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Chrysler 2005 Crossfire SRT6, Service Manual

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Chrysler 2005 Crossfire SRT6 Service Manual Download Page 2568

(P1600) ROUGH ROAD DETECTED (CONTINUED)

12.

INTERMITTENT WIRING AND CONNECTORS

The condition that caused this DTC to set is currently not present. Inspect the related wiring harness for a possible
intermittent condition.

Note: Check connectors — Clean/repair as necessary. Poor pin to terminal connections can set DTCs.

Note: Check for any Technical Service Bulletins that may apply.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors specific to this DTC. Wiggle the
wires while checking for shorts and/or open circuits.

Were there any problems found?

Yes

>> Repair as necessary.

Perform POWERTRAIN VERIFICATION TEST - VER 2.

No

>> The condition that caused this DTC to set is currently not present. Inspect the related wiring harness for

a possible intermittent condition.

9 - 644

ENGINE - ELECTRICAL DIAGNOSTICS

ZH

Summary of Contents for 2005 Crossfire SRT6

Page 1: ... 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 14 Fuel System 19 Steering 21 Transmission 22 Tires Wheels 23 Body 24 Heating Air Conditioning 25 Emissions Control Component and System Index DTC Index Service Manual Comment...

Page 2: ......

Page 3: ...umbers that provide specific information about the vehicle Refer to the VIN Code Breakdown table for decoding information CROSSFIRE VIN CODE BREAKDOWN POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Manufactured By DaimlerChrysler Corporation 2 Make C Chrysler 3 Vehicle Type 3 Passenger Car 4 Other A Restraint System Active Front And Side Air Bags 5 Car Line N Crossfire LHD P Crossf...

Page 4: ...re month and year Gross Vehicle Weight Rating GVWR Gross Axle Weight Rating GAWR Front Gross Axle Weight Rating GAWR Rear Month Day Hour MDH VECI LABEL DESCRIPTION All models are equipped with a Vehicle Emission Con trol Information VECI Label DaimlerChrysler Corpo ration permanently attaches the label in the engine compartment It cannot be removed without defacing the information and destroying t...

Page 5: ... the grade number the greater the bolt strength Identification is determined by the line marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 10 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the ...

Page 6: ...4 INTRODUCTION ZH ...

Page 7: ...ZH INTRODUCTION 5 ...

Page 8: ...ise versa CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F x 3 377 Kilopascals kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals kPa kPa x 0 145 psi Inches x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0...

Page 9: ...ZH INTRODUCTION 7 ...

Page 10: ...FERENCES DESCRIPTION Individual torque charts appear within many of the groups Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts 8 INTRODUCTION ZH ...

Page 11: ...EQUIREMENTS 5 FLUID CAPACITIES SPECIFICATIONS FLUID CAPACITIES 5 FLUID FILL CHECK LOCATIONS DESCRIPTION 5 LUBRICATION POINTS DESCRIPTION 6 MAINTENANCE SCHEDULES DESCRIPTION DESCRIPTION FLEXIBLE SERVICE SYSTEM FSS 6 DESCRIPTION MAINTENANCE SCHEDULES 8 HOISTING STANDARD PROCEDURE HOISTING 10 JUMP STARTING STANDARD PROCEDURE JUMP STARTING 11 EMERGENCY TOW HOOKS DESCRIPTION 12 TOWING STANDARD PROCEDUR...

Page 12: ...NGINE 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 INTER NAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE ...

Page 13: ...NERS WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL KEEP OUT OF REACH OF CHILDREN DISPOSE OF GLYCOL BASE COOLANT PROPERLY CON TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE PERSONAL INJURY CAN RESULT AVOID RADIATOR COOLING FAN WHEN ENG...

Page 14: ...an that of water CAUTION Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob lems associated with 100 percent ethylene glycol COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks cylinder heads and water pumps requires special corrosion protection Only MoparT Antifreeze Coolant 5 Year 100 000 Mile Formula is recommended This coolant offers th...

Page 15: ...vice required or recommended Filled at the factory with Pentosin CHF 11S Use Pentosin CHF 11S Mopar part number 05127381AA Steering noise and reduced component life may result if an unapproved fluid is used DESCRIPTION FUEL REQUIREMENTS Crossfire engines require the use of unleaded fuel to reduce exhaust emissions Use premium unleaded gasoline having a minimum octane rating of 91 R M 2 Higher octa...

Page 16: ...Powertrain Control Module PCM and the Controller Antilock Brake CAB via the Controller Area Network CAN data bus The data required for FSS from the CAN includes the following The four wheel speed sensors from the CAB Coolant temperature from the PCM Engine speed from the PCM Load torque from the PCM TRIP ODOMETER FSS INDICATOR This display in the instrument cluster shows the distance traveled sinc...

Page 17: ...cond symbol represents Service B Depending on operating conditions throughout the year the next service is calculated and displayed next to the this symbol in days remaining before the next service is required ZH LUBRICATION MAINTENANCE 0 7 ...

Page 18: ...o the ON RUN position or while driving when reaching the service warning threshold It can be cancelled manually by pressing the knob button to the left of the display Once the suggested term has passed the message plus either the symbol for Service A or the symbol for Service B preceded by a minus symbol blinks for approximately thirty seconds and a tone sounds every time when turning the key to t...

Page 19: ...ipers and washer system Check seat belts for damage and proper function Test hydraulic brakes and check parking brake function Inspection Check front and rear brake pads for lining thickness Check condition of front and rear brake discs Check tires for damage and general condition Check tire inflation pressures and correct if necessary Check major underbody components for leakage or damage if ther...

Page 20: ...on hoisting device on suspension components damage to vehicle can result The vehicle can be lifted with A twin post chassis hoist A ramp type drive on hoist FLOOR JACK When properly positioned a floor jack can be used to lift the vehicle Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails CAUTION Do not lift vehicle with a floor jack positioned...

Page 21: ...ND FACE FROM BATTERIES AT ALL TIMES CAUTION If the cause of starting problem on disabled vehicle is severe damage to booster vehicle charg ing system can result 1 Raise hood on disabled vehicle and visually inspect engine compartment for Battery cable clamp condition clean if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level Generator drive belt con...

Page 22: ...s should be used for EMERGENCY purposes only CAUTION DO NOT USE EMERGENCY TOW HOOKS FOR TOW TRUCK HOOK UP OR HIGHWAY TOWING TOWING STANDARD PROCEDURE TOWING WARNINGS AND PRECAUTIONS WARNING DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES FUEL LEAK CAN RESULT DO NOT VENTURE UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS DO NOT ALLOW PASSENGERS TO RIDE IN ...

Page 23: ...h wheels removed install lug nuts to retain brake rotors A towed vehicle should be raised until the lifted wheels are a minimum 100 mm 4 in from the ground Be sure there is at least 100 mm 4 in clearance between the tail pipe and the ground If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground to increase the ground clearance at the rear of th...

Page 24: ......

Page 25: ... or worn steering or suspension components 2 Tighten or replace components as necessary 3 Tires worn or out of balance 3 Replace or balance tires 4 Alignment 4 Align vehicle to specifications 5 Leaking steering dampener 5 Replace steering dampener VEHICLE INSTABILITY 1 Loose or worn wheel bearings 1 Adjust or replace wheel bearings 2 Loose or worn steering or suspension components 2 Tighten or rep...

Page 26: ...ring or suspension components 6 Repair as necessary 7 Cross caster out of specification 7 Align vehicle KNOCKING RATTLING OR SQUEAKING 1 Worn shock bushings 1 Replace shock 2 Loose worn or bent steering suspension components 2 Inspect tighten or replace components as necessary 3 Worn shock valve 3 Replace shock IMPROPER TRACKING 1 Loose worn or bent track bar 1 Inspect tighten or replace component...

Page 27: ...ched with a nut and cotter pin must be torqued to specification Then if the slot in the nut does not line up with the cotter pin hole tighten nut until it is aligned Never loosen the nut to align the cotter pin hole Note Periodic lubrication of the front suspension steering system components may be required Rubber bushings must never be lubricated Note Vehicles are delivered from the factory with ...

