGINE SPECIFICATIONS 2 Check piston ring to groove clearance Fig 105 For clearance specifications Refer to 9 ENGINE SPECIFICATIONS Fig 102 PISTON A...

Page 2733: ...r oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring 2 Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring expander during this step Fig 107 3 Install upper side rail first and then the lower side rail The No 1 and No 2 piston ...

Page 2734: ...emove the structural collar INSTALLATION CAUTION The collar must be tightened using this service procedure as damage to collar and or oil pan may occur 1 Install structural collar Fig 110 using the fol lowing tightening sequence Fig 107 SIDE RAIL INSTALLATION 1 SIDE RAIL END Fig 108 UPPER AND INTERMEDIATE RINGS Fig 109 PISTON RING END GAP POSITION 1 SIDE RAIL UPPER 2 NO 1 RING GAP 3 PISTON PIN 4 S...

Page 2735: ...the accessory drive belt splash shield and right front wheel 5 Lower vehicle 6 Connect negative battery cable ENGINE MOUNTING DESCRIPTION The engine mounting system are of molded rubber material and consist of three mounts right and a left side support the powertrain and a front mount con trol powertrain torque UPPER MOUNT REMOVAL 1 Support engine assembly with a floor jack so it will not rotate 2...

Page 2736: ...e cover 3 Remove radiator cooling fan assembly Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 4 Raise and support the vehicle 5 Remove both of the engine mount to cradle nuts Fig 114 6 Lower the vehicle 7 Connect the engine suport fixture and support engine weight 8 Remove the engine mount bolts and remove mount Fig 114 Fig 114 LEFT ENGINE MOUNT 1 BOLT 3 ENGINE MOUNT 2 BRACKET 4 LEFT EXHAUST MANIF...

Page 2737: ...ne support fixture and support the engine weight 6 Raise and support the vehicle 7 Remove the right mount bracket bolts Fig 115 8 Remove the engine mount top nut Fig 115 9 Remove the engine mount plate and engine mount Fig 115 INSTALLATION 1 Install the engine mount and plate Tighten bolts to 54 N m 40 lbs ft Fig 115 2 Install the engine mount upper nut Tighten nut to 101 N m 75 lbs ft Fig 115 3 I...

Page 2738: ...and hydraulic lash adjusters Fig 116 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE Check oil pressure using a gauge at oil pressure switch location 1 Remove the oil pressure switch Refer to 9 ENGINE LUBRICATION OIL PRESSURE SENSOR SWITCH REMOVAL 2 Install oil pressure test gauge Special Tool C 3292 with Adapter 8406 For Special Tool identifi cation Refer to 9 ENGINE SPECIAL TOOLS CAUTION If o...

Page 2739: ...LLECTION CENTER IN YOUR AREA TO CHANGE ENGINE OIL 1 Run engine until achieving normal operating temperature 2 Position the vehicle on a level surface and turn engine off 3 Open hood remove engine oil fill cap Fig 117 4 Raise vehicle on hoist 5 Place a suitable drain pan under crankcase drain 6 Remove oil pan drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for s...

Page 2740: ...parallel to oil pan rail 2 Install oil cooler attaching fastener and tighten to 54 N m 40 ft lbs Fig 119 3 Install oil filter Fig 119 4 Connect coolant hoses to oil cooler Fig 119 5 Fill cooling system Refer to 7 COOLING EN GINE COOLANT STANDARD PROCEDURE OIL FILTER REMOVAL NOTE When servicing the oil filter avoid deforming the filter can Install the remove install tool band strap against the base...

Page 2741: ...not necessary to recover the refrigerant from the refrigerant system to perform this proce dure 5 Remove the top air conditioning compressor bolts 6 Raise and support the vehicle NOTE It is not necessary to recover the refrigerant from the refrigerant system to perform this proce dure 7 Remove the lower air conditioning compressor mounting bolts and reposition the compressor with a suitable retain...

Page 2742: ...lbs 12 Lower vehicle 13 Install the upper A C compressor mounting bolts Tighten bolts to 28 N m 250 in lbs 14 Install the oil indicator tube 15 Install radiator fans core support and close out panel 16 Fill engine crankcase with proper oil to cor rect level 17 Connect negative battery cable OIL PRESSURE RELIEF VALVE REMOVAL 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 To r...

Page 2743: ... spring and retainer cap Fig 124 3 Install new cotter pin 4 Install the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION OIL PRESSURE SENSOR SWITCH REMOVAL 1 Raise vehicle on hoist 2 Position an oil collecting container under switch location 3 Disconnect electrical connector 4 Unscrew oil pressure switch from oil filter adapter Fig 125 INSTALLATION 1 Apply Mopart Thread Sealant to the s...

Page 2744: ...et metal screw into cap 3 Clamp screw into a vise and while supporting oil pump body remove cap by tapping oil pump body using a soft hammer Discard retainer cap and remove spring and relief valve Fig 127 4 Remove oil pump cover screws and lift off cover 5 Remove pump rotors 6 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 128 CLEANING 1 Clean all parts thoroughl...

Page 2745: ... and the straightedge replace pump assembly Fig 134 ONLY if rotors are in specs 9 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper 10 The relief valve spring Fig 135 has a free length of approximately 49 5 mm 1 95 in it should test between 101 110 N 23 25 lbs when com pressed to 34 mm 1 11 32 in Repla...

Page 2746: ...LVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install the crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 10 Install the accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 11 Fill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 12 Fill engine crankcase with proper oil to the correct level INTAKE MANIFOLD REMOVA...

Page 2747: ...E MANIFOLD 1 Perform fuel pressure release procedure Refer to 14 FUEL SYSTEM FUEL DELIVERY STAN DARD PROCEDURE 2 Drain the cooling system Refer to 7 COOL ING ENGINE COOLANT STANDARD PROCE DURE 3 Disconnect the upper radiator hose from the thermostat housing 4 Remove the upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 5 Reposition power steering fluid reservoir and bracket...

Page 2748: ...fold sup port brackets 7 Install the oil level indicater and oil fill tube to intake manifold bolts Fig 136 8 Install the EGR tube Refer to 25 EMIS SIONS CONTROL EXHAUST GAS RECIRCULA TION VALVE INSTALLATION 9 Connect vacuum lines to the following Fig 137 Positive Crankcase Ventilation PCV Valve EVAP Purge Solenoid Power Brake Booster Fig 138 UPPER INTAKE MANIFOLD RIGHT 1 UPPER INTAKE MANIFOLD 2 E...

Page 2749: ... bolt to the intake manifold 9 Connect electrical connectors to fuel injectors and coolant temperature sensor 10 Install power steering fluid reservoir and bracket 11 Install upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 12 Connect the upper radiator hose to the ther mostat housing 13 Fill the cooling system Refer to 7 COOL ING ENGINE COOLANT STANDARD PROCE DURE EX...

Page 2750: ...wer exhaust manifold retaining bolts Fig 143 10 Remove the oxygen sensor from the exhaust manifold INSTALLATION RIGHT EXHAUST MANIFOLD 1 Clean gasket surfaces 2 Position the exhaust manifold and gasket Install the retaining bolts Tighten bolts starting at the center working outward to 23 N m 200 in lbs Fig 143 3 Install exhaust system Connect the exhaust system hangers from the pipe assembly and i...

Page 2751: ...y drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove accessory drive belt tensioner 6 Remove bolts for power steering pump Repo sition power steering pump aside 7 Remove crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 8 Remove the lower front timing belt cover fas teners Fig 146 9 Lower the vehicle 10 Support the engine with a floor jack 11 Remove ...

Page 2752: ...CEDURE 2 Disconnect the negative battery cable 3 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 4 Remove camshaft sprockets Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 5 Remove rear timing belt cover bolts Fig 148 6 Remove the rear cover NOTE The rear timing belt cover has O rings to seal the water pump passages to cylinder bloc...

Page 2753: ...move both cylinder head covers and loosen the rocker arm assemblies 4 Remove the front timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 5 Mark belt running direction if timing belt is to be reused CAUTION When aligning timing marks always rotate engine by turning the crankshaft Failure to do so will result in valve and or piston damage 6 Rotate engine clockwise un...

Page 2754: ...d into the ten sioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed Fig 150 TIMING GEAR MARKS 1 RIGHT CAMSHAFT GEAR ALIGNMENT MARK 7 LEFT CAMSHAFT GEAR 2 RIGHT CAMSHAFT GEAR 8 LEFT CAMSHAFT GEAR ALIGNMENT MARK 3 CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS RIGHT 9 CRANKSHAFT GEAR ALIGNMENT MARK 4 TIMING BELT 10 CRANKSHAFT GEAR 5 WATER PUM...

Page 2755: ...t and gear Care must be taken not to scratch or nick the camshaft or cylin der head journals when moving camshaft 9 Hold camshaft sprockets with 36 mm 1 7 16 in box end wrench 10 Loosen and remove the camshaft gear retain ing bolt and washer The right bolt is 213 mm 8 3 8 in long and the left bolt is 255 mm 10 0 in long NOTE The camshaft timing gears are keyed to the camshaft 11 Remove the camshaf...

Page 2756: ...kshaft sprocket Special Tool 6641 must be used 1 Install crankshaft sprocket using Special Tools 6641 and C 4685 C1 Fig 157 2 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION INSTALLATION CAMSHAFT SPROCKETS CAUTION The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick up Fig 154 RIGHT C...

Page 2757: ...th a 36 mm 1 7 16 in wrench and tighten the camshaft bolts to the following Right side 102 N m 75 ft lbs 90 turn Left side 115 N m 85 ft lbs 90 turn 9 Remove dial indicator and install spark plug 10 Remove Special Tools 6642 11 Install cam retainer thrust plates and O rings Fig 158 12 Install front timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 13 Install e...

Page 2758: ...RM ADJUSTER ASSY INSTALLATION 9 Connect negative battery cable TIMING BELT TENSIONER PULLEY REMOVAL REMOVAL TENSIONER 1 For timing belt tensioner removal procedure Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL TIMING BELT REMOVAL TENSIONER PULLEY ASSEMBLY 1 Remove the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL TIMING BELT 2 Remove the timing bel...

Page 2759: ...g belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION TIMING BELT INSTALLATION TENSIONER 1 For timing belt tensioner installation procedure Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION TIM ING BELT Fig 160 TENSIONER PULLEY 1 TENSIONER PULLEY 2 PIVOT BOLT 3 TENSIONER BRACKET 9 94 ENGINE CS TIMING BELT TENSIONER PULLEY Continued ...

Page 2760: ...ystem consists of a catalytic con verter muffler and a resonator with connecting pipes in between The system is serviced in three sections the catalytic converter the muffler and the resona tor and tailpipe Fig 1 A torca clamp is used to con nect the joint between the muffler and catalytic converter A torca clamp is used to connect the muf fler and the resonator and tailpipe Support hanger rods wi...

Page 2761: ...or replace gasket 4 EGR Valve to EGR tube gasket leakage 4 Tighten fasteners or replace gasket 5 EGR tube to manifold tube leakage 5 Tighten tube nut 6 Exhaust down pipe to manifold leak 6 Tighten joint fasteners and or replace gasket 7 Exhaust flex joint 7 Replace catalytic converter assembly 8 Pipe and shell noise from front exhaust pipe 8 Characteristic of single wall pipe Fig 1 EXHAUST SYSTEM ...

Page 2762: ... the Exhaust Back Pressure Fitting Adaptor CH8519 3 Connect the Low Pressure Sensor 15 psi CH7063 to the back pressure fitting 4 Following the PEP module instruction manual connect all required cables to the DRB IIIt and PEP module Select the available menu options on the DRBIIIt display screen for using the digital pressure gauge function 5 Apply the park brake and start the engine 6 With transmi...

Page 2763: ...EM 1 Install and loose assemble the front resonator to the converter pipes 2 Place the exhaust system on two supports one on side of muffler one behind the resonator Connect the system to the exhaust manifold Do not tighten the nuts 3 Install the system s rubber isolators onto the support brackets Fig 2 4 Visually inspect the isolators They should be straight when viewing from front to back of the...

Page 2764: ... for efficient conversion of exhaust gases When a high oxygen content lean air fuel ratio is present for an extended period oxygen content in a catalyst can reach a maximum When a rich air fuel ratio is present for an extended period the oxygen content in the catalyst can become totally depleted When this occurs the catalyst fails to convert the gases This is known as catalyst 9punch through 9 Cat...

Page 2765: ...EN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CON VERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME 1 Disconnect negative battery cable at remote jumper terminal located at right strut tower 2 Raise vehicle on hoist 3 Remove exhaust system Refer to 11 EXHAUST SYSTEM REMOVAL 4 Remove the torca clamp 5 Seperate the catalyltic converter from the muffler ...

Page 2766: ... servicing the exhaust system care must be exercised not to dent or bend the bellows of the flex joint Should this occur the flex joint will eventually fail requiring replacement of the cata lytic converter 3 Remove resonator muffler assembly Refer to 11 EXHAUST SYSTEM RESONATOR REMOV AL 4 Loosen the torca clamp 5 Seperate the muffler from the catalytic con verter and remove from the vehicle Fig 5...

Page 2767: ...etrating oil to torca of component requiring removal CAUTION When servicing the exhaust system care must be exercised not to dent or bend the bellows of the flex joint Should this occur the flex joint will eventually fail requiring replacement of the cata lytic converter 3 Loosen the torca clamp nut Fig 1 4 Support the muffler resonator assembly 5 Remove the insulators from the muffler resona tor ...

Page 2768: ... 12 ENGINE CRADLE CROSSMEMBER REMOVAL 13 INSTALLATION 17 REAR CROSSMEMBER REMOVAL 19 INSTALLATION 23 REAR CROSSMEMBER BUSHING FRONT MOUNT REMOVAL 27 INSTALLATION 30 REAR CROSSMEMBER BUSHING REAR MOUNT REMOVAL 32 INSTALLATION 34 REAR CROSSMEMBER BUSHING SPRING LINK REMOVAL 36 INSTALLATION 36 BUMPERS SPECIFICATIONS TIGHTENING DESCRIPTION N m Ft Lbs In Lbs Front bumper reinforcement attaching nut 20 ...

Page 2769: ...PERS BUMPERS FRONT FASCIA INSTALLATION FRONT FASCIA REMOVAL 1 Release hood latch and open hood 2 Remove the headlamp assemblies Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEADLAMP REMOVAL 3 Hoist vehicle and support with safety stands as necessary 4 Remove the four screws attaching bottom of fascia air dam to radiator closure panel Fig 2 NOTE The whole front splash shield does not need to be re...

Page 2770: ... panel at each side of the grille 11 Remove bumper fascia from vehicle 12 Place fascia on a clean surface Fig 3 13 Remove spring clips attaching upper and lower fascia together Fig 4 14 Using a trim stick release locking tabs and separate the upper and lower fascia Fig 3 UPPER AND LOWER FRONT FASCIA 1 FRONT UPPER FASCIA 2 GRILLE 3 BRIGHT CHROME MOLDING 4 FRONT LOWER FASCIA Fig 4 INTERLOCKING SEAM ...

Page 2771: ...e bumper fascia into position on vehicle 7 Install grille to fascia Refer to 23 BODY EX TERIOR GRILLE INSTALLATION 8 Install screw attaching the upper grille support to the headlamp mounting panel at each side of the grille 9 Install push pins attaching the upper appear ance panel to upper crossmember 10 Raise vehicle and support with safety stands as necessary 11 Connect fog lamp wire connectors ...

Page 2772: ...BUMPERS REAR FASCIA REMOVAL 2 Remove rear bumper reinforcement Refer to 13 FRAME BUMPERS BUMPERS REAR BUMPER REINFORCEMENT REMOVAL 3 Remove two screws attaching reinforcement bracket left or right side Fig 9 or Fig 10 INSTALLATION 1 Place reinforcement bracket into position 2 Install two screws attaching reinforcement bracket left or right side Fig 9 or Fig 10 3 Tighten screws to 95 N m 70 ft lbs ...

Page 2773: ...to 27 N m 20 ft lbs torque Fig 11 4 Install rear bumper fascia Refer to 13 FRAME BUMPERS BUMPERS REAR FASCIA INSTALLATION REAR FASCIA REMOVAL 1 Open liftgate 2 Remove two push pin fasteners per side at the liftgate tower area Fig 12 3 Hoist and support vehicle with safety stands as necessary 4 Remove the four push pin fasteners attaching rear fascia to reinforcement bumper 5 Remove two screws each...

Page 2774: ...ight chrome molding from the upper fascia Fig 14 Using a trim stick start ing at the out edge of the fascia release the locking tabs Fig 15 Grip the molding and pull outward from the fascia while releasing the locking tabs 12 Remove molding from fascia Fig 13 INTERLOCKING SEAM TABS AND SPRING CLIPS 1 REAR UPPER FASCIA 2 REAR LOWER FASCIA 3 INTERLOCKING SEAM AND SPRING CLIPS Fig 14 REAR FASCIA BRIG...

Page 2775: ...een body side aperture and fas cia aperture brackets 8 Install the two screws attaching the upper fas cia in the tail lamp bucket area 9 Install two screws each side attaching fascia to rear fascia bracket in the wheelhouse 10 Install the four new push pin fasteners attaching rear fascia to reinforcement bumper 11 Lower vehicle 12 Install push pin fasteners two per side at the liftgate tower area ...

Page 2776: ...AME 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 frame alignment rack refer to instructions provided with equipment being used Adjust the vehicle PLP heights to the specified dimension above the work surface datum lin...

Page 2777: ...Fig 18 ENGINE COMPARTMENT 13 10 FRAME BUMPERS CS FRAME Continued ...

Page 2778: ...Fig 19 FRAME CS FRAME BUMPERS 13 11 FRAME Continued ...

Page 2779: ... Rear Engine Mount to Crossmember Mounting Bolt 163 120 Radiator Support Crossmember Attaching Bolts 51 38 Camber Link Bolt 68 50 Compression Link Bolt 68 50 Spring Link Bolt 109 80 Tension ink Bolt 68 50 Toe Link Nut 172 127 Stabilizer Absorber Bolt 102 75 Caliper Guide Pin Bolt 22 192 Propeller Mounting Bolt 54 40 Wheel Mounting Nut 135 100 SPECIAL TOOLS FRAME Driveline Support Fixture 8534B Dri...

Page 2780: ...nd secure with dipstick tube bolt Fig 21 Engine Support Fixture 8534B 1 SUPPORT TUBE 8534 1 2 BRACKET SLEEVE 8534 2 3 CROSS BAR 8534 3 4 CLAMP 8534 5 5 LIFT HOOK ASSEMBLY 6 LIFT BRACKET BOLT 8534 15 7 LIFT BRACKET BOLT 8534 7 8 LIFT BRACKET BOLT 8534 8 9 SUPPORT LEG 8534 4 Fig 22 Lift Bracket 8534 8 1 BRACKET 8534 8 Gage Curb Height 9094 Press Ball Joint C 4212F Fig 20 Battery 1 BATTERY POSITIVE C...

Page 2781: ... 3 clamp 8534 5 and support leg 8534 4 to support tube allowing sup port leg to rest on radiator upper support Fig 25 e Tighten cross bar to support tube clamp 8534 5 Fig 26 as well as mounting bracket sleeve 8534 2 thumb screw and hex nut to secure fixture Fig 27 Fig 23 Lift Bracket 8534 7 1 BRACKET 8534 7 2 REAR CYLINDER HEAD Fig 24 Support Tube and Sleeve Brackets 1 SUPPORT TUBE 8534 1 2 BRACKE...

Page 2782: ...ness from the support brackets to gain slack in harness Fig 27 Torque Thumb Screw and Pivot Nut 1 THUMB SCREW 2 PIVOT HEX NUT 3 BRACKET SLEEVE 8534 2 Fig 28 T Handle Bracket and Hook Assembly at Rear Lift Bracket 1 T HANDLE 8534 14 2 LIFTING BRACKET 8534 13 3 HOOK ASSEMBLY 8534 11 Fig 29 T Handle Bracket and Hook Assembly at Front Lift Bracket 1 LIFTING BRACKET 8534 13 2 T HANDLE 8534 14 3 HOOK AS...

Page 2783: ...and separate the brake line support bracket from cradle 12 Disconnect power steering hydraulic line bracket at cradle on passenger side Fig 32 13 Disconnect power steering oil cooler from cra dle Fig 33 14 Remove power steering rack and pinion mounting bolts Refer to 19 STEERING GEAR REMOVAL Fig 31 Stabilizer Bar Link To Strut 1 NUT 2 STRUT 3 STABILIZER BAR LINK Fig 32 Hose Routing Clip at Cradle ...

Page 2784: ...ILIZER BAR REMOVAL INSTALLATION 1 Install stabilizer bar onto engine cradle Refer to 2 SUSPENSION FRONT STABILIZER BAR INSTALLATION 2 Install cradle and fixture into position under vehicle 3 Slowly lower vehicle Fig 37 While lowering vehicle align engine front and rear mount studs to their respective thru holes in cradle Fig 34 Driveline Support Table 8874 1 DRIVELINE SUPPORT TABLE 8874 1 2 BRACKE...

Page 2785: ...he bolts 12 Position brake lines into the plastic support brackets and fasten the brackets 13 Install the fascia Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA INSTAL LATION 14 Position the lower control arms in place and install the control arm to cradle bolts Refer to 2 SUSPENSION FRONT LOWER CONTROL ARM INSTALLATION 15 Install sway bar links to strut attaching points Fig 40 Tighten link to stru...

Page 2786: ...UST SYSTEM REMOVAL NOTE It may be necessary to back off parking brake shoe adjustment to allow sufficient slack to disengage cable buttons from connectors in follow ing two steps 9 Slide left rear parking brake cable button inboard and remove from equalizer Fig 42 10 While holding parking brake cable connector on end of front cable secure with a pair of pliers at the front cable button slide right...

Page 2787: ...ody at all four mount bushing locations using a marker or crayon Fig 44 Do not use a scratch awl to mark location 15 Position under hoist utility jack or transmis sion jack under center of rear suspension crossmem ber Raise jack head to contact suspension crossmember and secure crossmember to jack 16 Remove lower mounting bolt and nut at each rear shock absorber Fig 45 Fig 43 Brake Hose Bracket At...

Page 2788: ...ember to drop Do not lower jack at a fast rate Lower jack just enough to allow spring removal Do not lower jack any further than necessary 23 Remove coil spring and isolator Fig 47 lower end first 24 Raise right side of crossmember back into mounted position It is not necessary to install mounting bolts 25 Remove both front and rear crossmember mounting bolts previously removed on left side of cro...

Page 2789: ...g to each side of rear suspen sion a Place a 13 mm 12 point box wrench over cable retainer on end of cable housing at cross member and collapse retainer fingers Fig 49 Remove cable from crossmember b Remove bolt and nut fastening spring link to crossmember Fig 50 Fig 49 Wrench Positioned To Release Cable Retainer 1 CABLE RETAINER 2 12 POINT BOX END WRENCH Fig 50 Spring Link Mounting 1 CROSSMEMBER ...

Page 2790: ...refully place knuckle with links and park ing brake cable attached as an assembly into mounting position on rear suspension crossmem ber b Install bolt and nut mounting camber link to crossmember Fig 54 Do not tighten at this time c Install bolt and nut mounting tension link to crossmember Fig 54 Do not tighten at this time d Install bolt and nut mounting compression link to crossmember Fig 53 e S...

Page 2791: ...nting hole in crossmember Slide cable retainer on end of cable housing into hole until retainer fin gers click into place 4 Install stabilizer bar with cushions and retain ers on crossmember 5 Install cushion retainer mounting bolts Fig 48 Do not tighten at this time 6 Install bolt and nut fastening stabilizer bar to each stabilizer link Fig 48 Do not tighten at this time 7 Tighten cushion retaine...

Page 2792: ...ssmember as necessary to acheive the measured distances shown in the figure Fig 56 22 Once mounts are lined up with location marks tighten all four crossmember mounting bolts to 163 N m 120 ft lbs torque 23 Tighten shock absorber lower mounting bolts to 102 N m 75 ft lbs torque 24 Remove jack from under crossmember 25 If equipped with AWD install rear driveline module and both rear half shafts Ref...

Page 2793: ...Fig 56 PLP Points 13 26 FRAME BUMPERS CS REAR CROSSMEMBER Continued ...

Page 2794: ... hose routing bracket to front of rear crossmember Fig 43 11 Remove screw mounting right rear brake hose routing bracket to front of rear crossmember Fig 43 NOTE In some cases it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle This can usually be accomplished before guide pi...

Page 2795: ...ack head to contact driveline module suspension crossmember and secure in place 18 Remove lower mounting bolt and nut at each rear shock absorber Fig 45 19 Remove both front and rear crossmember mounting bolts on left side of vehicle Fig 46 CAUTION To avoid damaging other components of vehicle do not lower crossmember any further than necessary to remove coil spring 20 Slowly lower jack allowing l...

Page 2796: ...jack at a fast rate As jack is lowered remove propeller shaft from alignment pin on end of rear driveline module input flange and support it with a bungee or cord keeping it at its normal height Do not allow pro peller shaft to hang on its own 29 Continue to lower jack until rear suspension module is at a comfortable working level 30 Remove rear suspension module from jack 31 Turn rear suspension ...

Page 2797: ...ure Installer Special Tool 9031 7 is positioned that it will clear compression link bracket when bushing is installed Fig 66 3 Using hand tools tighten Press screw drive pressing bushing into crossmember Install bushing until bushing can flange contacts surface of cross member 4 Remove tools 5 Verify bushing closely lines up with reference marks applied during removal 6 Place compression link back...

Page 2798: ...unted positions Once shock absorber lower mounting hole lines up with hole in spring link stop jacking 19 Install lower shock mounting bolt Fig 45 Do not tighten at this time 20 Raise left side of crossmember into mounted position and install previously removed mounting bolts Fig 46 Snug but do not fully tighten bolts at this time 21 Shift crossmember as necessary to line up mounts with location m...

Page 2799: ...le secure with a pair of pliers at the front cable button slide right rear parking brake cable button inboard and remove from cable connec tor Fig 42 10 Remove screw mounting left rear brake hose routing bracket to front of rear crossmember Fig 43 11 Remove screw mounting right rear brake hose routing bracket to front of rear crossmember Fig 43 NOTE In some cases it may be necessary to retract cal...

Page 2800: ...any further than necessary 25 Remove coil spring and isolator Fig 47 lower end first 26 Raise right side of crossmember back into mounted position It is not necessary to install mounting bolts 27 Remove both front and rear crossmember mounting bolts previously removed on left side of crossmember Fig 46 28 Slowly lower jack Do not lower jack at a fast rate As jack is lowered remove propeller shaft ...

Page 2801: ...r mounting bolts can be installed Fig 46 Install left side crossmember mounting bolts but not the right side bolts Fig 46 It is not necessary to tighten bolts at this point CAUTION To avoid damaging other components of vehicle do not lower crossmember any further than necessary to install coil spring 9 Slowly lower jack allowing right side of cross member to drop Do not lower jack at a fast rate L...

Page 2802: ...e when installing brake caliper onto adapter so guide pin bushings and sleeves do not get damaged by mounting bosses on adapter b Retract caliper guide pins to clear mounting bosses on caliper adapter when installing caliper c Install brake caliper in opposite way it was removed Starting with upper end carefully posi tion caliper and brake shoes over brake rotor and align outboard shoe s upper edg...

Page 2803: ...ing bushing into crossmember Install bushing until screw drive stops when bushing contacts Receiver on opposite side of crossmember 4 Remove tools 5 Swing spring link up to bushing in crossmember and install bolt and nut fastening spring link to cross member Fig 50 Do not tighten bolt at this time 6 Install rear spring as well as all components necessary to access it Refer to 2 SUSPENSION REAR HUB...

Page 2804: ...TALLATION 8 FUEL PRESSURE REGULATOR REMOVAL 10 INSTALLATION 15 FUEL PUMP MODULE REMOVAL 17 INSTALLATION 22 FUEL RAIL REMOVAL 26 INSTALLATION 26 FUEL TANK REMOVAL 26 INSTALLATION 34 FUEL TANK FILLER TUBE REMOVAL 37 INSTALLATION 37 FUEL DELIVERY SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Fuel Tank Strap 54 2 40 Filler Tube Clamp 3 4 30 Filler Tube Housing to Body 1 9 17 CS FUEL SYSTEM 14 1 ...

Page 2805: ... the negative battery cable 3 Fold the driverside rear seat and tilt forward Fig 1 4 Remove the 2 mounting bolts for the rear seat Fig 2 5 Disconnect the seat electrical connector Fig 3 6 Remove seat from vehicle Fig 4 Fig 1 REAR SEAT Fig 2 REAR SEAT MOUNTING Fig 3 REAR SEAT ELECTRICAL CONNECTOR Fig 4 REAR SEAT REMOVED 14 2 FUEL DELIVERY CS ...

Page 2806: ...al connector Fig 6 9 Remove the 14 screws for the mounting of the rear center console Fig 7 Fig 5 CENTER CONSOLE SCUFF PLATE Fig 6 CENTER CONSOLE ELECTRICAL CONNECTOR Fig 7 CONSOLE ASSEMBLY CENTER CONSOLE LEFT SIDE SCREWS CS FUEL DELIVERY 14 3 FUEL LEVEL SENDING UNIT SENSOR Continued ...

Page 2807: ...ews Fig 10 from console pocket under rubber mat Fig 9 CENTER CONSOLE RIGHT SIDE SCREWS CENTER CONSOLE FRONT SCREW BOTH SIDES Fig 8 CENTER CONSOLE CUP HOLDER SCREWS Fig 9 CENTER CONSOLE COMPARTMENT PAD 14 4 FUEL DELIVERY CS FUEL LEVEL SENDING UNIT SENSOR Continued ...

Page 2808: ...ade at an angle under the center console mounting bracket 14 Cut carpet along the mounting bracket for the center console THE CUT DOES NOT NEED TO BE MORE THAN 1 FOOT LONG Fig 13 15 Pull carpet back to access Fuel Pump Module Cover Fig 14 Fig 10 CENTER CONSOLE COMPARTMENT SCREWS Fig 11 DOOR SCUFF PLATE Fig 12 DOOR SCUFF PLATE REMOVED CENTER CONSOLE REMOVED CS FUEL DELIVERY 14 5 FUEL LEVEL SENDING ...

Page 2809: ...fuel pump mod ule Fig 15 and Fig 16 Fig 13 WHERE TO CUT CARPET 1 Cut NO longer than 1 Foot Fig 14 MODULE ACCESS COVER Fig 15 CUTTING ACCESS COVER Fig 16 CUTTING ACCESS COVER 14 6 FUEL DELIVERY CS FUEL LEVEL SENDING UNIT SENSOR Continued ...

Page 2810: ...electrical con nector Fig 19 21 Fuel Pump Module Lock ring contact points Fig 20 and Fig 21 22 Remove the Fuel Pump Module lock ring Fig 22 NOTE Use a brass punch to remove the 1 4 turn lock ring Fig 17 ACCESS COVER REMOVED Fig 18 REMOVING COVER SEALER Fig 19 ELECTRICAL VAPOR CONNECTOR Fig 20 PUMP MODULE LOCKING RING CS FUEL DELIVERY 14 7 FUEL LEVEL SENDING UNIT SENSOR Continued ...

Page 2811: ... level sending card to module 2 Connect the electrical connector for the fuel level sending card 3 Install the fuel pump module top to the module Fig 25 and Fig 26 4 Install the Fuel Pump Module lock ring Fig 22 NOTE Use a brass punch to Install the 1 4 turn lock ring Make sure all 5 tabs are properly seated 5 Connect the vapor line and electrical connector Fig 19 6 Connect the negative battery ca...

Page 2812: ...der rubber mat Fig 9 16 Install screws into cup holder pockets Fig 8 17 Install the 14 screws for the mounting of the rear center console 18 Connect the rear console electrical connector Fig 6 19 Install the rear console scuff plate Fig 5 20 Install seat into vehicle Fig 4 21 Connect the seat electrical connector Fig 3 22 Install the 2 mounting nuts for the rear seat Fig 2 Fig 25 MODULE TOP ALIGNM...

Page 2813: ... Pressure Release Procedure in this section 2 Disconnect the negative battery cable 3 Fold the driverside rear seat and tilt forward Fig 31 4 Remove the 2 mounting bolts for the rear seat Fig 32 5 Disconnect the seat electrical connector Fig 33 6 Remove seat from vehicle Fig 34 7 Remove the rear console scuff plate Fig 35 Fig 29 INSTALLING ACCESS PANEL Fig 30 PANEL PUSH PINS Fig 31 REAR SEAT Fig 3...

Page 2814: ...ole electrical connector Fig 36 Fig 33 REAR SEAT ELECTRICAL CONNECTOR Fig 34 REAR SEAT REMOVED Fig 35 CENTER CONSOLE SCUFF PLATE Fig 36 CENTER CONSOLE ELECTRICAL CONNECTOR CS FUEL DELIVERY 14 11 FUEL PRESSURE REGULATOR Continued ...

Page 2815: ... 40 13 Sill plate removed Fig 41 NOTE The carpet will have to cut to access the fuel pump module access cover Extreme care must be used when cutting the carpet The cut is made at an angle under the center console mounting bracket CENTER CONSOLE LEFT SIDE SCREWS CENTER CONSOLE RIGHT SIDE SCREWS CENTER CONSOLE FRONT SCREW BOTH SIDES Fig 37 CENTER CONSOLE CUP HOLDER SCREWS 14 12 FUEL DELIVERY CS FUEL...

Page 2816: ...Fig 38 CENTER CONSOLE COMPARTMENT PAD Fig 39 CENTER CONSOLE COMPARTMENT SCREWS Fig 40 DOOR SCUFF PLATE Fig 41 DOOR SCUFF PLATE REMOVED CS FUEL DELIVERY 14 13 FUEL PRESSURE REGULATOR Continued ...

Page 2817: ...Module Cover Fig 43 16 Cut seal for access panel for fuel pump mod ule Fig 44 and Fig 45 17 Access cover removed Fig 46 18 Clean sealer from floor pan and access cover Fig 47 CENTER CONSOLE REMOVED Fig 42 WHERE TO CUT CARPET 1 Cut NO longer than 1 Foot Fig 43 MODULE ACCESS COVER Fig 44 CUTTING ACCESS COVER 14 14 FUEL DELIVERY CS FUEL PRESSURE REGULATOR Continued ...

Page 2818: ... Use a socket to compress the 4 tabs that retain the regulator 27 Pry up regulator and remove regulator and o rings INSTALLATION 1 Lightly lubricate the O rings with clean engine oil and place them into opening in module 2 Push regulator down and into place 3 Install the module top to the module and gas ket seal 4 Ensure seal is properly positioned in the fuel tank groove 5 Install the Fuel Pump M...

Page 2819: ...ins into the holes Fig 53 14 Pull carpet back into place 15 Install the left rear door sill plate Fig 40 16 Install screws Fig 39 into console pocket under rubber mat Fig 38 17 Install screws into cup holder pockets Fig 37 18 Install the 14 screws for the mounting of the rear center console 19 Connect the rear console electrical connector Fig 36 20 Install the rear console scuff plate Fig 35 21 In...

Page 2820: ...and tilt forward Fig 54 4 Remove the 2 mounting bolts for the rear seat Fig 55 5 Disconnect the seat electrical connector Fig 56 6 Remove seat from vehicle Fig 57 7 Remove the rear console scuff plate Fig 58 8 Disconnect the rear console electrical connector Fig 59 Fig 53 PANEL PUSH PINS Fig 54 REAR SEAT Fig 55 REAR SEAT MOUNTING Fig 56 REAR SEAT ELECTRICAL CONNECTOR CS FUEL DELIVERY 14 17 FUEL PR...

Page 2821: ...for the mounting of the rear center console Fig 60 Fig 57 REAR SEAT REMOVED Fig 58 CENTER CONSOLE SCUFF PLATE Fig 59 CENTER CONSOLE ELECTRICAL CONNECTOR Fig 60 CONSOLE ASSEMBLY 14 18 FUEL DELIVERY CS FUEL PUMP MODULE Continued ...

Page 2822: ...move screws Fig 63 from console pocket under rubber mat Fig 62 CENTER CONSOLE LEFT SIDE SCREWS CENTER CONSOLE RIGHT SIDE SCREWS CENTER CONSOLE FRONT SCREW BOTH SIDES Fig 61 CENTER CONSOLE CUP HOLDER SCREWS CS FUEL DELIVERY 14 19 FUEL PUMP MODULE Continued ...

Page 2823: ...l pump module access cover Extreme care must be used when cutting the carpet The cut is made at an angle under the center console mounting bracket Fig 62 CENTER CONSOLE COMPARTMENT PAD Fig 63 CENTER CONSOLE COMPARTMENT SCREWS Fig 64 DOOR SCUFF PLATE Fig 65 DOOR SCUFF PLATE REMOVED 14 20 FUEL DELIVERY CS FUEL PUMP MODULE Continued ...

Page 2824: ...cuum area before removing fuel pump mod ule lock ring 20 Disconnect the vapor line and electrical con nector Fig 72 21 Remove the Fuel Pump Module lock ring Fig 74 NOTE Use a brass punch to remove the 1 4 turn lock ring Make contact only at the points shown Fig 73 22 Remove the fuel pump module top 23 Drain Fuel Tank use an approved GASO LINE draining station CENTER CONSOLE REMOVED Fig 66 WHERE TO...

Page 2825: ...ing tabs or the supply line fitting 27 Remove the fuel line from the top of the pump module Use a small screwdriver to pry tab back and tip hose to one side and then pry the tab on the other side back to release the hose 28 Tip fuel pump module on its side to remove fuel from the reservoir CAUTION Do not spill fuel on the inside of the vehicle 29 Remove the fuel pump module INSTALLATION 1 Install ...

Page 2826: ...ring 6 Connect the fuel line and electrical connector Fig 72 7 Connect the negative battery cable 8 Fill fuel tank Use the DRBIIIt scan tool to pressurize the fuel system Check for leaks 9 Disconnect the negative battery cable 10 Clean sealer from floor pan and access cover Fig 81 Fig 73 LOCKING RING CONTACT POINTS Fig 74 MODULE LOCK RING Fig 75 ELECTRICAL CONNECTOR Fig 76 RETURN HOSE AND FUEL LIN...

Page 2827: ... 15 Install the left rear door sill plate Fig 64 16 Install screws Fig 63 into console pocket under rubber mat Fig 62 17 Install screws into cup holder pockets Fig 61 18 Install the 14 screws for the mounting of the rear center console Fig 77 RETURN HOSE REMOVAL Fig 78 PUMP WITH TOP REMOVED Fig 79 MODULE TOP ALIGNMENT PINS Fig 80 Alignment PINS IN PLACE 14 24 FUEL DELIVERY CS FUEL PUMP MODULE Cont...