Page 28: ...icates the spring location 1 Is the eccentric repair bolt for adjusting caster 3 mm Range of adjustment 25 Caster CAMBER Camber is the inward or outward tilt of the wheel rel ative to the center of the vehicle Tilting the top of the wheel inward provides negative camber NEG Tilting the top of the wheel outward provides positive camber POS Incorrect camber will cause wear on the inside or outside e...

Page 29: ...st progressively toe outward as the steering is turned from center This eliminates tire scrubbing and undue tire wear when steering a vehi cle through a turn STEERING AXIS INCLINATION ANGLE Is measured in degrees and is the angle that the steering knuckles are tilted The inclination angle has a fixed relationship with the camber angle It will not change except when a spindle or ball stud is damage...

Page 30: ...eplace the tie rod link or replace the drag link Inspect the steering coupling It must not have any play If necessary replace the steering coupling Inspect the steering gear for play If play exists adjust the vehicle s steering gear STANDARD PROCEDURE CHASSIS ALIGNMENT INSPECTION 1 Observe the general information on chassis alignment inspection Refer to 2 SUSPENSION WHEEL ALIGN MENT STANDARD PROCE...

Page 31: ...on data media e g floppy disks credit cards etc could be rendered unusable Note Be sure to clean measurement points on the lower wishbone Note Remove any metal shavings on the measuring plate 2 Install the measuring plate in the recessed area in the lower control arm The groove in the measuring plate should be at an angle of 90 towards the direction of travel 3 Inspect the vehicle level at the fro...

Page 32: ...ction Wear protective gloves Note Inspect for prior installation of the eccentric repair bolt 3 For camber compress the front spring 1 Refer to 2 SUSPENSION FRONT SPRING REMOVAL 4 Install the repair bolt 2 Screw on the nut from the repair kit as far as it will go but do not tighten it so that the rubber mount on the wishbone can turn when the suspension is compressed and rebounded 5 Release the fr...

Page 33: ...ROCEDURE STANDARD PROCEDURE CHECKING AND ADJUSTING FRONT TOE IN 1 Set the steering wheel in the center position Note The steering gear is in the center position when the separating joint of the steering coupling and the marking notch on the steering gear are above each other Offset the steering wheel by a maximum of one tooth if necessary 2 Check the center position of the steering gear and steeri...

Page 34: ...od lengths Steering knuckle steering column or steering intermediate arm bent On vehicles involved in an accident excessive deviations in the front end longitudinal frame member frame cross member wheelhouse or the cowl dash panel which have a negative effect on the adjustment range for camber and caster which can result in greater differences in the toe out on turns between left and right STANDAR...

Page 35: ...ng points for the rear axle carrier between the left and right sides of the body Experience shows that bending caused by an accident also has an effect on the toe STANDARD PROCEDURE CHECKING AND ADJUSTING REAR AXLE TOE 1 Check the vehicle level at the front and rear axles and adjust if necessary Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE 2 Check the vehicle level at the front and rea...

Page 36: ...25 30 Total rear axle toe 0 33 7 ALIGNMENT SPECIFICATIONS Front Axle Toe 2 5 Rear Axle Toe 1 2 Front Camber 1 13 1 22 Front Caster 5 12 5 20 Rear Camber 1 08 1 13 Permissible difference in front axle camber between right and left side of vehicle 20 SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Steering idler arm to bearing bushing 30 22 266 Repair Nut 120 88 5 1060 Lock...

Page 37: ...EMOVAL 32 INSTALLATION 34 UPPER CONTROL ARM REMOVAL 36 INSTALLATION 37 SHOCK REMOVAL 37 INSTALLATION 38 SPRING REMOVAL 39 INSTALLATION 40 STABILIZER BAR REMOVAL 42 INSTALLATION 43 FRONT SUSPENSION STANDARD PROCEDURE ADJUSTING FRONT WHEEL BEARINGS 1 Remove the wheel and tire assembly 2 Install a wheel bolt 1 on the opposite side from the brake rotor retaining bolt 5 3 Press the brake pads back in t...

Page 38: ...dust cap 2 11 Remove the wheel bolt from the rotor 12 Install the front wheel and tire assembly SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Front Shock Absorber Upper Nut 18 13 159 Front Shock Absorber Lower Nut 55 41 487 Front Sway Bar To Lower Control Arm Nut 20 15 177 Front Sway Bar Bushing Nuts M10 40 30 354 M8 20 15 177 Front Sway Bar To Frame Nut 60 44 531 Upper...

Page 39: ...SPECIAL TOOLS C 3894 A Tie Rod Puller 9151 FRONT SPRING COMPRESSOR 9152 SPRING COMPRESSOR PLATES 9168 Ball Joint Puller ZH FRONT SUSPENSION 2 15 ...

Page 40: ...ations for the front brake calipers and hub bearing REMOVAL CAUTION When removing the steering knuckle the shock absorber must remain installed 1 Raise and support the vehicle 2 Remove the front wheel and tire assembly 3 Remove the front disc brake caliper 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 2 16 FRONT SUSPENSION ZH ...

Page 41: ...VAL 5 Remove the front wheel hub Refer to 2 SUS PENSION FRONT HUB BEARING REMOVAL 6 Remove the disc brake dust shield by removing the three hex bolts 1 7 Remove the Wheel Speed Sensor by removing the bolt and pulling the sensor straight out of the steer ing knuckle ZH FRONT SUSPENSION 2 17 ...

Page 42: ...l C 3894 A Two Jaw Puller slowly tighten the bolt until the tie rod end joint is pushed out of the steering knuckle Note An allen wrench may be required to hold the ball joint stud while removing the nut 9 Remove the lower control arm supporting ball joint from the steering knuckle by removing the nut 1 from the ball joint stud CAUTION Do not use pneumatic tools to tighten the bolt on the special ...

Page 43: ... Check the lower control arm supporting ball joint by performing the following 2 Remove the nuts 1 from the lower control arm supporting ball joint 3 Using Special Tool 9168 Ball Joint Puller 2 press out the lower control arm supporting ball joint 1 4 Check the lower control arm supporting ball joint It should be possible to move the ball pivot without any play binding or creaking noises Move the ...

Page 44: ... upper ball joint stud Tighten to 45 N m 33 ft lbs 2 Install the steering knuckle and nut to the lower ball joint stud 1 Tighten to 105 N m 77 ft lbs 3 Install the tie rod end and nut onto the steering knuckle Tighten to 50 N m 37 ft lbs 2 20 FRONT SUSPENSION ZH ...

Page 45: ... the disc brake dust shield and three hex bolts 1 Tighten to 22 N m 16 ft lbs 6 Install the front wheel hub Refer to 2 SUSPEN SION FRONT HUB BEARING INSTALLATION 7 Install the front disc brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION ZH FRONT SUSPENSION 2 21 ...

Page 46: ...in the front hub 1 of this vehicle is a roller bearing unit type This assembly combines the front wheel hub 1 and the front wheel bearing 2 into a two piece unit The hub nut 3 holds the bearing 2 and the front hub 1 to the steering knuckle s spindle The hub nut 3 has a locking bolt that locks the hub nut into position on the spindle The bearing is protected from outside elements by a metal dust ca...

Page 47: ...inspect the front disc brake caliper 1 Refer to 5 BRAKES HYDRAULIC MECHAN ICAL DISC BRAKE CALIPERS REMOVAL Inspect for any damage or wear 4 Remove and inspect the front disc brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL Inspect for any damage or wear ZH FRONT SUSPENSION 2 23 ...

Page 48: ...lt then remove the hub nut 3 and then remove the tapered roller bearing 2 7 Remove the front wheel hub 1 from the spindle INSPECTING HUB AND BEARINGS 1 Remove the bolts 1 and inspect the front disc brake dust shield and replace if necessary 2 24 FRONT SUSPENSION ZH ...

Page 49: ... and the radial seal ring The tapered roller bearings and bearing races can be reused if The tapered rollers and bearing races have a smooth grey running track No discoloration indicating intense heat is evi dent The roller cage and the face ends of the tapered rollers are not worn or damaged The bearing races sit tight in the wheel hub INSTALLATION 1 Pack the front wheel hub 1 with grease coat th...

Page 50: ...E CALIPERS INSTALLATION 5 Adjust the wheel bearing end play Refer to 2 SUSPENSION FRONT HUB BEARING DIAG NOSIS AND TESTING 6 Install the dust cap 4 CAUTION Before driving the vehicle operate the brake pedal several times until pressure in the brake system is built up and maintained 7 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE 2 26 FRONT SUSPENSION ZH ...

Page 51: ...move the front wheel and tire assembly 3 Remove the front disc brake caliper 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 4 Remove the front disc brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL ZH FRONT SUSPENSION 2 27 ...

Page 52: ...st shield by removing the three hex bolts 1 6 Remove the front shock absorber bolt 1 Refer to 2 SUSPENSION FRONT SHOCK REMOVAL 7 Remove the front spring 1 Refer to 2 SUS PENSION FRONT SPRING REMOVAL 2 28 FRONT SUSPENSION ZH ...

Page 53: ...9 Using Special Tool 9168 Ball Joint Puller 1 press out the outer ball joint stud from the steering knuckle CAUTION Do not use pneumatic tools to tighten the bolt on the special tool 10 Using Special Tool 9168 Ball Joint Puller 2 press out and remove the upper ball joint stud from the lower control arm ZH FRONT SUSPENSION 2 29 ...

Page 54: ...e steering knuckle 2 Install the lower ball joint onto the steering knuckle and the lower control arm 3 Install both nuts 1 and 2 Tighten to 105 N m 77 ft lbs 4 Install the front disc brake dust shield by installing and tightening the three hex bolts 1 2 30 FRONT SUSPENSION ZH ...

Page 55: ...AULIC MECHANICAL ROTORS INSTALLATION 6 Install the front disc brake caliper 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION 7 Install the compressed front spring 1 Refer to 2 SUSPENSION FRONT SPRING INSTALLATION ZH FRONT SUSPENSION 2 31 ...

Page 56: ...LATION 9 Install the front wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCE DURE LOWER CONTROL ARM REMOVAL 1 Raise and support the vehicle 2 Remove the front wheel and tire assembly 3 Remove the front spring Refer to 2 SUSPEN SION FRONT SPRING REMOVAL 2 32 FRONT SUSPENSION ZH ...

Page 57: ... 1 5 Pull the shock absorber out of the mounting bracket 6 Remove the sway bar from the lower control arm by removing the two nuts 1 then removing the clamp 7 Remove the nut 2 attaching the lower control arm to the lower ball joint ZH FRONT SUSPENSION 2 33 ...

Page 58: ...uckle CAUTION Support the lower control arm before removing mounting bolts 9 Remove the two bolts 1 attaching the lower con trol arm to the frame 10 Remove the lower control arm from the vehicle INSTALLATION 1 Install the lower control arm to the vehicle 2 Install the two bolts 1 attaching the lower control arm to the frame Tighten to 120 N m 88 ft lbs 2 34 FRONT SUSPENSION ZH ...

Page 59: ... knuckle lower ball joint Tighten to 45 N m 33 ft lbs 4 Install the sway bar clamp and bolts 1 to the lower control arm Tighten to 20 N m 15 ft lbs 5 Install the shock absorber bolt and nut 1 to the lower control arm Tighten to 55 N m 41 ft lbs ZH FRONT SUSPENSION 2 35 ...

Page 60: ...1 Raise and support the vehicle 2 Remove the front wheel and tire assembly 3 Wire tie the steering knuckle to the shock absorber arrow This is to hold the steering knuckle from falling away from the vehicle 4 Remove the ball joint nut 3 from the upper control arm 2 CAUTION Do not subject the brake hose or any wheel speed sensor harness to any tension CAUTION Do not use pneumatic tools to tighten t...

Page 61: ...5 N m 33 ft lbs 3 Remove the wire tie attaching the steering knuckle to the shock absorber 4 Lower the vehicle and check vehicle alignment Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE 5 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE SHOCK REMOVAL Note The vehicle must be standing on its wheels when removing the upper shock absorber mount ing nut 1 Remov...

Page 62: ...bsorber to the vehicle by insert ing the top first and then aligning the lower control arm mounting bracket to the shock absorber 3 Install the shock absorber lower bolt and nut 1 to the lower control arm Tighten to 55 N m 41 ft lbs 4 Slowly lower the vehicle making sure to guide the upper shock stud through the mounting hole 5 Install the rubber mount and washer over the shock absorber stud 6 Ins...

Page 63: ...sting on its wheels remove the upper shock absorber nut 1 2 Remove the washer and rubber mount 3 Raise and support the vehicle then remove the lower shock absorber bolt and nut 1 Remove the shock from the vehicle ZH FRONT SUSPENSION 2 39 ...

Page 64: ...ings or spring bodies 5 Using Special Tool 9151 Spring Compressor and 9152 Clamping Plates 1 carefully compress the front spring 6 Remove the nuts from the lower control arm mounting bolts 7 Carefully remove the lower control arm mounting bolts from the body 8 Lower the supporting device and swing the lower control arm down while holding the front spring When enough clearance has been achieved fro...

Page 65: ...se the front spring making sure it is in its correct mounting position 5 Lower and remove the supporting device so the lower control arm is in its down position 6 Install the shock absorber lower bolt and nut 1 to the lower control arm Tighten to 55 N m 41 ft lbs 7 Lower the vehicle while guiding the shock into the upper mounting surface 8 Install the rubber mount and washer over the shock absorbe...

Page 66: ...lower control arms 2 Remove the stabilizer bar bracket 4 from the retainer bracket 3 Remove retainer bracket 4 and bracket mounting plate if necessary 4 Remove the stabilizer bar 6 from the vehicle 5 Remove all rubber bushings 3 and 5 off of the stabilizer bar 6 2 42 FRONT SUSPENSION ZH ...

Page 67: ...stabilizer bar bolts to frame 5 Tighten both stabilizer bar hexagon socket bolts to the retainer 4 6 Tighten both right and left stabilizer bar bracket nuts to the lower control arm 2 Torque to 20 N m 15 ft lbs 7 Install the stabilizer bar retainer and mounting plate if removed 8 Tighten the retainer bolt 4 to frame if removed Torque to 60 N m 44 ft lbs 9 Tighten the lower retainer nut to the fast...

Page 68: ...k to Stabilizer Bar 30 22 266 Stabilizer Bar to Stabilizer Link Nut 20 15 177 Bolt Stabilizer Bar Clamp 20 15 177 Upper Shock Nut 18 13 159 Shock Absorber to Lower Control Arm 55 41 487 Rear Axle Carrier Nut 90 66 797 Rear Axle Carrier Rear Nut 90 66 797 Rear Axle Center Assembly At Front to Rear Axle Carrier 50 37 443 Rear Axle Center Assembly At Rear to Rear Axle Carrier 110 81 974 Lower Control...

Page 69: ...SPECIAL TOOLS C 3894 A Tie Rod Puller 9150 Rear Spring Compressor 9152 Spring Compressor Plates 9168 Ball Joint Puller 9199 BEARING TOOL ZH REAR SUSPENSION 2 45 ...

Page 70: ...efore tightening components to specified torque 1 Install the camber strut onto the vehicle 2 Install the outer camber strut bolt attaching the camber strut to the wheel carrier 3 Install the inner camber strut bolt attaching the camber strut to the rear axle carrier 4 Install the wheel and tire assembly 5 Lower the vehicle so it is not being supported by the lift 6 Tighten the outer camber strut ...

Page 71: ... Vehicle must be at normal ride height before tightening components to specified torque 2 Install the outer trailing link bolt 2 attaching the trailing link to the wheel carrier 3 Install the inner trailing link bolt 1 attaching the trailing link to the rear axle carrier 4 Install the wheel and tire assembly 5 Lower the vehicle so it is not being supported by the lift 6 Tighten the outer trailing ...