Page 2828: ...icle Fig 57 22 Connect the seat electrical connector Fig 56 23 Install the 2 mounting nuts for the rear seat Fig 55 24 Vacuum vehicle 25 Connect the negative battery cable Fig 81 ACCESS PANEL BOTTOM Fig 82 ACCESS PANEL SEALER Fig 83 INSTALLING ACCESS PANEL Fig 84 PANEL PUSH PINS CS FUEL DELIVERY 14 25 FUEL PUMP MODULE Continued ...

Page 2829: ...ush injectors into fuel injector rail until clips are in the correct position 4 Position fuel rail over cylinder heads and push rail into place Tighten fuel rail mounting bolts to 28 N m 250 in lbs torque 5 Connect the fuel supply tube quick connect fit ting to the fuel rail Refer to Quick Connect Fittings in the Fuel Delivery Section 6 Connect the electrical connectors to the fuel injectors 7 Ins...

Page 2830: ...e Fig 90 7 Remove the rear console scuff plate Fig 91 8 Disconnect the rear console electrical connector Fig 92 Fig 88 REAR SEAT MOUNTING Fig 89 REAR SEAT ELECTRICAL CONNECTOR Fig 90 REAR SEAT REMOVED Fig 91 CENTER CONSOLE SCUFF PLATE CS FUEL DELIVERY 14 27 FUEL TANK Continued ...

Page 2831: ...ve screws from cup holder pockets Fig 94 11 Remove screws Fig 96 from console pocket under rubber mat Fig 95 Fig 92 CENTER CONSOLE ELECTRICAL CONNECTOR Fig 93 CONSOLE ASSEMBLY CENTER CONSOLE LEFT SIDE SCREWS CENTER CONSOLE RIGHT SIDE SCREWS 14 28 FUEL DELIVERY CS FUEL TANK Continued ...

Page 2832: ...ate Fig 97 13 Sill plate removed Fig 98 CENTER CONSOLE FRONT SCREW BOTH SIDES Fig 94 CENTER CONSOLE CUP HOLDER SCREWS Fig 95 CENTER CONSOLE COMPARTMENT PAD Fig 96 CENTER CONSOLE COMPARTMENT SCREWS CS FUEL DELIVERY 14 29 FUEL TANK Continued ...

Page 2833: ...long the mounting bracket for the center console THE CUT DOES NOT NEED TO BE MORE THAN 1 FOOT LONG Fig 99 15 Pull carpet back to access Fuel Pump Module Cover Fig 100 16 Cut seal for access panel for fuel pump mod ule Fig 101 and Fig 102 Fig 97 DOOR SCUFF PLATE Fig 98 DOOR SCUFF PLATE REMOVED CENTER CONSOLE REMOVED Fig 99 WHERE TO CUT CARPET 1 Cut NO longer than 1 Foot 14 30 FUEL DELIVERY CS FUEL ...

Page 2834: ...ump Module lock ring Fig 106 NOTE Use a brass punch to remove the 1 4 turn lock ring 22 Remove the fuel pump module top 23 Drain Fuel Tank use an approved GASO LINE draining station 24 Raise vehicle and support 25 Remove the 2 bolts for the exhaust system mid flange Fig 107 Fig 100 MODULE ACCESS COVER Fig 101 CUTTING ACCESS COVER Fig 102 CUTTING ACCESS COVER Fig 103 ACCESS COVER REMOVED CS FUEL DE...

Page 2835: ...on floor 29 Disconnect the fuel tank electrical connector Fig 110 30 Disconnect the fuel line and EVAP line Fig 111 31 Disconnect the EVAP purge line Fig 112 32 Mark the driveshaft rear connection Fig 113 Fig 104 REMOVING COVER SEALER Fig 105 ELECTRICAL FUEL CONNECTOR Fig 106 MODULE LOCK RING Fig 107 Exhaust System Mid Flange 14 32 FUEL DELIVERY CS FUEL TANK Continued ...

Page 2836: ...7 Remove the fuel filler tube from the rubber hose at fuel tank Fig 116 38 Support the fuel tank with a transmission jack 39 Remove the 2 fuel tank straps Fig 117 40 Lower fuel tank and remove from vehicle Fig 118 Fig 108 MUFFLER HANGER EXHAUST HANGER Fig 109 EXHAUST HANGER REMOVED Fig 110 FUEL TANK ELECTRICAL CONNECTOR CS FUEL DELIVERY 14 33 FUEL TANK Continued ...

Page 2837: ...ge line Fig 112 6 Connect the fuel line and EVAP line 7 Connect the fuel tank electrical connector Fig 110 8 Support driveshaft on jack 9 Install the driveshaft support bearing Fig 115 10 Align the Marks on the driveshaft to the rear connection Fig 111 FUEL SUPPLY LINE AND EVAP LINES 1 EVAP Line 2 Fuel Line Fig 112 FUEL TANK EVAP PURGE LINE Fig 113 MARKING DRIVESHAFT Fig 114 DRIVESHAFT REAR CONNEC...

Page 2838: ...nge Fig 107 16 Install the left rear tire 17 Lower vehicle 18 Install the fuel pump module top to the mod ule 19 Install the Fuel Pump Module lock ring Fig 106 NOTE Use a brass punch to Install the 1 4 turn lock ring 20 Connect the fuel line and electrical connector Fig 105 21 Connect the negative battery cable Fig 115 DRIVESHAFT SUPPORT BEARING FUEL FILLER TUBE Fig 116 FILLER TUBE TO RUBBER HOSE ...

Page 2839: ... rear door sill plate Fig 97 30 Install screws Fig 96 into console pocket under rubber mat Fig 95 31 Install screws into cup holder pockets Fig 94 32 Install the 14 screws for the mounting of the rear center console 33 Connect the rear console electrical connector Fig 92 34 Install the rear console scuff plate Fig 91 35 Install seat into vehicle Fig 90 36 Connect the seat electrical connector Fig ...

Page 2840: ...e vent line to filler tube 7 Remove the fuel filler tube from the rubber hose at fuel tank Fig 124 8 Remove the filler tube INSTALLATION 1 Install the filler tube 2 Install 3 screws from filler neck to quarter panel 3 Connect the vent line to filler tube 4 Install the fuel filler tube from the rubber hose at fuel tank Fig 124 5 Install the left rear tire 6 Lower vehicle 7 Connect the negative batt...

Page 2841: ...or is located on the driver side of the vehicle Fig 1 above the differential housing The bottom of the sensor sits above the drive plate 1 Disconnect the negative and positive battery cable 2 Remove the battery 3 Disconnect electrical connector from crankshaft position sensor 4 Remove sensor mounting screw Remove sensor INSTALLATION 1 Install sensor and push sensor down until con tact is made with...

Page 2842: ...e in the correct position 4 Position fuel rail over cylinder heads and push rail into place Tighten fuel rail mounting bolts to 28 N m 250 in lbs torque 5 Connect the fuel supply tube quick connect fit ting to the fuel rail Refer to Quick Connect Fittings in the Fuel Delivery Section 6 Connect the electrical connectors to the fuel injectors 7 Install intake manifold plenum Refer to 9 ENGINE MANIFO...

Page 2843: ... battery cable 2 Remove the engine cover 3 Disconnect the electrical connector Fig 7 4 Remove the 4 mounting bolts Fig 8 5 Pull valve straight out of manifold Fig 9 INSTALLATION 1 Install the manifold tuning valve make sure that the alignment pin Fig 10 and notch line up 2 Install bolts and tighten 3 Connect the electrical connector 4 Install the engine cover 5 Connect the negative battery cable F...

Page 2844: ...egative battery cable O2 SENSOR REMOVAL The engines uses two heated oxygen sensors CAUTION When disconnecting the sensor electrical connector do not pull directly on wire going into sensor 1 Disconnect the negative battery cable 2 Disconnect the heated oxygen sensor electrical connector 3 Use a socket such as Snap On YA8875 or a crow foot wrench to remove oxygen sensor Fig 12 Fig 9 MTV VALVE REMOV...

Page 2845: ...he wiring clip to the heat shield Fig 13 4 Connect the negative battery cable THROTTLE BODY REMOVAL 1 Disconnect negative cable from battery 2 Remove the engine cover 3 Remove the air cleaner box Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Hold throttle lever in wide open position Remove throttle cable and speed control cables from throttle arm 5 Remove throttle cable bracket...

Page 2846: ...e throttle body slides into a socket in the TPS The socket has two tabs inside it The throttle shaft rests against the tabs When indexed correctly the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into posi tion If it is difficult to rotate the TPS into position install the sensor with th...

Page 2847: ...e the 4 bolts 5 Remove short runner valve Fig 20 INSTALLATION 1 Install short runner valve Fig 20 2 Install the 4 bolts and tighten 3 Install the link to short runner valve lever Fig 19 4 Connect the electrical connector to the short runner valve Fig 18 5 Connect the negative battery cable Fig 18 SHORT RUNNER VALVE Fig 19 SOLENOID LINK REMOVED Fig 20 SHORT RUNNER VALVE SOLENOID REMOVED 14 44 FUEL ...

Page 2848: ...3 FUEL PRESSURE REGULATOR REMOVAL 3 INSTALLATION 4 FUEL PUMP MODULE DESCRIPTION 4 OPERATION 4 REMOVAL 5 INSTALLATION 6 FUEL RAIL REMOVAL 7 INSTALLATION 8 FUEL TANK REMOVAL 8 INSTALLATION 11 FUEL TANK FILLER TUBE REMOVAL 11 INSTALLATION 12 FUEL DELIVERY SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Fuel Tank Strap 54 2 40 Filler Tube Clamp 3 4 30 Filler Tube Housing to Body 1 9 17 CS FUEL SYS...

Page 2849: ...g NOTE Use a brass punch to remove the 1 4 turn lock ring 8 Remove module top 9 Tip module on to it s side to drain fuel from reservoir in module 10 Drain fuel tank use an approved gasoline draining station 11 Disconnect electrical connector for fuel level sending card 12 Remove fuel level sending card by prying on locking tab Fig 3 and pulling card down toward bottom of the pump module There are ...

Page 2850: ...ATOR REMOVAL NOTE THE FUEL PRESSURE REGULATOR IS ON THE PASSENGER SIDE OF THE FUEL TANK 1 Release the fuel pressure refer to the Fuel Pressure Release Procedure in this section 2 Disconnect negative battery cable 3 Remove fuel tank Refer to 14 FUEL SYS TEM FUEL DELIVERY FUEL TANK REMOVAL 4 Vacuum area before removing module lock ring 5 Disconnect lines from top of the module 6 Remove module lock r...

Page 2851: ...ssenger side module Both modules have fuel level sending cards There are 2 hoses that connect the modules together one is the fuel supply line the other is a return or siphon hose The lines are removed from the fuel pump module when servicing either unit The ORVR Onboard Refueling Vapor Recovery control valve is in the passenger side module OPERATION The way the pump works is as follows fuel enter...

Page 2852: ... FUEL SYS TEM FUEL DELIVERY FUEL TANK REMOVAL 4 Vacuum area before removing fuel pump mod ule lock ring 5 Disconnect vapor line and electrical connector 6 Remove Fuel Pump Module lock ring NOTE Use a brass punch to remove the 1 4 turn lock ring Make contact only at the points shown Fig 8 7 Remove fuel pump module top 8 Drain Fuel Tank using an approved gasoline draining station 9 Disconnect electr...

Page 2853: ...uel from reservoir 15 Remove fuel pump module INSTALLATION 1 Install fuel pump module into fuel tank 2 Connect siphon and fuel line to fuel pump mod ule Fig 12 3 Connect fuel pump electrical connector to bot tom of module top Fig 9 4 The wire connector to the passenger side level sensor needs to be connected 5 Install fuel pump module top to module Fig 13 and Fig 14 6 Install Fuel Pump Module gask...

Page 2854: ...e upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 3 If the injector connectors are not tagged with their cylinder number tag them to identify the cor rect cylinder 4 Disconnect the fuel supply line from the fuel rail Fig 15 5 Remove the 4 mounting bolts from the fuel rail Fig 16 6 Lift fuel rail straight up off of cylinder head Fig 13 MODULE TOP ALIGNMENT PINS Fig 14 Alig...

Page 2855: ...to the fuel injectors 7 Install intake manifold plenum Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 8 Connect negative cable to battery FUEL TANK REMOVAL 1 Release the fuel pressure refer to the Fuel Pressure Release Procedure in this section 2 Disconnect the negative battery cable 3 Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container 4 Raise vehicle a...

Page 2856: ...veshaft rear connection Fig 22 14 Disconnect the driveshaft rear connection Fig 23 15 Remove the driveshaft support bearing Fig 24 16 Support driveshaft on jack Fig 19 FUEL TANK ELECTRICAL CONNECTOR Fig 20 FUEL SUPPLY LINE AND EVAP LINES 1 EVAP Line 2 Fuel Line Fig 21 FUEL TANK EVAP PURGE LINE Fig 22 MARKING DRIVESHAFT CS FUEL DELIVERY 14s 9 FUEL TANK Continued ...

Page 2857: ...nsmission jack 20 Remove the 2 fuel tank straps Fig 26 21 Lower fuel tank 22 Drain Fuel Tank use an approved GASO LINE draining station 23 Remove tank from vehicle Fig 27 Fig 23 DRIVESHAFT REAR CONNECTION Fig 24 DRIVESHAFT SUPPORT BEARING FUEL FILLER TUBE Fig 25 FILLER TUBE TO RUBBER HOSE Fig 26 FUEL TANK STRAPS 14s 10 FUEL DELIVERY CS FUEL TANK Continued ...

Page 2858: ... the center exhaust hanger rubber gro ments Fig 18 14 Install muffler hanger rubber groments Fig 17 15 Install the left rear tire 16 Lower vehicle 17 Connect the negative battery cable 18 Fill fuel tank Use the DRBIIIt scan tool to pressurize the fuel system Check for leaks FUEL TANK FILLER TUBE REMOVAL 1 Release the fuel pressure refer to the Fuel Pressure Release Procedure in this section 2 Disc...

Page 2859: ...t the vent line to filler tube 4 Install the fuel filler tube from the rubber hose at fuel tank Fig 29 5 Clip ground wire to body 6 Install the left rear tire 7 Lower vehicle 8 Connect the negative battery cable Fig 29 FILLER TUBE TO RUBBER HOSE 14s 12 FUEL DELIVERY CS FUEL TANK FILLER TUBE Continued ...

Page 2860: ...emove the battery 3 Disconnect electrical connector from crankshaft position sensor 4 Remove sensor mounting screw Remove sensor INSTALLATION 1 Install sensor and push sensor down until con tact is made with the transmission case Fig 2 While holding the sensor in this position install and tighten the retaining bolt to 12 N m 105 in lbs torque 2 Connect electrical connector to crankshaft posi tion ...

Page 2861: ...8 N m 250 in lbs torque 5 Connect the fuel supply tube quick connect fit ting to the fuel rail Refer to Quick Connect Fittings in the Fuel Delivery Section 6 Connect the electrical connectors to the fuel injectors 7 Install intake manifold plenum Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 8 Connect negative cable to battery IDLE AIR CONTROL MOTOR REMOVAL 1 Disconnect the negative bat...

Page 2862: ...nnector Fig 6 3 remove sensor from hose INSTALLATION 1 Install sensor into inlet hose 2 Connect and lock the electrical connector Fig 6 3 Connect the negative battery cable MANIFOLD TUNE VALVE REMOVAL 1 Disconnect the negative battery cable 2 Remove the engine cover 3 Disconnect the electrical connector Fig 7 4 Remove the 4 mounting bolts Fig 8 5 Pull valve straight out of manifold Fig 9 Fig 6 INT...

Page 2863: ...attery cable MAP SENSOR REMOVAL 1 Remove the negative battery cable 2 Disconnect the electrical connector from the MAP sensor 3 Remove bolt from sensor 4 Remove sensor INSTALLATION 1 The sensor mounts onto intake manifold ple num Fig 11 Tighten screws to 4 5 N m 40 in lbs torque Fig 8 MTV VALVE Fig 9 MTV VALVE REMOVED Fig 10 MTV LOCATING PIN Fig 11 MAP SENSOR O RING 14s 16 FUEL INJECTION CS MANIFO...

Page 2864: ... negative terminal The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor The customer may experience driveability issues if this is not performed 1 After removing the sensor the threads must be cleaned with an 18 mm X 1 5 6E tap If reusing the original sensor coat the sensor threads with an anti seize compound such as Lo...

Page 2865: ...ces INSTALLATION 1 Install throttle body Fig 16 2 Install 3 throttle body bolts and tighten 3 Connect electrical connectors to throttle body Fig 15 4 Install throttle cable bracket Fig 14 5 Hold throttle lever in wide open position Install throttle cable and speed control cables to throttle arm 6 Install the air cleaner box 7 Install the engine cover 8 Connect negative cable from battery THROTTLE ...

Page 2866: ...bs in the socket Tighten mounting screws to 5 1 N m 45 in lbs torque 2 After installing the TPS the throttle plate should be closed If the throttle plate is open install the sensor on the other side of the tabs in the socket 3 Attach electrical connector to the TPS 4 Connect the negative battery cable SHORT RUNNER VALVE SOLENOID REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the elec...

Page 2867: ...g 20 2 Install the 4 bolts and tighten 3 Install the link to short runner valve lever Fig 19 4 Connect the electrical connector to the short runner valve Fig 18 5 Connect the negative battery cable Fig 20 SHORT RUNNER VALVE SOLENOID REMOVED 14s 20 FUEL INJECTION CS SHORT RUNNER VALVE SOLENOID Continued ...

Page 2868: ... travel pushes and pulls the tie rods to change the direction of the vehicle s front wheels Power assist steering is provided by a belt driven rotary type pump It directs fluid through power steering fluid hoses to the power steering gear where it is used to assist the driver s turning effort Manual steering control of the vehicle can be main tained if power steering assist is lost However under t...

Page 2869: ... 6713 3 Install Adapter Special Tool 8185 2 in end of Pressure Hose Special Tool 6959 4 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 5 Unscrew tube nut and remove power steering fluid pressure hose from power steering gear Fig 2 6 Thread vehicle s power steering pressure hose into Adapter Special Tool 8185 2 connected to Ana lyzer Hose Fig 3 Tighten tube ...

Page 2870: ...e next step do not force the pump to operate against the stops for more than 4 seconds at a time as pump damage may result 6 Once pump has been verified as functioning correctly completely open valve on Power Steering Analyzer flow meter Turn steering wheel to extreme left until stop in steering gear is met Hold it there for 2 4 seconds then release it Now turn steering wheel to right until right ...

Page 2871: ...ontrol arm pivot bushing worn 5 Replace lower control arm pivot bushing 6 Loose strut assembly mounting fasteners at tower or knuckle 6 Tighten strut assembly fasteners to the specified torque 7 Power steering fluid hose touching the body of the vehicle 7 Adjust hose to proper position by loosening repositioning and tightening attachments to specified torque Do not bend tubing 8 Damaged front susp...

Page 2872: ... 4 Lube seal if external 5 Steering gear internally noisy 5 Replace steering gear if no other cause can be found SCRUBBING OR KNOCKING NOISE 1 Incorrect tire or wheel size 1 Replace incorrect size tire or wheel with size used as original equipment 2 Interference between steering gear and other vehicle components 2 Check for bent or misaligned components and correct as necessary 3 Steering gear int...

Page 2873: ... specified pressure 3 Excessive engine vibration 3 Ensure that the engine is tuned properly 4 Loose tie rod end jam nut 4 Tighten the inner to outer tie rod jam nut to the specified torque 5 Overcharged air conditioning system 5 Check air conditioning pump head pressure and correct as necessary 6 Grounded engine mount 6 Repair as necessary 7 Loose outer tie rod 7 Replace outer tie rod STEERING CAT...

Page 2874: ...per front wheel alignment 2 Check and adjust wheel alignment as necessary 3 Lack of lubrication causing binding in front lower control arm ball joints 3 Lubricate ball joints if ball joints are not a lubricated for life type of ball joint then inspect ball joint for wear replace lower control arm as necessary If ball joint is a lubricated for life ball joint replace lower control arm ball joint 4 ...

Page 2875: ...10 Defective steering gear rotary valve 10 Replace power steering gear NOTE Steering shudder can be expected in new vehicles and vehicles with recent steering system repairs Shudder should dissipate after the vehicle has been driven several weeks NOTE To evaluate this condition it may be nec essary to disconnect the coupling at the base of the steering column Turn the steering wheel and feel or li...

Page 2876: ...on of power steering fluid 1 Drain the power steering fluid from the system Flush the system with fresh clean power steering fluid drain then refill to the proper level NOTE Extremely cold temperatures may cause power steering fluid aeration Aeration should sub side as fluid warms SPECIFICATIONS POWER STEERING FASTENER TORQUE DESCRIPTION N m Ft Lbs In Lbs Cooler Mounting Screws 10 90 Gear Mounting...

Page 2877: ...Adapters Power Steering Analyzer 6893 Hose Power Steering Analyzer 6959 Adapters Power Steering Analyzer 8185A Puller C 3894 A Installer C 4063B Puller C 4333 19 10 STEERING CS STEERING Continued ...

Page 2878: ... YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS CHARGE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGINALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIR BAG SYSTEM THEY MUST NEVER BE...

Page 2879: ... Lift airbag from mount and disconnect two air bag squib connectors and horn connector Fig 1 Fig 2 Remove driver airbag 5 Disconnect speed control wiring connector at clockspring center terminal Fig 2 6 Remove steering wheel retaining nut Fig 3 7 Remove damper Fig 3 8 Remove steering wheel using standard wheel puller 9 Access and remove knee blocker airbag Refer to 8 ELECTRICAL RESTRAINTS KNEE BLO...

Page 2880: ...dash Fig 6 Tighten nuts to 12 N m 105 in lbs torque 2 Connect steering column coupling to intermedi ate shaft Fig 6 To do so a Match intermediate shaft to coupling pinch loop b Install coupling pinch bolt Tighten to 28 N m 21 ft lbs torque c Install hair pin at end of pinch bolt 3 Slide multi function switch mounting housing onto column and install mounting screw Tighten screw to 1 9 N m 17 in lbs...

Page 2881: ...components 15 Road test vehicle to ensure operation of steer ing SPECIFICATIONS STEERING COLUMN FASTENER TORQUE DESCRIPTION N m Ft Lbs In Lbs Driver Airbag Attaching Bolts 10 90 Steering Column Coupling Pinch Bolt 28 21 250 Steering Column Mounting Nuts 12 105 Steering Column Shroud Screws 2 18 Steering Wheel Retaining Nut 61 45 INTERMEDIATE SHAFT REMOVAL NOTE Before proceeding Refer to 19 STEERIN...

Page 2882: ...t Fig 8 To do so a Match intermediate shaft to coupling pinch loop b Install coupling pinch bolt Tighten to 28 N m 21 ft lbs torque c Install hair pin at end of pinch bolt 10 Remove steering wheel holder 11 Connect battery negative cable to battery post 12 Road test vehicle to ensure proper operation of steering INTERMEDIATE SHAFT EXTENSION REMOVAL 1 Access and remove intermediate shaft Refer to 1...

Page 2883: ...intermedi ate shaft and extension onto mounting studs on dash panel Fig 12 6 Install intermediate shaft and all components necessary to access it Refer to 19 STEERING COLUMN INTERMEDIATE SHAFT INSTALLA TION 7 Road test vehicle to ensure proper operation of steering SEAL SHAFT SILENCER SHELL COVER REMOVAL NOTE Before proceeding Refer to 19 STEERING COLUMN WARNING 1 Disconnect battery negative cable...

Page 2884: ... Tighten nuts to 2 8 N m 25 in lbs torque 6 Ensure intermediate shaft cover shield is extended down over top of gear housing closing off shaft area 7 Lower vehicle 8 Connect steering column coupling to intermedi ate shaft Fig 8 To do so a Match intermediate shaft to coupling pinch loop b Install coupling pinch bolt Tighten to 28 N m 21 ft lbs torque c Install hair pin at end of pinch bolt 9 Remove...

Page 2885: ...CONNECT THE BATTERY NEGATIVE GROUND CABLE AND ISOLATE IT THEN ALLOW THE SYSTEM CAPACITOR TO DISCHARGE FOR A MINIMUM OF TWO MINUTES BEFORE BEGINNING AIRBAG REMOVAL 3 Remove driver airbag mounting screws Fig 14 4 Lift airbag from mount and disconnect two air bag squib connectors and horn connector Fig 14 Fig 15 Remove driver airbag 5 Disconnect speed control wiring connector at clockspring center te...

Page 2886: ...nect speed control wiring connector at clockspring Fig 15 7 Connect two airbag squib connectors and horn connector to driver airbag Fig 14 8 Place driver airbag on steering wheel and install mounting screws Fig 14 Tighten screws to 10 N m 90 in lbs torque 9 Connect battery negative cable to battery post following special Diagnosis And Testing proce dure Refer to 8 ELECTRICAL RESTRAINTS DIAGNOSIS A...

Page 2887: ...ig 1 3 Remove negative battery cable from battery and isolate cable 4 Remove cap from power steering fluid reser voir 5 Using a siphon pump remove as much power steering fluid as possible from power steering fluid reservoir 6 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 7 Remove both front tire and wheel assemblies 8 If outer tie rods need to be transferr...

Page 2888: ... wheel opening Use care not to cut tie rod boots on shields as gear is removed 17 If necessary remove outer tie rods from inner tie rod threads Count how many rotations it takes to remove each outer tie rod for installation reference Fig 2 Using C 3894 A To Release Tie Rod 1 PULLER C 3894 A 2 OUTER TIE ROD 3 STEERING KNUCKLE 4 TIE ROD STUD Fig 3 Roll Pin Removal 1 REMOVER 6831A 2 KNURLED NUT 3 STE...

Page 2889: ...xtension to power steering gear shaft as follows Fig 6 a Insert Installer Special Tool 6831A exten sion and steering gear shaft b Slide roll pin onto Remover shaft c Thread knurled nut all way onto end of Installer d While holding Installer head stationary turn hex nut pulling roll pin into shafts Stop installing roll pin once it is centered intermediate shaft extension e Remove tool 8 Slide shaft...

Page 2890: ...ge to hoses may result STANDARD PROCEDURE POWER STEERING PUMP INITIAL OPERATION WARNING FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS CAUTION Use only MoparT Automatic Transmis sion Fluid MS 9602 in power steering system Use of other MoparT power steering fluids MS5931 and MS9933 should be avoided to ensure peak perfor mance of the power...

Page 2891: ...ator wiring harness routing clip from pump Fig 2 10 Raise and support vehicle Refer to LUBRI CATION MAINTENANCE HOISTING STAN DARD PROCEDURE 11 Remove right front tire and wheel assembly 12 Remove drive belt splash shield 13 Remove nut then hose tube routing clamp at A C compressor mounted bracket Fig 3 14 Remove nuts mounting front and rear motor mounts to engine cradle one nut each mount 15 Remo...

Page 2892: ...DISASSEMBLY PUMP PULLEY The only serviceable part of the power steering pump is the pulley The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle 1 Remove the power steering pump from the vehicle Refer to Removal And Installation in this section of the service manual 2 Remove the pulley from the shaft of the power steering pump...

Page 2893: ...k 5 Install two bolts fastening right motor mount to frame rail Tighten bolts to 68 N m 50 ft lbs torque 6 Reposition pressure and return hoses to their original locations at pump NOTE Before installing power steering pressure hose on power steering pump replace O ring on end of power steering pressure hose Lubricate O ring using clean power steering fluid 7 Install pressure hose into pump fitting...

Page 2894: ...t normal ambient temperature approximately 21 C to 27 C 70 F to 80 F Fig 10 Before removing the power steering filler cap wipe the reservoir filler cap free of dirt and debris Do not overfill the power steering system Use only Mopart ATF 4 Automatic Transmission Fluid MS 9602 in the power steering system For additional information on Automatic Transmission Fluid Refer to LUBRICATION MAINTENANCE FL...

Page 2895: ...r in place Fig 13 9 Slide reservoir upward off lower mounting bolt INSTALLATION 1 Slide fluid reservoir over lower mounting bolt and into place on engine 2 Install two upper mounting bolts securing res ervoir in place Fig 13 3 Tighten all three reservoir mounting bolts to 12 N m 105 in lbs torque 4 Install supply hose onto reservoir Fig 12 Slide hose clamp into position on fluid reservoir and atta...

Page 2896: ...talled past bead on fluid reservoir fitting 6 Install engine appearance cover 7 Connect negative battery cable on negative battery post 8 Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure Refer to 19 STEERING PUMP STANDARD PRO CEDURE 9 Inspect system for leaks CS PUMP 19 29 RESERVOIR Continued ...

Page 2897: ......

Page 2898: ... components CAUTION When servicing power steering compo nents do not pinch off power steering hoses in an any way to stop fluid flow Damage to hoses may result STANDARD PROCEDURE POWER STEERING PUMP INITIAL OPERATION WARNING FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS CAUTION Use only MoparT Automatic Transmis sion Fluid MS 9602 in pow...

Page 2899: ...steering fluid reservoir Refer to 19 STEERING PUMP RESERVOIR REMOVAL 7 Remove clamp then remove fluid supply hose from pump Fig 1 8 Disconnect pressure hose from pump Fig 1 9 Remove generator wiring harness routing clip from pump Fig 2 10 Raise and support vehicle Refer to LUBRI CATION MAINTENANCE HOISTING STAN DARD PROCEDURE 11 Remove right front tire and wheel assembly 12 Remove drive belt splas...

Page 2900: ...possibly other components will occur 21 Carefully raise accessory drive end of engine with floor jack approximately 2 inches or just enough to access pump mounting bolts 22 Remove three pump mounting bolts through pulley Fig 5 Fig 6 23 Remove pump with pulley from engine com partment DISASSEMBLY PUMP PULLEY The only serviceable part of the power steering pump is the pulley The procedure following ...

Page 2901: ...TALLATION PUMP 1 Install power steering pump back in engine compartment using reverse order of its removal 2 Install power steering pump on its mounting bracket Fig 6 3 Install three power steering pump mounting bolts through pulley Fig 6 Fig 5 Tighten pump mounting bolts to 23 N m 200 in lbs torque 4 Lower floor jack allowing engine to return to normal position Remove jack 5 Install two bolts fas...

Page 2902: ...G FLUID LEVEL CHECKING WARNING FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCU RATE FLUID LEVEL READING The fluid level can be read on the exterior of the power steering fluid reservoir The fluid level should be within the FILL RANGE when the fluid is at normal ambient temperature approximately 21 C to 27 C 70 F to 80 F Fig 10 Before removin...

Page 2903: ...sure hose to engine cradle Fig 14 4 Place pressure hose routing clamp over return hose routing clamp at right side of engine cradle and install screw fastening both to cradle Tighten screw to 10 N m 90 in lbs torque 5 Install routing clip securing return hose to pressure hose near drive belt Fig 11 6 Lower vehicle NOTE Before installing power steering pressure hose on power steering pump replace O...

Page 2904: ...from below using reverse order of removal NOTE Before installing power steering return hose on power steering gear wipe clean connections with a lint free cloth and replace O rings Lubricate O rings using clean power steering fluid 2 Install return hose into gear port Fig 12 Thread return hose tube nut into gear and tighten to 31 N m 275 in lbs torque 3 Position power steering fluid cooler on crad...

Page 2905: ...VOIR INSTALLA TION 3 Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure Refer to 19 STEERING PUMP STANDARD PRO CEDURE 4 Inspect system for leaks RESERVOIR REMOVAL 1 Remove negative battery cable from battery and isolate cable 2 Remove cap from power steering fluid reser voir 3 Using a siphon pump remove as much power steering fluid as possible from power ste...

Page 2906: ...e hose clamp into position on fluid reservoir and attach it Be sure hose clamp in installed past bead on fluid reservoir fitting 5 Install return hose onto reservoir Fig 15 Slide hose clamp into position on fluid reservoir and attach it Be sure hose clamp in installed past bead on fluid reservoir fitting 6 Install engine appearance cover 7 Connect negative battery cable on negative battery post 8 ...

Page 2907: ......

Page 2908: ...PTU FLUID DRAIN FILL 1 Raise vehicle on hoist 2 Remove PTU drain plug Drain fluid into suit able container 3 Install drain plug and torque to 35 N m 26 ft lbs 4 Remove PTU drain plug 5 Fill PTU with 1 0L 2 1 pts of Mopart 75W 90 Gear and Axle Lubricant 6 Install fill plug and torque to 35 N m 26 ft lbs 7 Lower vehicle REMOVAL 1 Remove right halfshaft assembly Refer to 3 DIFFERENTIAL DRIVELINE HALF...

Page 2909: ...icle Fig 1 PTU Bracket Rear Mount Assembly 1 COLLAR 2 BRACKET REAR MOUNT Fig 2 Oil Pan to Transaxle Collar 1 COLLAR 2 ENGINE OIL PAN 3 BOLT 4 Fig 3 Power Transfer Unit Mounting 1 BRACKET 2 HEAT SHIELD 3 BRACKET 4 BRACE 5 POWER TRANSFER UNIT Fig 4 Power Transfer Unit Lower Bolts 1 POWER TRANSFER UNIT 2 TRANSAXLE 21 2 POWER TRANSFER UNIT CS POWER TRANSFER UNIT Continued ...

Page 2910: ...3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 9 Install right halfshaft assembly Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION 10 Install engine cradle crossmember Refer to 13 FRAME BUMPERS FRAME ENGINE CRA DLE CROSSMEMBER INSTALLATION 11 Check and adjust PTU Fluid level The PTU holds 1 0L 2 1 pts of Mopart 75W 90 Gear and Axle Lubricant SPECIFICATIONS POWER TRANSFER UNIT TORQU...

Page 2911: ...stall the PTU to the transaxle Refer to 21 TRANSMISSION TRANSAXLE POWER TRANSFER UNIT INSTALLATION 3 Check PTU fluid level Refer to 21 TRANS MISSION TRANSAXLE POWER TRANSFER UNIT STANDARD PROCEDURE END COVER BALL BEARING REMOVAL 1 Remove right halfshaft assembly Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 2 Remove outer halfshaft seal Fig 6 3 Remove snap ring Fig 7 4 Remove bearing slip f...

Page 2912: ... 1 Remove power transfer unit Refer to 21 TRANSMISSION TRANSAXLE POWER TRANSFER UNIT REMOVAL 2 Using drill and suitable bit drill hole in input shaft seal to facilitate removal with slide hammer Fig 10 Use care not to damage the shaft seal ing surface 3 Using slide hammer and suitable screw remove input shaft seal Fig 8 Bearing Removal Installation 1 BEARING Fig 9 Outer Halfshaft Seal Installation...

Page 2913: ...L 2 Using suitable screwdriver remove outer half shaft seal Fig 12 INSTALLATION 1 Install outer halfshaft seal using Tools C 4171 and 6536A Fig 13 2 Install right halfshaft assembly Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION Fig 11 Input Shaft Seal Installation 1 TOOL C 4171 2 TOOL 9321 Fig 12 Outer Halfshaft Seal Removal 1 SCREWDRIVER 2 SEAL Fig 13 Outer Halfshaft Seal Installation...

Page 2914: ... LEVEL AND CONDITION CHECK 104 STANDARD PROCEDURE FLUID AND FILTER SERVICE 105 GEAR SHIFT BEZEL REMOVAL 107 INSTALLATION 107 GEAR SHIFT CABLE REMOVAL 107 INSTALLATION 108 ADJUSTMENTS GEARSHIFT CABLE ADJUSTMENT 111 GEAR SHIFT KNOB REMOVAL 112 INSTALLATION 112 HOLDING CLUTCHES DESCRIPTION 112 OPERATION 112 INPUT CLUTCH ASSEMBLY DISASSEMBLY 113 ASSEMBLY 122 OIL PUMP DESCRIPTION 138 OPERATION 138 DISA...

Page 2915: ... the following Three multiple disc input clutches Two multiple disc holding clutches Four hydraulic accumulators Two planetary gear sets Hydraulic oil pump Valve body Solenoid Pressure switch assembly Integral differential assembly Control of the transaxle is accomplished by fully adaptive electronics Optimum shift scheduling is accomplished through continuous real time sensor feedback information...

Page 2916: ... 14 TRANSFER SHAFT GEAR 3 OIL PUMP 9 2 4 CLUTCH 15 TRANSFER SHAFT 4 INPUT SPEED SENSOR 10 L R CLUTCH 16 DIFFERENTIAL 5 UNDERDRIVE CLUTCH 11 OUTPUT SPEED SENSOR 17 CONVERTER DRIVE PLATE 6 OVERDRIVE CLUTCH 12 REAR PLANET CARRIER OUTPUT SHAFT 18 INPUT SHAFT CS 41AE TE AUTOMATIC TRANSAXLE 21 9 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2917: ...empting any repair on a 41TE four speed automatic transaxle check for diagnostic trou ble codes DTC s using the DRB scan tool Refer to the Transmission Diagnostic Procedures Manual Transaxle malfunctions may be caused by these general conditions Poor engine performance Improper adjustments Hydraulic malfunctions Mechanical malfunctions Electronic malfunctions Diagnosis of these problems should alw...

Page 2918: ...ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER Shift Lever Position INPUT CLUTCHES HOLDING CLUTCHES Underdrive Overdrive Reverse 2 4 Low Reverse P PARK X R REVERSE X X N NEUTRAL X OD OVERDRIVE First X X Second X X Direct X X Overdrive X X D DRIVE First X X Second X X Direct X X L LOW First X X Second X X Direct X X Vehicle upshift and downshift speeds are increased when in these selector posit...

Page 2919: ...ther the solenoid assembly or PCM TCM is at fault TEST THREE OVERDRIVE CLUTCH CHECK 3rd and 2nd Gear 1 Attach gauge to the overdrive clutch tap 2 Move selector lever to the OD position 3 Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph Vehicle should be in 3rd gear 4 Overdrive clutch pressure should read 74 to 95 psi 5 Move selector lever t...

Page 2920: ...orn reaction shaft seal ring or a defective solenoid assembly is indi cated 5 If the underdrive clutch pressure is greater than 5 psi in Step 4 of Test Two A a defective sole noid assembly or PCM TCM is the cause PRESSURE CHECK SPECIFICATIONS Pressure Taps Gear Selector Position Actual Gear Underdrive Clutch Overdrive Clutch Reverse Clutch Torque Converter Clutch Off 2 4 Clutch Low Reverse Clutch ...