Page 72: ...al link 1 INSTALLATION 1 Install the lateral link onto the vehicle CAUTION The rear axle shaft must be horizontal when tightening the lateral link nuts 2 Install the outer lateral link ball joint attaching the lateral link to the wheel carrier CAUTION The rear axle shaft must be horizontal when tightening the lateral link nuts 3 Install the inner lateral link bolt attaching the lateral link to the...

Page 73: ...N Vehicle must be at normal ride height before tightening components to specified torque 2 Install the outer track bar bolt attaching the track bar to the wheel carrier 3 Install the inner track bar bolt attaching the track bar to the rear axle carrier 4 Install the wheel and tire assembly 5 Lower the vehicle so it is not being supported by the lift 6 Tighten the outer track bar bolt attaching the...

Page 74: ...e 2 Remove the rear tire and wheel assembly 3 Remove the rear lower control arm plastic shield by removing the bolts 1 attaching the cover to the lower control arm 4 Remove the rear spring 1 Refer to 2 SUSPEN SION REAR SPRING REMOVAL 2 50 REAR SUSPENSION ZH ...

Page 75: ...ION REAR SHOCK REMOVAL 6 Remove the rear stabilizer bar link 1 from the rear lower control arm 7 Remove the bolt attaching the rear lower control arm to the rear wheel carrier 8 Remove the rear lower control arm 4 from the vehicle ZH REAR SUSPENSION 2 51 ...

Page 76: ... torque 1 Install the bolt attaching the rear lower control arm 4 to the rear wheel carrier Tighten to 70 N m 52 ft lbs 2 Install the rear shock absorber 1 Refer to 2 SUSPENSION REAR SHOCK INSTALLATION 3 Install the rear spring 1 Refer to 2 SUSPEN SION REAR SPRING INSTALLATION 2 52 REAR SUSPENSION ZH ...

Page 77: ...he rear stabilizer bar link 1 to the rear lower control arm Tighten to 20 N m 15 ft lbs 6 Install the rear lower control arm plastic shield bolt 1 7 Install the wheel and tire assembly 8 Check vehicle alignment Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE ZH REAR SUSPENSION 2 53 ...

Page 78: ...d support vehicle 2 Remove the wheel and tire assembly 3 Remove the rear disc brake caliper bolts 1 4 Remove the rear disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 2 54 REAR SUSPENSION ZH ...

Page 79: ...to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL 6 Remove the parking brake shoe assembly Refer to 5 BRAKES PARKING BRAKE SHOES REMOVAL 7 Remove the parking brake cable 2 Refer to 5 BRAKES PARKING BRAKE CABLES REMOVAL ZH REAR SUSPENSION 2 55 ...

Page 80: ... 9 Remove the rear Wheel Speed Sensor 2 from the knuckle 10 Remove the rear axle halfshaft nut 1 from the rear hub assembly 11 Remove the rear disc brake dust shield by remov ing the hex bolts 1 from the rear hub assembly 2 56 REAR SUSPENSION ZH ...

Page 81: ... to 2 SUSPENSION REAR TOE LINK REMOVAL 13 Remove the trailing link nuts and bolts 1 2 Refer to 2 SUSPENSION REAR TRAILING LINK REMOVAL 14 Remove the lateral link nuts and bolts 1 2 Refer to 2 SUSPENSION REAR LATERAL LINK REMOVAL ZH REAR SUSPENSION 2 57 ...

Page 82: ... Remove the lower control arm Refer to 2 SUS PENSION REAR LOWER CONTROL ARM REMOVAL 17 Remove the knuckle 1 from the vehicle 18 Inspect the bearing assembly 5 for any wear or damage replace if necessary Refer to 2 SUS PENSION REAR HUB BEARING REMOVAL 2 58 REAR SUSPENSION ZH ...

Page 83: ...r axle halfshaft must be horizon tal when tightening all nuts and bolts 1 Install the knuckle to the vehicle 2 Install the trailing link nuts and bolts 1 2 Refer to 2 SUSPENSION REAR TOE LINK INSTALLA TION ZH REAR SUSPENSION 2 59 ...

Page 84: ...nstall the lateral link nuts and bolts 1 2 Refer to 2 SUSPENSION REAR LATERAL LINK INSTAL LATION 5 Install the track bar nuts and bolts 1 2 Refer to 2 SUSPENSION REAR TRACK BAR INSTALLA TION 6 Install the lower control arm Refer to 2 SUS PENSION REAR LOWER CONTROL ARM INSTALLATION 2 60 REAR SUSPENSION ZH ...

Page 85: ...ll the rear axle halfshaft to the rear hub assembly Note A new halfshaft outer retaining nut must be used 9 Install the rear axle halfshaft outer retaining nut 1 Tighten the halfshaft nut to 220 N m 164 ft lbs 10 Install the rear Wheel Speed Sensor 2 Refer to 5 BRAKES ELECTRICAL REAR WHEEL SPEED SENSOR INSTALLATION ZH REAR SUSPENSION 2 61 ...

Page 86: ...KES PARKING BRAKE CABLES INSTALLA TION 12 Install the parking brake shoe assembly 1 5 Refer to 5 BRAKES PARKING BRAKE SHOES INSTALLATION 13 Install the disc brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION 2 62 REAR SUSPENSION ZH ...

Page 87: ...PERS INSTALLATION 15 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE 16 Check vehicle alignment Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PRO CEDURE HUB BEARING REMOVAL 1 Raise and support the vehicle 2 Remove the disc brake calipers and bolts 1 ZH REAR SUSPENSION 2 63 ...

Page 88: ...LIC MECHANICAL ROTORS REMOVAL 4 Remove the parking brake shoes 1 5 Refer to 5 BRAKES PARKING BRAKE SHOES REMOVAL 5 Remove the rear axle halfshaft nut 1 6 Remove the rear axle halfshaft Refer to 3 DIF FERENTIAL DRIVELINE HALF SHAFT REMOVAL 2 64 REAR SUSPENSION ZH ...

Page 89: ...nge in vise 11 Fit the thrust piece with the large diameter on the rear axle halfshaft flange 12 Place the complete puller over the inner bearing race 13 Clamp it firmly at the upper grooves of the clamp ing pliers over the tapered sleeve of the puller 14 Pull the inner bearing race off the rear axle half shaft flange using the puller 15 Check the lateral and radial runout of the rear axle halfsha...

Page 90: ...e Insure that the snap ring is correctly fitted in the rear wheel carrier 2 Install the snap ring 4 into the rear wheel carrier Note Verify the pressure plate lies flush against the bearings inner race during insertion 3 Install the rear axle halfshaft flange 1 4 Install the parking brake shoes 1 5 Refer to 5 BRAKES PARKING BRAKE SHOES INSTALLA TION 2 66 REAR SUSPENSION ZH ...

Page 91: ...the rear disc brake caliper bolts 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION 7 Install the rear axle halfshaft Refer to 3 DIFFER ENTIAL DRIVELINE HALF SHAFT INSTALLA TION 8 Install wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE ZH REAR SUSPENSION 2 67 ...

Page 92: ... and tire assemblies 3 Remove the right and left wheel speed sensors 2 Refer to 5 BRAKES ELECTRICAL REAR WHEEL SPEED SENSOR REMOVAL 4 Remove the rear brake hoses 1 from the rear brake calipers Refer to 5 BRAKES HYDRAULIC MECHANICAL BRAKE LINES REMOVAL 2 68 REAR SUSPENSION ZH ...

Page 93: ... PENSION REAR SPRING REMOVAL 6 Remove the rear shocks 1 Refer to 2 SUS PENSION REAR SHOCK REMOVAL 7 Remove the rear parking brake cables 2 from the parking brake equalizer 1 Refer to 5 BRAKES PARKING BRAKE CABLES REMOVAL ZH REAR SUSPENSION 2 69 ...

Page 94: ...l carrier 9 Remove the propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 10 Remove the rear stabilizer bar links 2 from the stabilizer bar 1 11 Block and support the rear axle carrier 1 with a suitable lifting device 2 2 70 REAR SUSPENSION ZH ...

Page 95: ...he rear differential housing down approxi mately 4 5 inches allowing enough room for the stabilizer bar to be removed from the vehicle 15 Remove the rear stabilizer bar clamps 3 by removing the nuts 1 from the studs and then removing the stabilizer bar 2 16 Remove the rear stabilizer bar from the vehicle by maneuvering it over the axle carrier and away from the vehicle ZH REAR SUSPENSION 2 71 ...

Page 96: ...r differential housing and install the four bolts 1 attaching it to the vehicle Tighten to 90 N m 66 ft lbs 3 Install the rear spring 1 Refer to 2 SUSPEN SION REAR SPRING INSTALLATION 4 Install the rear shock 1 Refer to 2 SUSPEN SION REAR SHOCK INSTALLATION 2 72 REAR SUSPENSION ZH ...

Page 97: ...the rear stabilizer clamps 1 3 6 Install the rear stabilizer bar links 2 to the rear control arm Tighten to 30 N m 22 ft lbs 7 Tighten the rear stabilizer clamp nuts 1 Tighten to 20 N m 15 ft lbs ZH REAR SUSPENSION 2 73 ...

Page 98: ...PELLER SHAFT INSTALLATION 9 Install the rear parking brake cables 2 to the park ing brake equalizer 1 Refer to 5 BRAKES PARKING BRAKE CABLES INSTALLATION 10 Install the rear brake hoses 1 to the rear brake calipers Refer to 5 BRAKES HYDRAULIC ME CHANICAL BRAKE LINES INSTALLATION 2 74 REAR SUSPENSION ZH ...

Page 99: ...2 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE SHOCK REMOVAL Note The vehicle must be resting on its wheels before removing the top shock absorber mounting hardware 1 Remove the shock absorber upper mounting hard ware 1 2 Raise and support the vehicle ZH REAR SUSPENSION 2 75 ...

Page 100: ...ng the cover to the lower control arm 4 Remove the shock absorber 1 from the lower control arm 5 Inspect the shock absorber INSTALLATION 1 Install the shock absorber 1 onto the lower control arm then install the bolt and nut 2 Tighten to 55 N m 41 ft lbs 2 76 REAR SUSPENSION ZH ...

Page 101: ...rm plastic cover and bolt 1 3 Slowly lower the vehicle while guiding the top of the shock into the mounting hole in the frame 4 Install the top shock absorber mounting hardware 1 Tighten to 18 N m 13 ft lbs ZH REAR SUSPENSION 2 77 ...

Page 102: ...aise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the control arm cover by removing the bolts 1 from the cover 4 Remove the lower shock bolts 2 from the lower control arm 2 78 REAR SUSPENSION ZH ...

Page 103: ...ecial Tool 9152 Compressor Plates and 9150 Spring Compressor 1 compress the rear spring 8 Remove the rear bolts on the lower control arm 4 attaching the control arm to the frame 9 Remove the lifting device 10 Swing the lower control arm 2 down away from the mounting flange 1 11 Carefully remove the spring from the vehicle ZH REAR SUSPENSION 2 79 ...

Page 104: ...l arm 2 up and install the bolt attaching the control arm to the frame 1 3 Carefully release the spring 1 insuring the spring properly aligns with the spring perch detents 4 Install the lower shock mount 1 to the lower con trol arm Tighten to 55 N m 41 ft lbs 2 80 REAR SUSPENSION ZH ...

Page 105: ...RE 7 Check vehicle alignment Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE REAR AXLE CARRIER REMOVAL 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the rear support brackets convertible only by removing the bolts 2 then removing the rear support brackets 1 ZH REAR SUSPENSION 2 81 ...

Page 106: ...amage the hose 6 Using wire or cord hang the calipers from the rear strut assembly Support the caliper firmly to prevent the weight of the caliper from being supported by the brake hose 7 Remove rear portion of the exhaust pipes including muffler Refer to 11 EXHAUST SYSTEM MUF FLER REMOVAL 8 Remove the parking brake rear cables 2 from the parking brake cable equalizer 1 Refer to 5 BRAKES PARKING B...

Page 107: ...CAL REAR WHEEL SPEED SENSOR REMOVAL 10 Remove the left and right rear axle halfshaft nuts 1 11 Remove the rear axle halfshafts Refer to 3 DIF FERENTIAL DRIVELINE HALF SHAFT REMOVAL 12 Remove the rear springs 1 Refer to 2 SUS PENSION REAR SPRING REMOVAL ZH REAR SUSPENSION 2 83 ...

Page 108: ...pump from the rear strut assembly Support the fuel pump firmly to prevent the weight of the pump from being sup ported by the fuel line 16 Remove the propeller shaft assembly from the rear axle differential carrier Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 17 Remove the rear differential carrier Refer to 3 DIFFERENTIAL DRIVELINE REAR AXLE REAR CARRIER REMOVAL 18 Remove the front t...

Page 109: ...ame 20 Remove the rear axle carrier 1 from the vehicle by lowering it out of the vehicle with a suitable tool 2 Note Only remove the following components from the rear axle carrier 21 Remove the camber strut bolt 1 Refer to 2 SUSPENSION REAR TOE LINK REMOVAL ZH REAR SUSPENSION 2 85 ...

Page 110: ... Refer to 2 SUSPENSION REAR TRAILING LINK REMOVAL 23 Remove the lateral link bolt 1 Refer to 2 SUSPENSION REAR LATERAL LINK REMOVAL 24 Remove the track bar bolt inner Refer to 2 SUSPENSION REAR TRACK BAR REMOVAL 2 86 REAR SUSPENSION ZH ...

Page 111: ...2 SUSPENSION REAR STABILIZER BAR REMOVAL 26 Remove the lower control arm Refer to 2 SUS PENSION REAR LOWER CONTROL ARM REMOVAL INSTALLATION 1 Install the camber strut bolt 1 Refer to 2 SUS PENSION REAR TOE LINK INSTALLATION ZH REAR SUSPENSION 2 87 ...

Page 112: ...to 2 SUS PENSION REAR TRAILING LINK INSTALLA TION 3 Install the lateral link bolt 1 Refer to 2 SUS PENSION REAR LATERAL LINK INSTALLA TION 4 Install the track bar bolt Refer to 2 SUSPEN SION REAR TRACK BAR INSTALLATION 2 88 REAR SUSPENSION ZH ...

Page 113: ...arm Refer to 2 SUS PENSION REAR LOWER CONTROL ARM INSTALLATION 7 Install the rear axle carrier 1 by raising it up and installing the four bolts to the frame Tighten to 90 N m 66 ft lbs 8 Install the rear axle differential carrier Refer to 3 DIFFERENTIAL DRIVELINE REAR AXLE REAR CARRIER INSTALLATION ZH REAR SUSPENSION 2 89 ...

Page 114: ...OPELLER SHAFT INSTALLATION 10 Install the fuel pump assembly Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP INSTALLATION 11 Install the rear shock absorbers 1 Refer to 2 SUSPENSION REAR SHOCK INSTALLATION 12 Install the rear springs 1 Refer to 2 SUSPEN SION REAR SPRING INSTALLATION 2 90 REAR SUSPENSION ZH ...

Page 115: ...TALLATION 14 Install the right and left Wheel Speed Sensors 2 Refer to 5 BRAKES ELECTRICAL REAR WHEEL SPEED SENSOR INSTALLATION 15 Install the parking brake rear cables 2 to the parking brake cable equalizer 1 Refer to 5 BRAKES PARKING BRAKE CABLES INSTAL LATION ZH REAR SUSPENSION 2 91 ...

Page 116: ...he wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE Note Final torque for the rear support bracket must be made at curb weight 19 Install the rear support bracket 1 by installing the support bracket then installing the bolts 2 Tighten to 60 N m 44 ft lbs Refer to 13 FRAME BUMPERS FRAME BRACKET INSTALLATION 20 Check vehicle alignment Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDAR...