Page 2921: ...rse clutch feed hole rear of case between 2 bolt holes Then look in the area where the low reverse piston contacts the first separator plate Watch carefully for the piston to move forward The piston should return to its origi nal position after the air pressure is removed UNDERDRIVE CLUTCH Because this clutch piston cannot be seen its oper ation is checked by function Air pressure is applied to th...

Page 2922: ...ng and not on the converter itself Pump seal or gasket leaks usually travel down the inside of the converter hous ing Fig 7 TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are Torque converter weld leaks at the outside diam eter weld Fig 8 Torque converter hub weld Fig 8 REMOVAL 1 Open hood 2 Disconnect battery cables Fig 9 3 Remove battery hold down clamp 4 Remove battery Fi...

Page 2923: ... Disconnect and remove crankshaft position sen sor Fig 11 10 Disconnect input speed sensor connector Fig 12 11 Disconnect output speed sensor connector Fig 12 12 Disconnect transaxle range sensor connector Fig 12 13 Disconnect solenoid pressure switch assembly connector Fig 12 Fig 10 Battery Tray 1 DRAIN HOLE HOSE ATTACHMENT 2 BATTERY TRAY 3 BOLTS Fig 11 Crankshaft Position Sensor 1 CRANK POSITION...

Page 2924: ...rom steering gear Fig 16 Remove roll pin using Tool 6831A Fig 15 Slide shaft extension off of gear Fig 13 Transmission Harness Retainers 1 TRANSMISSION HARNESS Fig 14 Brake Lines at Hydraulic Control Unit 1 FRONT BRAKE LINES Fig 15 Roll Pin Removal 1 TOOL 6831A 2 ROLL PIN 3 STEERING GEAR 4 INTERMEDIATE SHAFT EXTENSION Fig 16 Intermediate Shaft Extension at Gear 1 INTERMEDIATE SHAFT EXTENSION 2 ROL...

Page 2925: ...stall to vehicle allowing brackets to rest on inner fender ledges Fig 20 d Assemble cross bar 8534 3 clamp 8534 5 and support leg 8534 4 to support tube allowing sup port leg to rest on radiator upper support Fig 21 Fig 17 Engine Support Fixture 8534B 1 SUPPORT TUBE 8534 1 2 BRACKET SLEEVE 8534 2 3 CROSS BAR 8534 3 4 CLAMP 8534 5 5 LIFT HOOK ASSEMBLY 6 LIFT BRACKET BOLT 8534 15 7 LIFT BRACKET BOLT...

Page 2926: ... drivetrain 19 Raise vehicle on hoist 20 Remove both front tire wheel assemblies Fig 21 Crossbar and Support Leg 1 CROSS BAR 8534 3 2 CLAMP 8534 5 3 SUPPORT LEG 8534 4 Fig 22 Clamp 8534 5 1 CLAMP 8534 5 Fig 23 Torque Thumb Screw and Pivot Nut 1 THUMB SCREW 2 PIVOT HEX NUT 3 BRACKET SLEEVE 8534 2 Fig 24 T Handle Bracket and Hook Assy at Rear Lift Bracket 1 T HANDLE 8534 14 2 LIFTING BRACKET 8534 13...

Page 2927: ... power steering hydraulic line bracket at cradle on passenger side Fig 28 Fig 25 T Handle Bracket and Hook Assy at Front Lift Bracket 1 LIFTING BRACKET 8534 13 2 T HANDLE 8534 14 3 HOOK ASSEMBLY 8534 11 Fig 26 Engine Support Fixture 8534B 1 LIFT BRACKET HOOK ASSEMBLY Fig 27 Stabilizer Bar Link To Strut 1 NUT 2 STRUT 3 STABILIZER BAR LINK Fig 28 Hose Routing Clip at Cradle 1 BOLT 2 PRESSURE HOSE 3 ...

Page 2928: ...line Support Table Tool 8874 into position Fig 32 Fig 33 Fig 29 Cooler Mounting Screws 1 RETURN HOSE 2 COOLER BOLTS 3 POWER STEERING COOLER 4 STEERING GEAR Fig 30 Hoses at Steering Gear 1 STEERING GEAR 2 PRESSURE HOSE 3 RETURN HOSE 4 FITTINGS Fig 31 Powertrain Torque Strut 1 STRUT 2 BRACKET Fig 32 Driveline Support Table 8874 1 DRIVELINE SUPPORT TABLE 8874 1 2 BRACKET 8874 4 3 BRACKET 8874 3 CS 41...

Page 2929: ...nd power steering hydraulic lines through as they will remain attached to cradle assembly 34 Remove engine front mount bracket Fig 35 35 Disconnect starter motor electrical connectors Fig 36 Remove starter motor and shim Fig 33 Driveline Support Table in Position 1 DRIVELINE SUPPORT TABLE 8874 Fig 34 Locating Brackets at Cradle 1 SLIDING BRACKETS WITH LOCATORS Fig 35 Engine Front Mount Bracket 1 M...

Page 2930: ...r bellhousing to block bolts 41 Lower engine transaxle at overhead fixture 42 Raise vehicle 43 Install transmission jack into position Secure transaxle to jack 44 Remove two 2 transaxle to engine lower bolts 45 Lower transaxle from engine compartment DISASSEMBLY NOTE If transaxle is being overhauled clutch and or seal replacement or replaced it is neces sary to perform the PCM TCM Quick Learn Proc...

Page 2931: ...lts Fig 43 Fig 39 Power Transfer Unit Lower Bolts 1 POWER TRANSFER UNIT 2 TRANSAXLE Fig 40 Oil Pan to Transaxle Collar 1 COLLAR 2 ENGINE OIL PAN 3 BOLT 4 Fig 41 Torque Converter Dust Shield 1 DUST SHIELD 2 BOLT 2 3 RETAINER Fig 42 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET 21 24 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2932: ...ssembly from the manual valve Damage can result Fig 43 Remove Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 44 Remove Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 3 OIL FILTER Fig 45 Remove Oil Filter 1 OIL FILTER 2 O RING Fig 46 Remove Valve Body Attaching Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY CS 41AE TE AUTOMATIC TRANSAXLE 21 25 41AE TE AUTOMATIC TRANSAXL...

Page 2933: ...ssembly 10 Remove underdrive and overdrive accumula tors Fig 49 Fig 50 Fig 51 Fig 47 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 48 Remove Valve Body 1 VALVE BODY Fig 49 Remove Underdrive and Overdrive Accumulators 1 RETURN SPRING 2 UNDERDRIVE CLUTCH ACCUMULATOR 3 SEAL RING 2 4 OVERDRIVE CLUTCH ACCUMULATOR Fig 50 Accumulator Underdrive...

Page 2934: ...Overdrive 1 ACCUMULATOR PISTON OVERDRIVE 2 RETURN SPRING 3 SEAL RING 4 SEAL RING Fig 52 Remove Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 53 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 54 Remove Low Reverse Accumulator Piston 1 SEAL RINGS 2 PISTON 3 PISTON 4 PETROLATUM 5 SUITABLE TOOL CS 41AE TE AUTOMATIC TRANSAXLE 21 27 41AE TE AUTOMATIC TRANSAXLE Contin...

Page 2935: ...move oil pump to case bolts Fig 57 CAUTION Be sure input speed sensor is removed before removing oil pump 17 Install pullers Tool C 3752 as shown in Fig 58 Fig 55 Remove Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 56 Measure Input Shaft End Play Using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 57 Remove Pump Attaching Bolts 1 PUM...

Page 2936: ... bypass valve Fig 62 21 Remove 1 needle bearing Fig 63 Fig 59 Remove Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP Fig 60 Oil Pump Removed 1 OIL PUMP 2 GASKET Fig 61 Remove Oil Pump Gasket 1 PUMP GASKET Fig 62 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 63 Remove Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT CS 41AE TE AUTOMATIC TRANSAXLE 21 29 41AE TE AUTOMATIC TR...

Page 2937: ...EMBLY 2 4 THRUST WASHER Fig 65 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 66 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS Fig 67 Remove Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL 21 30 41AE T...

Page 2938: ...ve snap ring NOTE Verify that Tool 5058 is centered properly over the 2 4 clutch retainer before compressing If necessary fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly 28 Remove 2 4 clutch retainer Fig 71 Fig 68 Remove Rear Sun Gear 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 69 Number 7 Bearing 1 7 NEEDLE BEARING 2 REAR SUN G...

Page 2939: ...Clutch Return Spring 1 2 4 CLUTCH RETURN SPRING Fig 73 Remove 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 74 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 LONG TAB Fig 75 Remove Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP 21 32 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOM...

Page 2940: ...Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 77 Remove Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 78 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 79 Remove Rear Cover Bolts 1 REAR COVER BOLTS 2 REAR COVER 3 USE SEALANT ON BOLTS CS 41AE TE AUTOMATIC TRANSAXLE 21 33 41AE TE AUTOMATIC TRANSAX...

Page 2941: ...AR COVER 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 AS SHOWN Fig 81 Remove Transfer Shaft Gear Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 82 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT Fig 83 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407 6 2 TRANSFER SHAFT GEAR 3 SPECIAL TOOL L4407A 21 34 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANS...

Page 2942: ...ect Shim 1 TRANSFER SHAFT GEAR 2 BEARING CUP RETAINER 3 SHIM SELECT Fig 85 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 86 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 87 Remove Transfer Shaft Bearing Cup 1 WRENCHES 2 TOOL 6062 3 TRANSFER SHAFT BEARING CUP RETAINER CS 41AE TE...

Page 2943: ... Remove Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 89 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 90 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 91 Remove Transfer Shaft Bearing Cone 1 ARBOR PRESS RAM 2 TRANSFER SHAFT 3 TOOL P 334 4 BEARING C...

Page 2944: ...ft gear to shaft bolt and washer Fig 95 Fig 92 Remove Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 93 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 94 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 95 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER CS 41AE TE AUTOMATIC TRANSAXLE 21 37 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2945: ...e Fig 99 Fig 96 Remove Output Gear 1 OUTPUT GEAR 2 BUTTON TOOL 6055 3 WRENCHES 4 TOOL L4407A 5 BOLTS TOOL L4407 6 Fig 97 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 98 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 99 Remove Rear Carrier Assembly 1 REAR CARRIER ASSEMBLY 21 38 41AE TE AUTOMATIC TRANSAXLE CS 4...

Page 2946: ...48 WITH JAWS 5048 3 AND BUTTON 6055 2 WRENCHES 3 REAR CARRIER ASSEMBLY Fig 101 Low Reverse Spring Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 102 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 103 Remove Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 ...

Page 2947: ...and replace if necessary Fig 107 Fig 104 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 105 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 106 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 107 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE ...

Page 2948: ...tch Piston 1 LOW REVERSE CLUTCH PISTON 2 D RING SEAL 3 D RING SEAL Fig 109 Remove Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 110 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 111 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET CS 41AE TE AUTOMATIC TRANSAXL...

Page 2949: ...OL MODULES TRANS MISSION CONTROL MODULE STANDARD PROCEDURE 1 Install both output bearing cups using Tool 5050 Fig 114 2 Install low reverse piston retainer gasket Fig 115 Make sure gasket holes line up with case Fig 112 Remove Output Bearing Inner Cup 1 OUTPUT BEARING CUPS REPLACE IN PAIRS 2 HAMMER 3 BRASS DRIFT Fig 113 Remove Output Bearing Outer Cup 1 TOOL 6062 Fig 114 Install Both Output Bearin...

Page 2950: ...tainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 117 Install Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 118 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 D RING SEAL 3 D RING SEAL Fig 119 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER CS 41AE TE ...

Page 2951: ...23 Fig 120 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 121 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 122 Install Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 123 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON 21 44 41AE TE AUTOMATIC...

Page 2952: ...l in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 125 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 126 Install Rear Carrier Bearing Cone 1 ARBOR PRESS RAM 2 TOOL 6053 3 NEW BEARING CONE 4 REAR CARRIER ASSEMBLY Fig 127 Install Rear Carrier Assembly 1 REAR CARRIER ASSEM...

Page 2953: ...re output gear end play as shown in Fig 129 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining bolt and washer To remove the output gear use Tool L4407A h Remove the gauging shim and install the proper shim determined by the chart Use grease to hold the shim in place Fig 128 Install Output Gear B...

Page 2954: ...412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14mm 0 163 in 4412823AB 0 79mm 0 031 in 3 66mm 0 144 in 4412811AB 0 33mm 0 013 in 4 14mm 0 163 in 4412823AB 0 81mm 0 032 in 3 66mm 0 144 in 4412811AB 0 36mm 0 014 in 4 10mm 0 161 in 4412822AB 0 84mm 0 033 ...

Page 2955: ... 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 131 Install Output Gear 1 WRENCHES 2 TOOL 6261 WITH STUD 3 OUTPUT GEAR Fig 132 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 133 Tighten Output Gear to 271 N m 200 ft lbs 1 OUTPUT GEAR 2 TORQUE WREN...

Page 2956: ...e stirrup strap bolts to 23 N m 200 in lbs Fig 138 Fig 135 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 136 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 137 Turn Stirrup Clockwise Against Bolt Flats 1 RETAINING STRAP 2 STIRRUP Fig 138 Tighten Stirrup Strap Bolts To 23 N m 200 in lbs 1 RETAINING STRAP 2 STIRRUP CS 41AE TE AUTOMATIC TRANSAXLE 21 49 41AE T...

Page 2957: ... Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 140 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 141 Install Bearing Cup to Shaft 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 142 Install Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR 21 50 41AE TE AUT...

Page 2958: ...RS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 144 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RETAINER 5 USE REMOVED BEARING CUP TO SUPPORT RETAINER Fig 145 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 146 Install Transfer Gear Bearing Cone 1 ARBOR PRESS RAM...

Page 2959: ...505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm 0 154 in 4412817AB 0 13mm 0 005 in 4 58mm 0 180 in 4412834AB 0 84mm 0 033 in 3 86mm 0 152 in 4412816AB 0 15mm 0 006 in 4 54mm 0 178 in 4412833AB 0 86mm 0 034 in 3 82mm 0 150 in 4412815AB 0 18mm 0 007 ...

Page 2960: ... 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 10mm 0 161 in 4412822AB 1 30mm 0 051 in 3 38mm 0 133 in 4412804AB 0 61mm 0 024 in 4 10mm 0 161 in 4412822AB 1 32mm 0 052 in 3 38mm 0 133 in 4412804AB 0 64mm 0 025 in 4 06mm 0 160 in 4412821AB 1 35mm 0 05...

Page 2961: ...peat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopart ATF RTV MS GF41 to transfer gear cover Fig 150 37 Install transfer gear cover to case bolts and torque to 20 N m 175 in lbs torque Fig 151 Fig 148 Install Transfer Shaft Gear 1 WRENCHES 2 SPECIAL TOOL 6261 3 OUTPUT GEAR 4 TRANSFER SHAFT GEAR Fig 149 Tighten Transfer Gear Nut to 271 N m 200 ft lbs 1 TRANSFER SHA...

Page 2962: ...flat side up Fig 155 Fig 152 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 153 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 154 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 155 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP CS 41AE TE AUTOMAT...

Page 2963: ... plate to achieve specifications LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in 44 Install 2 4 clutch pack Fig 159 Fig 156 Tapered Snap Ring Instructions Fig 157 Snap Ring Installed 1 SCREWDRIVER 2 TAPERED SNAP RING INSTALL AS SHOWN Fig 158 Check Low Revers...

Page 2964: ... mea surement in four 4 places Take average of read ings If clearance is outside this range the clutch is assembled improperly There is no adjustment for 2 4 clutch clearance Fig 160 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 161 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4 CLUTCH RETURN SPRING Fig 162 Install 2 4 Clutch Retain...

Page 2965: ...rolatum to retain b Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole If view through input speed sensor hole is not as shown in Fig 169 the input clutch assembly is not seated prop erly c Remove oil pump o ring Fig 170 Be sure to reinstall oil pump o ring after selecting the proper 4 thrust plate Fig 164 Number 7 Bearing...

Page 2966: ...No 4 thrust plate chart to select the proper No 4 thrust plate NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1 60mm 0 063 in 3836237AB 1 73mm 0 068 in 4431666AB 1 80mm 0 071 in 3836238AB 1 96mm 0 077 in 4431667AB 2 03mm 0 080 in Fig 168 Select Thinnest No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 169 View Through Input Spee...

Page 2967: ...ed if transaxle failure has occurred Do not attempt to reuse or clean old valve 55 Install cooler bypass valve with o ring end towards rear of case Fig 174 56 Install oil pump gasket Fig 175 Fig 172 Install Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER Fig 173 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 174 Install Cooler Bypass Valve 1 COOLER...

Page 2968: ...r plug Fig 179 Fig 176 Install Oil Pump 1 OIL PUMP 2 GASKET Fig 177 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 178 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 179 Install Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG CS 41AE TE AUTOMATIC TRANSAXLE 21 61 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2969: ...g 180 Install Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 181 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 182 Accumulator Overdrive 1 ACCUMULATOR PISTON OVERDRIVE 2 RETURN SPRING 3 SEAL RING 4 SEAL RING Fig 183 Install Underdrive and Overdrive Accumulators 1 RETURN SPRING 2 UNDERDRIVE CLUTCH ACCUMULATOR 3 SEAL RING 2 4 OVERDRIVE ...

Page 2970: ... filter and new o ring Fig 186 66 Apply an 1 8 bead of Mopart ATF RTV MS GF41 to oil pan and immediately install to case Fig 187 Fig 184 Install Valve Body 1 VALVE BODY Fig 185 Install Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 186 Install Oil Filter 1 OIL FILTER 2 O RING Fig 187 Install Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 3 OIL FILTER CS 41AE...

Page 2971: ...vehicle 7 Install four 4 torque converter to driveplate bolts and torque to 88 N m 65 ft lbs 8 Install torque converter dust shield Fig 190 9 Loosely assemble engine to transmission collar Fig 191 10 AWD models a Install PTU lower bracket b Install PTU into position Install two 2 lower PTU to bracket bolts and torque to 28 N m 21 ft lbs Fig 192 c Install PTU to transaxle upper bolts and torque to ...

Page 2972: ...R 2 ENGINE OIL PAN 3 BOLT 4 Fig 192 Power Transfer Unit Lower Bolts 1 POWER TRANSFER UNIT 2 TRANSAXLE Fig 193 Power Transfer Unit Mounting 1 BRACKET 2 HEAT SHIELD 3 BRACKET 4 BRACE 5 POWER TRANSFER UNIT Fig 194 PTU Bracket Rear Mount Assembly 1 COLLAR 2 BRACKET REAR MOUNT CS 41AE TE AUTOMATIC TRANSAXLE 21 65 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2973: ... to body While lower ing vehicle align engine front and rear mount studs to their respective thru holes in cradle 16 Aligning index scribe mark placed upon disas sembly Install four 4 cradle to body bolts and torque to 162 N m 120 ft lbs 17 Verify that power steering and brake hydrau lic lines can be properly routed and installed Fig 195 Starter Motor and Shim 1 STARTER MOTOR 2 SHIM 3 BOLTS Fig 19...

Page 2974: ...0 ft lbs 21 Using Tool 6831A install steering shaft to gear coupler Fig 198 Fig 199 22 Connect power steering hoses to steering gear Fig 200 Torque fittings to 31 N m 23 ft lbs Fig 198 Intermediate Shaft Extension at Gear 1 INTERMEDIATE SHAFT EXTENSION 2 ROLL PIN 3 STEERING GEAR Fig 199 Roll Pin Installation 1 INSTALLER 6831A 2 KNURLED NUT 3 ROLL PIN 4 STEERING GEAR SHAFT 5 INTERMEDIATE SHAFT EXTE...

Page 2975: ...kets to struts Fig 204 29 Connect ABS sensors Fig 205 30 Install both front tire wheel assemblies 31 Connect front brake lines to hydraulic control unit Fig 206 Fig 201 Cooler Mounting Screws 1 RETURN HOSE 2 COOLER BOLTS 3 POWER STEERING COOLER 4 STEERING GEAR Fig 202 Hose Routing Clip at Cradle 1 BOLT 2 PRESSURE HOSE 3 RETURN HOSE 4 CLIP Fig 203 Stabilizer Bar Link To Strut 1 NUT 2 STRUT 3 STABIL...

Page 2976: ...spective retainers Fig 208 Fig 205 Sensor Mounting To Front Hub And Bearing 1 MOUNTING SCREW 2 HUB AND BEARING 3 ROUTING CLIP 4 FRONT WHEEL SPEED SENSOR Fig 206 Brake Lines at Hydraulic Control Unit 1 FRONT BRAKE LINES Fig 207 Transmission Connectors 1 SOLENOID PACK CONNECTOR 2 INPUT SPEED SENSOR CONNECTOR 3 OUTPUT SPEED SENSOR CONNECTOR 4 TRANSMISSION RANGE SENSOR CONNECTOR Fig 208 Transmission H...

Page 2977: ...fer to 5 BRAKES STANDARD PROCEDURE 47 Add power steering fluid as required 48 Check and adjust transaxle fluid level Refer to Refer to 21 TRANSMISSION TRANSAXLE AU TOMATIC 41TE FLUID STANDARD PROCE DURE 49 AWD models Check and adjust PTU fluid level Refer to procedure in this group 50 Align front end Refer to Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE Fig 209 Crankshaft Position Sen...

Page 2978: ...SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 MPH CS 41AE TE AUTOMATIC TRANSAXLE 21 71 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2979: ...Neutral Speed Over 8 MPH 21 72 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2980: ...Reverse CS 41AE TE AUTOMATIC TRANSAXLE 21 73 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2981: ...Reverse Block Shift to Reverse W Speed Over 8 mph 21 74 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2982: ...First Gear CS 41AE TE AUTOMATIC TRANSAXLE 21 75 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2983: ...Second Gear 21 76 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2984: ...Second Gear EMCC CS 41AE TE AUTOMATIC TRANSAXLE 21 77 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2985: ...Direct Gear 21 78 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2986: ...Direct Gear CC On CS 41AE TE AUTOMATIC TRANSAXLE 21 79 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2987: ...Overdrive 21 80 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2988: ...Overdrive EMCC CS 41AE TE AUTOMATIC TRANSAXLE 21 81 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2989: ...Overdrive CC On 21 82 41AE TE AUTOMATIC TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2990: ...4 in Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0 76 2 64 mm 0 030 0 104 in Reverse Clutch Select Snap Ring 0 89 1 37 mm 0 035 0 054 in Overdrive Clutch No Selection 1 07 3 25 mm 0 042 0 128 in Underdrive Clutch Select Pressure Plate 0 94 1 50 mm 0 037...

Page 2991: ...ear Stirrup Strap 23 17 Bolt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear Cover 20 175 Bolt Valve Body to Case 12 105 Fitting Oil Cooler Line 12 105 Nut Tranfer Gear 271 200 Tap Transaxle Pressure 5 45 Screw L R Clutch Retainer 5 45 Screw Solenoid Pressure Switch Assy Connec...

Page 2992: ...uller C 637 Pressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 CS 41AE TE AUTOMATIC TRANSAXLE 21 85 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 2993: ... Gear Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 21 86 41AE TE AUTOMATIC TRANSAXLE CS ACCUMULATOR Continued ...

Page 2994: ...ust Button L 4539 2 Adapter L 4559 Adapter L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 CS 41AE TE AUTOMATIC TRANSAXLE 21 87 ACCUMULATOR Continued ...

Page 2995: ...Compressor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 21 88 41AE TE AUTOMATIC TRANSAXLE CS ACCUMULATOR Continued ...

Page 2996: ...Disk 6057 Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 CS 41AE TE AUTOMATIC TRANSAXLE 21 89 ACCUMULATOR Continued ...

Page 2997: ...r 6302 Installer 6536 A Puller 7794 A End Play Socket Set 8266 Input Clutch Pressure Fixture 8391 Driveline Support Table 8874 Driveline Support Fixture 8534B 21 90 41AE TE AUTOMATIC TRANSAXLE CS ACCUMULATOR Continued ...

Page 2998: ...ollecting in the respective accumulator chamber against the piston and spring s The intended result is a smooth firm clutch application AUTOSTICK SWITCH DESCRIPTION Autostick is a driver interactive transmission fea ture that offers manual gear shifting capability to provide you with more control Autostick allows you to maximize engine braking eliminate undersirable upshifts and downshifts and imp...

Page 2999: ...emper ature fault Transmission Oil Temperature 255 F Engine Coolant Temperature 240 F AUTOMATIC OVERRIDES For safety durability and driveability some shifts are executed automatically or prevented AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS TYPE OF SHIFT APPROXIMATE SHIFT POINT 3 5L 4 3 coast downshift 13 mph 3 2 coast downshift 9 mph 2 1 coast downshift 5 mph 1 2 upshift 6600 engin...

Page 3000: ...he reverse clutch is applied the front sun gear assembly is driven FINAL DRIVE DISASSEMBLY NOTE The differential is serviced as an assembly Differential service is limited to bearing cups and cones Any other differential component failure must be remedied by differential assembly and transfer shaft replacement The transfer shaft should be removed for differen tial repair and bearing turning torque...

Page 3001: ...48 4 Collets and L 4539 2 Button to remove the differential bear ing cone on the bearing retainer side Fig 220 Fig 221 Fig 222 Fig 218 Differential Retainer Bolts 1 DIFFERENTIAL RETAINER BOLTS Fig 219 Remove Bearing Retainer 1 DIFFERENTIAL BEARING RETAINER 2 TOOL L 4435 Fig 220 Position Button and Collets Onto Differential and Bearing Ring Gear Side 1 SPECIAL TOOL L 4539 2 2 SPECIAL TOOL 5048 3 SP...

Page 3002: ...nion shaft retainers Fig 225 Fig 222 Remove Differential Bearing Cone Ring Gear Side 1 SPECIAL TOOL 5048 2 RING GEAR Fig 223 Position Bearing Cup Remover Tool in Retainer 1 SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARING RETAINER Fig 224 Remove Bearing Cup 1 SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARING RETAINER Fig 225 Ring Gear to Case Bolts 1 DIFFERENTIAL CASE 2 PINION SHAFT RETAINER 3 RING GEAR 4 RING G...

Page 3003: ...washer Fig 229 Fig 226 Ring Gear Removal 1 DIFFERENTIAL CASE 2 RING GEAR Fig 227 Separating Differential Support with Screwdrivers 1 DIFFERENTIAL SUPPORT 2 DIFFERENTIAL CASE 3 SCREWDRIVER 4 RELIEF 2 180 APART Fig 228 Differential Support Removal 1 DIFFERENTIAL SUPPORT 2 DIFFERENTIAL CASE Fig 229 Side Gear Thrust Washer Removal 1 SIDE GEAR THRUST WASHER 21 96 41AE TE AUTOMATIC TRANSAXLE CS FINAL DR...

Page 3004: ...ferential side gear Fig 233 Fig 230 Side Gear Removal 1 DIFFERENTIAL SIDE GEAR Fig 231 Pinion Shaft Removal 1 PINION SHAFT Fig 232 Pinion Gear and Washer Removal 1 PINION GEAR 2 TABBED WASHER 3 LOCATING TAB 4 NOTCH Fig 233 Side Gear Removal 1 DIFFERENTIAL SIDE GEAR CS 41AE TE AUTOMATIC TRANSAXLE 21 97 FINAL DRIVE Continued ...

Page 3005: ...ll side gear thrust washer to differential case Fig 235 2 Install side gear to differential case Fig 236 3 Install both pinion gears and washers to case while orientating washer tabs to notch in case Fig 237 Fig 234 Side Gear Thrust Washer Removal 1 THRUST WASHER Fig 235 Thrust Washer Installation 1 THRUST WASHER Fig 236 Side Gear Installation 1 DIFFERENTIAL SIDE GEAR Fig 237 Pinion Gear and Washe...

Page 3006: ... into position while aligning through holes Fig 241 Fig 238 Pinion Shaft Installation 1 PINION SHAFT Fig 239 Side Gear Installation 1 DIFFERENTIAL SIDE GEAR Fig 240 Side Gear Thrust Washer 1 SIDE GEAR THRUST WASHER Fig 241 Diff Support Installation 1 DIFFERENTIAL SUPPORT 2 DIFFERENTIAL CASE CS 41AE TE AUTOMATIC TRANSAXLE 21 99 FINAL DRIVE Continued ...

Page 3007: ...ng retainer Fig 245 13 Using Miller Special Tool L 4520 and C 4171 install differential bearing to extension housing NOTE Use MoparT Silicone Rubber Adhesive Seal ant or equivalent on retainer and extension hous ing adapter plate to seal to case Fig 242 Ring Gear Installation 1 DIFFERENTIAL CASE 2 RING GEAR Fig 243 Ring Gear to Case Bolts 1 DIFFERENTIAL CASE 2 PINION SHAFT RETAINER 3 RING GEAR 4 R...

Page 3008: ...SAXLE AUTO MATIC 41TE FINAL DRIVE ADJUSTMENTS 17 Apply a bead of Mopart Silicone Rubber Adhesive Sealant to differential cover and install to case Fig 248 18 Install and torque cover to case bolts to 19 N m 165 in lbs Fig 249 Fig 246 Differential Bearing Retainer 1 DIFFERENTIAL BEARING CUP 2 DIFFERENTIAL BEARING RETAINER Fig 247 Differential Retainer Bolts 1 DIFFERENTIAL RETAINER BOLTS Fig 248 Ins...

Page 3009: ...f the turning torque was too high when mea sured install a 0 05 mm 0 002 inch thinner shim If the turning torque is was too low install a 0 05 mm 0 002 inch thicker shim Repeat until 5 18 inch pounds turning torque is obtained Oil Baffle is not required to be installed when making shim selection f Install the proper shim under the bearing cup Make sure the oil baffle is installed properly in the b...

Page 3010: ...assembly vertically on the support stand and install Miller Special Tool L 4436 A into the bearing retainer 6 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated 7 Attach a dial indicator to the case and zero the dial Place the tip on the end of Special Tool L 4436 A 8 Place a large screwdriver to each side of the ring gear and lift Check th...

Page 3011: ...ssion fluid level shown on the indicator according to the chart 7 Check transmission for leaks Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid level too high When the transaxle has...

Page 3012: ...nly fluids of the type labeled MoparT ATF 4 should be used A filter change should be made at the time of the transmission oil change The magnet on the inside of the oil pan should also be cleaned with a clean dry cloth NOTE If the transaxle is disassembled for any rea son the fluid and filter should be changed Fig 253 Transmission Fluid Temperature Chart 1 MAX LEVEL 2 MIN LEVEL CS 41AE TE AUTOMATI...

Page 3013: ...xle make certain that dipstick is fully seated into the dipstick opening DIPSTICK TUBE FLUID SUCTION METHOD ALTERNATIVE 1 When performing the fluid suction method make sure the transaxle is at full operating temper ature 2 To perform the dipstick tube fluid suction method use a suitable fluid suction device Vacula or equivalent 3 Insert the fluid suction line into the dipstick tube NOTE Verify tha...

Page 3014: ...BLE REMOVAL 1 Raise hood 2 Disconnect battery negative cable 3 Disconnect gearshift cable from transaxle man ual valve lever Fig 258 4 Remove gearshift cable from transaxle bracket 5 From inside vehicle remove gearshift knob Fig 259 Fig 256 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 257 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 258 Gearshift Cab...

Page 3015: ...embly from vehicle INSTALLATION 1 Install gearshift cable to vehicle Secure grom met 2 Install gearshift cable to shift mechanism Fig 264 Fig 259 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 260 Gearshift Bezel Removal Installation 1 GEARSHIFT BEZEL 2 LAMP CONNECTOR Fig 261 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR 21 108 41AE TE ...

Page 3016: ...le Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 263 Gearshift Cable at Mechanism 1 GEARSHIFT CABLE 2 SHIFT MECHANISM Fig 264 Gearshift Cable at Mechanism 1 GEARSHIFT CABLE 2 SHIFT MECHANISM CS 41AE TE AUTOMATIC TRANSAXLE 21 109 GEAR SHIFT CABLE Continued ...

Page 3017: ...ole Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 266 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR Fig 267 Gearshift Bezel Removal Installation 1 GEARSHIFT BEZEL 2 LAMP CONNECTOR 21 110 41AE TE AUTOMATIC TRANSAXLE CS GEAR SHIFT CABLE Continued ...

Page 3018: ...ark P gearshift cable is adjusted properly No adjustment is required 6 If engine does not start in either park P or neutral N perform adjustment procedure ADJUSTMENT 1 Park the vehicle on level ground and set the parking brake 2 Place the gearshift lever in gated park P and remove ignition key 3 Loosen the cable adjustment screw at the transaxle manual valve lever Fig 270 4 Pull the gearshift leve...

Page 3019: ... In Use chart in Diag nosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever 2 4 CLUTCH The 2 4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2 4 clutch piston When the 2 4 clutch is applied the front sun gear assembly is held or grounded to the transaxle case Fig 270 Gearshift Cable Adjustme...

Page 3020: ...ch reaction plate to release pressure from snap ring Fig 273 3 Remove reverse clutch snap ring Fig 274 4 Pry up and remove reverse clutch reaction plate Fig 275 Fig 273 Tapping Reaction Plate 1 4 THRUST PLATE SELECT 2 TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY 4 REVERSE CLUTCH REACTION PLATE Fig 274 Reverse Clutch Snap Ring 1 REAC...

Page 3021: ... 276 Tag components for assembly identification Fig 276 Reverse Clutch Assembly 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY 21 114 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3022: ...sure plate wave snap ring Fig 277 9 Remove OD clutch pack Fig 277 Tag com ponents for assembly identification Fig 277 Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 4 5 CLUTCH STEEL 3 6 INPUT CLUTCH ASSEMBLY CS 41AE TE AUTOMATIC TRANSAXLE 21 115 INPUT CLUTCH ASSEMBLY Continued ...

Page 3023: ...ate and 2 needle bearing Fig 278 Fig 278 Overdrive Underdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY 21 116 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3024: ...cation CAUTION Compress return spring just enough to remove or install snap ring 13 Using Tool 5059A and an arbor press com press UD clutch piston spring enough to remove snap ring Fig 280 Fig 281 Fig 279 Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 4 SNAP RING FLAT 5 CLUTCH PLATE 6 INPUT CLUTCH ASSEMBLY CS 41AE TE AUTOMATIC TRANSAXLE 21 117 INPUT CLUTCH ASSE...

Page 3025: ...on Fig 284 18 Using Tool 6057 and an arbor press compress return OD Reverse piston return spring just enough to remove snap ring Fig 285 Fig 280 UD Spring Retainer Snap Ring 1 SNAP RING PLIERS 2 ARBOR PRESS RAM 3 SNAP RING 4 SPECIAL TOOL 5059A Fig 281 Underdrive Clutch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSE...

Page 3026: ... ASSEMBLY 2 PLASTIC HAMMER Fig 284 Pull Retainer from Piston 1 OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 285 Remove Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING CS 41AE TE AUTOMATIC TRANSAXLE 21 119 INPUT CLUTCH ASSEMBLY Continued ...

Page 3027: ...nput shaft from input shaft hub Fig 287 Fig 286 Remove Input Shaft Snap Ring 1 INPUT SHAFT 2 SHARP POINTED TOOL 3 SNAP RING 4 O RINGS 5 SEALS Fig 287 Remove Input Shaft 1 ARBOR PRESS RAM 2 SOCKET 3 SEAL 4 O RINGS 5 INPUT SHAFT 6 SEAL 7 INPUT SHAFT HUB ASSEMBLY 21 120 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3028: ...ton 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING CS 41AE TE AUTOMATIC TRANSAXLE 21 121 INPUT CLUTCH ASSEMBLY Continued ...

Page 3029: ... 2 ARBOR PRESS RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 290 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 291 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 292 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RIN...

Page 3030: ...g 293 Install OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 294 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO ALIGN SPLINES 2 OD REV PISTON Fig 295 Install Input Hub Tapered Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS CS 41AE TE AUTOMATIC TRANSAXLE...

Page 3031: ...ton 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING 21 124 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3032: ...tall snap ring Fig 297 Underdrive Clutch Piston 1 PISTON Fig 298 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 299 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING Fig 300 Install UD Spring Retainer and Snap Ring 1 ARBOR PRESS RAM 2 SNAP RING PLIERS 3 SNAP RING 4 OD REVER...

Page 3033: ...rive Clutch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSEMBLY 21 126 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3034: ...OTE Snap ring ends must be located within one finger of the input clutch hub Be sure that snap ring is fully seated by pushing with screwdriver into snap ring groove all the way around Fig 302 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 303 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 304 Install Last UD Clutch Disc 1...

Page 3035: ...nd record UD clutch pack measurement in four 4 places 90 apart 19 Take average of four measurements and com pare with UD clutch pack clearance specification Underdrive clutch pack clearance must be 0 94 1 50 mm 0 037 0 059 in 20 If necessary select the proper reaction plate to achieve specifications UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5 837 5 937 mm 0 230 0 234 in 4659940AB 6 147 6 248 m...

Page 3036: ...Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 4 SNAP RING FLAT 5 CLUTCH PLATE 6 INPUT CLUTCH ASSEMBLY CS 41AE TE AUTOMATIC TRANSAXLE 21 129 INPUT CLUTCH ASSEMBLY Continued ...

Page 3037: ... Fig 310 Set Up Dial Indicator to Measure UD Clutch Clearance 1 DIAL INDICATOR 2 UNDERDRIVE CLUTCH Fig 311 Press Down on UD Clutch Pack and Zero Dial Indicator 1 DIAL INDICATOR 2 UNDERDRIVE CLUTCH Fig 312 Install OD Clutch Pack 1 OVERDRIVE CLUTCH PACK 21 130 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3038: ...ssure plate flat snap ring Fig 315 Fig 316 Fig 313 Install Waved Snap Ring 1 OVERDRIVE PRESSURE PLATE WAVED SNAP RING 2 SCREWDRIVER Fig 314 OD Reverse Pressure Plate 1 OVERDRIVE REVERSE PRESSURE PLATE 2 STEP SIDE DOWN Fig 315 Install Flat Snap Ring 1 ARBOR PRESS RAM 2 TOOL 5059A 3 FLAT SNAP RING CS 41AE TE AUTOMATIC TRANSAXLE 21 131 INPUT CLUTCH ASSEMBLY Continued ...

Page 3039: ...Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 4 5 CLUTCH STEEL 3 6 INPUT CLUTCH ASSEMBLY 21 132 41AE TE AUTOMATIC TRANSAXLE CS INPUT CLUTCH ASSEMBLY Continued ...