Page 117: ...AFTS TABLE OF CONTENTS page page HALFSHAFTS DESCRIPTION 2 OPERATION 3 DIAGNOSIS AND TESTING DRIVELINE 3 REMOVAL 4 INSTALLATION 5 SPECIFICATIONS TORQUE 6 CV BOOT INNER REMOVAL 6 INSTALLATION 8 CV BOOT OUTER REMOVAL 12 INSTALLATION 14 CV JOINT REMOVAL 18 INSPECTION 20 INSTALLATION 23 ZH DIFFERENTIAL DRIVELINE 3 1 ...

Page 118: ...HALFSHAFTS DESCRIPTION Articulated halfshafts deliver power from the rear differential to the wheels through constant velocity C V joints that minimize vibration 3 2 HALFSHAFTS ZH ...

Page 119: ...ISE AND OR VIBRATION IN TURNS A clicking noise and or a vibration could be caused by one of the following conditions 1 Damaged inner or outer C V boots or retaining clamps This will result in the loss and or contamination of the joint grease resulting in inadequate lubrication of the joint 2 Noise may also be caused by another component of the vehicle coming in contact with the halfshafts CLUNKING...

Page 120: ...move the rear wheels 3 Remove the rear knuckle 1 Refer to 2 SUS PENSION REAR KNUCKLE REMOVAL Note The axle halfshafts are seated in the differ ential side gears using expandable snap rings It is necessary to forcefully pry the halfshaft out of the differential 4 Insert a pry bar between the differential housing and the halfshaft 1 5 Pry against differential housing until the halfshaft retaining sn...

Page 121: ...ng surface of the halfshaft 2 Lightly lubricate the oil seal sealing surface of the halfshaft with clean lubricant 3 Insert the halfshaft 1 outer end through the wheel hub 4 Install the halfshaft into the differential side gear as far as possible by hand 5 Forcefully push the halfshaft into the differential side gear until the snap ring is engaged with the differential side gear Note Grasp the hal...

Page 122: ...t be used 7 Install the rear wheels Refer to 22 TIRES WHEELS STANDARD PROCEDURE SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Halfshaft Outer Retaining Nut 220 164 CV BOOT INNER REMOVAL 1 Remove the halfshaft from the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 3 6 HALFSHAFTS ZH ...

Page 123: ...n the jaws of the vise to pre vent any damage to the axle halfshaft 5 Remove the C V boot from the inner C V joint housing and slide it down the axle halfshaft 6 Wipe away the grease to expose the inner C V joint and the halfshaft 7 Using a soft faced hammer sharply hit the end of the C V joint housing to dislodge the housing from the internal circlip on the axle halfshaft 8 Slide the inner C V jo...

Page 124: ...NSPECTION INSTALLATION 1 Clean and inspect the C V joint for wear and pit ting Replace as required Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT C V JOINT INSPECTION 2 Remove any road grime and debris from the axle shaft splines 3 Before installing the C V boot cover the shaft splines to protect the C V boot during installation 4 Slide the new C V boot onto the axle halfshaft 3 8 HALFSHAFTS ZH ...

Page 125: ... onto the axle halfshaft by using a soft faced hammer and tap ping the end of the stub axle with nut installed until the outer C V joint is fully seated on the axle halfshaft Note Do not use any other type of grease other than what is supplied in the C V boot service package 7 Pack approximately 1 2 the amount of grease pro vided in the C V boot service package into the outer C V joint cavity 8 Pa...

Page 126: ... V boot outer end into the sealing groove 1 of the C V joint housing 10 Install the C V boot inner end into the sealing groove of the axle halfshaft 11 Position the inner C V boot retaining clamp 1 and the outer C V boot retaining clamp 2 into the sealing grooves on the C V boot 12 Position the crimping tool 1 on the C V boot retaining clamp 3 3 10 HALFSHAFTS ZH ...

Page 127: ... crimping tool must be closed completely for proper sealing 13 Crimp the new C V boot retaining clamp 3 14 Install the half shaft to the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION ZH HALFSHAFTS 3 11 ...

Page 128: ...lfshaft from the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 2 Remove the outer C V boot retaining clamp 2 from the axle halfshaft 3 Remove the inner C V boot retaining clamp 1 from the C V joint housing 3 12 HALFSHAFTS ZH ...

Page 129: ...he axle halfshaft 6 Wipe away the grease to expose the outer C V joint and the halfshaft 7 Using a soft faced hammer sharply hit the end of the C V joint housing to dislodge the housing from the internal circlip on the axle halfshaft 8 Slide the outer C V joint off the end of the halfshaft 9 Slide the C V boot off of the axle halfshaft 10 Thoroughly clean and inspect the outer C V joint assembly f...

Page 130: ...r to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT C V JOINT INSPECTION 2 Remove any road grime and debris from the axle shaft splines 3 Before installing the C V boot cover the shaft splines to protect the C V boot during installation 4 Slide the new C V boot onto the axle halfshaft 3 14 HALFSHAFTS ZH ...

Page 131: ...ully seated on the axle halfshaft Note The C V joint assembly must be installed on axle halfshaft until the C V joint assembly is seated against the circlip on the halfshaft Note Do not use any other type of grease other than what is supplied in the C V boot service package 7 Pack approximately 1 2 the amount of grease pro vided in the C V boot service package into the outer C V joint cavity 8 Pac...

Page 132: ... V boot outer end into the sealing groove 1 of the C V joint housing 10 Install the C V boot inner end into the sealing groove of the axle halfshaft 11 Position the inner C V boot retaining clamp 1 and the outer C V boot retaining clamp 2 into the sealing grooves on the C V boot 12 Position the crimping tool 1 on the C V boot retaining clamp 3 3 16 HALFSHAFTS ZH ...

Page 133: ... crimping tool must be closed completely for proper sealing 13 Crimp the new C V boot retaining clamp 3 14 Install the half shaft to the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION ZH HALFSHAFTS 3 17 ...

Page 134: ...haft from the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 2 Remove the inner C V boot retaining clamp 1 from the axle halfshaft 3 Remove the outer C V boot retaining clamp 2 from the C V joint housing 3 18 HALFSHAFTS ZH ...

Page 135: ...axle halfshaft 6 Wipe away the grease to expose the C V joint and the halfshaft 7 Using a soft faced hammer sharply hit the end of the C V joint housing to dislodge the housing from the internal circlip on the axle halfshaft 8 Slide the C V joint off the end of the halfshaft 9 Thoroughly clean and inspect the C V joint assem bly for any signs of excessive wear Refer to 3 DIFFERENTIAL DRIVELINE HAL...

Page 136: ...rk the positions of joint ring joint hub and the bearing cage with a suitable marking tool 1 2 Rotate the bearing cage inside of the joint hub arrow and remove the bearing balls one at a time 3 Remove the joint hub and the bearing cage from the joint ring 3 20 HALFSHAFTS ZH ...

Page 137: ...ON 1 Inspect the roller tracks in the C V joint housing 1 bearing cage 2 and joint hub 4 Inspect the bearing balls 3 for signs of pitting or wear 2 If these parts are extremely worn the entire C V joint must be replaced Smooth areas and tracks caused by the ball bearings are no reason to replace the C V joint ZH HALFSHAFTS 3 21 ...

Page 138: ... guide it into place 2 Insert one bearing ball paying attention to the alignment marks on the joint hub and bearing cage 3 Insert the joint hub with the bearing cage and the bearing ball in the joint ring while ensuring that the markings are properly aligned 3 22 HALFSHAFTS ZH ...

Page 139: ...e to allow the bearing balls to be inserted one after the other 5 The C V joint is now ready to be installed on the halfshaft INSTALLATION 1 Align the splines on the axle halfshaft 1 with the splines on the C V joint assembly 3 ZH HALFSHAFTS 3 23 ...

Page 140: ...other than what is supplied in the C V boot service package 3 Pack approximately 1 2 the amount of grease pro vided in the C V boot service package into the outer C V joint cavity 4 Pack the remaining amount of grease into the C V boot Note The C V boot must be positioned on the axle halfshaft so the raised bead on the inside of the C V boot is in the groove on the axle halfshaft 5 Install the C V...