Page 3040: ...nce is 1 07 3 25 mm 0 042 0 128 in If not within specifications the clutch is not assembled properly There is no adjustment for the OD clutch clearance 28 Install reverse clutch pack two frictions one steel Fig 318 29 Install reverse clutch reaction plate with the flat side down towards reverse clutch Fig 319 Fig 317 Measure OD Clutch Pack Clearance 1 DIAL INDICATOR 2 OD REVERSE REACTION PLATE Fig...

Page 3041: ...y 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY Fig 320 Install Reverse Clutch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH REACTION PLATE Fig 322 Pry Up Reaction Plate to Seat Against Snap Ring 1 SCREWDRIVER 2 SNAP RING 3 SCREWDRIVER 4 MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING 21 134 41AE TE AUTOMATIC TRANSAXLE CS IN...

Page 3042: ...ion The reverse clutch pack clearance is 0 89 1 37 mm 0 035 0 054 in Select the proper reverse clutch snap ring to achieve specifications REVERSE CLUTCH SNAP RING THICKNESS 4377195 1 53 1 58 mm 0 060 0 062 in 4412871 1 77 1 83 mm 0 070 0 072 in 4412872 2 02 2 07 mm 0 080 0 082 in 4412873 2 27 2 32 mm 0 090 0 091 in 36 To complete the assembly reverse clutch and overdrive clutch must be removed 37 ...

Page 3043: ...verdrive and reverse clutch as shown Rechecking these clutch clearances is not necessary Fig 326 Install Underdrive Shaft Assembly 1 UNDERDRIVE SHAFT ASSEMBLY 2 2 NEEDLE BEARING Fig 327 Install No 3 Thrust Washer 1 3 THRUST WASHER NOTE 5 TABS 2 UNDERDRIVE SHAFT ASSEMBLY Fig 328 Install No 3 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 DABS OF PETROLATUM FOR RETENTION 3 3 THRUST PLATE NOTE 3 TABS Fig ...

Page 3044: ...derdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY CS 41AE TE AUTOMATIC TRANSAXLE 21 137 INPUT CLUTCH ASSEMBLY Continued ...

Page 3045: ...t area decreases it forces pressurized fluid into the pump outlet and to the valve body DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage 1 Remove the reaction shaft support bolts 2 Remove reaction shaft support from pump housing Fig 332 3 Remove the pump gears Fig 333 and check for wear and damage on pump housing and gears Fig 331 Oil Pump As...

Page 3046: ...hould be 0 020 0 046 mm 0 0008 0 0018 in Clearance between inner gear side and the reaction shaft support should be 0 020 0 046 mm 0 0008 0 0018 in ASSEMBLY 1 Assemble oil pump as shown in Fig 335 2 Install and torque reaction shaft support to oil pump housing bolts to 28 N m 20 ft lbs torque PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located between the input clutch assembly and t...

Page 3047: ...ing Tool C 3981 B remove oil pump seal Fig 337 INSTALLATION 1 Using Tool C 4193 install oil pump seal Fig 338 2 Install transaxle to vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE INSTALLATION SHIFT INTERLOCK CABLE REMOVAL 1 Disconnect battery negative cable 2 Remove instrument panel lower silencer panel 3 Remove inflatable knee blocker Fig 339 Fig 337 Remove Oil Pump Seal 1 TOOL C 3981...

Page 3048: ...STRUMENT PANEL 3 INSTRUMENT PANEL BRACKET 4 INFLATABLE KNEE BLOCKER 5 INSTRUMENT PANEL REINFORCEMENT 6 MOUNTING SCREWS Fig 340 BTSI Cable at Ignition Cylinder 1 RETAINER 2 CONNECTOR 3 IGNITION CYLINDER 4 SOLENOID CABLE Fig 341 Ignition Key Switch Positions 1 LOCK 2 ACC 3 ON 4 START CS 41AE TE AUTOMATIC TRANSAXLE 21 141 SHIFT INTERLOCK CABLE Continued ...

Page 3049: ...ig 342 BTSI Cable at Ignition Cylinder 1 RETAINER 2 CONNECTOR 3 IGNITION CYLINDER 4 SOLENOID CABLE Fig 343 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 344 Gearshift Bezel Removal Installation 1 GEARSHIFT BEZEL 2 LAMP CONNECTOR Fig 345 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR 21 142 41AE TE AUTOMATIC TRANSAXLE CS SHIFT INTERLOCK ...

Page 3050: ...gnition key is in ACC position Fig 348 Fig 346 Front Floor Console Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 347 BTSI Cable at Mechanism 1 CAM 2 BTSI CABLE Fig 348 Ignition Key Switch Positions 1 LOCK 2 ACC 3 ON 4 START CS 41AE TE AUTOMATIC TRANSAXLE 21 143 SHIFT INTERLOCK CABLE Continued ...

Page 3051: ...hift mechanism cam and then secure cable housing to shift mecha nism Fig 350 6 Adjust interlock cable Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC 41TE SHIFT INTERLOCK CABLE ADJUSTMENTS 7 Install center console assembly Fig 351 Fig 349 BTSI Cable at Ignition Cylinder 1 RETAINER 2 CONNECTOR 3 IGNITION CYLINDER 4 SOLENOID CABLE Fig 350 BTSI Cable at Mechanism 1 CAM 2 BTSI CABLE 21 144 41AE TE AUTOM...

Page 3052: ...e Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 352 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR Fig 353 Gearshift Bezel Removal Installation 1 GEARSHIFT BEZEL 2 LAMP CONNECTOR CS 41AE TE AUTOMATIC TRANSAXLE 21 145 SHIFT INTERLOCK CABLE Continued ...

Page 3053: ...to self adjust Press locking clip Fig 359 by hand to secure adjustment 6 If the interlock cable is not being replaced the pin will not exist Loosen the locking clip Fig 359 on the interlock cable to allow cable to self adjust Press locking clip Fig 359 by hand to secure adjust ment Fig 354 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 355 Gearshift Knob Removal Installation ...

Page 3054: ...on 5 Return shifter to 9PARK9 and try to remove the key 5 Key can be removed after returning to 9LOCK9 position 6 With the key removed try to shift out of 9PARK9 6 Shifter cannot be shifted out of 9PARK9 NOTE Any failure to meet these expected responses requires system adjustment or repair 7 Install the bezel on the shifter console 8 Install shifter handle Fig 357 PRNDL Surround Bezel Removal Inst...

Page 3055: ...nsmission Shift Interlock BTSI sys tem If the expected response differs from the vehi cle s response then system repair and or adjustment is necessary ACTION EXPECTED RESPONSE 1 Turn key to the 9ACC9 position and depress brake pedal 1 Shifter CAN be shifted out of park 2 Turn key to the 9ON9 position with foot off of brake pedal 2 Shifter CANNOT be shifted out of park 3 Turn key to the 9ON9 positi...

Page 3056: ...from the rear of the BTSI solenoid 4 Insert the ignition key and turn it to the ON position 5 Back probe the wire connector s terminal num ber 2 with a test light The test light should illumi nate If not there is an open or short in the ignition feed circuit leading to the BTSI solenoid Repair the open or short 6 Next back probe the wire connector with a test light placing the test light in series...

Page 3057: ...ipped disconnect traction control switch connec tor 4 Remove front center console assembly as shown in Fig 366 Fig 363 Gearshift Knob Removal Installation 1 SET SCREW 2 GEARSHIFT KNOB Fig 364 Gearshift Bezel Removal Installation 1 GEARSHIFT BEZEL 2 LAMP CONNECTOR Fig 365 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR 21 150 41AE TE AUTOMATIC TRANSAXLE CS ...

Page 3058: ...m shift mechanism Fig 368 Fig 366 Front Floor Console Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 367 BTSI Cable at Mechanism 1 CAM 2 BTSI CABLE Fig 368 Gearshift Cable at Mechanism 1 GEARSHIFT CABLE 2 SHIFT MECHANISM CS 41AE TE AUTOMATIC TRANSAXLE 21 151 SHIFT MECHANISM Continued ...

Page 3059: ...hift cable to mechanism Fig 371 3 Install shift interlock cable to mechanism Fig 372 4 Adjust shift interlock cable Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE SHIFT INTERLOCK CABLE ADJUST MENTS Fig 369 Gearshift Mechanism Removal Installation 1 SHIFT MECHANISM 2 NUT 4 Fig 370 Gearshift Mechanism Removal Installation 1 SHIFT MECHANISM 2 NUT 4 Fig 371 Gearshift Cable at Mechanism 1 GEARSHIFT ...

Page 3060: ...73 Front Floor Console Removal Installation 1 FRONT CONSOLE ASSEMBLY 2 SCREW 12 Fig 372 BTSI Cable at Mechanism 1 CAM 2 BTSI CABLE Fig 374 PRNDL Surround Bezel Removal Installation 1 BEZEL 2 TRACTION CONTROL SWITCH CONNECTOR CS 41AE TE AUTOMATIC TRANSAXLE 21 153 SHIFT MECHANISM Continued ...

Page 3061: ...hydraulic circuit information to the PCM TCM Likewise the pressure switches can only be service by replacing the assem bly OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire The PCM TCM energizes or operates the solenoids individually by grounding the return wire of the sole noid needed When a solenoid is energized the sole noid val...

Page 3062: ...1st CL OP OP 2nd OP CL OP D OP OP CL OD OP CL CL OP OPEN CL CLOSED A Diagnostic Trouble Code DTC will set if the PCM TCM senses any switch open or closed at the wrong time in a given gear The PCM TCM also tests the 2 4 and OD pressure switches when they are normally off OD and 2 4 are tested in 1st gear OD in 2nd gear and 2 4 in 3rd gear The test simply verifies that they are opera tional by looki...

Page 3063: ...e 3 bolts Fig 380 to 13 N m 110 in lbs 3 Install input speed sensor Fig 379 and torque to 27 N m 20 ft lbs 4 Connect input speed sensor connector Fig 378 5 Install solenoid pressure switch 8 way connec tor and torque to 4 N m 35 in lbs Fig 378 6 Install air cleaner assembly 7 Connect battery negative cable 8 If solenoid pressure switch assembly was replaced perform TCM Quick Learn procedure Refer ...

Page 3064: ...compares the input speed signal with output speed signal to determine the following Transmission gear ratio Speed ratio error detection CVI calculation The PCM TCM also compares the input speed sig nal and the engine speed signal to determine the fol lowing Torque converter clutch slippage Torque converter element speed ratio REMOVAL 1 Disconnect battery negative cable 2 Disconnect input speed sen...

Page 3065: ...rs It is threaded into the transaxle case Fig 388 sealed with an o ring Fig 389 and is consid ered a primary input to the Powetrain Transmission Control Module Fig 385 Transmission Connectors 1 SOLENOID PACK CONNECTOR 2 INPUT SPEED SENSOR CONNECTOR 3 OUTPUT SPEED SENSOR CONNECTOR 4 TRANSMISSION RANGE SENSOR CONNECTOR Fig 386 Input Turbine Speed Sensor 1 INPUT SPEED SENSOR Fig 387 O ring Location 1...

Page 3066: ...signal and sends the vehicle speed message across the communication bus to the BCM The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver The vehicle speed signal pulse is roughly 8000 pulses per mile REMOVAL 1 Disconnect battery negative cable 2 Raise vehicle on hoist 3 Disconnect output speed sensor connector Fig 391 Fig 389 O Ring Location 1 OUTPUT SPEED SENS...

Page 3067: ...ch engagement also provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly IMPELLER The impeller Fig 395 is an integral part of the converter housing The impeller consists of curved blades placed rad...

Page 3068: ...er 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL CS 41AE TE AUTOMATIC TRANSAXLE 21 161 TORQUE CONVERTER Continued ...

Page 3069: ... through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 396 Turbine 1 TURBINE VANE 2 ENGINE ROTATION 3 INPUT SHAFT 4 PORTION OF TORQUE CONVERTER COVER 5 ENGINE ROTATION 6 OIL FLOW WITHIN TURBINE SECTION 21 162 41AE TE AUTOMATIC TRANSAXLE CS TORQUE CONVERTER Contin...

Page 3070: ...ngs to slip If the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this mechanical lock up OPERATION The converter impeller Fig 400 driving member which is integral to the converter housing and bolted to the engine drive pla...

Page 3071: ... happens the over run ning clutch of the stator locks and holds the stator from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine begins to match ...

Page 3072: ... condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper ...

Page 3073: ...nitors the termi nals to verify that the voltage is greater than 3 volts TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor TRS is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body The electrical connector extends through the transaxle case Fig 404 The Transmission Range Sensor TRS has four switch contacts that monitor sh...

Page 3074: ...d temperature being substituted for actual temperature Calculated temperature is a pre dicted fluid temperature which is calculated from a combination of inputs Battery ambient temperature Engine coolant temperature In gear run time since start up REMOVAL 1 Remove valve body assembly from transaxle Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC 41TE VALVE BODY REMOVAL 2 Remove transmission range se...

Page 3075: ...solenoid switch valve controls line pressure from the LR CC solenoid In one position it allows the low reverse clutch to be pressurized In the other it directs line pressure to the converter control and converter clutch valves MANUAL VALVE The manual valve is operated by the mechanical shift linkage Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solen...

Page 3076: ...low of fluid to the torque converter LOW REVERSE SWITCH VALVE The low reverse clutch is applied from different sources depending on whether low 1st gear or reverse is selected The low reverse switch valve alternates positions depending on from which direc tion fluid pressure is applied By design when the valve is shifted by fluid pressure from one channel the opposing channel is blocked The switch...

Page 3077: ...and install to vehicle allowing brackets to rest on inner fender ledges Fig 413 d Assemble cross bar 8534 3 clamp 8534 5 and support leg 8534 4 to support tube allowing sup port leg to rest on radiator upper support Fig 414 Fig 410 Engine Support Fixture 8534B 1 SUPPORT TUBE 8534 1 2 BRACKET SLEEVE 8534 2 3 CROSS BAR 8534 3 4 CLAMP 8534 5 5 LIFT HOOK ASSEMBLY 6 LIFT BRACKET BOLT 8534 15 7 LIFT BRA...

Page 3078: ...e fix ture and drivetrain 4 Disconnect gearshift cable from manual valve lever Fig 414 Crossbar and Support Leg 1 CROSS BAR 8534 3 2 CLAMP 8534 5 3 SUPPORT LEG 8534 4 Fig 415 Clamp 8534 5 1 CLAMP 8534 5 Fig 416 Torque Thumb Screw and Pivot Nut 1 THUMB SCREW 2 PIVOT HEX NUT 3 BRACKET SLEEVE 8534 2 Fig 417 T Handle Bracket and Hook Assy at Rear Lift Bracket 1 T HANDLE 8534 14 2 LIFTING BRACKET 8534 ...

Page 3079: ...nt with screw jack or equivalent Remove engine cradle crossmember to body bolts Lower cradle at front approximately 10 inches to facilitate valve body removal 11 Remove oil pan bolts Fig 420 12 Remove oil pan Fig 421 13 Remove oil filter Fig 422 Fig 418 T Handle Bracket and Hook Assy at Front Lift Bracket 1 LIFTING BRACKET 8534 13 2 T HANDLE 8534 14 3 HOOK ASSEMBLY 8534 11 Fig 419 Engine Support F...

Page 3080: ...ual valve if the valve body is mishandled or dropped DISASSEMBLY NOTE If valve body assembly is being recondi tioned the PCM TCM Quick Learn Procedure must be performed Refer to 8 ELECTRICAL ELEC TRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE Fig 422 Oil Filter 1 OIL FILTER 2 O RING Fig 423 Valve Body Attaching Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 424 Push ...

Page 3081: ... Manual Shaft Seal 1 SEAL 2 MANUAL SHAFT Fig 427 Remove Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL VALVE CONTROL PIN 3 RETAINING SCREW Fig 428 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 429 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING 21 174 41AE TE AUTOMATIC TRANSAXL...

Page 3082: ...heck balls 8 Remove oil screen Fig 433 Fig 430 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON Fig 431 Remove Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY Fig 432 Remove Transfer Plate 1 TRANSFER PLATE Fig 433 Remove Oil Screen 1 OIL SCREEN CS 41AE TE AUTOMATIC TRANSAXLE 21 175 VALVE BODY Continued ...

Page 3083: ...ies for reassem bly identification 13 Remove dual retainer plate using Tool 6301 Fig 438 14 Remove regulator valve spring retainer Fig 439 Fig 434 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 435 Remove Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 436 Remove Thermal Valve 1 THERMAL VALVE 21 176 41AE TE AUTOMATIC TRANSAXLE CS VALVE BODY Continued ...

Page 3084: ... 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 438 Remove Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 439 Remove Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER CS 41AE TE AUTOMATIC TRANSAXLE 21 177 VALVE BODY Continued ...

Page 3085: ...ES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in Fig 441 2 Install regulator valve spring retainer Fig 442 3 Install dual retainer plate using Tool 6301 Fig 443 Fig 441 Springs and Valves Location 1 VALVE BODY 5 MANUAL VALVE 2 T C REGULATOR VALVE 6 CONVERTER CLUTCH SWITCH VALVE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 R...

Page 3086: ...g 445 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 442 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 443 Install Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 444 Valve Retainer Location 1 RETAINER 2 RETAINER CS 41AE TE AUTOMATIC TRANSAXLE 21 179 VALVE BODY Continued ...

Page 3087: ...ll Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 446 Install Thermal Valve 1 THERMAL VALVE Fig 447 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY 21 180 41AE TE AUTOMATIC TRANSAXLE CS VALVE BODY Continued ...

Page 3088: ...bind Fig 450 11 Install twenty four transfer plate to valve body screws Fig 451 and torque to 5 N m 45 in lbs Fig 448 Install Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 449 Install Oil Screen 1 OIL SCREEN Fig 450 Install Transfer Plate 1 TRANSFER PLATE Fig 451 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY CS 41AE TE AUTOMATIC TRANSAXL...

Page 3089: ...and torque to 5 N m 45 in lbs Fig 452 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON Fig 453 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 454 Install Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 455 Install Transmission Range Sensor Re...

Page 3090: ...nstall transaxle oil filter Fig 459 Inspect the o ring and replace if necessary 3 Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry Install an 1 8 bead of Mopart Silicone Rubber Adhesive Seal ant to the oil pan and install Fig 460 Torque oil pan to transaxle case bolts Fig 461 to 19 N m 165 in lbs 4 Raise engine cradle crossmember into position Fig 456 Manual Shaft...

Page 3091: ...smission range sensor connector 12 Install manual valve lever to manual shaft 13 Install gearshift cable to manual valve lever 14 Install battery and tray 15 Connect battery negative cable 16 Fill transaxle with Mopart ATF 4 Transmis sion fluid Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 41TE FLUID STANDARD PROCEDURE Fig 461 Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 460 Oil Pan ...

Page 3092: ...eplaced it is neces sary to perform the PCM TCM Quick Learn Proce dure Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN TRANSMIS SION CONTROL MODULE STANDARD PROCE DURE NOTE This procedure does not include final drive differential disassembly 1 Remove input and output speed sensors 2 Remove three 3 solenoid pressure switch assembly to case bolts 3 Remove solenoid pressure switch assembl...

Page 3093: ...e valve body to case bolts Fig 5 Fig 2 Remove Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 3 Remove Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 3 OIL FILTER Fig 4 Remove Oil Filter 1 OIL FILTER 2 O RING Fig 5 Remove Valve Body Attaching Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY 21s 2 TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 3094: ...n and year When disassem bling mark accumulator spring location to ease assembly 10 Remove underdrive and overdrive accumula tors Fig 8 11 Remove low reverse accumulator snap ring Fig 9 Fig 6 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 7 Remove Valve Body 1 VALVE BODY Fig 8 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND S...

Page 3095: ... 0 13 0 64 mm 0 005 0 025 in If outside of this range a 4 thrust plate change is required Record indicator reading for reference upon reassembly Fig 10 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 11 Low Reverse Accumulator Piston 1 ACCUMULATOR PISTON Fig 12 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS Fig 13 Measure Input Shaft End Play Using End Play Set 8266 1 T...

Page 3096: ...n in Fig 15 17 Remove oil pump assembly Fig 16 Fig 17 Fig 14 Remove Pump Attaching Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 15 Install Tool C 3752 1 PULLERS TOOL C 3752 2 PUMP Fig 16 Remove Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP Fig 17 Oil Pump Removed 1 OIL PUMP 2 GASKET CS TRANSAXLE 21s 5 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 3097: ...ig 19 20 Remove 1 needle bearing Fig 20 21 Remove input clutch assembly Fig 21 Fig 18 Remove Oil Pump Gasket 1 PUMP GASKET Fig 19 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 20 Remove Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 21 Remove Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER 21s 6 TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 3098: ... NEEDLE BEARING 2 REAR SUN GEAR Fig 22 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 23 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS Fig 24 Remove Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL CS T...

Page 3099: ...ecessary fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly NOTE The 2 4 Clutch Piston has bonded seals which are not individually serviceable Seal replace ment requires replacement of the piston assembly 27 Remove 2 4 clutch retainer Fig 28 28 Remove 2 4 clutch return spring Fig 29 Fig 26 Number 7 Bearing 1 7 NEEDLE BEARING 2...

Page 3100: ... 30 Remove 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 31 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 LONG TAB Fig 32 Remove Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP Fig 33 Remove One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH CS TRANSAXLE 21s 9 41AE TE AUTOMATIC TRANSA...

Page 3101: ...ction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 35 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 36 Remove Rear Cover Bolts 1 REAR COVER BOLTS 2 REAR COVER 3 USE SEALANT ON BOLTS Fig 37 Remove Rear Cover 1 REAR COVER 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 AS SHOWN 21s 10 TRANSAXLE CS 41AE TE AUTOMATIC TRAN...

Page 3102: ...t Gear Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 39 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT Fig 40 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407 6 2 TRANSFER SHAFT GEAR 3 SPECIAL TOOL L4407A Fig 41 Remove Transfer Shaft Gear and Select Shim 1 TRANSFER SHAFT GEAR 2 BEARING CUP RETAINER 3 SHIM SELECT CS TRANSAXLE 21s 11 41AE TE AUTOMATIC ...

Page 3103: ...iner 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 43 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 44 Remove Transfer Shaft Bearing Cup 1 WRENCHES 2 TOOL 6062 3 TRANSFER SHAFT BEARING CUP RETAINER Fig 45 Remove Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RI...

Page 3104: ...al 48 Remove output shaft stirrup strap bolts Fig 49 Fig 46 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 47 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 48 Remove Transfer Shaft Bearing Cone 1 ARBOR PRESS RAM 2 TRANSFER SHAFT 3 TOOL P 334 4 BEARING CONE Fig 49 Remove Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING...

Page 3105: ...shaft Fig 53 Fig 50 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 51 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 52 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 53 Remove Output Gear 1 OUTPUT GEAR 2 BUTTON TOOL 6055 3 WRENCHES 4 TOOL L4407A 5 BOLTS TOOL L4407 6 21s 14 TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 3106: ...in Fig 57 Fig 54 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 55 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 56 Remove Rear Carrier Assembly 1 REAR CARRIER ASSEMBLY Fig 57 Remove Rear Carrier Bearing Cone 1 TOOL 5048 WITH JAWS 5048 3 AND BUTTON 6055 2 WRENCHES 3 REAR CARRIER ASSEMBLY CS TRANSAXLE 21s 15 41...

Page 3107: ...rse Spring Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 59 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 60 Remove Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 61 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON 21s 1...

Page 3108: ...t requires replacement of the piston assembly 62 Remove low reverse clutch piston Fig 65 Fig 62 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 63 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 64 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER...

Page 3109: ... Remove Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 67 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 68 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 69 Remove Output Bearing Inner Cup 1 OUTPUT BEARING CUPS REPLACE IN PAIRS 2 HAMMER 3 BRASS DRIFT 21s ...

Page 3110: ...STANDARD PROCEDURE 1 Install both output bearing cups using Tool 5050 Fig 71 2 Install low reverse piston retainer gasket Fig 72 Make sure gasket holes line up with case 3 Install low reverse piston retainer Fig 73 Fig 70 Remove Output Bearing Outer Cup 1 TOOL 6062 Fig 71 Install Both Output Bearing Cups 1 OUTPUT BEARING CUPS 2 WRENCHES 3 TOOL 5050 Fig 72 Install Piston Retainer Gasket 1 GASKET HO...

Page 3111: ...acket assembly Fig 77 Fig 76 Fig 74 Install Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 75 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 BONDED SEAL 3 BONDED SEAL Fig 76 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER Fig 77 Guide Bracket 1 GUIDE BRACKET 2...

Page 3112: ...w reverse piston and install snap ring as shown in Fig 82 Fig 78 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 79 Install Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 80 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 81 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING...

Page 3113: ...NG OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 83 Install Rear Carrier Bearing Cone 1 ARBOR PRESS RAM 2 TOOL 6053 3 NEW BEARING CONE 4 REAR CARRIER ASSEMBLY Fig 84 Install Rear Carrier Assembly 1 REAR CARRIER ASSEMBLY Fig 85 Install Output Gear Bearing Cone 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 5052 4 OUTPUT GEAR 21s 22 TRANSAXLE CS 41AE TE AUTOMATIC TRANSA...

Page 3114: ... to the trans axle case measure output gear end play as shown in Fig 86 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining bolt and washer To remove the output gear use Tool L4407A h Remove the gauging shim and install the proper shim determined by the chart Use grease to hold the shim in place F...

Page 3115: ... 147 in 4412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14mm 0 163 in 4412823AB 0 79mm 0 031 in 3 66mm 0 144 in 4412811AB 0 33mm 0 013 in 4 14mm 0 163 in 4412823AB 0 81mm 0 032 in 3 66mm 0 144 in 4412811AB 0 36mm 0 014 in 4 10mm 0 161 in 4412822AB 0 84...

Page 3116: ...install a 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 88 Install Output Gear 1 WRENCHES 2 TOOL 6261 WITH STUD 3 OUTPUT GEAR Fig 89 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 90 Tighten Output Gear to 271 N m 200 ft lbs 1 OUTPUT GEAR 2 TORQU...

Page 3117: ... 22 Torque stirrup strap bolts to 23 N m 200 in lbs Fig 95 Fig 92 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 93 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 94 Turn Stirrup Clockwise Against Bolt Flats 1 RETAINING STRAP 2 STIRRUP Fig 95 Tighten Stirrup Strap Bolts To 23 N m 200 in lbs 1 RETAINING STRAP 2 STIRRUP 21s 26 TRANSAXLE CS 41AE TE AUTOMATIC T...

Page 3118: ...Tabs On Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 97 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 98 Install Bearing Cup to Shaft 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 99 Install Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR CS TRANSAXLE ...

Page 3119: ...ING PLIERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 101 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RETAINER 5 USE REMOVED BEARING CUP TO SUPPORT RETAINER Fig 102 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 103 Install Transfer Gear Bearing Cone 1 ARBOR P...

Page 3120: ...183 in 4505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm 0 154 in 4412817AB 0 13mm 0 005 in 4 58mm 0 180 in 4412834AB 0 84mm 0 033 in 3 86mm 0 152 in 4412816AB 0 15mm 0 006 in 4 54mm 0 178 in 4412833AB 0 86mm 0 034 in 3 82mm 0 150 in 4412815AB 0 18m...

Page 3121: ... 0 136 in 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 10mm 0 161 in 4412822AB 1 30mm 0 051 in 3 38mm 0 133 in 4412804AB 0 61mm 0 024 in 4 10mm 0 161 in 4412822AB 1 32mm 0 052 in 3 38mm 0 133 in 4412804AB 0 64mm 0 025 in 4 06mm 0 160 in 4412821AB 1 ...

Page 3122: ... shim Repeat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopart ATF RTV MS GF41 to transfer gear cover Fig 107 37 Install transfer gear cover to case bolts and torque to 20 N m 175 in lbs torque Fig 108 Fig 105 Install Transfer Shaft Gear 1 WRENCHES 2 SPECIAL TOOL 6261 3 OUTPUT GEAR 4 TRANSFER SHAFT GEAR Fig 106 Tighten Transfer Gear Nut to 271 N m 200 ft lbs 1 TRAN...

Page 3123: ...ate with flat side up Fig 112 Fig 109 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 110 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 111 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 112 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP 21s 32 TR...

Page 3124: ...T PART NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in 44 Install 2 4 clutch pack Fig 116 NOTE The 2 4 Clutch Piston has bonded seals which are not individually serviceable Seal replace ment requires replacement of the piston assembly Fig 113 Tapered Snap Ring Instructions Fig 114 Snap Ring Inst...

Page 3125: ...d record mea surement in four 4 places Take average of read ings If clearance is outside this range the clutch is assembled improperly There is no adjustment for 2 4 clutch clearance Fig 117 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 118 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4 CLUTCH RETURN SPRING Fig 119 Install 2 4 Clutc...

Page 3126: ...er rear annulus assembly and 6 needle bearing Fig 123 51 Install front sun gear assembly and 4 thrust washer Fig 124 Fig 121 Number 7 Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 122 Install Rear Sun Gear and 7 Needle Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 123 Install Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PU...

Page 3127: ...own in Fig 128 f Measure the input shaft end play with the transaxle in the vertical position Input shaft end play must be within 0 005 to 0 025 inch For example if end play reading is 0 055 inch select No 4 Thrust Plate which is 0 071 to 0 074 thick This should provide an input shaft end play read ing of 0 020 inch which is within specifications g Refer to the No 4 thrust plate chart to select th...

Page 3128: ...Install input clutch assembly Fig 129 54 Install 1 caged needle bearing Fig 130 CAUTION The cooler bypass valve must be replaced if transaxle failure has occurred Do not attempt to reuse or clean old valve 55 Install cooler bypass valve with o ring end towards rear of case Fig 131 Fig 129 Install Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER Fig 130 Install Caged Needle Bearing 1...

Page 3129: ... lbs Fig 134 59 Install low reverse accumulator Fig 135 Fig 132 Install Oil Pump Gasket 1 PUMP GASKET Fig 133 Install Oil Pump 1 OIL PUMP 2 GASKET Fig 134 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 135 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS 21s 38 TRANSAXLE CS 41AE TE AUTOMATIC TRANSAXLE Continued ...

Page 3130: ... Install valve body to transaxle Fig 139 Rotate manual valve shaft fully clockwise to ease installation Make sure park rod rollers are posi tioned within park guide bracket Fig 136 Install Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 137 Install Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 138 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND SPRING 2 UN...

Page 3131: ...19 N m 165 in lbs 68 Install solenoid pressure switch assembly and gasket to case Fig 143 Fig 140 Install Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 141 Install Oil Filter 1 OIL FILTER 2 O RING Fig 142 Install Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPART ATF RTV MS GF41 3 OIL FILTER Fig 143 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMB...

Page 3132: ...d a cover or plug The overdrive and underdrive accumulators are located within the transaxle case and are retained by the valve body Fig 145 The low reverse accumulator Fig 146 is also located within the transaxle case but the assembly is retained by a cover and a snap ring Fig 144 Solenoid Pack to Transaxle Bolts 1 BOLTS 2 SOLENOID AND PRESSURE SWITCH ASSEMBLY Fig 145 Underdrive and Overdrive Acc...

Page 3133: ...ifferential pinion and side gears are supported in the case by thrust washers and a pinion shaft Dif ferential pinion and side gears make it possible for front tires to rotate at different speeds while corner ing VALVE BODY REMOVAL NOTE If valve body is replaced or reconditioned the PCM Quick Learn Procedure must be per formed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL M...

Page 3134: ...tick tube bolt Fig 149 Battery 1 BATTERY POSITIVE CABLE 2 THERMO WRAP 3 BATTERY NEGATIVE CABLE Fig 150 Battery Tray 1 DRAIN HOLE HOSE ATTACHMENT 2 BATTERY TRAY 3 BOLTS Fig 151 Engine Support Fixture 8534B 1 SUPPORT TUBE 8534 1 2 BRACKET SLEEVE 8534 2 3 CROSS BAR 8534 3 4 CLAMP 8534 5 5 LIFT HOOK ASSEMBLY 6 LIFT BRACKET BOLT 8534 15 7 LIFT BRACKET BOLT 8534 7 8 LIFT BRACKET BOLT 8534 8 9 SUPPORT LE...

Page 3135: ...r 8534 3 clamp 8534 5 and support leg 8534 4 to support tube allowing sup port leg to rest on radiator upper support Fig 155 e Tighten cross bar to support tube clamp 8534 5 Fig 156 as well as mounting bracket sleeve 8534 2 thumb screw and hex nut to secure fixture Fig 157 Fig 153 Lift Bracket 8534 7 1 BRACKET 8534 7 2 REAR CYLINDER HEAD Fig 154 Support Tube and Sleeve Brackets 1 SUPPORT TUBE 8534...

Page 3136: ...ront and rear to engine cradle crossmember nuts Fig 157 Torque Thumb Screw and Pivot Nut 1 THUMB SCREW 2 PIVOT HEX NUT 3 BRACKET SLEEVE 8534 2 Fig 158 T Handle Bracket and Hook Assy at Rear Lift Bracket 1 T HANDLE 8534 14 2 LIFTING BRACKET 8534 13 3 HOOK ASSEMBLY 8534 11 Fig 159 T Handle Bracket and Hook Assy at Front Lift Bracket 1 LIFTING BRACKET 8534 13 2 T HANDLE 8534 14 3 HOOK ASSEMBLY 8534 1...

Page 3137: ...roximately 10 inches to facilitate valve body removal 11 Remove oil pan bolts Fig 161 12 Remove oil pan Fig 162 13 Remove oil filter Fig 163 14 Remove the valve body to transaxle case bolts Fig 164 NOTE To ease removal of the valve body turn the manual valve lever fully clockwise to low or first gear Fig 161 Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 162 Oil Pan 1 OIL PAN 2 1 8 INC...

Page 3138: ...n Procedure must be performed Refer to 8 ELECTRICAL ELEC TRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Remove manual shaft seal Fig 167 2 Remove Transmission Range Sensor retaining screw Fig 168 Fig 165 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 166 Valve Body Removal Installation 1 VALVE BODY Fig 167 Manual ...

Page 3139: ...Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 170 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 171 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5 PISTON Fig 172 Remove Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY...

Page 3140: ...e clutch 5 check valve Fig 175 10 Remove separator plate Fig 176 Fig 173 Remove Transfer Plate 1 TRANSFER PLATE Fig 174 Remove Oil Screen 1 OIL SCREEN Fig 175 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 176 Remove Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY CS TRANSAXLE 21s 49 VALVE BODY Continued ...

Page 3141: ...ing assemblies for reassem bly identification Fig 178 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 177 Remove Thermal Valve 1 THERMAL VALVE 21s 50 TRANSAXLE CS VALVE BODY Continued ...

Page 3142: ... 15 Remove remaining retainers as shown in Fig 181 Fig 179 Remove Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 180 Remove Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 181 Valve Retainer Location 1 RETAINER 2 RETAINER CS TRANSAXLE 21s 51 VALVE BODY Continued ...

Page 3143: ...ANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in Fig 182 2 Install regulator valve spring retainer Fig 183 Fig 182 Springs and Valves Location 1 VALVE BODY 5 MANUAL VALVE 2 T C REGULATOR VALVE 6 CONVERTER CLUTCH SWITCH VALVE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE Fig 183 Install Regulator Valve Spring Retai...

Page 3144: ...Fig 186 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 184 Install Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 185 Valve Retainer Location 1 RETAINER 2 RETAINER Fig 186 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE CS TRANSAXLE 21s 53...

Page 3145: ...e to separator plate Fig 189 9 Install oil screen to separator plate Fig 190 Fig 187 Install Thermal Valve 1 THERMAL VALVE Fig 188 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 189 Install Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 190 Install Oil Screen 1 OIL SCREEN 21s 54 TRANSAXLE CS VALVE BODY Continued ...

Page 3146: ...as shown in Fig 193 13 Torque 2 4 Accumulator retainer to 5 N m 45 in lbs Fig 194 Fig 191 Install Transfer Plate 1 TRANSFER PLATE Fig 192 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY Fig 193 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5 PISTON Fig 194 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLAT...

Page 3147: ...C CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install accumulators and springs as previously removed Install valve body assembly to transaxle Fig 198 Install and torque valve body to transaxle case bolts Fig 199 to 12 N m 105 in lbs Fig 195 Install Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 196 Install ...

Page 3148: ... 8534B 8 Raise vehicle 9 Install and torque engine front and rear mount to cradle nuts to 54 N m 40 ft lbs 10 Lower vehicle 11 Connect transmission range sensor connector 12 Install manual valve lever to manual shaft 13 Install gearshift cable to manual valve lever 14 Install battery and tray 15 Connect battery negative cable 16 Fill transaxle with Mopart ATF 4 Transmis sion fluid Refer to 21 TRAN...

Page 3149: ......

Page 3150: ... WHEEL INSPECTION 17 CLEANING WHEEL AND WHEEL TRIM CARE 18 SPECIFICATIONS WHEEL 18 STUDS FRONT REMOVAL 18 INSTALLATION 19 STUDS REAR REMOVAL 19 INSTALLATION 19 TIRES WHEELS DIAGNOSIS AND TESTING TIRE AND WHEEL VIBRATION Tire and wheel imbalance runout and force varia tion can cause vehicles to exhibit steering wheel vibration VISUAL INSPECTION Visual inspection of the vehicle is recommended prior ...

Page 3151: ... one at a time Fig 2 and rotate the tire and wheel System radial runout should not exceed 0 76 mm 0 030 inch with no tread dips or steps Tread dips and steps can be identified by spikes of the dial indicator gauge Tread 9dips9 Rapid decrease then increase in dial indicator reading over 101 6 mm 4 0 inch of tread circumference Tread 9steps9 Rapid decrease or increase in dial indicator reading over ...

Page 3152: ...dexing match mounting the tire to the wheel as described below a Remount the tire on the rim 180 degrees from its original location Fig 6 Ensure the tire bead is properly seated b Re measure the total runout Mark the tire at the high spot and record the measurement If runout is still excessive perform the following If the new high spot is within 102 mm 4 0 inch of the first high spot on the tire r...

Page 3153: ...ce nor do they automatically mean the assembly compo nents are out of specification Do not replace compo nents based on radial force values alone Balancing runout diagnosis re indexing and subjective road testing must be performed as outlined in previous sections of this diagnosis and testing procedure Use the Radial Force equipment to identify suspect assemblies and minimize the radial forces Aft...

Page 3154: ... imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbalance the area of imbalance Place half of this weight on the inner rim flange and the other half on the outer rim flange Fig 8 For dynamic balancing the balance equipment is designed to indicate the location and amount of weight to be applied to both the inner and outer rim flanges Fig 9 The alu...

Page 3155: ... studs or wheel mounting nuts 1 Position the tire and wheel assembly on the wheel mounting studs using the hub pilot as a guide Place and hold the wheel flush up against the mount ing surface 2 Loosely install all 5 wheel mounting nuts Lightly snug the wheel nuts then progressively tighten them in the proper sequence Fig 11 Tighten wheel mounting nuts to 135 N m 100 ft lbs 3 Lower the vehicle Fig ...

Page 3156: ...remains active even if no tire pressure related message is displayed in the instru ment cluster If any road tire pressure has exceeded the low or high pressure ON threshold Refer to Table TPM THRESHOLD PRESSURES the TPM system will display a message in the instrument cluster and sound a chime This message will be displayed for the rest of the ignition cycle or until either the Low or High Tire pre...

Page 3157: ...for vehicles equipped with the Tire Pressure Monitoring system Tire sealants can clog tire pres sure sensors CAUTION Tire pressure sensor valve stem caps and cores are specially designed for the sensors Due to risk of corrosion do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core CAUTION Do not attempt to install a tire...

Page 3158: ...now read 9TRAIN LEFT FRONT SENSOR9 NOTE There is a 60 second timer for training first sensor and a 60 second timer between training remaining sensors If any of these timers expire CMTC will abort training procedure NOTE If at any time instrument cluster display reads TRAINING ABORTED move vehicle ahead at least one foot and repeat entire retraining proce dure 5 Starting at left front tire place Re...

Page 3159: ...ng a tire pressure sensor replace sealing grommet at base of valve stem 1 Wipe area clean where sensor sealing grommet contacts wheel Make sure surface of wheel is not damaged 2 Install sensor in wheel as shown Fig 14 Do not attempt to mount sensor otherwise damage may occur 3 Using a thin wall socket install special sensor nut Fig 14 Tighten nut to 4 N m 35 in lbs torque CAUTION Over torquing the...

Page 3160: ...ny tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread li...

Page 3161: ...nt manufacturers NOT be mixed They may be mixed with a temporary spare tire when necessary A maximum speed of 80 km h 50 mph is recom mended while a temporary spare is in use Radial ply tires have the same load carrying capac ity as other types of tires of the same size They also use the same recommended inflation pressures DESCRIPTION REPLACEMENT TIRES WARNING FAILURE TO EQUIP THE VEHICLE WITH TI...

Page 3162: ...mes of suspen sion and steering travel interference with vehicle components may cause tire damage DESCRIPTION SPARE TIRE TEMPORARY The temporary convenience spare tire is designed for emergency use only The original tire should be repaired and reinstalled or replaced with a new at the first opportunity The temporary convenience spare tire should be inflated to the pressure listed on its sidewall D...

Page 3163: ...VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART 22 14 TIRES WHEELS CS TIRES Continued ...

Page 3164: ...sen to provide safe operation vehicle stability and a smooth ride The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle usually on the driver s side B pil lar A quality air pressure gauge is recommended to check tire air pressure Tire pressure should be checked cold once per month Check tire pressure more frequently when the weather temp...

Page 3165: ...er exceed the maximum speed capacity of the tire For information on tire identification and speed ratings Refer to 22 TIRES WHEELS TIRES DESCRIPTION STANDARD PROCEDURE TIRE LEAK REPAIRING For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 22 The tire should be replaced if the puncture is located in the si...

Page 3166: ...the wheel s finish The wheel studs and nuts are designed for specific wheel applications and must be replaced with equiv alent parts All aluminum wheels have wheel mounting lug nuts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels DIAGNOSIS AND TESTING WHEEL INSPECTION Inspect wheels for Excessive runout Dents cracks or irregular bends Damaged wheel st...

Page 3167: ...TE Before proceeding Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION CAUTION Wheel mounting studs MUST NOT be hammered out of hub flange of hub and bearing assembly If a stud is removed by hammering it out damage to hub and bearing assembly will occur leading to premature bearing failure 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove front wheel and tire...

Page 3168: ...emature bearing failure 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove rear wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Access and remove rear brake rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTOR REMOVAL 4 Back off shoe adjustment until adjuster threads bottom Fig 28 5 Using appropriate tools remove spring at adjuster Fig 28 6 Pull upward ...

Page 3169: ... at adjuster Fig 28 NOTE When measuring brake drum diameter diam eter should be measured in center of shoe contact surface area 5 Using Brake Shoe Gauge Special Tool C 3919 or equivalent measure inside diameter of parking brake drum portion of rotor Fig 31 Fig 28 Shoe Adjuster And Spring 1 ADJUSTER STAR WHEEL 2 ADJUSTER ACCESS HOLE IN SUPPORT PLATE 3 SPRING Fig 29 C 4150A Positioned For Stud Remov...

Page 3170: ...e rotor and components removed to access it Refer to 5 BRAKES HYDRAULIC ME CHANICAL ROTOR INSTALLATION 9 Install wheel and tire assembly Refer to 22 TIRES WHEELS INSTALLATION Tighten wheel mounting lug nuts in proper sequence to 135 N m 100 ft lbs torque 10 Adjust parking brake shoes Refer to 5 BRAKES PARKING BRAKE SHOES ADJUST MENT 11 Lower vehicle 12 Road test vehicle to ensure proper operation ...

Page 3171: ......

Page 3172: ... WARNING USE A OSHA APPROVED BREATHING FILTER WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA PERSONAL INJURY CAN RESULT AVOID PROLONGED SKIN CONTACT WITH PETRO LEUM OR ALCOHOL BASED CLEANING SOL VENTS PERSONAL INJURY CAN RESULT DO NOT STAND UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS PERSONAL INJURY CAN RESULT CAUTION When holes must be drilled or punched in an inne...

Page 3173: ...s on right turns hoist the right side of the vehi cle For hoisting recommendations Refer to LUBRI CATION MAINTENANCE HOISTING STANDARD PROCEDURE WATER LEAK DETECTION 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 inte rior trim covers or panels to gain visual access to the leak area If the hose c...

Page 3174: ...igid and Flexible Any of these plastics may require the use of an adhesion promoter for repair These types of plas tic are used extensively on DaimlerChrysler Motors vehicles Always follow repair material manufactur er 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 R...

Page 3175: ...ANELS PET THERMOPLASTIC POLYESTER RYNITE TRIM PBT PPO PBT PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT PBTP POCAN VALOX WHEEL COVERS FENDERS GRILLES PBTP EEBC POLYBUTYLENE THEREPTHALATE EEBC ALLOY BEXLOY 9M9 PBTP EEBC FASCIAS ROCKER PANEL MOLDINGS PC POLYCARBONATE LEXAN MERLON CALIBRE MAKROLON PC TAIL LIGHT LENSES IP TRIM VALANCE PANELS PC ABS PC ABS ALLOY GERMAX BAY BLENDS PULSE...

Page 3176: ...DS NORYL AZDEL MARLOX DYLON PRAVEX INNER FENDER SPOILERS KICK PANELS PP EPDM PP EPDM ALLOY PP EPDM SPOILERS GRILLES PUR POLYURETHANE COLONELS PUR PU FASCIAS BUMPERS PUR PC PUR PC ALLOY TEXIN BUMPERS PVC POLYVINYL CHLORIDE APEX GEON VINYLITE BODY MOLDINGS WIRE INSULATION STEERING WHEELS RIM REACTION INJECTED MOLDED POLYURETHANE RIM BAYFLEX FRONT FASCIAS MODULAR WINDOWS RRIM REINFORCED REACTION INJE...

Page 3177: ...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 Semi rigid or flexible repair materials should be used for semi rigid or flexible backing rein forcement Fig 2 and Fig 3 Open ...

Page 3178: ...d However a backer panel open fiberglass tape or matted material must be bonded from behind Fig 7 Fig 6 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 i...

Page 3179: ...ch to cover mesh for added strength PANEL PATCH INSTALLATION 1 Make a paper or cardboard pattern the size and shape of the cutout hole in the panel 2 Trim 3 mm 0 125 in from edges of pattern so patch will have a gap between connecting surfaces 3 Using the pattern as a guide cut the patch to size 4 Cut scrap pieces of patch material into 50 mm 2 in squares to use as patch supports to sustain the pa...

Page 3180: ...ll screws 17 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 Fig 13 With compressed air blow dust from around patch 18 Apply adhesive backed nylon mesh dry wall tape over gaps around patch Fig 14 19 Mix enough adhesive to cover the entire patch area 20 Apply adhesive over the mesh around patch and smooth ep...

Page 3181: ...tip melt the material securing the components together Do not over heat the affected area dam age to the exterior of the trim panel may occur b If the heat staked material is broken or miss ing 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 apply ing the glue Once the new material is in place it may be neces...

Page 3182: ...2 N m 105 in lbs Outside Handle Cover Fastener 4 N m 37 in lbs Front and Rear Door hinge To Body 34 N m 25 ft lbs Front and Rear Door hinge To Door 34 N m 25 ft lbs Front Door Latch Striker to B Pillar Screws 28 N m 250 in lbs Front Door Outside B Pillar Applique Molding 3 N m 30 in lbs Front Door Glass Run Lower Channel Screw 6 N m 55 in lbs Front Door Power Regulator Screw 9 N m 80 in lbs Rear D...

Page 3183: ...ri cated During the winter season external door lock cylinders should be lubricated to assure proper oper ation when exposed to water and ice Prior to the application of any lubricant the parts con cerned should be wiped clean to remove dust and grit If necessary a suitable solvent can be used to clean the item to be lubricated After lubricating a component any excess oil or grease should be remov...

Page 3184: ... 4755 16 REMOVER MOLDINGS C 4829 17 PLIERS HEADLINER CLIP 6967 18 OUTER BELT MOLDING REMOVER 9093 19 Fig 16 STICK TRIM C 4755 Fig 17 REMOVER MOLDINGS C 4829 Fig 18 PLIERS HEADLINER CLIP 6967 Fig 19 OUTER BELT MOLDING REMOVER 9093 CS BODY 23 13 BODY Continued ...

Page 3185: ...PANEL DESCRIPTION 25 REMOVAL 25 INSTALLATION 27 WATERSHIELD REMOVAL 27 INSTALLATION 27 WINDOW REGULATOR REMOVAL 28 INSTALLATION 28 GLASS RUN LOWER CHANNEL REMOVAL 29 INSTALLATION 30 FRONT DOOR APPLIQUE REMOVAL 1 Roll door glass down 2 Remove outer door belt molding as necessary 3 Remove door glass run channel Refer to 23 BODY DOOR FRONT GLASS RUN CHANNEL REMOVAL 4 Remove screws attaching front edg...

Page 3186: ...k strap to door end frame Tighten nuts to 11 N m 90 in lbs torque 3 Install door speaker if equipped 4 Install front door watershield Refer to 23 BODY DOOR FRONT WATERSHIELD INSTAL LATION 5 Install front door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 6 Place check strap into position on A pillar 7 Install screws attaching check strap to A pillar Fig 2 Tighten screws to 12 N m...

Page 3187: ...oor end frame 10 Remove door from vehicle INSTALLATION 1 Steady door on lifting device and place door into position 2 Loosely install bolts attaching upper hinge to door end frame Fig 6 3 Loosely install bolts attaching lower hinge to door end frame 4 Connect door harness to body wiring harness 5 Ensure lock tab attaching wire connector halves together is connected 6 Connect positive lock slide on...

Page 3188: ...fer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 4 Tighten hinge bolts to 34 N m 25 ft lbs torque UP DOWN NOTE Up down door adjustment is done by loosen ing either the hinge to the hinge pillar fasteners or the hinge to door fasteners and moving the door to the correct position NOTE The body side half of door hinges are keyed to the body with a locator nub embossed in hinge which engages...

Page 3189: ...tall inner belt molding Refer to 23 BODY WEATHERSTRIP SEALS FDR INNER BELT WEATHERSTRIP INSTALLATION 7 Verify door glass operation and fit 8 Install watershield Refer to 23 BODY DOOR FRONT WATERSHIELD INSTALLATION 9 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION DOOR GLASS RUN CHANNEL REMOVAL 1 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Remo...

Page 3190: ...vailable from automotive paint suppliers Refer to instructions supplied with the specific product for proper usage INSTALLATION 1 Door header blackout tape cannot be reused a Remove tape residue from door b Clean back of door header blackout tape with Mopart Super Kleen or equivalent c Wipe door header blackout tape dry with lint free cloth d Apply a single coat of Mopart TPO Molding Prep to tape ...

Page 3191: ...tside handle bracket to outer door panel Tighten to 4 N m 37 in lbs torque Fig 10 OUTSIDE DOOR HANDLE BRACKET ASSEMBLY 1 OUTSIDE DOOR HANDLE BRACKET ASSEMBLY 2 DOOR HANDLE LINKAGE Fig 11 OUTSIDE HANDLE AND LATCH ASSEMBLY 1 FRONT DOOR OUTSIDE HANDLE BRACKET ASSEMBLY 2 REAR STUD SCREW 3 LATCH TO OUTSIDE HANDLE LINKAGE 4 LATCH TO OUTSIDE HANDLE KEY CYLINDER LINKAGE 5 DOOR HANDLE COVER ATTACHING SCREW...

Page 3192: ...ODY DOOR FRONT TRIM PANEL REMOVAL 10 Verify door handle assembly operation For adjustment Refer to 23 BODY DOOR FRONT LATCH ADJUSTMENTS 11 Make door handle adjustment FRAME CLOSEOUT MOLDING REMOVAL 1 Open door 2 Lower door window glass 3 Remove door trim panel Refer to 23 BODY DOOR FRONT FRONT DOOR TRIM PANEL REMOVAL 4 Remove door inner belt molding Refer to 23 BODY WEATHERSTRIP SEALS FRONT DOOR I...

Page 3193: ...inge from vehicle INSTALLATION NOTE It is not necessary to remove the door to replace the hinges if they are replace one at a time 1 Hinge pins can be serviced remove spring nut and remove pin Install new pin and install spring nut Fig 16 CAUTION When installing a new hinge make sure that the head of each hinge pin is fully seated into the door hinge Also remove the plastic shipping clip and repla...

Page 3194: ...moval 8 Remove door latch from door using care not to damage cables or rods INSTALLATION NOTE The screws attaching the door latch to the door end frame have nylon patches on the threads All screws must be replaced when the latch has been removed 1 Place door latch in position on door inner panel Fig 18 2 Position cables through access hole in water shield 3 Install latch cover to inner panel retai...

Page 3195: ...Mark outline of door striker on B pillar to aid in installation 2 Remove screws attaching door latch striker to B pillar Fig 20 3 Remove door latch striker from vehicle 4 Retrieve any shims found between latch striker and B pillar INSTALLATION 1 Position latch striker and any shims retrieved on vehicle Fig 20 2 Loosely install screws attaching latch striker to B pillar 3 Align latch striker to out...

Page 3196: ...nnel in inner belt weatherstrip at top of door by lifting while gently jiggling CAUTION Do not allow door trim panel to hang by the wire connector or wiring 8 Move top of trim panel away from door while supporting bottom trim panel Fig 25 9 Disconnect inside handle cable end from clip and pull conduit end out from bracket Fig 26 10 Disconnect lock knob conduit end from bracket Slide cable barrel e...

Page 3197: ...OTE HANDLE ATTACHING SCREW Fig 24 DOOR TRIM PANEL 1 PULL HANDLE ATTACHING SCREW 2 ENSURE MECHANICAL ELECTRICAL AND LOCK CLIP ARE THROUGH THE INNER PANEL 3 TRIM ATTACHING SCREW 4 TOP EDGE OF DOOR TRIM PANEL 5 DOOR TRIM PANEL 6 TRIM PANEL LOCATORS Fig 25 DISCONNECT DOOR TRIM PANEL 1 LATCH LOCK KNOB CABLE 2 LATCH INSIDE HANDLE CABLE 3 SPEAKER TWEETER 4 DOOR TRIM PANEL 5 POWER WINDOW SWITCH CONNECTOR ...

Page 3198: ...g 23 9 Install screw inside arm rest pull cup and close remote handle trim plug Fig 22 10 Raise door glass 11 Close door WATERSHIELD REMOVAL 1 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL NOTE Care must be taken when routing electrical wiring cables through access holes to prevent tearing of liner material 2 Route wiring bundle for power locks switch bezel window switch an...

Page 3199: ...el rear access hole 11 Extract front guide rail through front access hole Fig 30 INSTALLATION 1 Insert window regulator through the rear access hole Fig 29 2 Place window regulator in position on inner door panel 3 Place screw heads on guide rails in position through key hole slots in inner door panel 4 Tighten screws to attach front and rear guide rails to inner door panel to 9 N m 80 in lbs 5 Ti...

Page 3200: ... door glass run lower channel from inner door panel 5 Extract door glass run lower channel through front access hole Fig 29 POWER WINDOW REGULATOR ASSEMBLY 1 DOOR ASSEMBLY 2 FRONT DOOR POWER WINDOW REGULATOR 3 REGULATOR ATTACHING SCREWS Fig 30 FRONT DOOR WINDOW REGULATOR 1 WINDOW REGULATOR 2 ELECTRIC MOTOR Fig 31 DOOR GLASS RUN LOWER CHANNEL 1 DOOR ASSEMBLY 2 GLASS CHANNEL ATTACHING SCREWS 3 DOOR ...

Page 3201: ...n screws attaching door glass run lower channel to inner door panel to 6 N m 55 in lbs torque 3 Place watershield into position Refer to 23 BODY DOOR FRONT WATERSHIELD INSTAL LATION 4 Install door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION 23 30 DOOR FRONT CS GLASS RUN LOWER CHANNEL Continued ...

Page 3202: ...E REMOVAL REMOVAL B PILLAR 1 Roll door glass down 2 Remove outer door belt molding as necessary 3 Remove screws attaching front edge of applique to door frame Fig 1 4 Remove applique from vehicle REMOVAL C PILLAR 1 Roll door glass down 2 Remove door trim panel Refer to 23 BODY DOORS REAR DOOR TRIM PANEL REMOVAL 3 Remove rear door inner belt molding weather strip Refer to 23 BODY WEATHERSTRIP SEALS...

Page 3203: ...DOORS REAR TRIM PANEL INSTALLA TION CHECK STRAP REMOVAL 1 Remove screws attaching door check strap to B pillar Fig 3 2 Remove check strap from B pillar 3 Remove rear door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 4 Remove rear door watershield Refer to 23 BODY DOORS REAR WATERSHIELD REMOVAL 5 Remove rear door speaker if equipped 6 Remove nuts attaching check strap to door end frame...

Page 3204: ...rness from body wiring har ness 7 Support door on suitable lifting device 8 Remove bolts attaching lower hinge to door end frame Fig 7 9 Steady door on lifting device and remove bolts attaching upper hinge to door end frame 10 Remove door from vehicle INSTALLATION 1 Steady door on lifting device and place door into position 2 Loosely install bolts attaching upper hinge to door end frame Fig 7 3 Lo...

Page 3205: ...ay require grinding off nubs to float body side 1 Support the door with a suitable lifting device 2 Loosen the hinge to hinge pillar fasteners Refer to 23 BODY DOORS REAR HINGE REMOVAL 3 Adjust the door to the correct position Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 4 Tighten to hinge pillar fasteners to 27 N m 20 ft lbs torque Refer to 23 BODY DOORS REAR HINGE INSTALLATION NO...

Page 3206: ...6 Install the latch striker Refer to 23 BODY DOORS REAR LATCH STRIKER INSTALLA TION DOOR FIXED GLASS RUN CHANNEL REMOVAL 1 Lower door window glass 2 Remove door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 3 Remove watershield Refer to 23 BODY DOORS REAR WATERSHIELD REMOVAL 4 Remove inner belt weatherstrip Refer to 23 BODY WEATHERSTRIP SEALS REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 5...

Page 3207: ...ted in glass run 7 Install speaker 8 Install watershield Refer to 23 BODY DOORS REAR WATERSHIELD INSTALLATION 9 Install door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 10 Close door DOOR HEADER BLACK OUT TAPE REMOVAL 1 Warm the door header blackout tape and door metal to approximately 27 C 80 F using a suitable heat lamp or heat gun Fig 13 2 Pull stick on blackout tape from pai...

Page 3208: ...IP 1 INSERT FLAT TOOL TO HOLD GLASS IN THE UP POSITION 2 DOOR GLASS 3 ATTACHING REGULATOR SCREW S TO INNER DOOR PANEL 4 REAR DOOR REGULATOR LIFT PLATE BRACKET 5 REGULATOR LIFT PLATE Fig 11 REGULATOR LIFT PLATE BRACKET 1 REGULATOR LIFT PLATE BRACKET 2 REAR DOOR WINDOW REGULATOR Fig 12 GLASS AND LIFT PLATE 1 GLASS AND LIFT PLATE 2 DOOR ASSEMBLY CS DOORS REAR 23 37 DOOR HEADER BLACK OUT TAPE Continue...

Page 3209: ...ing door lock linkage to out side door handle 6 Engage clip attaching door latch linkage to outer door handle 7 Check outside handle for proper operation 8 Install the watershield as necessary to gain access to the outside door handle Refer to 23 BODY DOORS REAR WATERSHIELD INSTAL LATION 9 Install door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 10 Verify door handle assembly op...

Page 3210: ... 16 3 Remove B pillar trim to access inside out bolts to pillar 4 Support door on suitable lifting device 5 Remove bolts attaching hinge to B pillar 6 Remove bolts attaching rear door to door hinge 7 Remove door hinge from vehicle INSTALLATION NOTE It is not necessary to remove the door to replace the hinges if they are replace one at a time 1 Hinge pins can be serviced remove spring nut and remov...

Page 3211: ...LUSH SPECIFICATIONS and Refer to 23 BODY DOORS REAR DOOR INSTALLA TION LATCH REMOVAL 1 Remove door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 2 Remove watershield Refer to 23 BODY DOORS REAR WATERSHIELD REMOVAL 3 Raise door glass 4 Disconnect clips holding lock and latch rods to outside door handle Fig 19 5 Disengage wire connector from power door lock motor if equipped 6 Remove scr...

Page 3212: ...hole and remove the mylar tape covering it Fig 20 2 Insert a 5 32 inch hex wrench through hole and into adjustment screw Loosen screw 3 Operate outside handle several times to release any restriction because of misalignment 4 Tighten adjustment screw to 3 N m 30 in lbs 5 Test handle for proper operation LATCH STRIKER REMOVAL 1 Mark outline of door striker on C pillar to aid in installation 2 Remov...

Page 3213: ...m behind inside remote handle Fig 23 5 Disengage push in fasteners attaching trim to door panel around perimeter of trim panel Fig 24 6 Tilt trim panel outward to clear locator pins on backside of trim panel 7 Disconnect trim panel from retainer channel in inner belt weatherstrip at top of door by lifting while gently jiggling 8 Move trim panel away from door and disengage actuator cables attachin...

Page 3214: ...el outward to align locator pins into position on backside of trim panel Fig 24 6 Applying hand pressure engage push pin fas teners attaching trim panel to door around perimeter of trim panel Fig 22 REMOVE REAR DOOR TRIM PANEL 1 DOOR WIRE HARNESS 2 REMOTE LOCK REAR ACTUATOR CABLE 3 REAR DOOR 4 RELEASE HANDLE ACTUATOR CABLE 5 PLASTIC NUT 6 DOOR INSIDE REMOTE HANDLE BRACKET 7 REMOTE HANDLE BRACKET T...

Page 3215: ...M REST PULL HANDLE ATTACHING SCREW 2 ENSURE MECHANICAL ELECTRICAL AND LOCK CLIP ARE THROUGH INNER PANEL 3 DOOR TRIM ATTACHING SCREW 4 TOP EDGE OF DOOR TRIM PANEL 5 DOOR TRIM PANEL 6 TRIM PANEL LOCATORS 7 ARMREST PULL CUP PLUG Fig 25 DISCONNECT REAR DOOR TRIM PANEL 1 RELEASE HANDLE ACTUATOR 2 REMOTE LOCK ACTUATOR CABLE 3 DOOR TRIM PANEL 4 POWER WINDOW SWITCH CONNECTOR 5 DOOR WIRE HARNESS 23 44 DOOR...

Page 3216: ... of liner material 2 Pull courtesy light wiring through watershield 3 Route wiring switch bezel window switch and remote handle cables through watershield 4 Insure that enough adhesive remains to securely retain the watershield to inner door panel Replace as necessary 5 Install door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION WINDOW REGULATOR REMOVAL 1 Remove door trim panel Ref...

Page 3217: ...or into inner door panel Fig 31 2 Tighten screws attaching regulator and window motor to inner door panel Fig 30 Tighten screws to 9 N m 80 in lbs torque 3 Connect wire connector to power window motor Fig 29 4 Connect door glass to lift plate bracket Fig 28 Refer to 23 BODY DOORS REAR DOOR GLASS INSTALLATION Fig 28 REGULATOR LIFT PLATE AND SPRING CLIP 1 INSERT FLAT TOOL TO HOLD GLASS IN THE UP POS...

Page 3218: ...panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION Fig 30 POWER WINDOW REGULATOR AND MOTOR 1 DOOR ASSEMBLY 2 DOOR BELT INNER REINFORCEMENT 3 REGULATOR TO INNER DOOR PANEL ATTACHING SCREWS 4 DOOR INNER PANEL 5 DOOR WIRING HARNESS 6 WINDOW LIFT MOTOR CONNECTOR 7 WINDOW REGULATOR Fig 31 REAR DOOR WINDOW REGULATOR 1 REAR DOOR WINDOW REGULATOR 2 WINDOW MOTOR CS DOORS REAR 23 47 WINDOW REGULATOR ...

Page 3219: ...MOVAL 60 INSTALLATION 60 SIDE RAIL REMOVAL 60 INSTALLATION 60 RADIATOR CROSSMEMBER REMOVAL 60 INSTALLATION 61 RADIATOR CLOSURE PANEL REMOVAL 61 INSTALLATION 61 REAR WHEELHOUSE SPLASH SHIELD REMOVAL 62 INSTALLATION 62 SIDE VIEW MIRROR REMOVAL 62 INSTALLATION 62 SIDE VIEW MIRROR GLASS REMOVAL 64 INSTALLATION 64 SPOILER REMOVAL 64 INSTALLATION 64 SILENCER REMOVAL 65 INSTALLATION 65 ACCESSORY DRIVE SP...

Page 3220: ...ess sill outside applique 3 Remove splash shield screws attaching the for ward end of the front sill outside applique Fig 3 4 Remove plastic rivets Starting at the front of the sill outside applique working to the rear 5 Remove splash shield screw attaching rearward edge of rear sill outside applique 6 Using a trim stick C 4755 or equivalent disen gage the locking tabs and two sided tape attaching...

Page 3221: ...dhesion Do not apply excessive force or damage to body panels may result NOTE Replace damage push pins 9 Install sill door inner seals Set push pins into position and press to the lock position 10 Install rear wheel and straighten front wheel 11 Lower vehicle APPLIQUE ROOF SIDE APERTURE DESCRIPTION REMOVAL 1 Remove side rail right left Fig 4 If equipped with luggage rack remove luggage rack assemb...

Page 3222: ...K SIDE RAIL 4 SIDE APERTURE APPLIQUE 5 PLASTIC RETAINER S 6 BODY SIDE 7 RIVET NUT S Fig 5 SIDE APERTURE TO ROOF APPLIQUE 1 TWO WAY LOCATING PINS 2 SIDE APERTURE APPLIQUE FRONT 3 FOUR WAY LOCATING PIN Fig 6 D PILLAR APERTURE APPLIQUE 1 D PILLAR APERTURE APPLIQUE 2 LOCATING PINS CS EXTERIOR 23 51 APPLIQUE ROOF SIDE APERTURE Continued ...

Page 3223: ...ue from painted surface of vehicle 4 Use a 3M Scotch Brite Molding Adhesive and Stripe Removal Disc or equivalent to clean adhesive residue from painted surfaces These products are available from automotive paint suppliers Refer to instructions supplied with the specific product for proper usage INSTALLATION 1 If molding is to be reused a Remove tape residue from molding b Clean back of molding wi...

Page 3224: ...3 REAR DOOR OUTSIDE MOLDING 4 FRONT DOOR OUTSIDE MOLDING 5 FRONT DOOR PANEL Fig 9 FRONT AND REAR DOOR OUTSIDE APPLIQUE 1 REAR DOOR PANEL 2 ADHESIVE TAPE BACKING 3 REAR DOOR OUTSIDE APPLIQUE 4 FRONT DOOR OUTSIDE APPLIQUE 5 FRONT DOOR PANEL CS EXTERIOR 23 53 BODY SIDE CLADDING Continued ...

Page 3225: ...TALLATION 1 Open hood as necessary 2 Place cowl plenum grille into position 3 Press down on cowl plenum grille to lock the locking tabs 4 Install the two 2 push pin fasteners securing cowl plenum grille to top cowl plenum panel Fig 10 5 Remove wiper arms Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER ARMS INSTAL LATION EXHAUSTER REMOVAL 1 Using a trim stick C 4755 or equivalent pry exhauster grille f...

Page 3226: ... as a plastic or wood trim stick gently pry up at corners and remove 4 Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover INSTALLATION 1 Clean panel surface with isopropy alcohol 2 Align name plates to reference points 3 Install and press securely to full adhesive con tact 4 Clean away any reference points FRONT FENDER REMOVAL 1 Remove head...

Page 3227: ...to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 9 Tighten all fender screws to 9 N m 80 in lbs torque 10 Place fender and fascia into position tighten fasteners Fig 17 11 Install splash shield Refer to 23 BODY EX TERIOR LF WHEELHOUSE SPLASH SHIELD INSTALLATION 12 Install headlamp assembly Fig 13 FENDER TO SILL ATTACHING SCREWS 1 FRONT FENDER 2 ATTACHING SCREWS Fig 14 FENDER TO A PILLAR ATTA...

Page 3228: ...el filter door GRILLE REMOVAL 1 Remove radiator closure Refer to 23 BODY EXTERIOR CLOSURE PANEL REMOVAL 2 Remove front fascia Fig 19 Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA REMOVAL 3 Remove grille from front fascia Fig 20 Using care and depress push pin s fasteners to release the grille 4 Remove bright chrome molding from Grille Fig 21 5 Depress molding locking tabs and pull outward to rele...

Page 3229: ...stands as necessary 2 Remove front wheel 3 Remove five screws and four push pin fasteners attaching splash shield to inner wheelhouse Fig 22 4 Remove splash shield from vehicle INSTALLATION 1 Place splash shield into position 2 Install five screws and four push pin fasteners attaching splash shield to inner wheelhouse Fig 22 3 Install front wheel 4 Remove safety stands and lower vehicle as necessa...

Page 3230: ...s the lower edge of the cross bar lever to lock it into position on each side 3 Place luggage rack assembly into position on vehicle Fig 23 NOTE To ensure proper sealing of the threads new screws should be used 4 Install new attaching screws into the RIV nuts and tighten screws to 6 N m 55 in lbs torque Fig 24 NOTE To minimize wind noise both crossbars should be repositioned to the rear of the veh...

Page 3231: ...to the lock posi tion 6 Verify that the crossbars are secure to side rails If loose remove and reinstall crossbars SIDE RAIL REMOVAL 1 Remove side rail attaching screws 2 Remove side rail from vehicle INSTALLATION 1 Place side rail into position NOTE To ensure proper sealing of the threads new screws should be used 2 Install new attaching screws into the RIV nuts and tighten screws to 6 N m 55 in ...

Page 3232: ... panel Refer to 23 BODY EXTERIOR CLOSURE PANEL INSTAL LATION RADIATOR CLOSURE PANEL REMOVAL 1 Open hood 2 Remove four push pins attaching radiator clo sure panel to radiator crossmember 3 Remove one bolt on each side attaching to radi ator crossmember Fig 27 4 Remove six screws attaching radiator closure to the upper grille 5 Remove radiator closure panel from vehicle INSTALLATION 1 Place radiator...

Page 3233: ... Refer to 13 FRAME BUMPERS BUMPERS REAR FASCIA APERTURE BRACKET INSTALLA TION 4 Install screw attaching rear wheelhouse splash shield to cladding 5 Install rear wheel 6 Remove safety stands and lower vehicle SIDE VIEW MIRROR REMOVAL 1 Using a trim stick C 4755 or equivalent move the front door frame molding Refer to 23 BODY DOOR FRONT MOLDING REMOVAL 2 Remove door trim panel and water dam Refer to...

Page 3234: ...REAR WHEELHOUSE SPLASH SHIELD 1 REAR FASCIA ATTACHING BRACKET 2 PUSH PIN S 3 CLADDING TO REAR SPLASH SHIELD SCREW S 4 REAR WHEELHOUSE SPLASH SHIELD Fig 29 MIRROR WIRE CONNECTOR 1 OUTSIDE MIRROR WIRE CONNECTORS 2 DOOR ASSEMBLY Fig 30 FOAM STUFFIER 1 MIRROR WIRE CONNECTOR 2 FOAM STUFFIER 3 DOOR MIRROR FLAG REINFORCEMENT 4 DOOR ASSEMBLY CS EXTERIOR 23 63 SIDE VIEW MIRROR Continued ...

Page 3235: ...er the center portion of the mirror to engage the mirror glass holder s attaching fingers to the correspond ing 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 SPOILER REMOVAL 1 Open liftgate before disconnecting battery 2 Open hood disconne...

Page 3236: ...cer from vehicle INSTALLATION 1 Insert silencer between cowl side and fender forward of wiring connector and brackets Fig 33 2 Push silencer rearward until setting to trim edges of body door hinges upper and lower and cen ter fender mounting bracket 3 Install front wheelhouse splash shield Refer to 23 BODY EXTERIOR LF WHEELHOUSE SPLASH SHIELD INSTALLATION 4 Install front wheel 5 Remove safety stan...

Page 3237: ...Turn adjustment bumper out Fig 1 3 Remove bumper from radiator crossmember bracket INSTALLATION 1 Place adjustment bumper into position Fig 1 2 Turn adjustment bumper in about half way 3 Easily close hood to check height of hood Check hood gap and flush Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICA TIONS 4 Adjust as necessary 5 Close hood EMBLEM REMOVAL 1 Open hood 2 Remove 3 attaching n...

Page 3238: ...wl finger tight if necessary Fig 4 and or Fig 5 4 Place hood in position on vehicle With assis tance from a helper at the opposite side of the vehicle to support the hood install pivot bolts and bushings to hold upper and lower hinge halves together and tighten bolt to 28 N m 250 in lbs torque Fig 3 5 Install cowl plenum grille Refer to 23 BODY EXTERIOR COWL GRILLE INSTALLATION 6 When installing h...

Page 3239: ...Fig 4 2 Install top bolts attaching hood to hinge finger tight 3 When installing hood align all marks and secure bolts The hood should be aligned Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 4 Verify hood operation and alignment 5 Tighten bolt to 14 N m 120 in lbs 6 Close hood HOOD SEAL REMOVAL 1 Open hood 2 Remove hood seal Fig 6 3 Using a trim stick C 4755 or equivalent disen gag...

Page 3240: ...RIOR SIDE COWL TRIM REMOVAL 5 Remove screws attaching hood release handle to cowl panel and release cable from clip Fig 8 6 Disconnect rubber grommet from dash panel behind instrument panel 7 Pull release cable through hole in dash panel 8 Remove cable and handle from vehicle INSTALLATION 1 Assemble cable and handle onto vehicle 2 Push release cable through hole in dash panel Fig 8 3 Connect rubbe...

Page 3241: ...bolts to 14 N m 10 ft lbs torque OVERSLAM BUMPER REMOVAL 1 Open hood 2 Pull and turn to remove Fig 6 3 Remove overslam bumper from vehicle INSTALLATION 1 Place overslam bumper into position Fig 6 2 Press and turn to seat bumper Fig 8 REMOTE HOOD RELEASE HANDLE AND CABLE 1 COWL SIDE PANEL 2 DASH PANEL 3 HOOD PROP ROD CLIP 4 UPPER RADIATOR CROSSMEMBER 5 HOOD LATCH 6 REMOTE HOOD LATCH HANDLE AND CABL...

Page 3242: ...lbs torque 3 Remove support holding hood 4 Close hood SILENCER PAD REMOVAL 1 Open hood 2 Remove fasteners attaching hood silencer to hood Fig 11 3 Remove hood silencer from vehicle INSTALLATION 1 Place hood silencer in position on hood Fig 11 2 Install fastener attaching hood silencer to hood 3 Close hood Fig 10 HOOD PROP ROD 1 ATTACHING SCREW 2 HOOD PROP ROD 3 PROP ROD STORAGE CLIP Fig 11 HOOD IN...

Page 3243: ...s to the clus ter bezel Fig 1 8 Using a trim stick or equivalent gently pry out on cluster bezel around edges and remove from instrument panel Fig 2 9 Disconnect the electrical connector to the instrument panel switch pod EVIC NAV Clock and Hazard Switch INSTALLATION 1 Connect the electrical connector to the instru ment panel switch pod EVIC NAV Clock and Haz ard Switch 2 Position the cluster beze...

Page 3244: ...bly into instrument panel 4 Close glove box door GLOVE BOX LATCH REMOVAL 1 Open glove box 2 Push in on sides of glove box bin and lower door 3 Pivot glove box downward and disengage hinge hooks from instrument panel 4 Remove glove box 5 Remove the assembly screws 6 Disassemble the glove box 7 Separate the latch from the glove box assembly INSTALLATION 1 Install the latch onto the glove box assembl...

Page 3245: ... instrument panel Refer to 23 BODY INTERIOR FLOOR CONSOLE BASE ASSEMBLY REMOVAL 5 Remove nuts attaching the floor braces to instrument panel Fig 3 Refer to 23 BODY IN STRUMENT PANEL INSTRUMENT PANEL FLOOR BRACKET REMOVAL 6 Remove steering column opening cover Refer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER REMOVAL 7 Remove inflatable knee blocker four mounting screws Fig 4 8 Remove...

Page 3246: ...ANDLE STEERING COLUMN OUTER COVER 1 INSTRUMENT PANEL TRIM OUTLET PLATE 2 ATTACHING SCREWS 3 INSTRUMENT PANEL PARKING BRAKE RELEASE HANDLE BRACKET 4 INSTRUMENT PANEL 5 INFLATABLE KNEE BLOCKER AIRBAG 6 INSTRUMENT PANEL STEERING COLUMN OPENING COVER 7 INSTRUMENT PANEL CLUSTER POCKET 8 BRAKE RELEASE HANDLE 9 BRAKE HANDLE BRACKET ASSEMBLY CS INSTRUMENT PANEL 23 75 INSTRUMENT PANEL ASSEMBLY Continued ...