Page 141: ...ot retaining clamp 2 into the seal ing grooves on the C V boot 8 Position the crimping tool 1 on the C V boot retaining clamp 3 Note The jaws of the crimping tool must be closed completely for proper sealing 9 Crimp the new C V boot retaining clamp 3 ZH HALFSHAFTS 3 25 ...

Page 142: ...FITTED SLEEVES REMOVAL REMOVAL CENTERING SLEEVES 38 REMOVAL FITTED SLEEVES 39 INSTALLATION INSTALLATION CENTERING SLEEVES 39 INSTALLATION FITTED SLEEVES 39 PROPELLER SHAFT DESCRIPTION A two piece driveshaft links the transmission and rear axle through two flexible disks and one universal joint to minimize driveline vibrations WARNING Use exact replacement hardware for attaching the propeller shaft...

Page 143: ...ITION POSSIBLE CAUSES CORRECTION PROPELLER SHAFT NOISE 1 Undercoating or other foreign material on shaft 1 Clean exterior of shaft and wash with solvent 2 Loose or bent U joint yoke or excessive runout 2 Install new yoke 3 Incorrect driveline angularity 3 Measure and correct driveline angles 4 Worn U joint bearings 4 Install new U joint 5 Propeller shaft damaged or out of balance 5 Install new pro...

Page 144: ...0 Install a screw clamp 1 at position 1 11 Start the engine and re check for vibration If there is little or no change in vibration move the clamp to one of the other three positions Repeat the vibration test 12 If there is no difference in vibration at the other positions the source of the vibration may not be the propeller shaft 13 If the vibration decreased install a second clamp and repeat the...

Page 145: ... center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements 4 Refer to Runout Specifications chart 5 If the propeller shaft runout is out of specification remove the propeller shaft index the shaft 180 and re install the propeller shaft Measure shaft runout again 6 If the propeller shaft runout is now withi...

Page 146: ...nge to the transmission output flange and the rear axle pinion flange to maintain proper balance of the driveline Mark each bolt and its location so that each bolt is installed to its original position 9 Remove the three rear propeller shaft bolts 1 from the rear axle pinion flange 10 Remove the rear propeller shaft from the rear axle pinion flange 11 Remove the three front propeller shaft bolts f...

Page 147: ...upport the propeller shaft with a jack stand 3 Align the center bearing bracket and install the bolts 1 Tighten the bolts to 30 N m 22 ft lbs 4 Install the rear propeller shaft to the rear axle pin ion flange Note Final torque must be made with vehicle at normal ride height 5 Install the three rear propeller shaft bolts 1 to the rear axle pinion flange Tighten the bolts to 60 N m 44 ft lbs 6 Insta...

Page 148: ...all the transmission mount bolts 1 Tighten the bolts to 45 N m 33 ft lbs 12 Install the transmission crossmember bolts 2 Tighten the bolts to 45 N m 33 ft lbs 13 Install the rear exhaust heat shield and nuts 1 Tighten the nuts to 10 N m 89 in lbs 14 Remove the jack stand supporting the transmis sion 15 Install the exhaust system Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 16 Lower ...

Page 149: ...for tube lengths over 30 inches For tube lengths under 30 inches the maximum allowed runout is 0 020 in 0 50 mm for the full length of the tube RUNOUT SPECIFICATIONS LOCATION In mm Front Of Shaft 0 020 0 50 Center Of Shaft 0 025 0 63 Rear Of Shaft 0 020 0 50 SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Center Bearing Bracket Bolts 45 33 Heat Shield Nuts 10 89 Rear Axle...

Page 150: ...eller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT CEN TER BEARING REMOVAL 2 Separate the propeller shaft sections 3 Use a jaw puller to remove the rubber mount and the bearing 2 from the propeller shaft 1 3 34 PROPELLER SHAFT ZH ...

Page 151: ...TS DISASSEMBLY Note Individual components of cardan universal joints are not serviceable If worn or leaking they must be replaced as an assembly 1 Remove the propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 2 Tap the outside of the bearing cap assembly with a drift to loosen the snap ring 3 Remove the snap rings 1 from both sides of the yoke 4 Set the yoke in an arbor pre...

Page 152: ...ng cap 7 If the bearing cap will not pull out of the yoke by hand after pressing tap the yoke ear near the bearing cap to dislodge the cap 8 To remove the opposite bearing cap turn the yoke over and straighten the universal joint in the open hole Then carefully press the end of the universal joint until the remaining bearing cap can be removed 3 36 PROPELLER SHAFT ZH ...

Page 153: ...n occur 1 Apply Extreme Pressure EP N L G I Grade 1 or 2 grease to the inside of the yoke bores 2 Position the universal joint 1 in the yoke 2 with its grease fitting if equipped pointing up 3 Place a bearing cap 1 over the trunnion 2 and align the cap with the yoke bore Keep the needle bearings upright in the bearing cap ZH PROPELLER SHAFT 3 37 ...

Page 154: ...r ing cap 7 Add grease to the grease fitting if equipped 8 Install the propeller shaft Refer to 3 DIFFEREN TIAL DRIVELINE PROPELLER SHAFT INSTALLATION CENTERING AND FITTED SLEEVES REMOVAL REMOVAL CENTERING SLEEVES 1 Remove the propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 2 Mark the flexible disk 4 relative to the flange 2 3 Remove the flexible disk 4 from the flange 2...

Page 155: ...vities with heavy duty Mopar grease 3 Press in the new sleeves 4 Measure the sleeve depth from the top of the sleeve to the face of the flange 5 Assemble the flange and the flexible disk with the new sleeve as marked 6 Install the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION INSTALLATION FITTED SLEEVES 1 Clean and inspect the flexible disk and flange Replace any w...

Page 156: ...uareness Gear noise usually happens at a specific speed range The noise can also occur during a specific type of driving condition These conditions are acceleration deceleration coast or constant load When road testing first warm up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest Shift out of gear and coast t...

Page 157: ...s Loose wheel studs Worn U joint s Damaged rear wheel hub bearings Loose pinion gear nut Excessive pinion yoke run out Damaged halfshafts Check for loose or damaged front end components or engine transmission mounts These components can contrib ute to what appears to be a rear end vibration Do not overlook engine accessories brackets and drive belts All driveline components should be examined befo...

Page 158: ... 4 Worn pinion seal 4 Replace seal 5 Worn scored yoke 5 Replace yoke and seal 6 Differential cover not properly sealed 6 Remove clean and reseal cover AXLE OVERHEATING 1 Lubricant level low 1 Fill differential to correct level 2 Improper grade of lubricant 2 Fill differential with the correct fluid type and quantity GEAR TEETH BROKE 1 Overloading 1 Replace differential 2 Erratic clutch operation 2...

Page 159: ... axle to proper specifications 9 Install the differential housing fill plug 1 Tighten the fill plug to 50 N m 37 ft lbs SPECIFICATIONS SPECIFICATIONS DIFFERENTIAL LUBRICANT Use synthetic SAE 75W 85 axle lubricant that meets MB 231 1 such as Mopar 05136035AA An SAE 80W 90 GL 5 MIL 2105 E Synthetic Axle Lubricant may be substituted Reduced axle durability may result if an unapproved product is used ...

Page 160: ...SPECIAL TOOLS 3 44 REAR DIFFERENTIAL ZH ...

Page 161: ... STANDARD PRO CEDURE 4 Support the differential housing with a jack 5 Separate the halfshafts from the differential connecting flanges and tie them to the rear differential carrier Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 6 Remove the differential housing front mounting bolt 1 7 Remove the two differential housing rear mounting bolts 1 8 Carefully remove the differential housing from t...

Page 162: ...ousing rear mounting bolts to 110 N m 82 ft lbs 5 Tighten the differential housing front mounting bolt and nut to 45 N m 33 ft lbs 6 Connect the halfshafts to the rear differential connecting flanges Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION 7 Remove the differential housing support jack 8 Install the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 9 ...