Page 3247: ...move both cowl side trim panel Refer to 23 BODY INTERIOR COWL SIDE TRIM PANEL REMOVAL 24 Disconnect the antenna lead connector Refer to 8 ELECTRICAL AUDIO ANTENNA BODY CABLE REMOVAL 25 Remove the glove box a Push in on sides of glove box bin and lower door b Pivot glove box downward and disengage hinge hooks from instrument panel c Remove glove box from vehicle 26 Disconnect the airbag module elec...

Page 3248: ...NSTALLATION 1 With the help of an assistant place the instru ment panel into vehicle inserting instrument panel locator pins into body As you install the instrument Fig 8 INSTRUMENT PANEL TOP COVER 1 INSTRUMENT PANEL TOP COVER 2 AREA TO CHECK FIT AND FINISH 3 LOCKING TABS 4 LOCATING PIN S Fig 7 TOP COVER AND INSTRUMENT PANEL 1 INSTRUMENT TOP COVER 2 MOUNTING SCREWS 3 INSTRUMENT PANEL 4 ATTACHING N...

Page 3249: ...ndshield opening Fig 10 4 Connect right side electrical connector at A pil lar 5 Connect 3 electrical connectors behind cowl panel 6 Connect HVAC electrical connectors 7 Install top cover Fig 8 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP PAD INSTALLATION 8 Install the glove box Fig 10 INSTRUMENT PANEL SLIP BRACKETS 1 MOUNTING SCREWS 2 INSTRUMENT PANEL 3 INSTRUMENT PANEL SLIP BRACKETS Fi...

Page 3250: ...l two screws attaching instrument panel trim plate Fig 5 27 Install inflatable knee blocker four mounting screws 28 Install steering column opening cover Refer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER INSTALLATION 29 Install nuts attaching the floor braces to instrument panel Fig 3 Refer to 23 BODY IN STRUMENT PANEL INSTRUMENT PANEL FLOOR BRACKET INSTALLATION 30 Install two screws...

Page 3251: ...anel Refer to 23 BODY INTERIOR CENTER CONSOLE CLOSE OUT PANEL INSTALLATION 6 Install front floor console Refer to 23 BODY INTERIOR FRONT FLOOR CONSOLE INSTALLA TION Fig 12 FLOOR BRACKET AND BRACES TO INSTRUMENT PANEL 1 FLOOR BRACE TO INSTRUMENT PANEL 2 INSTRUMENT PANEL CENTER BRACE 3 ATTACHING NUTS 4 FLOOR BRACKET Fig 13 TOP COVER INSTRUMENT PANEL 1 INSTRUMENT TOP COVER 2 MOUNTING SCREWS 3 INSTRUM...

Page 3252: ...er may be hard to unsnap from the instrument panel Use care not to mar scuff or damage the instrument panel pad 3 Pull top cover upward to disengage mounting clips attaching front of top cover 4 Remove top cover from vehicle by pulling rear ward to disengage forward clips INSTALLATION 1 Place instrument panel top cover into position Fig 14 2 Push top cover forward to engage mounting clips front of...

Page 3253: ...age locator tab on right Starting from upper right corner engage clip at lower right squeeze clip to lower right panel Engage left clip 3 Install two screws attaching the steering col umn opening cover to instrument panel Fig 15 PARK BRAKE RELEASE HANDLE STEERING COLUMN OUTER COVER 1 INSTRUMENT PANEL TRIM OUTLET PLATE 2 ATTACHING SCREWS 3 INSTRUMENT PANEL PARKING BRAKE RELEASE HANDLE BRACKET 4 INS...

Page 3254: ...ADLINER REMOVAL 93 INSTALLATION 94 LIFTGATE SILL SCUFF PLATE REMOVAL 95 INSTALLATION 96 QUARTER TRIM PANEL REMOVAL 96 INSTALLATION 96 REAR DOOR SCUFF PLATE REMOVAL 97 INSTALLATION 97 REAR FLOOR CONSOLE REMOVAL 97 INSTALLATION 98 REAR FLOOR STOWAGE BIN REMOVAL 98 INSTALLATION 98 REAR HEADER TRIM REMOVAL 99 INSTALLATION 99 REAR VIEW MIRROR REMOVAL 99 INSTALLATION 99 SHIFTER BEZEL REMOVAL 100 INSTALL...

Page 3255: ...ll access cover 5 Install upper B pillar trim cover 6 Place seat belt anchor in position on floor so webbing is pointed rearward and slightly outboard 7 Install bolt attaching lower seat belt anchor to floor Tighten all seat belt bolts to 39 N m 29 ft lbs torque 8 Verify that seat belt anchor does not interfere with seat track travel B PILLAR UPPER TRIM REMOVAL 1 Remove bolt attaching lower seat b...

Page 3256: ...DY INTERIOR REAR FLOOR CONSOLE REMOVAL 8 Floor console base assembly Refer to 23 BODY INTERIOR FLOOR CONSOLE REMOVAL 9 Remove front and rear sill scuff plates Refer to 23 BODY INTERIOR FRONT DOOR SILL SCUFF PLATE REMOVAL and Refer to 23 BODY INTERIOR REAR DOOR SCUFF PLATE REMOVAL 10 Remove cowl side trim panels Refer to 23 BODY INTERIOR COWL SIDE TRIM REMOVAL 11 Remove the floor stowage bin Refer ...

Page 3257: ...ERIOR COWL SIDE TRIM INSTALLA TION 11 Install front and rear sill scuff plates Refer to 23 BODY INTERIOR FRONT DOOR SILL SCUFF PLATE INSTALLATION and Refer to 23 BODY INTERIOR REAR DOOR SILL SCUFF PLATE INSTALLATION 12 Install floor console base assembly Refer to 23 BODY INTERIOR FLOOR CONSOLE BASE ASSEMBLY INSTALLATION 13 Install rear floor console Refer to 23 BODY INTERIOR REAR FLOOR CONSOLE INS...

Page 3258: ...all attaching screw COWL SIDE TRIM PANEL REMOVAL 1 Remove instrument panel side cover 2 Remove front door sill scuff plate Refer to 23 BODY INTERIOR FRONT DOOR SCUFF PLATE REMOVAL 3 Remove A pillar cowl side trim panel from vehicle by disengaging hidden clips Fig 8 INSTALLATION 1 Place a pillar cowl side trim panel in position Fig 8 2 Press on A pillar trim to engage locking clips 3 Install front ...

Page 3259: ...e sill scuff plate Refer to 23 BODY INTERIOR LIFTGATE SILL SCUFF PLATE REMOVAL 3 Remove bolt attaching second row seat belt lower anchor to quarter trim panel Refer to 8 ELECTRICAL RESTRAINTS SEAT BELT RETRACTOR REMOVAL 4 Remove upper trim panel from liftgate if equipped with power liftgate Fig 10 Refer to 23 BODY LIFTGATE TRIM PANEL REMOVAL 5 Disconnect power liftgate link from ball head bracket ...

Page 3260: ...TE 1 POWER LIFTGATE LINK 2 BODY SIDE 3 LOCATOR PINS 4 SEAT BELT 5 ATTACHING SCREWS 6 D PILLAR UPPER TRIM MOLDING 7 4 WAY LOCATOR PIN Fig 11 D PILLAR UPPER TRIM MOLDING 1 LOCATING PINS 2 4 WAY LOCATING PIN 3 ATTACHING SCREWS 4 D PILLAR UPPER TRIM PANEL 5 SEAT BELT SLOT IN MOLDING 6 D PILLAR Fig 12 D PILLAR REINFORCEMENT MOLDING 1 D PILLAR 2 ATTACHING SCREW 3 D PILLAR REINFORCEMENT 4 PLASTIC NUT CS ...

Page 3261: ... into position Fig 14 2 Raise front floor console and connect wiring harness 3 Install front floor console sidewall attaching screws three per side 4 Install two attaching screws to bottom of bin 5 Install two attaching screws to bottom of cup holder 6 Install two screws attaching front floor console to the lower instrument panel 7 Install transmission range indicator surround bezel Fig 13 8 Insta...

Page 3262: ...mbly into position Fig 15 2 Install wire harnesses through console base into position 3 Connect wire connectors 4 Install two screws attaching L brackets to instrument panel 5 Install nine attaching nuts and washers to weld studs 6 Install shift mechanism Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC 41TE SHIFT MECHANISM INSTALLATION 7 Install front and rear floor consoles Refer to 23 BODY INTERIO...

Page 3263: ... engage push pins to door sill Fig 15 FRONT FLOOR CONSOLE BASE ASSEMBLY BLOWER HOUSING 1 INSTRUMENT PANEL 2 ATTACHING L BRACKETS 3 ATTACHING NUTS 4 ATTACHING SCREWS 5 FRONT FLOOR CONSOLE BASE ASSEMBLY AND BLOWER HOUSING 6 WIRE CONNECTOR 7 TELEMATICS COMMUNICATION UNIT 8 FLOOR PAN 9 FLOOR PAN STUDS 10 FLOOR CONSOLE STUFFER Fig 16 FRONT DOOR SILL SCUFF PLATE 1 FRONT DOOR SILL 2 FRONT DOOR SILL SCUFF...

Page 3264: ... trim as necessary Refer to 23 BODY INTERIOR C PILLAR TRIM REMOVAL 11 Remove overhead console if equipped Refer to 8 ELECTRICAL OVERHEAD CONSOLE REMOVAL 12 Remove overhead DVD video screen if equipped Refer to 8 ELECTRICAL AUDIO VIDEO SCREEN REMOVAL 13 Disconnect wire harness connectors at the left A pillar Fig 17 14 Disconnect wire harness connector and wire clips at the right A pillar Fig 18 15 ...

Page 3265: ...ad DVD video screen if equipped Refer to 8 ELECTRICAL AUDIO CD CHANGER INSTALLATION 9 Install overhead console if equipped Refer to 8 ELECTRICAL OVERHEAD CONSOLE INSTAL LATION 10 Install C pillar upper trim Refer to 23 BODY INTERIOR C PILLAR TRIM REMOVAL 11 Install D pillar trim Refer to 23 BODY IN TERIOR D PILLAR TRIM INSTALLATION 12 Install liftgate header trim Refer to 23 BODY INTERIOR REAR HEA...

Page 3266: ...anity mirrors 19 Connect negative battery cable LIFTGATE SILL SCUFF PLATE REMOVAL 1 Using trim stick C 4755 disengage push pins attaching liftgate sill scuff plate to liftgate sill 2 Remove liftgate sill scuff plate from vehicle Fig 22 Fig 21 VIDEO SCREEN MOUNTING BRACKET 1 ROOF PANEL 2 ROOF BOW NUMBER ONE 3 VIDEO SCREEN BRACKET 4 U NUT S 5 ROOF BOW NUMBER TWO 6 PUSH PIN FASTENER 7 FOAM TAPE 8 HEA...

Page 3267: ... side panel 13 Pull quarter trim panel free enough to reach behind trim panel to disconnect power outlet connec tor and speaker connector 14 Remove quarter trim panel from vehicle INSTALLATION 1 Place quarter trim panel into position Fig 23 2 Reach behind trim panel connect power outlet connector and speaker connector 3 Set locators pins into position and pressing on panel to engage the locking ta...

Page 3268: ...ng tabs and remove floor console scuff plate Fig 25 2 Remove four attaching screw under scuff plate 3 Open cup holder and remove two attaching screws on the bottom 4 Remove sidewalls attaching screws three per side 5 Remove rear floor console from vehicle Fig 23 QUARTER TRIM PANEL 1 BODY SIDE 2 LOCATION PINS 3 QUARTER TRIM PANEL 4 POWER OUTLET WIRE CONNECTOR 5 POWER OUTLET MOUNT AND CAP 6 POWER OU...

Page 3269: ... 1 Open liftgate 2 Open rear floor storage bin lid Fig 26 3 Remove attaching screws 4 in the bottom of bin 4 Remove floor storage bin from vehicle INSTALLATION 1 Place floor storage bin into position Fig 26 2 Install attaching screws 4 in the bottom of bin 3 Close rear floor storage bin lid 4 Close liftgate Fig 25 REAR FLOOR CONSOLE 1 FRONT FLOOR CONSOLE 2 ATTACHING SCREWS 3 FLOOR CONSOLE SCUFF PL...

Page 3270: ... mirror base set screw 3 Slide the mirror base upward and off the sup port button INSTALLATION 1 Position the mirror base at the support button and slide it downward onto the button Fig 28 2 Tighten the set screw 1 N m 15 in lbs torque 3 If equipped connect mirror wire connector s Fig 26 FLOOR STORAGE BIN 1 PUSH PIN 2 WHEELHOUSE SILENCER 3 BODY SIDE PANEL 4 FLOOR STORAGE BIN 5 ATTACHING SCREWS 6 F...

Page 3271: ...connect wire connector 4 Remove shift bezel from vehicle INSTALLATION 1 Place shift bezel into position Fig 29 2 Connect wire connector 3 Press on shifter bezel to engage locking tabs 4 Install shifter knob Refer to 21 TRANSMIS SION TRANSAXLE AUTOMATIC 41TE GEAR SHIFT KNOB INSTALLATION Fig 28 REAR VIEW MIRROR 1 MIRROR WIRE CONNECTOR s 2 MIRROR SUPPORT BUTTON 3 REAR VIEW MIRROR 4 SET SCREW 5 WINDSH...

Page 3272: ...abel availability and ensure the label is installed 1 Place sun visor in position on vehicle 2 Connect illuminated vanity mirror wire connec tor into body harness if equipped 3 Place sun visor in position on roof 4 Install attaching screws sun visor to roof header Fig 30 5 Engage sun visor into center support Fig 29 TRANSMISSION RANGE INDICATOR SURROUND BEZEL 1 INSTRUMENT PANEL 2 AUTOSTICK SHIFTER...

Page 3273: ...VAL LOWER 109 INSTALLATION INSTALLATION UPPER 110 INSTALLATION LOWER 110 OUTSIDE HANDLE REMOVAL 1 Remove liftgate trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 2 Disconnect the exterior handle electrical con nectors Fig 1 3 Remove the two screws attaching liftgate han dle to liftgate inner panel 4 Remove the exterior handle license plate light assembly INSTALLATION...

Page 3274: ...necessary paint replacement hinge before installation 2 Place hinge in position on vehicle 3 Align hinge to marks on liftgate 4 Install bolts attaching hinge to liftgate Fig 2 Tighten bolts to 33 N m 24 ft lbs torque 5 Align hinge to marks on roof header 6 Install nuts attaching liftgate hinge to roof header Tighten bolts to 23 N m 17 ft lbs torque 7 Verify liftgate alignment Refer to 23 BODY BODY...

Page 3275: ...Remove liftgate sill scuff plate Refer to 23 BODY INTERIOR LIFTGATE SCUFF PLATE REMOVAL 3 Mark outline of striker on sill to aid installa tion 4 Remove screws attaching striker to sill Fig 4 5 Remove striker from vehicle INSTALLATION 1 Place striker in position on vehicle Fig 4 2 Align striker to outline mark on sill 3 Install screws attaching striker to sill Tighten screws to 28 N m 21 ft lbs tor...

Page 3276: ...heck liftgate for proper alignment Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 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 opening up holes in the body If an inward or outward adjustment is needed use a body sealer on the hinge to body mating surface In out 1 Remove...

Page 3277: ...6 Using a trim stick C 4755 or equivalent gently pry out wiring grommet to liftgate light bar 7 Remove liftgate light bar from vehicle INSTALLATION 1 Place the liftgate light bar wiring harness through liftgate 2 Line up the four liftgate light bar retaining screws and install Fig 5 and Fig 6 3 Connect the liftgate light bar electrical connec tor inside the liftgate 4 Install the liftgate inner tr...

Page 3278: ... seated into the ball socket 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 Fig 6 LIFTGATE LIGHT BAR REMOVE INSTALL 1 LIFTGATE LIGHT BAR HARNESS GROMMET 2 LIFTGATE LIGHT BAR 3 LIFTGATE 4 OUTER LIFTGATE PANEL 5 LIFTGATE LIGHT BAR ELECTRICAL CONNECTOR 6 LIFTGATE WIRING HARNESS 7 INNER LIFTGATE PANEL Fig...

Page 3279: ... BODY SIDE 1 Place liftgate stop bumper into position 2 Install screws attaching liftgate stop bumper to body Fig 9 3 Close liftgate INSTALLATION LIFTGATE SIDE 1 Place liftgate stop bumper into position 2 Install rivets attaching liftgate stop bumper to liftgate Fig 9 3 Close liftgate Fig 8 SUPPORT CYLINDER RETAINING CLIP 1 RETAINING CLIP 2 BALL SOCKET 3 BALL STUD Fig 9 LIFTGATE BUMPERS 1 BLIND RI...

Page 3280: ...en liftgate 2 Remove liftgate upper trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 3 Remove two 2 upper screws attaching trim panel Fig 11 4 Remove six 6 lower screws attaching trim panel 5 Remove liftgate trim panel from vehicle 6 Gently pull trim panel away from liftgate to disengage pins and grommets 7 Remove trim panel from vehicle Fig 10 LIFTGATE UPPER TRIM PAN...

Page 3281: ...l into position Fig 11 3 Push trim panel against liftgate to engage pins and grommets 4 Install six 6 lower screws attaching trim panel 5 Install two 2 upper screws attaching trim panel 6 Install liftgate upper trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 7 Close liftgate Fig 11 LIFTGATE LOWER TRIM PANEL 1 LIFTGATE LOWER TRIM PANEL 2 LOCATING PIN 3 LOWER TRIM...

Page 3282: ... COLOR CODE EXTERIOR COLOR DAIMLERCHRYSLER COLOR CODE BRIGHT SILVER METALLIC CLEAR COAT WS2 LIGHT ALMOND PEARL METALLIC CLEAR COAT ZKJ BRILLIANT BLACK CRYSTAL PEARL COAT AXR MIDNIGHT BLUE PEARL COAT BB8 BUTANE BLUE METALLIC CLEAR COAT ABE ONYX GREEN PEARL COAT YJR DEEP MOLTEN RED PEARL COAT BR8 SATIN JADE PEARL COAT AP4 INFERNO RED TINTED PEARL COAT WEL STONE WHITE CLEAR COAT SW1 INTERIOR COLORS I...

Page 3283: ...DARD PROCEDURE PAINT TOUCH UP 1 Scrape loose paint and corrosion from inside scratch or chip 2 Clean affected area with MOPARt Tar Road Oil Remover or equivalent 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 sur face finish The applicator brush should be wet enough to puddle fill the scratch or chip without run ning Do not st...

Page 3284: ... CRAS ASSEMBLY REMOVAL 125 INSTALLATION 126 SECOND ROW SEAT CUSHION FOAM COVER REMOVAL 129 INSTALLATION 130 SECOND ROW SEAT RISER REMOVAL 130 INSTALLATION 130 SECOND ROW SEAT SIDE SHIELD REMOVAL 131 INSTALLATION 131 THIRD ROW SEAT REMOVAL 131 INSTALLATION 131 THIRD ROW SEAT BACK CUSHION FOAM COVER REMOVAL 132 INSTALLATION 133 THIRD ROW SEAT CUSHION COVER REMOVAL 133 INSTALLATION 134 THIRD ROW FOLD...

Page 3285: ... from vehicle INSTALLATION 1 Place front seat into vehicle 2 Connect wire connectors under seat Fig 2 3 Place front seat studs into mounting holes 4 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 5 Install four nuts attaching seat to floor pan Fig 1 6 Tighten nuts to 88 N m 65 ft lbs torque 7 For right side front seat install muffler to body heat shield Ref...

Page 3286: ...ion seat back to seat assembly 2 Install seat back by slide it downward onto the seat assembly Fig 4 3 Install seat back recliner attaching bolts Tighten to 48 N m 35 ft lbs torque Fig 3 4 Position seat back cover and engage J straps 5 Install front seat inner panel Refer to 23 BODY SEATS FRONT SEAT INNER PANEL INSTALLATION 6 Install front seat shields Refer to 23 BODY SEATS FRONT SHIELDS INSTALLA...

Page 3287: ...e front seat outer trim ring panel if equipped Fig 5 5 Disengage seat back cover J straps attaching to front seat back frame Fig 6 6 Remove front seat back foam cover from front seat back frame 7 Separate front seat back cushion foam from seat cover Fig 7 Fig 4 FRONT SEAT BACK SIDE COVER 1 FRONT SEAT BACK 2 J STRAPS 3 HEATING ELEMENT WIRE HARNESS Fig 5 FRONT SEAT OUTER TRIM RING PANEL Fig 6 SEAT B...

Page 3288: ...L 1 Disconnect and isolate the battery negative cable 2 Remove front seat Refer to 23 BODY SEATS FRONT SEAT REMOVAL 3 Remove front seat back from seat assembly Refer to 23 BODY SEATS FRONT SEAT BACK REMOVAL 4 Disengage seat back cover J straps and push pins attaching to seat cushion foam cover to seat pan Fig 8 5 Remove seat cushion foam cover from seat pan 6 Separate seat cushion foam from seat c...

Page 3289: ...n gage the front seat inner panel starting with the cen ter edges and pulling outward to disengage locking clips Fig 10 2 Remove front seat inner panel from seat Fig 11 and Fig 12 INSTALLATION 1 Place front seat inner panel into position Fig 11 and Fig 12 2 Push on front seat inner panel to engage lock ing clips Fig 10 Fig 10 SEAT INNER PANEL 1 FRONT SEAT 2 FRONT SEAT INNER PANEL 3 TRIM STICK Fig ...

Page 3290: ...IELD 1 Remove upper adjuster inboard attaching screw Fig 14 2 Pull rear edge away from upper adjuster inboard rear shield to release locking tab 3 Remove upper adjuster inboard rear shield attaching screw and remove shield FRONT SHIELD 1 Remove front shield attaching screws Fig 15 2 Pull forward on front shield edge by the upper adjuster outboard shield to disengage locking tabs Fig 14 and Fig 16 ...

Page 3291: ... UPPER ADJUSTER OUTBOARD AND REAR SHIELD 1 Place upper adjuster outboard rear shield into position and install attaching screw Fig 14 and Fig 17 2 Place upper adjuster outboard shield into posi tion 3 Press on rear edge upper adjuster outboard shield locking tabs to upper adjuster outboard rear shield to engage locking tabs 4 Install front attaching screw LOWER RISER SHIELD 1 Place lower riser shi...

Page 3292: ... shaft 2 Install screw to hold recliner handle to recliner spline shaft Fig 20 SEAT ARMREST REMOVAL 1 Using a small flat blade pry cap from side of armrest Fig 21 2 Remove bolt attaching armrest to seat back 3 Remove armrest from seat back INSTALLATION 1 Place armrest in position on seat back 2 Install bolt attaching armrest to seat back Tighten bolt to 29 N m 21 ft lbs torque 3 Install side cap i...

Page 3293: ...at to floor pan Fig 23 3 Tilt seat forward and disconnect heated seat wire connector Fig 24 4 Remove seat from vehicle INSTALLATION 1 Place second row seat into position in vehicle 2 Connect heated seat wire connector Fig 24 3 Install two nuts attaching seat to floor pan Tighten nuts to 54 N m 40 ft lbs torque Fig 23 4 Install headrest Refer to 23 BODY SEATS HEADREST INSTALLATION 5 Connect battery...

Page 3294: ...12 Remove trim ring Fig 27 13 Disengage inner J straps from trim ring Fig 28 14 Disconnect wiring harness for heated seats at inner shield and feed back harness through hole in shield 15 Remove seat back foam cover and heating har ness assembly together keep trim attached to foam pad NOTE Use care not to damage wire harness during removal procedure 16 Disconnect heat seat wire harness from three a...

Page 3295: ...for heated seats at inner shield 7 Install trim ring Fig 27 8 Engage inner J straps to trim ring Fig 28 9 Install screws attaching trim ring to seat back frame Fig 26 and Fig 27 10 Engage outer J straps at seat back Fig 25 Fig 27 TRIM RING FOR SEAT BACK FRAME 1 SECOND ROW SEAT BACK FRAME 2 TRIM RING FOR SEAT BACK FRAME 3 SEAT BACK CUSHION Fig 28 SEAT BACK J STRAPS 1 J STRAPS 2 SECOND ROW SEAT BACK...

Page 3296: ...headrest and sleeves Refer to 23 BODY SEATS HEADREST REMOVAL 3 Remove second row seat Refer to 23 BODY SEATS SECOND ROW SEAT REMOVAL 4 Disconnect heat element wire harness 5 Remove armrest Refer to 23 BODY SEATS SEAT ARMREST REMOVAL 6 Remove seat inner panel Refer to 23 BODY SEATS SECOND ROW SEAT INNER PANEL REMOVAL 7 Remove outboard side handle lift on back side of handle where it engages retaine...

Page 3297: ...l two bolts and five nuts attaching lower recliner bracket to riser and leg assembly Fig 45 Tighten nuts to 48 N m 35 ft lbs torque and tighten bolts to 29 N m 35 ft lbs torque 3 Place seat cushion pan into position 4 Install four seat cushion pan nuts Fig 44 5 Place seat cushion foam and cover in position on seat pan Fig 43 Fig 32 SECOND ROW SEAT BACK COVER 1 SECOND ROW SEAT BACK COVER 2 J STRAPS...

Page 3298: ...ng install procedure Fig 35 SEAT BACK J STRAPS 1 J STRAPS 2 SECOND ROW SEAT BACK COVER Fig 36 HEATED SEAT WIRE HARNESS 1 Wire harness fasteners Fig 37 SECOND ROW SEAT BACK CUSHION AND COVER REMOVAL 1 SECOND ROW SEAT RECLINER TORQUE ROD 2 SEAT BACK FOAM COVER Fig 38 SECOND ROW SEAT BACK FRAME AND COVER 1 SEAT BACK FOAM PAD 2 SEAT BACK COVER 3 SEAT BACK FRAME CS SEATS 23 127 SECOND ROW SEAT BACK FRA...

Page 3299: ... and Fig 38 Fig 39 SECOND ROW SEAT BACK FRAME OUTBOARD SIDE BOLTS 1 SEAT BACK FRAME 2 ATTACHING BOLTS Fig 40 SECOND ROW SEAT BACK FRAME INBOARD SIDE BOLTS 1 SEAT BACK FRAME 2 INBOARD ATTACHING BOLTS Fig 41 SEAT CUSHION REAR J STRAP 1 HEATED SEAT WIRE HARNESS 2 J STRAP Fig 42 SEAT CUSHION REAR PUSH PINS 1 PUSH PIN FASTENERS 23 128 SEATS CS SECOND ROW SEAT BACK FRAME RECLINER TORQUE ROD CRAS ASSEMBL...

Page 3300: ...21 Connect heat element wire harness 22 Install second row seat Refer to 23 BODY SEATS SECOND ROW SEAT INSTALLATION 23 Install headrest and sleeves Refer to 23 BODY SEATS HEADREST INSTALLATION 24 Connect battery negative cable SECOND ROW SEAT CUSHION FOAM COVER REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove headrest Refer to 23 BODY SEATS HEADREST REMOVAL 3 Remove second row ...

Page 3301: ...ide 11 Connect heat element wire harness 12 Install first row seat Refer to 23 BODY SEATS SECOND ROW SEAT INSTALLATION 13 Install headrest Refer to 23 BODY SEATS HEADREST INSTALLATION 14 Connect battery negative cable SECOND ROW SEAT RISER REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove headrest Refer to 23 BODY SEATS HEADREST REMOVAL 3 Remove second row seat Refer to 23 BODY ...

Page 3302: ... seat front covers Fig 50 5 Remove the third row seat front two attaching bolts 6 Remove seat from vehicle INSTALLATION 1 Place seat into position in vehicle 2 Install third row seat front two attaching bolts and tighten to 88 N m 65 ft lbs torque Fig 50 3 Install third row seat front covers 4 Install third row seat two rear attaching bolts and tighten to 88 N m 65 ft lbs torque Fig 49 5 Install r...

Page 3303: ...ld flat cable from handle and remove handle 7 Remove load floor panel by using a trim tool and lifting up the edges to disengage the push pins Fig 53 8 Remove two bolts on outboard side of seat attaching drive link assembly Fig 54 9 Remove drive link assembly 10 Remove outboard seat back shield Fig 50 THIRD ROW SEATS 1 ATTACHING WASHERS AND BOLTS 2 THIRD ROW BUCKET SEATS 3 FLOOR PAN 4 CARPETING 5 ...

Page 3304: ... shield 7 Install one screw attaching inboard shield 8 Install two bolts attaching drive link assembly Tighten to 10 N m 7 ft lbs torque 9 Align load floor panel and push pins fasteners with holes in seat frame and press into position 10 Connect fold flat cable to handle and press handle into position on load floor panel 11 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION ...

Page 3305: ...on foam pad Fig 62 2 Install seat cushion cover and foam pad seat pan Fig 61 3 Engage J straps Fig 60 and Fig 59 4 Install cushion assembly onto the seat risers 5 Install cushion assembly by sliding the front links onto the riser pins and twisting the cushion assembly to engage the rear sliders onto the riser tracks Fig 58 6 Install two bolts attaching front cushion pan to link and risers Fig 57 T...

Page 3306: ...e fold flat cable from handle Fig 63 3 Release tab attaching fold flat handle to load floor panel Fig 64 4 Disconnect fold flat cable from handle and remove handle from load floor panel Fig 60 THIRD ROW SEAT CUSHION 1 SEAT CUSHION PAN 2 SEAT CUSHION FOAM AND COVER 3 J STRAPS Fig 61 THIRD ROW SEAT CUSHION FOAM PAD 1 SEAT CUSHION COVER 2 SEAT CUSHION FOAM PAD Fig 62 THIRD ROW SEAT CUSHION COVER 1 SE...

Page 3307: ...re not to stretch or kink cable 5 Release tab attaching fold flat handle to load floor panel Fig 67 6 Disconnect fold flat cable from handle and remove handle from load floor panel 7 Remove load floor panel Refer to 23 BODY SEATS SEAT BACK REMOVAL 8 Remove two bolts on outboard side of seat attaching drive link assembly Fig 68 9 Remove drive link assembly 10 Remove outboard seat back shield Fig 69...

Page 3308: ... flat cable to handle Fig 66 7 Place handle into position on load floor panel Fig 72 8 Depress tab and press handle into seated posi tion 9 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION 10 Install rear floor stowage bin Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY INSTALLATION 11 Close liftgate Fig 68 DRIVE LINK AND SHIELD 1 DRIVE LINK AND SHIELD Fig 69 OUTBOARD SE...

Page 3309: ...ther bezel if equipped Fig 76 INSTALLATION 1 Align load floor panel and push pins fasteners with holes in seat frame and press into position 2 Connect fold flat cable to handle 3 Place handle into position on load floor panel 4 Press handle into full seated position 5 Place third row child seat tether bezel into position 6 Press bezel into the full seated position Fig 72 INSTALL FOLD FLAT HANDLE 1...

Page 3310: ...bolts on outboard side of seat attaching drive link assembly Fig 78 5 Remove drive link assembly 6 Remove two bolts attaching front cushion pan to link and riser assemblies Fig 79 7 Remove cushion assembly by sliding the front links off of the riser pins and twisting the cushion assembly to disengage the rear sliders from the riser tracks Fig 80 8 Disengage J straps Fig 76 REMOVE CHILD SEAT TETHER...

Page 3311: ... onto the riser tracks Fig 80 7 Install two bolts attaching front cushion pan to link and risers Fig 79 Tighten to 29 N m 21 ft lbs torque 8 Install drive link assembly 9 Install two bolts attaching drive link assembly Fig 78 Tighten to 10 N m 7 ft lbs torque 10 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION 11 Install rear floor stowage bin Refer to 23 BODY INTERIOR REA...

Page 3312: ...two nuts attaching outboard fold flat mechanism to outboard riser Fig 88 9 Remove outboard fold flat mechanism INSTALLATION 1 Place outboard fold flat mechanism into posi tion 2 Install two bolts attaching outboard fold flat mechanism to outer seat back Install two nuts attaching outboard fold flat mechanism to outboard riser Fig 88 3 Connect fold flat cable to outboard fold flat mechanism Fig 87 ...

Page 3313: ...ing a trim tool and lifting up the edges to disengage the push pins Fig 91 8 Remove inboard pivot drive shield screw Fig 92 9 Disengage J straps to uncover inboard pivot Fig 93 10 Remove two bolts attaching inboard free pivot to inner seat back Remove two nuts attaching inboard free pivot to inboard riser 11 Remove inboard free pivot assembly INSTALLATION 1 Place inboard free pivot assembly into p...

Page 3314: ... 94 5 Remove drive link and shield assembly INSTALLATION 1 Place drive link shield assembly into position 2 Install two bolts on outboard side of seat attaching drive link assembly Fig 94 Tighten to 10 N m 7 ft lbs torque 3 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION 4 Install rear floor stowage bin Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY INSTALLATION 5 Clos...

Page 3315: ...side of seat attaching drive link assembly Fig 95 Tighten to 10 N m 7 ft lbs torque 4 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION 5 Install rear floor stowage bin Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY INSTALLATION 6 Close liftgate THIRD ROW INBOARD PIVOT SHIELD REMOVAL 1 Open liftgate 2 Remove rear floor stowage bin Refer to 23 BODY INTERIOR REAR FLOOR STO...

Page 3316: ...n seat frame and press into position 4 Connect fold flat cable to handle and press handle into position on load floor panel 5 Install third row seat Refer to 23 BODY SEATS THIRD ROW SEAT INSTALLATION 6 Install rear floor stowage bin Refer to 23 BODY INTERIOR REAR FLOOR STOWAGE TRAY INSTALLATION 7 Close liftgate CS SEATS 23 145 THIRD ROW INBOARD PIVOT SHIELD Continued ...

Page 3317: ... AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE VAPORS THAT ARE EMITTED FROM THE URE THANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY USE THEM IN A WELL VENTI LATED 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 ureth...

Page 3318: ...LASS WARNING LIFTGATE GLASS REMOVAL EXTERIOR METHOD 1 Remove rear wiper arm 2 Remove interior trim covers 3 Disconnect wires for electrically heated win dow if equipped Fig 2 4 Using a sharp cold knife cut urethane adhe sive attaching the liftgate glass to the liftgate A power cutting device can be used if available Fig 3 5 Remove liftgate glass from vehicle LIFTGATE GLASS REMOVAL INTERIOR METHOD ...

Page 3319: ...ed to the shape of the new glass 3 Using a grease pencil mark the glass and lift gate in several locations to aid installation 4 Remove replacement glass from liftgate open ing 5 Position the liftgate glass inside up on a suit able work surface with two padded wood 10 cm by 10 cm by 50 cm 4 in by 4 in by 20 in blocks placed parallel 75 cm 2 5 ft apart Fig 4 WARNING DO NOT USE SOLVENT BASED GLASS C...

Page 3320: ... marks 14 Slowly lower glass to liftgate glass opening fence Ensure spacers on bottom edge of glass contact sheet metal ledge Then push glass inward until flush to liftgate surface 15 Clean excess urethane from exterior with Mopart Super Kleen or equivalent 16 Apply 150 mm 6 in lengths of 50 mm 2 in masking tape spaced 250 mm 10 in apart to hold molding in place until urethane cures 17 Install lif...

Page 3321: ...8 Remove windshield from vehicle WINDSHIELD REMOVAL INTERIOR METHOD 1 Remove inside rear view mirror 2 Remove instrument panel top cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 3 Remove A pillar trim covers 4 Remove A pillar exterior molding 5 Place protective covers over instrument panel and hood 6 Using a reciprocating or oscillating power knife cut urethane adhesive...

Page 3322: ...ks are visible 8 Apply Glass Primer 15 mm 0 6 in wide around perimeter of windshield Allow at least three minutes drying time Fig 9 9 Using a razor knife remove as much original urethane as possible Do not damage paint on wind shield fence 10 Apply pinch weld primer 19 mm 0 75 in wide around the windshield fence Allow at least three minutes drying time 11 If a low viscosity urethane adhesive is us...

Page 3323: ...N 18 Install cowl cover and wipers 19 Install inside rear view mirror 20 After urethane has cured remove tape strips and water test windshield to verify repair Fig 9 WINDSHIELD PREPARATION FOR INSTALLATION 1 WINDSHIELD GLASS 2 GLASS PRIMER CLEANER MSCF 128 3 NAPTHA VMP 1316 4 15 mm 0 6 in WIDE 5 URETHANE SEALER MSCD 927 6 5 0 mm 0 2 in WIDE 7 3 0 mm 0 1 in WIDE 8 12 7 mm 0 5 in WIDE 9 9 5 mm 0 4 i...

Page 3324: ...p in that position Pressing and holding the close button will close the sunroof If the close button is released before the glass fully closes the sunroof will stop in that position The vent switch operates in a similar manor The sunroof will also operate for up to fifteen minutes after the ignition key is turned off for cus tomer comfort and convenance while parking DIAGNOSIS AND TESTING SUNROOF R...

Page 3325: ...1 Glass Assembly 8 Insulator 2 Screw s 9 Motor 3 Motor Clip 10 Lace 4 Motor Cover 11 Wind Deflector 5 U Frame Assembly 12 Sun Shade 6 Rear Drain Covers 13 Water Channel 7 Screw s 14 Screw s 23 154 SUNROOF CS SUNROOF Continued ...

Page 3326: ...t close Broken or disengaged trough guide Binding cable Faulty circuit Faulty control switch Faulty sunroof module Faulty drive motor Sunroof vents but does not open Binding cable or mechanism Faulty circuit Faulty switch Faulty sunroof module Sunroof does not vent Binding cable or mechanism Faulty circuit Faulty control switch Faulty sunroof module Sunroof water leak Drain tubes clogged or kinked...

Page 3327: ...r 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 hous ing drain trough If water flow is restricted use com pressed air to blow out any material plugging the drain system Retest system again To further check for a disconnected drain hose 1 Remove A ...

Page 3328: ...r anchor 6 Remove third seat lower anchor 7 Remove quarter trim bolster 8 Remove trim panel screws 9 Remove quarter trim panel 10 Disconnect the drain hose from the sunroof housing 11 Drain any liquid from hose connection if nec essary 12 Repair or remove tube as necessary Fig 6 Fig 2 OVERHEAD CONSOLE 1 OVERHEAD CONSOLE 2 POWER SUNROOF SWITCH 3 SUNROOF SWITCH RETAINING CLIP PART OF CONSOLE 4 OVERH...

Page 3329: ...e new drain hose to the sunroof housing and test drainage Fig 3 2 Install headliner Refer to 23 BODY INTERI OR HEADLINER INSTALLATION 3 Install sunroof opening trim lace 4 Connect the control switch wire connector and install control switch 5 Verify sunroof operation and alignment Fig 5 FRONT RIGHT DRAIN TUBE 1 GROMMET 2 FRONT RIGHT DRAIN TUBE 3 DRAIN TUBE TO WIRE CLIP 4 BODY WIRE HARNESS Fig 6 RE...

Page 3330: ...LY OPERATING SUNROOF THIS PROCEDURE IS USE TO SET SUNROOF MOTOR TO SUNROOF ASSEMBLY TIMING 1 Manually push the sunroof guide assembly to the full forward position until it is locked into posi tion This is verified by attempting to push the guide assembly rearward Fig 8 NOTE The guide rail will be raised above the U frame assembly when in the lock position 2 Remove the sunroof glass Refer to 23 BOD...

Page 3331: ...eration and alignment ADJUSTMENTS SUNROOF GLASS PANEL ADJUSTMENT 1 Move the sunshade rearward to the open posi tion 2 Move the sunroof glass panel to the fully closed position 3 Loosen the forward attaching screws on each side enough to make the front of the glass to adjust up or down 4 Adjust the front surface of the sunroof glass panel 0 00 mm to 1 75 mm 0 00 in to 0 07 in below the top surface ...

Page 3332: ...LATION 1 Ensure that u nuts are in position in the roof bow 2 Fig 13 2 Raise sunroof module assembly and guide it carefully into position Fig 12 3 While supporting the sunroof assembly start the attaching screws Tighten the attaching screws in sequence to 6 N m 53 in lbs torque Fig 14 4 Connect sunroof wire connector Fig 11 5 Connect the drain tubes to the sunroof Refer to 23 BODY SUNROOF DRAIN TU...

Page 3333: ...ROOF U NUTS 4 ROOF BOW 2 5 ROOF PANEL 6 SUNROOF WIRE CONNECTOR 7 BODY WIRE HARNESS 8 SUNROOF MODULE TO ROOF ATTACHING SCREW S AND WASHER S Fig 13 ATTACHING U NUTS 1 U NUTS 2 ROOF BOW 2 Fig 14 TIGHTENING SEQUENCE 1 POWER SUNROOF MODULE 2 LOCATION S 23 162 SUNROOF CS MODULE ASSEMBLY Continued ...

Page 3334: ...VAL 2 Remove the retaining screws Fig 1 3 Carefully slide water channel forward to release tabs from U frame and remove from vehicle INSTALLATION 1 Carefully place water channel onto U frame and slide it rearward to lock tabs Fig 1 2 Install the water channel attaching screws Fig 1 3 Position glass panel on to mechanism lift arms 4 Start the glass attaching screws and hand tighten 5 Adjust sunroof...

Page 3335: ...MOVAL 168 INSTALLATION 168 FRONT INNER BELT MOLDING WEATHERSTRIP REMOVAL 168 INSTALLATION 168 LIFTGATE OPENING WEATHERSTRIP REMOVAL 169 INSTALLATION 169 LIFTGATE UPPER SECONDARY WEATHERSTRIP REMOVAL 170 INSTALLATION 170 REAR DOOR HEADER WEATHERSTRIP REMOVAL 170 INSTALLATION 170 REAR DOOR INNER BELT MOLDING WEATHERSTRIP REMOVAL 171 INSTALLATION 171 REAR DOOR MOUNTED WEATHERSTRIP REMOVAL 171 INSTALL...

Page 3336: ...eal and push pins to engage into door sill Fig 2 3 Close door Fig 1 DOOR AND LIFTGATE OPENING WEATHERSTRIPS 1 LIFTGATE OPENING WEATHERSTRIP 2 LIFTGATE OPENING FRAME REINFORCEMENT 3 BODY SIDE OUTER PANEL 4 FRONT DOOR BODY MOUNTED WEATHERSTRIP 5 BODY SIDE INNER PANEL 6 REAR DOOR MOUNTED WEATHERSTRIP 7 LIFTGATE OPENING FRAME REINFORCEMENT 8 STUFFER Fig 2 DOOR TRIM INNER SEAL AND PUSH PIN S 1 REAR DOO...

Page 3337: ...plate 3 Pull front door weatherstrip from door opening fence Fig 1 and Fig 4 4 Remove door opening weatherstrip from vehi cle INSTALLATION 1 Place front door opening weatherstrip into posi tion starting at the upper rear corner of the B pillar Fig 1 and Fig 4 2 Work the weatherstrip down the B pillar to the floor pan Leave slack to ensure completion of the weatherstrip throughout the entire openin...

Page 3338: ...down on outer belt molding and rotate upper part of tool outward from vehicle approxi mately 6 8 cm 2 5 3 in then lift up on molding to disengage from locking tab 9 Repeat step 3 and 4 at as necessary till outer belt molding is free 10 Remove outer belt molding weatherstrip INSTALLATION 1 Place outer belt molding weatherstrip into posi tion Fig 5 2 Press down or tap lightly on outer belt molding u...

Page 3339: ...Close front door FRONT INNER BELT MOLDING WEATHERSTRIP REMOVAL 1 Remove the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Rotate the inner belt molding outboard while pulling up to disengage the retention tabs Fig 8 3 Remove inner belt molding from door INSTALLATION 1 Place inner belt molding into position 2 Press down on inner belt molding to engage the retention tabs Fig 8 3 I...

Page 3340: ...s of the fence flange 3 Align the paint dot on the inner side of weath erstrip with right side upper corner of liftgate open ing Be sure to leave slack in the weatherstrip between the two upper corners of opening 4 Secure weatherstrip down the right side of opening including the upper and lower right side cor ners 5 Secure weatherstrip to upper portion of liftgate opening between the left and righ...

Page 3341: ...therstrip 2 Clean liftgate surface with Mopart Super Kleen or equivalent Wipe surface dry with lint free cloth 3 Remove protective cover from tape on back of upper secondary weatherstrip 4 Apply weatherstrip to liftgate between liftgate hinges There is less than 1 8 in clearance between the hinges 5 Using a roller tool roll weatherstrip onto lift gate with enough force to assure adhesion Do not ap...

Page 3342: ...R MOUNTED WEATHERSTRIP REMOVAL 1 Open front door 2 Using a trim stick C 4755 or equivalent disen gage the push pins attaching rear door mounted weatherstrip to door frame Fig 12 3 Remove weatherstrip from door frame INSTALLATION 1 Place front door mounted weatherstrip into position Fig 12 2 Press on attaching push pins fasteners to attach weatherstrip to lower door and engage upper rear door mount...

Page 3343: ...peat step 3 and 4 at as necessary till outer belt molding is free 8 Remove outer belt molding weatherstrip INSTALLATION 1 Place outer belt molding weatherstrip into posi tion Fig 13 2 Press down or tap lightly on outer belt molding until fully seated 3 Install rear door fixed glass run channel Refer to 23 BODY DOORS REAR REAR DOOR FIXED GLASS RUN CHANNEL INSTALLATION 4 Remove front inner molding w...

Page 3344: ...p throughout the entire opening 3 Starting at B pillar going along the under side of the header and down the B pillar leaving slack to ensure proper installation of the bottom portion of the weatherstrip 4 Joint the two end of the weatherstrip together and ensure complete seating of weatherstrip 5 Install rear door sill scuff plate 6 Close front door Fig 15 REAR DOOR OPENING WEATHERSTRIP 1 C PILLA...

Page 3345: ...Y OPENING DIMENSIONS 177 SEALER LOCATIONS SPECIFICATIONS BODY SEALING LOCATIONS 181 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 185 WELD LOCATIONS SPECIFICATIONS WELD LOCATION 205 GAP AND FLUSH SPECIFICATIONS GAP AND FLUSH MEASUREMENTS INDEX DESCRIPTION FIGURE GAP FLUSH MEASUREMENTS 1 23 174 BODY STRUCTURE CS ...

Page 3346: ...Fig 1 GAP AND FLASH MEASUREMENTS CS BODY STRUCTURE 23 175 GAP AND FLUSH Continued ...

Page 3347: ...EAR DOOR BELOW BELT LINE 4 5 1 5 PARALLEL WITHIN 1 5 FRONT DOOR 0 5 OVER FLUSH TO REAR DOOR 1 5 CONSISTENT WITHIN 1 5 10 REAR DOOR APPLIQUE TO QUARTER GLASS ABOVE BELT LINE 4 5 1 5 PARALLEL WITHIN 1 5 REAR DOOR APPLIQUE 6 5 OVER FLUSH TO QUARTER GLASS 2 5 CONSISTENT WITHIN 1 5 11 REAR DOOR TO REAR QUARTER BELOW BELT LINE 4 5 1 5 PARALLEL WITHIN 1 5 REAR DOOR 0 5 OVER FLUSH TO REAR QUARTER CONSISTE...

Page 3348: ...G DIMENSIONS SPECIFICATIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE FRONT DOOR 2 LIFTGATE 3 LIFTGATE WINDOW 4 REAR DOOR 5 REAR QUARTER WINDOW 6 WINDSHIELD 7 Fig 2 FRONT DOOR CS BODY STRUCTURE 23 177 ...

Page 3349: ...Fig 3 LIFTGATE Fig 4 LIFTGATE WINDOW 23 178 BODY STRUCTURE CS OPENING DIMENSIONS Continued ...

Page 3350: ...Fig 5 REAR DOOR Fig 6 REAR QUARTER WINDOW CS BODY STRUCTURE 23 179 OPENING DIMENSIONS Continued ...

Page 3351: ...Fig 7 WINDSHIELD 23 180 BODY STRUCTURE CS OPENING DIMENSIONS Continued ...

Page 3352: ...OCATIONS INDEX DESCRIPTION FIGURE DASH PANEL 1 OF 4 8 DASH PANEL 2 OF 4 9 DASH PANEL 3 OF 4 10 DASH PANEL 4 OF 4 11 ENGINE BOX 12 INNER REAR QUARTER PANEL 1 OF 2 13 INNER REAR QUARTER PANEL 2 OF 2 14 Fig 8 DASH PANEL 1 OF 4 CS BODY STRUCTURE 23 181 ...

Page 3353: ...Fig 9 DASH PANEL 2 OF 4 Fig 10 DASH PANEL 3 OF 4 23 182 BODY STRUCTURE CS SEALER LOCATIONS Continued ...

Page 3354: ...Fig 11 DASH PANEL 4 OF 4 Fig 12 ENGINE BOX CS BODY STRUCTURE 23 183 SEALER LOCATIONS Continued ...

Page 3355: ...Fig 13 INNER REAR QUARTER PANEL 1 OF 2 Fig 14 INNER REAR QUARTER PANEL 2 OF 2 23 184 BODY STRUCTURE CS SEALER LOCATIONS Continued ...

Page 3356: ...LETE 1 OF 4 16 BODY COMPLETE 2 OF 4 17 BODY COMPLETE 3 OF 4 18 BODY COMPLETE 4 OF 4 19 BODY SIDE APERTURE COMPLETE 1 OF 2 20 BODY SIDE APERTURE COMPLETE 2 OF 2 21 BODY SIDE APERTURE COMPLETE INNER 22 BODY SIDE APERTURE COMPLETE OUTER 23 DASH ASSEMBLY 24 ENGINE BOX COMPLETE 25 FRONT RAILS 26 INNER REAR WHEELHOUSE LEFT SIDE 27 INNER REAR WHEELHOUSE RIGHT SIDE 28 REAR FLOOR TO LADDER 29 ROOF 1 OF 2 3...

Page 3357: ...Fig 15 A PILLAR Fig 16 BODY COMPLETE 1 OF 4 23 186 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3358: ...Fig 17 BODY COMPLETE 2 OF 4 Fig 18 BODY COMPLETE 3 OF 4 CS BODY STRUCTURE 23 187 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3359: ...Fig 19 BODY COMPLETE 4 OF 4 23 188 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3360: ...Fig 20 BODY SIDE APERTURE COMPLETE 1 OF 2 CS BODY STRUCTURE 23 189 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3361: ...Fig 21 BODY SIDE APERTURE COMPLETE 2 OF 2 23 190 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3362: ...Fig 22 BODY SIDE APERTURE COMPLETE INNER CS BODY STRUCTURE 23 191 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3363: ...Fig 23 BODY SIDE APERTURE COMPLETE OUTER 23 192 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3364: ...Fig 24 DASH ASSEMBLY Fig 25 ENGINE BOX COMPLETE CS BODY STRUCTURE 23 193 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3365: ...Fig 26 FRONT RAILS 23 194 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3366: ...Fig 27 INNER REAR WHEELHOUSE LEFT SIDE CS BODY STRUCTURE 23 195 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3367: ...Fig 28 INNER REAR WHEELHOUSE RIGHT SIDE 23 196 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3368: ...Fig 29 REAR FLOOR TO LADDER CS BODY STRUCTURE 23 197 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3369: ...Fig 30 ROOF 1 OF 2 23 198 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3370: ...Fig 31 ROOF 2 OF 2 CS BODY STRUCTURE 23 199 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3371: ...Fig 32 UNDERBODY 23 200 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3372: ...Fig 33 UNDERBODY COMPLETE 1 OF 4 CS BODY STRUCTURE 23 201 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3373: ...Fig 34 UNDERBODY COMPLETE 2 OF 4 23 202 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3374: ...Fig 35 UNDERBODY COMPLETE 3 OF 4 CS BODY STRUCTURE 23 203 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3375: ...Fig 36 UNDERBODY COMPLETE 4 OF 4 23 204 BODY STRUCTURE CS STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 3376: ...E 8 OF 8 52 BODY SIDE APERTURE COMPLETE INNER 1 OF 6 53 BODY SIDE APERTURE COMPLETE INNER 2 OF 6 54 BODY SIDE APERTURE COMPLETE INNER 3 OF 6 55 BODY SIDE APERTURE COMPLETE INNER 4 OF 6 56 BODY SIDE APERTURE COMPLETE INNER 5 OF 6 57 BODY SIDE APERTURE COMPLETE INNER 6 OF 6 58 BODY SIDE APERTURE COMPLETE OUTER 1 OF 6 59 BODY SIDE APERTURE COMPLETE OUTER 2 OF 6 60 BODY SIDE APERTURE COMPLETE OUTER 3 ...

Page 3377: ...T SIDE 2 OF 2 93 INNER REAR WHEELHOUSE RIGHT SIDE 1 OF 2 94 INNER REAR WHEELHOUSE RIGHT SIDE 2 OF 2 95 LADDER COMPLETE 1 OF 4 96 LADDER COMPLETE 2 OF 4 97 LADDER COMPLETE 3 OF 4 98 LADDER COMPLETE 4 OF 4 99 MID LADDER ASSEMBLY 1 OF 3 100 MID LADDER ASSEMBLY 2 OF 3 101 MID LADDER ASSEMBLY 3 OF 3 102 MISCELLANEOUS COWL PLENUM 103 MISCELLANEOUS FRONT HINGE PILLAR B PILLAR CROSSMEMBER 104 MISCELLANEOU...

Page 3378: ...PLETE 2 OF 9 128 UNDERBODY COMPLETE 3 OF 9 129 UNDERBODY COMPLETE 4 OF 9 130 UNDERBODY COMPLETE 5 OF 9 131 UNDERBODY COMPLETE 6 OF 9 132 UNDERBODY COMPLETE 7 OF 9 133 UNDERBODY COMPLETE 8 OF 9 134 UNDERBODY COMPLETE 9 OF 9 135 FRONT FENDER BEAM REINFORCEMENT 136 B PILLAR TAPPING PLATES REINFORCEMENT 137 C PILLAR NUT PLATES TAPPING PLATES 138 ROOF RAIL B PILLAR REINFORCEMENT 139 C PILLAR REINFORCEM...

Page 3379: ...Fig 37 BODY COMPLETE 1 OF 8 23 208 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3380: ...Fig 38 BODY COMPLETE 2 OF 8 CS BODY STRUCTURE 23 209 WELD LOCATIONS Continued ...

Page 3381: ...Fig 39 BODY COMPLETE 3 OF 8 23 210 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3382: ...Fig 40 BODY COMPLETE 4 OF 8 CS BODY STRUCTURE 23 211 WELD LOCATIONS Continued ...

Page 3383: ...Fig 41 BODY COMPLETE 5 OF 8 23 212 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3384: ...Fig 42 BODY COMPLETE 6 OF 8 CS BODY STRUCTURE 23 213 WELD LOCATIONS Continued ...

Page 3385: ...Fig 43 BODY COMPLETE 7 OF 8 23 214 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3386: ...Fig 44 BODY COMPLETE 8 OF 8 CS BODY STRUCTURE 23 215 WELD LOCATIONS Continued ...

Page 3387: ...Fig 45 BODY SIDE APERTURE COMPLETE 1 OF 8 23 216 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3388: ...Fig 46 BODY SIDE APERTURE COMPLETE 2 OF 8 CS BODY STRUCTURE 23 217 WELD LOCATIONS Continued ...

Page 3389: ...Fig 47 BODY SIDE APERTURE COMPLETE 3 OF 8 23 218 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3390: ...Fig 48 BODY SIDE APERTURE COMPLETE 4 OF 8 CS BODY STRUCTURE 23 219 WELD LOCATIONS Continued ...

Page 3391: ...Fig 49 BODY SIDE APERTURE COMPLETE 5 OF 8 23 220 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3392: ...Fig 50 BODY SIDE APERTURE COMPLETE 6 OF 8 CS BODY STRUCTURE 23 221 WELD LOCATIONS Continued ...

Page 3393: ...Fig 51 BODY SIDE APERTURE COMPLETE 7 OF 8 23 222 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3394: ...Fig 52 BODY SIDE APERTURE COMPLETE 8 OF 8 CS BODY STRUCTURE 23 223 WELD LOCATIONS Continued ...

Page 3395: ...Fig 53 BODY SIDE APERTURE COMPLETE INNER 1 OF 6 23 224 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3396: ...Fig 54 BODY SIDE APERTURE COMPLETE INNER 2 OF 6 CS BODY STRUCTURE 23 225 WELD LOCATIONS Continued ...

Page 3397: ...Fig 55 BODY SIDE APERTURE COMPLETE INNER 3 OF 6 23 226 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3398: ...Fig 56 BODY SIDE APERTURE COMPLETE INNER 4 OF 6 CS BODY STRUCTURE 23 227 WELD LOCATIONS Continued ...

Page 3399: ...Fig 57 BODY SIDE APERTURE COMPLETE INNER 5 OF 6 23 228 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3400: ...Fig 58 BODY SIDE APERTURE COMPLETE INNER 6 OF 6 CS BODY STRUCTURE 23 229 WELD LOCATIONS Continued ...

Page 3401: ...Fig 59 BODY SIDE APERTURE OUTER COMPLETE 1 OF 6 23 230 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3402: ...Fig 60 BODY SIDE APERTURE OUTER COMPLETE 2 OF 6 CS BODY STRUCTURE 23 231 WELD LOCATIONS Continued ...

Page 3403: ...Fig 61 BODY SIDE APERTURE OUTER COMPLETE 3 OF 6 23 232 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3404: ...Fig 62 BODY SIDE APERTURE OUTER COMPLETE 4 OF 6 CS BODY STRUCTURE 23 233 WELD LOCATIONS Continued ...

Page 3405: ...Fig 63 BODY SIDE APERTURE OUTER COMPLETE 5 OF 6 23 234 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3406: ...Fig 64 BODY SIDE APERTURE OUTER COMPLETE 6 OF 6 CS BODY STRUCTURE 23 235 WELD LOCATIONS Continued ...

Page 3407: ...Fig 65 DASH ASSEMBLY 1 OF 3 23 236 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3408: ...Fig 66 DASH ASSEMBLY 2 OF 3 CS BODY STRUCTURE 23 237 WELD LOCATIONS Continued ...

Page 3409: ...Fig 67 DASH ASSEMBLY 3 OF 3 23 238 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3410: ...Fig 68 ENGINE BOX 1 OF 15 CS BODY STRUCTURE 23 239 WELD LOCATIONS Continued ...

Page 3411: ...Fig 69 ENGINE BOX 2 OF 15 23 240 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3412: ...Fig 70 ENGINE BOX 3 OF 15 CS BODY STRUCTURE 23 241 WELD LOCATIONS Continued ...

Page 3413: ...Fig 71 ENGINE BOX 4 OF 15 23 242 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3414: ...Fig 72 ENGINE BOX 5 OF 15 CS BODY STRUCTURE 23 243 WELD LOCATIONS Continued ...

Page 3415: ...Fig 73 ENGINE BOX 6 OF 15 23 244 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3416: ...Fig 74 ENGINE BOX 7 OF 15 CS BODY STRUCTURE 23 245 WELD LOCATIONS Continued ...

Page 3417: ...Fig 75 ENGINE BOX 8 OF 15 23 246 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3418: ...Fig 76 ENGINE BOX 9 OF 15 CS BODY STRUCTURE 23 247 WELD LOCATIONS Continued ...

Page 3419: ...Fig 77 ENGINE BOX 10 OF 15 23 248 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3420: ...Fig 78 ENGINE BOX 11 OF 15 CS BODY STRUCTURE 23 249 WELD LOCATIONS Continued ...

Page 3421: ...Fig 79 ENGINE BOX 12 OF 15 23 250 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3422: ...Fig 80 ENGINE BOX 13 OF 15 CS BODY STRUCTURE 23 251 WELD LOCATIONS Continued ...

Page 3423: ...Fig 81 ENGINE BOX 14 OF 15 23 252 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3424: ...Fig 82 ENGINE BOX 15 OF 15 CS BODY STRUCTURE 23 253 WELD LOCATIONS Continued ...

Page 3425: ...Fig 83 ENGINE BOX COMPLETE 1 OF 6 23 254 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3426: ...Fig 84 ENGINE BOX COMPLETE 2 OF 6 CS BODY STRUCTURE 23 255 WELD LOCATIONS Continued ...

Page 3427: ...Fig 85 ENGINE BOX COMPLETE 3 OF 6 23 256 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3428: ...Fig 86 ENGINE BOX COMPLETE 4 OF 6 CS BODY STRUCTURE 23 257 WELD LOCATIONS Continued ...

Page 3429: ...Fig 87 ENGINE BOX COMPLETE 5 OF 6 23 258 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3430: ...Fig 88 ENGINE BOX COMPLETE 6 OF 6 CS BODY STRUCTURE 23 259 WELD LOCATIONS Continued ...

Page 3431: ...Fig 89 FRONT RAILS 1 OF 3 23 260 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3432: ...Fig 90 FRONT RAILS 2 OF 3 CS BODY STRUCTURE 23 261 WELD LOCATIONS Continued ...

Page 3433: ...Fig 91 FRONT RAILS 3 OF 3 23 262 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3434: ...Fig 92 INNER REAR WHEELHOUSE LEFT SIDE 1 OF 2 CS BODY STRUCTURE 23 263 WELD LOCATIONS Continued ...

Page 3435: ...Fig 93 INNER REAR WHEELHOUSE LEFT SIDE 2 OF 2 23 264 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3436: ...Fig 94 INNER REAR WHEELHOUSE RIGHT SIDE 1 OF 2 CS BODY STRUCTURE 23 265 WELD LOCATIONS Continued ...

Page 3437: ...Fig 95 INNER REAR WHEELHOUSE RIGHT SIDE 2 OF 2 23 266 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3438: ...Fig 96 LADDER COMPLETE 1 OF 4 CS BODY STRUCTURE 23 267 WELD LOCATIONS Continued ...

Page 3439: ...Fig 97 LADDER COMPLETE 2 OF 4 23 268 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3440: ...Fig 98 LADDER COMPLETE 3 OF 4 CS BODY STRUCTURE 23 269 WELD LOCATIONS Continued ...

Page 3441: ...Fig 99 LADDER COMPLETE 4 OF 4 23 270 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3442: ...Fig 100 MID LADDER ASSEMBLY 1 OF 3 CS BODY STRUCTURE 23 271 WELD LOCATIONS Continued ...

Page 3443: ...Fig 101 MID LADDER ASSEMBLY 2 OF 3 23 272 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3444: ...Fig 102 MID LADDER ASSEMBLY 3 OF 3 CS BODY STRUCTURE 23 273 WELD LOCATIONS Continued ...

Page 3445: ...Fig 103 MISCELLANEOUS COWL PLENUM 23 274 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3446: ...Fig 104 MISCELLANEOUS FRONT HINGE PILLAR B PILLAR CROSSMEMBER CS BODY STRUCTURE 23 275 WELD LOCATIONS Continued ...

Page 3447: ...Fig 105 MISCELLANEOUS REAR RAIL CLOSE OUT 23 276 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3448: ...Fig 106 MISCELLANEOUS UPPER AND LOWER LIFTGATE FRAME CS BODY STRUCTURE 23 277 WELD LOCATIONS Continued ...

Page 3449: ...Fig 107 PLENUM 1 OF 3 23 278 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3450: ...Fig 108 PLENUM 2 OF 3 CS BODY STRUCTURE 23 279 WELD LOCATIONS Continued ...

Page 3451: ...Fig 109 PLENUM 3 OF 3 23 280 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3452: ...Fig 110 REAR FLOOR TO LADDER 1 OF 4 CS BODY STRUCTURE 23 281 WELD LOCATIONS Continued ...

Page 3453: ...Fig 111 REAR FLOOR TO LADDER 2 OF 4 23 282 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3454: ...Fig 112 REAR FLOOR TO LADDER 3 OF 4 CS BODY STRUCTURE 23 283 WELD LOCATIONS Continued ...

Page 3455: ...Fig 113 REAR FLOOR TO LADDER 4 OF 4 23 284 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3456: ...Fig 114 ROOF 1 OF 3 CS BODY STRUCTURE 23 285 WELD LOCATIONS Continued ...

Page 3457: ...Fig 115 ROOF 2 OF 3 23 286 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3458: ...Fig 116 ROOF 3 OF 3 CS BODY STRUCTURE 23 287 WELD LOCATIONS Continued ...

Page 3459: ...Fig 117 UNDERBODY 1 OF 10 23 288 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3460: ...Fig 118 UNDERBODY 2 OF 10 CS BODY STRUCTURE 23 289 WELD LOCATIONS Continued ...

Page 3461: ...Fig 119 UNDERBODY 3 OF 10 23 290 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3462: ...Fig 120 UNDERBODY 4 OF 10 CS BODY STRUCTURE 23 291 WELD LOCATIONS Continued ...

Page 3463: ...Fig 121 UNDERBODY 5 OF 10 23 292 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3464: ...Fig 122 UNDERBODY 6 OF 10 CS BODY STRUCTURE 23 293 WELD LOCATIONS Continued ...

Page 3465: ...Fig 123 UNDERBODY 7 OF 10 23 294 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3466: ...Fig 124 UNDERBODY 8 OF 10 CS BODY STRUCTURE 23 295 WELD LOCATIONS Continued ...

Page 3467: ...Fig 125 UNDERBODY 9 OF 10 23 296 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3468: ...Fig 126 UNDERBODY 10 OF 10 CS BODY STRUCTURE 23 297 WELD LOCATIONS Continued ...

Page 3469: ...Fig 127 UNDERBODY COMPLETE 1 OF 9 23 298 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3470: ...Fig 128 UNDERBODY COMPLETE 2 OF 9 CS BODY STRUCTURE 23 299 WELD LOCATIONS Continued ...

Page 3471: ...Fig 129 UNDERBODY COMPLETE 3 OF 9 23 300 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3472: ...Fig 130 UNDERBODY COMPLETE 4 OF 9 CS BODY STRUCTURE 23 301 WELD LOCATIONS Continued ...

Page 3473: ...Fig 131 UNDERBODY COMPLETE 5 OF 9 23 302 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3474: ...Fig 132 UNDERBODY COMPLETE 6 OF 9 CS BODY STRUCTURE 23 303 WELD LOCATIONS Continued ...

Page 3475: ...Fig 133 UNDERBODY COMPLETE 7 OF 9 23 304 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3476: ...Fig 134 UNDERBODY COMPLETE 8 OF 9 CS BODY STRUCTURE 23 305 WELD LOCATIONS Continued ...

Page 3477: ...Fig 135 UNDERBODY COMPLETE 9 OF 9 23 306 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3478: ...Fig 136 FRONT FENDER BEAM REINFORCEMENT Fig 137 B PILLAR TAPPING PLATES REINFORCEMENT CS BODY STRUCTURE 23 307 WELD LOCATIONS Continued ...

Page 3479: ...Fig 138 C PILLAR NUT PLATES TAPPING PLATES 23 308 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3480: ...Fig 139 ROOF RAIL B PILLAR REINFORCEMENT CS BODY STRUCTURE 23 309 WELD LOCATIONS Continued ...

Page 3481: ...Fig 140 C PILLAR REINFORCEMENT BRACKETS 23 310 BODY STRUCTURE CS WELD LOCATIONS Continued ...

Page 3482: ...Fig 141 SUN ROOF OPENING REINFORCEMENT CS BODY STRUCTURE 23 311 WELD LOCATIONS Continued ...

Page 3483: ......

Page 3484: ...l and inte gral computer contains a power button which allows the system to be completely turned off The display shows only the outside temperature when the system is off a dual zone button which allows the selection of either single driver or dual driver and passenger temperature control two temperature set buttons for completely inde pendent side to side temperature control of the dis charged ai...

Page 3485: ... override fea tures The indicator light in both the AUTO HI or AUTO LO buttons will turn off when the system is being used in the manual mode The fan speed air flow distribution and outside air recirculated air can be manually adjusted The front blower control can be set to any fixed blower speed by pressing the rocker switch up or down This allows the front occupants to control the volume of air ...

Page 3486: ...oupling is fully closed This will reduce the amount of effort required to make the connection 1 Connect a tachometer to monitor the engine speed 2 Remove the caps from the refrigerant system service ports and attach a manifold gauge set to monitor the refrigerant system pressures 3 Set the heater air conditioner controls so that the compressor is engaged the air within the vehicle is being recircu...

Page 3487: ...stem by two 16 mm 5 8 inch inside diameter heater hoses With the engine idling at normal running tempera ture set the heater A C controls as follows Temper ature control to full Heat Mode control to Floor Blower control to the highest speed setting Using a test thermometer check the air temperature coming from the center floor outlets and compare this read ing to the Temperature Reference Chart TE...

Page 3488: ...the underhood specifica tion label for the A C unit HEATER A C SYSTEM SPECIFICATION CHART Item Description Notes Compressor Nippondenso 10S17 ND 8 PAG Oil Low PSI Control A C Pressure Transducer Liquid line mounted voltage input to Powertrain Control Module PCM PCM opens compressor clutch relay below 0 451 volts High PSI Control A C Pressure Transducer Liquid line mounted voltage input to PCM PCM ...

Page 3489: ...2 17 Heater A C Control Screws 2 17 Heater A C Unit Housing Bracket Screw 3 26 Heater A C Unit Housing Screws 2 17 Heater A C Unit Housing Stud Nuts 7 62 Heater Core Tube Sealing Plate Screws 3 27 Heater Inlet Tube Bolts 10 89 Hood Latch Bolts 14 10 123 Instrument Panel Outlet Screws 2 17 Liquid Line to Condenser Nut 23 17 Liquid Line to Expansion Valve Nut 23 17 Liquid Lines to Filter drier Bolts...

Page 3490: ...18 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 19 OPERATION 19 REMOVAL 19 INSTALLATION 19 INFRARED TEMPERATURE SENSOR DESCRIPTION 20 OPERATION 20 REMOVAL 20 INSTALLATION 20 MODE DOOR ACTUATOR DESCRIPTION 21 OPERATION 21 REMOVAL 22 INSTALLATION 22 POWER MODULE DESCRIPTION 22 OPERATION 23 REMOVAL 23 INSTALLATION 23 RECIRCULATION DOOR ACTUATOR DESCRIPTION 24 OPERATION 24 REMOVAL 24 INSTALLATION 25 A C ...

Page 3491: ...wing proce dure 1 Using feeler gauges measure the air gap between the clutch plate and the clutch pulley fric tion surfaces 2 If the air gap is not between 0 5 and 0 9 mm 0 020 and 0 035 in add or subtract shims until the desired air gap is obtained NOTE The shims may compress after tightening the compressor shaft bolt Check the air gap in four or more places on the clutch plate to verify that the...

Page 3492: ...e oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal 11 Tap the clutch plate lightly with a plastic hammer and remove the clutch plate and shim s from the compressor shaft Fig 3 Be certain not to lose the shim or shims CAUTION Do not pry between the clutch plate unit and the pulley to remove the clutch plate from the compressor shaft as this may damage...

Page 3493: ...sor Be cer tain that the clutch coil pigtail wires are properly ori ented and routed so that they are not pinched between the compressor front cover and the clutch coil NOTE A new snap ring must be used to secure the clutch coil to the compressor The bevel side of the snap ring must face outward 2 Using snap ring pliers Special Tool C 4574 or equivalent install the external snap ring that secures ...

Page 3494: ...top of the compressor 18 Reinstall the serpentine accessory drive belt onto the front of the engine Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLA TION 19 Install the radiator fan assembly Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 20 Reconnect the battery negative cable 21 If a new clutch plate and or clutch pulley are being installed the new clutch components must be burnished...

Page 3495: ...al sys tem and the ISO designation for each terminal is molded into the base adjacent to each terminal OPERATION The compressor clutch relay is an electromechani cal switch that uses a low current input from the Powertrain Control Module PCM to control the high current output to the compressor clutch electromag netic coil The movable common feed contact point is held against the fixed normally clo...

Page 3496: ... 2 Position the compressor clutch relay to the proper receptacle in the IPM 3 Align the compressor clutch relay terminals with the terminal cavities in the IPM relay recepta cle 4 Push down firmly on the compressor clutch relay until the terminals are fully seated in the ter minal cavities in the IPM receptacle 5 Install and latch the cover onto the IPM 6 Reconnect the battery negative cable A C H...

Page 3497: ...RING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POS...

Page 3498: ...ng the refrigerant in the system The A C pressure transducer is diagnosed using a DRBIIIt scan tool Refer to Body Diagnostic Procedures DIAGNOSIS AND TESTING A C PRESSURE TRANSDUCER The A C pressure transducer is tested using a DRBIIIt scan tool Refer to the appropriate diagnos tic information Before testing the A C pressure transducer be certain that the transducer wire har ness connection is cle...

Page 3499: ...d back signal to the heater A C control module This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door The heater A C con trol module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code DTC for any problems it detects in the blend door actuator circuits Th...

Page 3500: ... 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 The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interfer ence that can be generated as the electromagnetic fiel...

Page 3501: ... 1 Disconnect and isolate the battery negative cable 2 Unlatch and remove the cover from the Inte grated Power Module IPM Fig 13 3 See the fuse and relay layout map molded into the inner surface of the IPM cover for front blower motor relay identification and location 4 Remove the front blower motor relay from the IPM by pulling the relay straight up INSTALLATION 1 See the fuse and relay layout ma...

Page 3502: ...ator freezing The external loca tion of the sensor and the use of a screw allows the sensor to be removed or installed from the expansion valve without disturbing the refrigerant in the sys tem The evaporator temperature sensor is diagnosed using a DRBIIIt scan tool Refer to Body Diagnostic Procedures REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the air cleaner housing from...

Page 3503: ... ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILU...

Page 3504: ...eater A C control module through the vehicle electrical sys tem by a dedicated two wire lead and connector from the HVAC wire harness The mode door actuator can move the mode door in two directions When the heater A C control module pulls the voltage on one side of the motor connection high and the other con nection low the mode door will move in one direction When the module reverses the polarity...

Page 3505: ...POSSIBLE PERSONAL INJURY 1 Position the mode door actuator onto the heat er AC housing If necessary rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage 2 Install and tighten the two screws that secure the mode door actuator to the distribution housing Tighten the screws to 2 N m 17 in lbs 3 Reconnect the HVAC wire harness connector for...

Page 3506: ...sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening then roll the glove box downward 4 Reach through the glove box opening to access and disconnect the instrument panel wire harness connector for the power module from the module con nector receptacle 5 Reach through the glove box opening to access and disconnec...

Page 3507: ...the motor the recirculation air door moves in the opposite direction When the module makes the voltage to both connec tions high or both connections low the recirculation air door stops and will not move These same motor connections also provide a feedback signal to the heater A C control module This feedback signal allows the module to monitor the operation and rela tive position of the recircula...

Page 3508: ...ry rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door 2 Install and tighten the two screws that secure the recirculation door actuator to the lower intake air housing Tighten the screws to 2 N m 17 in lbs 3 Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle 4 Reconne...

Page 3509: ... can set the rear switch to any fan speed including OFF or AUTO While in the Auto position the rear fan speed will be automatically controlled Refer to Body Diagnostic Procedures for further diag nostic information REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a trim stick or other suitable wide flat blade tool gently pry the outer perimeter of the rear blower motor control p...

Page 3510: ...osite direction When the module makes the voltage to both connections high or both connections low the mode doors stop and will not move These same motor connections also provide a feedback signal to the heater A C control module This feedback signal allows the module to monitor the operation and relative position of the mode door actuator and the mode doors The heater A C control module learns th...

Page 3511: ...ated PWM circuit strategy The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage The resulting output drives the power module circuitry which adjusts the voltage output received from the blower motor relay to change or maintain the desired blower speed Refer to Body Diagnostic Procedures for further diag nostic information REMO...

Page 3512: ... odor air filter is standard equipment Fig 1 The filter element is the same size as the air conditioner evaporator to ensure ample filtering capacity A removable door on the bottom of the heat er A C unit housing below the glove box provides easy access to the filter element for replacement Refer to the owner s manual for recommended service intervals REMOVAL 1 Locate the air filter door on the bo...

Page 3513: ...r service replacement Instrument Panel Outlets There are four panel outlets in the instrument panel one located near each outboard end of the instrument panel fac ing the rear of the vehicle and two located near the top of the instrument panel center bezel The out board outlets can be removed individually for service replacement The two center bezel outlets are ser viced as an assembly Front Floor...

Page 3514: ...BEZEL INSTAL LATION 5 Reconnect the battery negative cable INSTALLATION INSTRUMENT PANEL OUTLETS 1 Position the instrument panel outlet into the panel duct opening in the instrument panel 2 Install the two instrument panel outlet screws Tighten to 2 N m 17 in lbs 3 Position the instrument panel end cover onto the instrument panel 4 Using hand pressure press the instrument panel end cover firmly an...

Page 3515: ...BAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Check the fuse Fuse 10 40 ampere in the Intelligent Power Module IPM If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse 2 Turn the ignition switch to the On position Be certain that the heater A C control power is ...

Page 3516: ...Fig 6 Blower Motor Noise Vibration Diagnosis CS DISTRIBUTION FRONT 24 33 BLOWER MOTOR Continued ...