Page 163: ...ut of way Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 5 Disconnect the halfshafts at the differential con necting flanges and position them aside Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 6 Use the torque meter 1 to measure resistance to rotation at the pinion flange Record the amount of friction torque 7 Using the Special Tool C 3281 Flange Wrench 2 to hold the pinion fl...

Page 164: ...Tighten the nut to 180 N m 133 ft lbs 5 Check the resistance to rotation torque If the resis tance is less than the previously recorded value tighten the pinion in 5 N m 44 in lbs increments until the resistance amount is reached 6 Connect the halfshafts to the differential connecting flanges Refer to 3 DIFFERENTIAL DRIV ELINE HALF SHAFT INSTALLATION 7 Install the propeller shaft Refer to 3 DIFFER...

Page 165: ...E STAN DARD PROCEDURE 10 Lower the vehicle AXLE SHAFT SEALS REMOVAL 1 Remove the halfshaft 1 Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT REMOVAL CAUTION Do not scrape or damage the surface of the seal bore 2 Remove the axle shaft seal 1 with a suitable pry ing tool ZH REAR DIFFERENTIAL 3 49 ...

Page 166: ...l with hypoid gear oil 2 Using the Special Tool 9223 Drift 1 drive the new axle shaft seal 2 into the differential housing 3 Install the halfshaft 1 Refer to 3 DIFFEREN TIAL DRIVELINE REAR AXLE AXLE SHAFT SEALS INSTALLATION 3 50 REAR DIFFERENTIAL ZH ...

Page 167: ...OVAL REAR DISC BRAKE PADS 20 INSTALLATION FRONT DISC BRAKE PADS 22 INSTALLATION REAR DISC BRAKE PADS 24 DISC BRAKE CALIPERS DESCRIPTION 25 OPERATION 25 REMOVAL FRONT DISC BRAKE CALIPER 26 REMOVAL REAR BRAKE CALIPER 29 DISASSEMBLY FRONT DISC BRAKE CALIPER 30 CLEANING DISC BRAKE CALIPER 31 INSPECTION DISC BRAKE CALIPER 31 ASSEMBLY FRONT DISC BRAKE CALIPER 31 INSTALLATION FRONT DISC BRAKE CALIPER 32 ...

Page 168: ...HD 54 INSTALLATION INSTALLATION 56 INSTALLATION RHD 57 PEDAL DESCRIPTION 59 OPERATION 59 REMOVAL REMOVAL 60 REMOVAL RHD 61 INSTALLATION INSTALLATION 63 INSTALLATION RHD 64 PARKING BRAKE OPERATION 66 DIAGNOSIS AND TESTING PARKING BRAKE 67 ADJUSTMENTS ADJUSTMENT 68 CABLES REMOVAL 70 INSTALLATION 72 LEVER REMOVAL 74 INSTALLATION 76 SHOES REMOVAL 78 INSTALLATION 80 BRAKE FLUID LEVEL SENSOR REMOVAL 82 ...

Page 169: ... BAS BRAKE BOOSTER 2 BAS SOLENOID VALVE 3 AIR FILTER 4 AIR FILTER 5 POPPET VALVE 6 BAS RELEASE SWITCH 7 VACUUM PISTON 8 BAS DIAPHRAGM TRAVEL SENSOR 9 COMPRESSION SPRING 10 OUTPUT ROD 11 CABLE CONNECTOR FOR RELEASE SWITCH AND SOLENOID VALVE 12 VACUUM CONNECTION 13 POWER DIAPHRAGM ZH BRAKES BASE 5 3 ...

Page 170: ...CENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM EXERCISE CARE WHEN SERVICING BRAKE PARTS DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING USE A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF ASBESTOS FIBERS FROM BRAKE COMPO NENTS IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE CLEANING SHOULD BE DONE WITH A WATER DAMPENED CLOTH DO NOT SAND OR GRIND BRAKE LINING U...

Page 171: ...e preliminary check PRELIMINARY BRAKE CHECK 1 Check the condition of the tires and wheels Damaged wheels and worn damaged or under inflated tires can cause a pull shudder vibration and a condition similar to grab 2 If a complaint was based on noise while braking check the suspension components Jounce the front and the rear of vehicle and listen for anything that might be caused by a loose worn or ...

Page 172: ...on is to inspect and replace all the worn components SPONGY PEDAL A spongy pedal is most often caused by air in the system However substandard brake hoses can cause a spongy pedal The proper course of action is to bleed the system and replace the substandard quality brake hoses if sus pected HARD PEDAL OR HIGH PEDAL EFFORT A hard pedal or high pedal effort may be due to a brake pad that is water s...

Page 173: ...a pull A damaged front tire bruised ply separation can also cause a pull A common and frequently misdiagnosed pull condition is where direction of pull changes after a few stops The cause is a combination of brake drag followed by fade at one of the brake units As the dragging brake overheats efficiency is so reduced that fade occurs Since the opposite brake units are still functioning normally it...

Page 174: ...n spots metal to metal contact occurs If the condition is allowed to continue rotors may become so scored that replacement is necessary BRAKE CHATTER Brake chatter is usually caused by loose or worn components or glazed burnt linings Rotors with hard spots can also contribute to chatter Additional causes of chatter are out of tolerance rotors brake pads not securely attached to the calipers loose ...

Page 175: ... 116 and ISO 4925 DO NOT pump the brake pedal at any time while bleeding Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system This will make additional bleeding operations necessary DO NOT allow the master cylinder to run out of fluid during bleeding operations An empty cylinder will allow addi tional air to be drawn into the system Check the...

Page 176: ...se 28 mm 1 10 in SRT 32 mm 1 25 in Service Limit Thickness Base 26 mm 1 02 in SRT 30 mm 1 18 in Minimum Thickness Base 25 4 mm 0 99 in SRT 29 4 mm 1 16 in Max Thickness Variation Base 0 013 mm 0 0005 in SRT 0 013 mm 0 0005 in Disc Brake Pad New Thickness pad backing plate Base 19 6 mm 0 77 in SRT 19 6 mm 0 77 in Service Limit Thickness pad backing plate Base 14 mm 0 55 in SRT 14 mm 0 55 in Minimum...

Page 177: ...m 0 87 in Service Limit Thickness Base 7 6 mm 0 30 in SRT 19 4 mm 0 76 in Minimum Thickness Base 7 3 mm 0 29 in SRT 20 mm 0 79 in Max Thickness Variation Base 0 013 mm 0 0005 in SRT 0 013 mm 0 0005 in Disc Brake Pad New Thickness pad backing plate Base 15 5 mm 0 61 in SRT 15 5 mm 0 61 in Service Limit Thickness pad backing plate Base 11 mm 0 43 in SRT 11 mm 0 43 in Minimum Thickness pad only Base ...

Page 178: ... the fabric casing of the hose is exposed due to cracks or abrasions Also check brake hose installation Faulty installation can result in kinked twisted hoses or contact with the wheels and tires or other chassis components All of these conditions can lead to scuffing cracking and eventual failure The steel brake lines should be inspected periodically for evidence of corrosion twists kinks leaks o...

Page 179: ...e inverted flare STANDARD PROCEDURE ISO FLARING A pre formed metal tube is recommended and preferred for all repairs However double wall steel tube can be used for emergency repair when factory replacement parts are not readily available Special bending tools are needed to avoid kinking or twisting of metal brake tubes Special flaring tools are needed to make double inverted flares or ISO flares T...

Page 180: ...ainted surface Brake fluid can damage paint 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Disconnect the brake hose 4 from the caliper 3 4 Disconnect the brake hose 3 at the brake line 2 connecting point and remove the hose 5 14 BRAKES BASE ZH ...

Page 181: ...ainted surface Brake fluid can damage paint 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Disconnect the brake hose 1 from the brake line connection 4 Disconnect the brake hose at the caliper 1 and remove the hose ZH BRAKES BASE 5 15 ...

Page 182: ...INSTALLATION FRONT BRAKE HOSE 1 Connect the brake hose 3 to the brake line