Page 3517: ...from the assembly from the vehicle INSTALLATION The blower motor and blower wheel are serviced only as a balanced unit If either component is faulty or damaged the entire unit must be replaced WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING Refer to 24 HEATING AIR CONDI TIONING PL...

Page 3518: ...NG WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAU TIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIB...

Page 3519: ...rigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING FRONT REFRIGERANT STAN DARD PROCEDURE REFRIGERANT RECOVERY 2 Drain the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 3 Disconnect and isolate the battery negative cable 4 Disconnect the liquid line and suction line from the expansion valve Refer to 24 HEATING AIR CONDITIONING PLUM...

Page 3520: ...E REFRIGERANT SYSTEM EVACUATE 10 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE INSTRUMENT PANEL DUCTS REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE...

Page 3521: ...wer motor speed is con trolled by an electronic blower power module which uses a pulse width modulated input from the ATC module and feedback from the blower motor to regu late the blower motor ground path it provides DIAGNOSIS AND TESTING BLOWER MOTOR NOISE OR VIBRATION Refer to the Blower Motor Noise Vibration Diagno sis chart Fig 1 REMOVAL The rear blower motor and blower wheels are ser viced o...

Page 3522: ...Fig 1 CS DISTRIBUTION REAR 24 39 BLOWER MOTOR Continued ...

Page 3523: ...e base and duct assembly 8 Install the eight screws that secure the support brackets to the floor console base and duct assembly Tighten the screws to 2 N m 17 in lbs 9 Install the body wire harness bracket onto the console rear support bracket 10 Connect the body wire harness connectors to the rear blower motor power module and the rear mode door actuator 11 Reconnect the battery negative cable 1...

Page 3524: ...wo support brackets the rear blower motor housing and the hands free module Tighten the screws to 2 N m 17 in lbs 4 Install the gear shift assembly Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE SHIFT MECHANISM INSTALLATION 5 Install the body wire harness bracket onto the console support bracket 6 Connect the body wire harness connectors to the rear blower motor power module floor console mode ...

Page 3525: ...EATER CORE 56 INSTALLATION INSTALLATION HEATER CORE EXTENSION TUBES 57 INSTALLATION HEATER CORE 58 HEATER INLET HOSE REMOVAL 58 INSTALLATION 59 HEATER RETURN HOSE REMOVAL 59 INSTALLATION 59 LIQUID LINE REMOVAL 60 INSTALLATION 61 SUCTION LINE REMOVAL 62 INSTALLATION 62 FILTER DRIER DESCRIPTION 63 OPERATION 63 REMOVAL 63 INSTALLATION 64 REFRIGERANT DESCRIPTION 64 OPERATION 64 DIAGNOSIS AND TESTING D...

Page 3526: ...ING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST EXPO SURE MAY IRRITATE THE EYES NOSE AND OR THROAT WEAR EYE PROTECTION WHEN SERVIC ING THE AIR CONDITIONING REFRIGERANT SYS TEM SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT IF EYE CONTACT OCCURS SEEK MEDICAL ATTEN TION IMMEDIATELY WARNING DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME POISONOUS GAS IS CREATED WHEN REFRIGE...

Page 3527: ...gaskets cannot be serviced with O rings The gaskets are not reusable and new gaskets do not require lubrication before installing CAUTION When installing a refrigerant line avoid sharp bends that may restrict refrigerant flow A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose Sharp bends will reduce the flow of refrige...

Page 3528: ...ormal refrigerant migration within the refrigerant system caused by ambient temperature changes The refrigerant migration may wash the refrigerant oil out of the compressor NOTE Prior to a vehicle being removed from ser vice or stored for more than two weeks the com pressor should be operated to ensure adequate refrigerant oil distribution throughout the system components Turn on the air condition...

Page 3529: ...ompressor This will determine how much oil the replacement compressor must contain before it is installed Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT OIL STAN DARD PROCEDURE REFRIGERANT OIL LEVEL INSTALLATION 1 Install the A C compressor mount onto the engine 2 Install the four A C compressor mount bolts to the engine Two to the engine block and two to the oil pan Torque the bo...

Page 3530: ...n the front of the engine compartment behind the radiator grille mounted to the radiator The condenser cannot be repaired and if faulty or damaged it must be replaced The con denser may be removed from the radiator for service without removing the radiator from the vehicle OPERATION The condenser is a heat exchanger that allows the high pressure refrigerant gas being discharged by the compressor t...

Page 3531: ... seal from the discharge line fit ting and discard 11 Install plug in or tape over the opened dis charge line fitting and the condenser inlet port 12 Remove the nut that secures the liquid line fitting to the condenser outlet port on the right side of the condenser 13 Disconnect the liquid line fitting from the con denser outlet port 14 Remove the seal from the liquid line fitting and discard 15 I...

Page 3532: ...BING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 19 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE A C DISCHARGE LINE REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING ...

Page 3533: ... PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 15 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE A C EVAPORATOR DESCRIPTION The evaporator is located in the heater A C unit housing behind the instrument panel The evapora tor is positioned in the heater A C housing so that all a...

Page 3534: ... 8 Pull the top of the distribution housing away from the evaporator housing far enough to disengage the two hook formations on the bottom of the distri bution housing from the two receptacles on the evap orator housing Fig 9 9 Remove the two screws that secure the upper intake air housing to the lower intake air housing 10 Remove the three screws that secure the upper intake air housing to the to...

Page 3535: ...ntake air housing to the top of the out board end of the evaporator housing Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening Tighten the screws to 2 N m 17 in lbs 6 Install and tighten the two screws that secure the upper intake air housing to the lower intake air housing Tighten the screws to 2 N m 17 in lbs 7 Engage the two hook formations on ...

Page 3536: ...hould only be tested following testing of the compressor NOTE Liquid CO2 is required to test the expansion valve This material is available from most welding supply facilities Liquid CO2 is also available from companies which service and sell fire extinguish ers When testing the expansion valve the work area and the vehicle temperature must be 21 to 27 C 70 to 85 F To test the expansion valve 1 Co...

Page 3537: ...n sion valve to the evaporator tube tapping plate 15 Remove the expansion valve from the evapo rator tube tapping plate 16 Remove the seals from the evaporator inlet and outlet tube fittings and discard 17 Install plugs in or tape over the opened evap orator inlet and outlet tube fittings and both expan sion valve ports 18 If necessary remove the evaporator tempera ture sensor retainer and the tem...

Page 3538: ...heater core REMOVAL REMOVAL HEATER CORE EXTENSION TUBES WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMBING WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIA...

Page 3539: ...encer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside 4 Remove the brake lamp switch from its mount ing bracket Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH REMOVAL 5 Disconnect the power brake booster input rod push rod from the pin on the brake pedal arm Refer to 5 BRAKES ABS HYDRAULIC ME CHANICAL POWER BRAK...

Page 3540: ...or tape from both heater core tube fittings and both heater core ports 2 Position the heater core tubes and sealing plate as a unit beneath the instrument panel 3 Align the engine compartment ends of both heater core tubes with the openings in the dash panel seal and push them simultaneously forward through the seal far enough to engage the heater core ends of the tubes with the heater core supply...

Page 3541: ...eater core tube sealing plate to the heater core sup ply and return ports Tighten the screw to 3 N m 27 in lbs 7 Reconnect the power brake booster input rod push rod to the pin on the brake pedal arm Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER INSTALLATION 8 Reinstall the brake lamp switch into its mount ing bracket Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH INS...

Page 3542: ...f of each end of the heater return hose Fig 18 CAUTION DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses Excessive pressure may damage or deform the tubes heater core causing an engine coolant leak 3 Disconnect each hose end by carefully twisting the hose back and forth on the tube while gently pulling it away from the end of the tube 4 If necessary carefull...

Page 3543: ...ir seal Fig 19 7 Remove the nut that secures the liquid line fit ting to the condenser outlet port on the right side of condenser Fig 20 8 Disconnect the liquid line fitting from the con denser outlet port 9 Remove the seal from the liquid line fitting and discard 10 Install plug in or tape over the opened liquid line fitting and the condenser outlet port 11 Disengage the routing clip retainer on ...

Page 3544: ...liquid line fitting and the filter drier inlet port 3 Lubricate a new rubber o ring seal with clean refrigerant oil and install it on the liquid line fitting 4 Reconnect the front section of the liquid line to the filter drier 5 Install and tighten the bolt that secures the liquid line fitting to the filter drier Tighten the bolt to 11 N m 100 in lbs 6 Position the front section of the liquid line...

Page 3545: ...ION LINE REMOVAL The air conditioner suction line includes the low side service port on the section of tubing located near the expansion valve WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING and Refer to 24 HEATING AIR CON DITIONING PLUMBING CAUTION 1 Recover the refrigerant from ...

Page 3546: ...4 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 15 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE FILTER DRIER DESCRIPTION The filter drier is mounted in a bracket secured to the right front strut tower in the engine compart ment The filter drier is con...

Page 3547: ...R CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE 9 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERANT DESCRIPTION The refrigerant used in this air conditioning sys tem is a HydroFluoroCarbon HFC type R 134a Unlike R 12 which is a ChloroFluoroCarbon CFC R 134a refrigerant does not contain ozone depleting chlorine R 134a ref...

Page 3548: ...e equipment couplings to the refrigerant system service ports be certain that the valve of each coupling is fully closed This will reduce the amount of effort required to make the connection 1 Remove the caps from the refrigerant system service ports and attach a manifold gauge set or a R 134a refrigerant recovery recycling charging sta tion that meets SAE Standard J2210 to the refriger ant system...

Page 3549: ...Y 1 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 2 Connect and dispense 0 283 kilograms 0 625 pounds or 10 ounces of R 134a refrigerant into the evacuated refrigerant system Refer to 24 HEAT ING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE 3 Proceed to the ...

Page 3550: ...th Black stripe attaches to the suction low side service port This port is located on the suction line near the compressor at the front of the engine compartment HIGH PRESSURE GAUGE HOSE The high pressure hose Red with Black stripe attaches to the discharge high side service port This port is located on the liquid line near the filter drier at the rear of the engine compartment RECOVERY RECYCLING ...

Page 3551: ...th the suction and discharge valves and turn off the vacuum pump If the refrigerant system fails to reach the specified vacuum the system has a leak that must be corrected Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT RE FRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM LEAKS 4 If the refrigerant system maintains the speci fied vacuum for thirty minutes restart the vacuum pump open both the su...

Page 3552: ...stem performance PAG refrigerant oil is much more hygroscopic than min eral oil and will absorb any moisture it comes into contact with even moisture in the air The PAG oil container should always be kept tightly capped until it is ready to be used After use recap the oil con tainer immediately to prevent moisture contamina tion STANDARD PROCEDURE REFRIGERANT OIL LEVEL WARNING REFER TO THE APPLICA...

Page 3553: ...MBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING 1 Lubricate the A C service port valve core with clean refrigerant oil prior to installation Use only refrigerant oil of the type recommended for the com pressor in the vehicle 2 Remove the tape or plug from the A C service port 3 Using a standard Schrader type valve core tool install and tighten the replacement val...

Page 3554: ... Once the MIL is extinguished the PCM must pass the diagnostic test for the most recent DTC for 40 warm up cycles 80 warm up cycles for the Fuel System Monitor and the Misfire Monitor A warm up cycle can best be described by the following The engine must be running A rise of 40 F in engine temperature must occur from the time when the engine was started Engine coolant temperature must crossover 16...

Page 3555: ...ic circuit monitors that check fuel emission engine and ignition perfor mance These monitors use information from various sensor circuits to indicate the overall operation of the fuel engine ignition and emission systems and thus the emissions performance of the vehicle The fuel engine ignition and emission systems monitors do not indicate a specific component prob lem They do indicate that there ...

Page 3556: ...n chamber when the exhaust gases are no longer recirculated While this test does not directly measure the operation of the EGR system it can be inferred from the shift in the O2S data whether the EGR system is operating correctly Because the O2S is being used the O2S test must pass its test before the EGR test Also looks at EGR linear potentiometer for feedback MISFIRE MONITOR Excessive engine mis...

Page 3557: ...p orative system leaks The NVLD seals the canister vent during engine off conditions If the EVAP system has a leak of less than the failure threshold the evaporative system will be pulled into a vacuum either due to the cool down from operating temperature or diurnal ambient temperature cycling The diurnal effect is considered one of the primary contributors to the leak determi nation by this diag...

Page 3558: ...rates between 750 and 2000 RPM Suppose the sensor s output circuit shorts to ground when engine operates above 2400 RPM resulting in 0 volt input to the PCM Because the condition happens at an engine speed above the maximum threshold 2000 rpm the PCM will not store a DTC There are several operating conditions for which the PCM monitors and sets DTC s Refer to Moni tored Systems Components and Non ...

Page 3559: ...osphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister The canister temporarily holds the vapors The Powertrain Control Module PCM allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions Fig 1 All engines use a proportional purge solenoid sys tem The PCM contr...

Page 3560: ...TION LINE 7 TANK VAPOR LINE 8 VAPOR LINE TO CANISTER 9 CHECK VALVE N C 10 CONTROL VALVE 11 NATURAL VACUUM LEAD DETECTION NVLD 12 LIQUID SEPARATOR IF EQUIPPED 13 ENGINE WIRING HARNESS TO NVLD 14 VAPOR CANISTER 15 PURGE LINE 16 PURGE DEVICE 17 WITHOUT NVLD 18 BREATHER ELEMENT 19 FLOW CONTROL ORIFICE 20 SERVICE PORT 21 WITH NVLD CS EVAPORATIVE EMISSIONS 25 7 EVAPORATIVE EMISSIONS Continued ...

Page 3561: ...el filler cap incorporates a two way relief valve that is closed to atmosphere during normal operating conditions The relief valve is calibrated to open when a pressure of 17 kPa 2 5 psi or vacuum of 2 kPa 0 6 in Hg occurs in the fuel tank When the pressure or vacuum is relieved the valve returns to the normally closed position CAUTION Remove the fuel filler cap to release fuel tank pressure befor...

Page 3562: ... to the vapor canister Vapor is absorbed in the canister until vapor flow in the lines stops either following shut off or by having the fuel level in the tank rise high enough to close the control valve The control valve Refer to 14 FUEL SYS TEM FUEL DELIVERY FUEL TANK OPERATION contains a float that rises to seal the large diameter vent path to the canister At this point in the fueling of the veh...

Page 3563: ...ECIRCULATION LINE 7 TANK VAPOR LINE 8 VAPOR LINE TO CANISTER 9 CHECK VALVE N C 10 CONTROL VALVE 11 NATURAL VACUUM LEAD DETECTION NVLD 12 LIQUID SEPARATOR IF EQUIPPED 13 ENGINE WIRING HARNESS TO NVLD 14 VAPOR CANISTER 15 PURGE LINE 16 PURGE DEVICE 17 WITHOUT NVLD 18 BREATHER ELEMENT 19 FLOW CONTROL ORIFICE 20 SERVICE PORT 21 WITH NVLD 25 10 EVAPORATIVE EMISSIONS CS ORVR Continued ...

Page 3564: ... Defective vapor vent handling component Defective fill nozzle PCV VALVE DESCRIPTION The PCV valve contains a spring loaded plunger The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum DIAGNOSIS AND TESTING PCV SYSTEM WARNING APPLY PARKING BRAKE AND OR BLOCK WHEELS BEFORE PERFORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING 1 W...

Page 3565: ... determined intervals and engine conditions Purge Free Cells Purge free memory cells are used to identify the fuel vapor content of the evaporative canister Since the evaporative canister is not purged 100 of the time the PCM stores information about the evapora tive canister s vapor content in a memory cell The purge free cells are constructed similar to cer tain purge normal cells The purge free...

Page 3566: ...4 REMOVAL 15 INSTALLATION 15 TUBE REMOVAL 1 Remove the 2 bolts from tube flange at rear of intake manifold Fig 1 2 Remove the tube bracket bolt Fig 2 3 Remove the 2 flange bolts at EGR valve Fig 3 Fig 1 EGR AT INTAKE MANIFOLD Fig 2 TUBE BRACKET Fig 3 EGR VALVE AND TUBE CS EXHAUST GAS RECIRCULATION 25 13 ...

Page 3567: ...tem allows a predetermined amount of hot exhaust gas to recirculate and dilute the incoming air fuel mixture The diluted air fuel mixture reduces peak flame temperature during com bustion The electric EGR transducer contains an electri cally operated solenoid and a back pressure trans ducer Fig 5 The Powertrain Control Module PCM operates the solenoid The PCM determines when to energize the soleno...

Page 3568: ...conditions This system does not allow EGR at idle A failed or malfunctioning EGR system can cause engine spark knock sags or hesitation rough idle engine stalling and increased emissions REMOVAL 1 Disconect the negative and then the positive battery cable 2 Remove battery 3 Unlock and disconnect the electrical connector from the EGR valve Fig 6 4 Remove the 2 EGR tube bolts Fig 7 5 Remove the 2 mo...

Page 3569: ...if the MIL is illuminated and a fault is stored from another monitor In these situations the Task Manager postpones monitors pending resolu tion of the original fault The Task Manager does not run the test until the problem is remedied For example when the MIL is illuminated for an Oxygen Sensor fault the Task Manager does not run the Catalyst Monitor until the Oxygen Sensor fault is remedied Sinc...

Page 3570: ... trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a warm up cycle counter DTCs are auto matically erased following 40 warm up cycles if the component does not fail again For misfire and fuel system monitors the compo nent must pass the test under a Similar Conditions Window in order to record a good trip A Similar Con ditions Window is when engine RPM i...

Page 3571: ... different Similar conditions Windows Fuel System and Misfire FUEL SYSTEM Fuel System Similar Conditions Window An indicator that Absolute MAP When Fuel Sys Fail and RPM When Fuel Sys Failed are all in the same range when the failure occurred Indicated by switch ing from NO to YES Absolute MAP When Fuel Sys Fail The stored MAP reading at the time of failure Informs the user at what engine load the...

Page 3572: ... in accessing the Similar Conditions Window Adaptive Memory Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correction 200 Rev Counter Counts 0 100 720 degree cycles SCW Cat 200 Rev Counter Counts when in similar conditions SCW FTP 1000 Rev Counter Counts 0 4 when in similar conditions Misfire Good Trip Counter Cou...

Page 3573: ......

Page 3574: ...UTOMATIC 5 39 ADJUSTER TAPPET NOISE DIAGNOSIS DIAGNOSIS AND TESTING LASH 9 45 ADJUSTER UNLOCKING STANDARD PROCEDURE AUTOMATIC 5 40 AERATION DIAGNOSIS AND TESTING COOLING SYSTEM 7 2 AFTER AN AIRBAG DEPLOYMENT STANDARD PROCEDURE SERVICE 8O 6 AIR CLEANER ELEMENT INSTALLATION 9 27 AIR CLEANER ELEMENT REMOVAL 9 27 AIR CLEANER HOUSING INSTALLATION 9 27 AIR CLEANER HOUSING REMOVAL 9 27 AIR CONTROL MOTOR ...

Page 3575: ...8F 12 BATTERY HOLDDOWN INSTALLATION 8F 12 BATTERY HOLDDOWN OPERATION 8F 12 BATTERY HOLDDOWN REMOVAL 8F 12 BATTERY REPLACEMENT STANDARD PROCEDURE 8N 20 8Ns 20 BATTERY SYSTEM CLEANING 8F 5 BATTERY SYSTEM DESCRIPTION 8F 1 BATTERY SYSTEM DIAGNOSIS AND TESTING 8F 2 BATTERY SYSTEM INSPECTION 8F 5 BATTERY SYSTEM OPERATION 8F 2 BATTERY SYSTEM SPECIFICATIONS 8F 6 BATTERY SYSTEM SPECIAL TOOLS SPECIAL TOOLS ...

Page 3576: ...BLE RIGHT REAR REMOVAL PARKING 5 45 BRAKE CALIPER CLEANING DISC 5 16 BRAKE CALIPER FRONT ASSEMBLY DISC 5 16 BRAKE CALIPER FRONT DISASSEMBLY DISC 5 14 BRAKE CALIPER FRONT INSTALLATION DISC 5 17 BRAKE CALIPER FRONT REMOVAL DISC 5 13 BRAKE CALIPER INSPECTION DISC 5 16 BRAKE CALIPER REAR REMOVAL DISC 5 17 BRAKE CALIPER ADAPTER FRONT INSTALLATION DISC 5 24 BRAKE CALIPER ADAPTER FRONT REMOVAL DISC 5 23 ...

Page 3577: ...HANGE STANDARD PROCEDURE DIFFERENTIAL ASSEMBLY FLUID 3 48 CHANGE STANDARD PROCEDURE ENGINE OIL AND FILTER 9 74 CHANGE STANDARD PROCEDURE OVERRUNNING CLUTCH HOUSING FLUID 3 49 CHANGER DESCRIPTION CD DVD 8A 7 CHANGER INSTALLATION CD DVD 8A 8 CHANGER OPERATION CD DVD 8A 7 CHANGER REMOVAL CD DVD 8A 7 CHANNEL INSTALLATION DOOR FIXED GLASS RUN 23 35 CHANNEL INSTALLATION DOOR GLASS RUN 23 18 CHANNEL INST...

Page 3578: ... BEARINGS STANDARD PROCEDURE 9 54 CONNECTOR INSTALLATION 8W 01 11 CONNECTOR REMOVAL 8W 01 11 CONNECTOR GROUND AND SPLICE INFORMATION DESCRIPTION 8W 01 7 CONNECTOR GROUND SPLICE LOCATION DESCRIPTION 8W 91 1 CONSOLE DESCRIPTION OVERHEAD 8M 1 CONSOLE DIAGNOSIS AND TESTING OVERHEAD 8M 2 CONSOLE INSTALLATION FRONT FLOOR 23 90 CONSOLE INSTALLATION REAR FLOOR 23 98 CONSOLE REMOVAL FRONT FLOOR 23 90 CONSO...

Page 3579: ...SHAFT POSITION SENSOR REMOVAL 14 38 14s 13 CRANKSHAFT REAR OIL SEAL RETAINER INSTALLATION 9 63 CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL 9 63 CRANKSHAFT SPROCKET INSTALLATION 9 91 CRANKSHAFT SPROCKET REMOVAL 9 90 CROSSBAR INSTALLATION LUGGAGE RACK 23 60 CROSSBAR REMOVAL LUGGAGE RACK 23 60 CROSSMEMBER INSTALLATION ENGINE CRADLE 13 17 CROSSMEMBER INSTALLATION RADIATOR 23 61 CROSSMEMBER INSTALLATION ...

Page 3580: ...N CHANNEL INSTALLATION 23 35 DOOR FIXED GLASS RUN CHANNEL REMOVAL 23 35 DOOR GLASS INSTALLATION 23 18 23 36 DOOR GLASS REMOVAL 23 18 23 36 DOOR GLASS RUN CHANNEL INSTALLATION 23 18 DOOR GLASS RUN CHANNEL REMOVAL 23 18 DOOR HEADER BLACK OUT TAPE INSTALLATION 23 19 23 36 DOOR HEADER BLACK OUT TAPE REMOVAL 23 19 23 36 DOOR HEADER WEATHERSTRIP INSTALLATION FRONT 23 166 DOOR HEADER WEATHERSTRIP INSTALL...

Page 3581: ...ON 9 70 ENGINE OIL DESCRIPTION FLEXIBLE FUEL 0 3 ENGINE OIL DIESEL ENGINES DESCRIPTION 0 6 ENGINE OIL AND FILTER CHANGE STANDARD PROCEDURE 9 74 ENGINE OIL AND LUBRICANTS DESCRIPTION 0 1 ENGINE OIL COOLER DESCRIPTION 9 75 ENGINE OIL COOLER INSTALLATION 9 75 ENGINE OIL COOLER OPERATION 9 75 ENGINE OIL COOLER REMOVAL 9 75 ENGINE OIL LEAK INSPECTION DIAGNOSIS AND TESTING 9 10 ENGINE OIL LEVEL CHECK ST...

Page 3582: ...N INSTALLATION REAR 23 98 FLOOR STOWAGE BIN REMOVAL REAR 23 98 FLOW AND PRESSURE TEST DIAGNOSIS AND TESTING POWER STEERING 19 1 FLOW CHECK DIAGNOSIS AND TESTING COOLING SYSTEM 7 2 FLUID DESCRIPTION AUTOMATIC TRANSAXLE 0 4 FLUID AND FILTER SERVICE STANDARD PROCEDURE 21 105 FLUID CAPACITIES SPECIFICATIONS 0 6 FLUID CHANGE STANDARD PROCEDURE DIFFERENTIAL ASSEMBLY 3 48 FLUID CHANGE STANDARD PROCEDURE ...

Page 3583: ...LLATION 14 26 14s 8 FUEL RAIL REMOVAL 14 26 14s 7 FUEL REQUIREMENTS DESCRIPTION 0 4 FUEL REQUIREMENTS DIESEL ENGINE DESCRIPTION 0 6 FUEL TANK INSTALLATION 14 34 14s 11 FUEL TANK REMOVAL 14 26 14s 8 FUEL TANK FILLER TUBE INSTALLATION 14 37 14s 12 FUEL TANK FILLER TUBE REMOVAL 14 37 14s 11 FULL OPEN SWITCH DESCRIPTION 8N 10 8Ns 10 FULL OPEN SWITCH DIAGNOSIS AND TESTING 8N 10 8Ns 10 FULL OPEN SWITCH ...

Page 3584: ...NSOR FRONT SEATS DESCRIPTION 8G 12 HEATED SEAT SENSOR FRONT SEATS DIAGNOSIS AND TESTING 8G 12 HEATED SEAT SENSOR FRONT SEATS OPERATION 8G 12 HEATED SEAT SENSOR FRONT SEATS REMOVAL 8G 13 HEATED SEAT SWITCH DESCRIPTION DRIVER 8G 10 HEATED SEAT SWITCH DESCRIPTION PASSENGER 8G 18 HEATED SEAT SWITCH DIAGNOSIS AND TESTING DRIVER 8G 10 HEATED SEAT SWITCH DIAGNOSIS AND TESTING PASSENGER 8G 18 HEATED SEAT ...

Page 3585: ...INSTALLATION 21 6 INPUT SHAFT SEAL REMOVAL 21 5 INSTRUMENT CLUSTER DESCRIPTION 8J 1 INSTRUMENT CLUSTER INSTALLATION 8J 6 INSTRUMENT CLUSTER OPERATION 8J 1 INSTRUMENT CLUSTER REMOVAL 8J 6 INSTRUMENT CLUSTER WARNING 8J 5 INSTRUMENT CLUSTER SELF TEST STANDARD PROCEDURE 8J 6 INSTRUMENT PANEL ANTENNA CABLE INSTALLATION 8A 8 INSTRUMENT PANEL ANTENNA CABLE REMOVAL 8A 8 INSTRUMENT PANEL ASSEMBLY INSTALLAT...

Page 3586: ... INSTALLATION NATURAL VAC 25 9 LEAK DETECTION ASSY REMOVAL NATURAL VAC 25 8 LEAK INSPECTION DIAGNOSIS AND TESTING ENGINE OIL 9 10 LEAK REPAIRING STANDARD PROCEDURE TIRE 22 16 LEAK TEST DIAGNOSIS AND TESTING COOLING SYSTEM 7 2 LEAKAGE DIAGNOSIS AND TESTING TORQUE CONVERTER HOUSING FLUID 21 14 LEAKAGE TEST DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESSURE 9 9 LEAKS DIAGNOSIS AND TESTING REFRIGERANT...

Page 3587: ...EXHAUST 9 85 MANIFOLD INSTALLATION LEFT EXHAUST 9 85 MANIFOLD INSTALLATION LOWER INTAKE 9 84 MANIFOLD INSTALLATION RIGHT EXHAUST 9 85 MANIFOLD INSTALLATION UPPER INTAKE 9 83 MANIFOLD LEFT INSPECTION EXHAUST 9 84 MANIFOLD REMOVAL CROSSOVER PIPE EXHAUST 9 85 MANIFOLD REMOVAL LEFT EXHAUST 9 84 MANIFOLD REMOVAL LOWER INTAKE 9 82 MANIFOLD REMOVAL RIGHT EXHAUST 9 85 MANIFOLD REMOVAL UPPER INTAKE 9 81 MA...

Page 3588: ... INSTALLATION WINDOW 8N 39 MOTOR OPERATION BLOWER 24 32 24 38 MOTOR OPERATION LIFTGATE DRIVE UNIT 8N 11 8Ns 11 MOTOR OPERATION LUMBAR 8N 30 8Ns 29 MOTOR OPERATION RECLINER 8N 35 8Ns 33 MOTOR REMOVAL BLOWER 24 34 24 38 MOTOR REMOVAL DRIVE 23 159 MOTOR REMOVAL FRONT WIPER 8R 12 MOTOR REMOVAL IDLE AIR CONTROL 14 39 14s 14 MOTOR REMOVAL LIFTGATE DRIVE UNIT 8N 12 8Ns 11 MOTOR REMOVAL LUMBAR 8Ns 29 MOTO...

Page 3589: ...PTION 8N 15 8Ns 14 OPTICAL SENSOR INSTALLATION 8N 16 8Ns 15 OPTICAL SENSOR OPERATION 8N 15 8Ns 15 OPTICAL SENSOR REMOVAL 8N 15 8Ns 15 ORVR OPERATION 25 9 OUT STANDARD PROCEDURE AUTOMATIC ADJUSTER LOCKING 5 39 OUT TAPE INSTALLATION DOOR HEADER BLACK 23 19 23 36 OUT TAPE REMOVAL DOOR HEADER BLACK 23 19 23 36 OUTBOARD LATCH ASSEMBLY INSTALLATION THIRD ROW 23 141 OUTBOARD LATCH ASSEMBLY REMOVAL THIRD ...

Page 3590: ...ING A C 24 3 PERFORMANCE TEST DIAGNOSIS AND TESTING HEATER 24 4 PIN BUSHINGS ASSEMBLY CALIPER GUIDE 5 20 PIN BUSHINGS DISASSEMBLY CALIPER GUIDE 5 18 PINCH SENSOR DESCRIPTION 8N 16 8Ns 16 PINCH SENSOR DIAGNOSIS AND TESTING 8N 16 8Ns 16 PINCH SENSOR INSTALLATION 8N 16 8Ns 16 PINCH SENSOR OPERATION 8N 16 8Ns 16 PINCH SENSOR REMOVAL 8N 16 8Ns 16 PINION FACTOR SETTING STANDARD PROCEDURE 8E 11 PINS FRON...

Page 3591: ...SIS AND TESTING CHECKING ENGINE OIL 9 73 PRESSURE INSTALLATION HOSE POWER STEERING 19s 6 PRESSURE REMOVAL HOSE POWER STEERING 19s 5 PRESSURE CAP DESCRIPTION 7 23 PRESSURE CAP OPERATION 7 23 PRESSURE CAP TESTING DIAGNOSIS AND TESTING COOLING SYSTEM 7 23 PRESSURE CAP TO FILLER NECK SEAL DIAGNOSIS AND TESTING 7 24 PRESSURE FOR HIGH SPEED OPERATION STANDARD PROCEDURE TIRE 22 16 PRESSURE LEAKAGE TEST D...

Page 3592: ...RIPTION AWD 0 6 REAR DRIVELINE MODULE NOISE DIAGNOSIS AND TESTING 3 29 REAR DRIVELINE MODULE OPERATION DIAGNOSIS AND TESTING 3 30 REAR FASCIA INSTALLATION 13 8 REAR FASCIA REMOVAL 13 6 REAR FASCIA TO APERTURE BRACKET INSTALLATION 13 9 REAR FASCIA TO APERTURE BRACKET REMOVAL 13 8 REAR FLOOR CONSOLE INSTALLATION 23 98 REAR FLOOR CONSOLE REMOVAL 23 97 REAR FLOOR STOWAGE BIN INSTALLATION 23 98 REAR FL...

Page 3593: ...FITTING STANDARD PROCEDURE PISTON 9 67 RING PANEL INSTALLATION FRONT SEAT OUTER TRIM 23 119 RING PANEL REMOVAL FRONT SEAT OUTER TRIM 23 119 RINGS DESCRIPTION PISTON 9 67 RINGS INSTALLATION PISTON 9 68 RINGS REMOVAL PISTON 9 68 RISER INSTALLATION SECOND ROW SEAT 23 130 RISER REMOVAL SECOND ROW SEAT 23 130 ROAD TEST DIAGNOSIS AND TESTING 21 11 ROCKER ARM DESCRIPTION 9 44 ROCKER ARM SHAFTS DESCRIPTIO...

Page 3594: ...AL MEMORY HEATED 8E 13 SEAT ARMREST INSTALLATION 23 121 SEAT ARMREST REMOVAL 23 121 SEAT BACK INSTALLATION FRONT 23 115 SEAT BACK REMOVAL FRONT 23 115 SEAT BACK CUSHION FOAM COVER INSTALLATION THIRD ROW 23 133 SEAT BACK CUSHION FOAM COVER REMOVAL THIRD ROW 23 132 SEAT BACK CUSHION FOAM COVER INSTALLATION FRONT 23 117 SEAT BACK CUSHION FOAM COVER INSTALLATION SECOND ROW 23 124 SEAT BACK CUSHION FOA...

Page 3595: ...3 124 SECOND ROW SEAT BACK CUSHION FOAM COVER REMOVAL 23 123 SECOND ROW SEAT BACK FRAME RECLINER TORQUE ROD CRAS ASSEMBLY INSTALLATION 23 126 SECOND ROW SEAT BACK FRAME RECLINER TORQUE ROD CRAS ASSEMBLY REMOVAL 23 125 SECOND ROW SEAT CUSHION FOAM COVER INSTALLATION 23 130 SECOND ROW SEAT CUSHION FOAM COVER REMOVAL 23 129 SECOND ROW SEAT LOAD FLOOR PANEL INSTALLATION 23 125 SECOND ROW SEAT LOAD FLO...

Page 3596: ...ELDS REMOVAL FRONT SEAT 23 119 SHIFT BEZEL INSTALLATION GEAR 21 107 SHIFT BEZEL REMOVAL GEAR 21 107 SHIFT CABLE INSTALLATION GEAR 21 108 SHIFT CABLE REMOVAL GEAR 21 107 SHIFT INTERLOCK CABLE INSTALLATION 21 143 SHIFT INTERLOCK CABLE REMOVAL 21 140 SHIFT INTERLOCK SYSTEM DESCRIPTION 21 148 SHIFT INTERLOCK SYSTEM DIAGNOSIS AND TESTING 21 148 SHIFT INTERLOCK SYSTEM OPERATION 21 148 SHIFT KNOB INSTALL...

Page 3597: ...9 SUCTION LINE INSTALLATION 24 62 SUCTION LINE REMOVAL 24 62 SUN VISOR INSTALLATION 23 101 SUN VISOR REMOVAL 23 101 SUNROOF DESCRIPTION 23 153 SUNROOF DIAGNOSIS AND TESTING 23 153 SUNROOF GLASS PANEL ADJUSTMENT ADJUSTMENTS 23 160 SUNSHADE INSTALLATION 23 163 SUNSHADE REMOVAL 23 163 SUPPLY INSTALLATION HOSE POWER STEERING 19 27 19s 8 SUPPLY PCM OUTPUT OPERATION 5 VOLT 8E 10 SUPPLY REMOVAL HOSE POWE...

Page 3598: ...ENSOR REMOVAL AMBIENT 8M 6 TEMP SENSOR REMOVAL ENGINE COOLANT 7 19 TEMPERATURE SENSOR DESCRIPTION EVAPORATOR 24 19 TEMPERATURE SENSOR DESCRIPTION INFRARED 24 20 TEMPERATURE SENSOR DIAGNOSIS AND TESTING AMBIENT 8M 6 TEMPERATURE SENSOR INSTALLATION BATTERY 8F 17 TEMPERATURE SENSOR INSTALLATION EVAPORATOR 24 19 TEMPERATURE SENSOR INSTALLATION INFRARED 24 20 TEMPERATURE SENSOR INSTALLATION INTAKE AIR ...

Page 3599: ...RIVER POWER SEAT 8N 29 8Ns 27 TRACK DIAGNOSIS AND TESTING PASSENGER POWER SEAT 8N 34 8Ns 32 TRACK INSTALLATION DRIVER POWER SEAT 8N 30 8Ns 28 TRACK INSTALLATION PASSENGER POWER SEAT 8N 34 8Ns 33 TRACK OPERATION DRIVER POWER SEAT 8N 29 8Ns 27 TRACK OPERATION PASSENGER POWER SEAT 8N 34 8Ns 32 TRACK REMOVAL DRIVER POWER SEAT 8N 30 8Ns 28 TRACK REMOVAL PASSENGER POWER SEAT 8N 34 8Ns 33 TRANS COOLER IN...

Page 3600: ...EMOVAL MANIFOLD TUNE 14 40 14s 15 VALVE REMOVAL OIL PRESSURE RELIEF 9 77 VALVE REMOVAL PCV 25 12 VALVE AND VALVE SEAT REFACING STANDARD PROCEDURE 9 42 VALVE BODY ASSEMBLY 21s 52 VALVE BODY ASSEMBLY 21 178 VALVE BODY DESCRIPTION 21 167 VALVE BODY DISASSEMBLY 21s 47 VALVE BODY DISASSEMBLY 21 173 VALVE BODY INSTALLATION 21s 56 VALVE BODY INSTALLATION 21 183 VALVE BODY OPERATION 21 168 VALVE BODY REMO...

Page 3601: ...8 WHEEL ASSEMBLY ALUMINUM WHEEL INSTALLATION TIRE 22 6 WHEEL ASSEMBLY ALUMINUM WHEEL REMOVAL TIRE 22 6 WHEEL BALANCE STANDARD PROCEDURE TIRE 22 5 WHEEL INSPECTION DIAGNOSIS AND TESTING 22 17 WHEEL SPECIFICATIONS 22 18 WHEEL TRIM CARE CLEANING WHEEL 22 18 WHEEL VIBRATION DIAGNOSIS AND TESTING TIRE 22 1 WHEELHOUSE SPLASH SHIELD INSTALLATION FRONT 23 58 WHEELHOUSE SPLASH SHIELD INSTALLATION REAR 23 6...

Page 3602: ...______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Dealership Technician Dealer Code Retail Customer Manual Title Year Number and Page _________________________________________________ _____________________________________________...

Page 3603: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 8 ...

Search results

Summary of Contents for 2004 Pacifica

Reviews:

Chrysler 2004 Pacifica, Service Manual, Page: 3578 / 3603

Search results

Summary of Contents for 2004 Pacifica

Reviews: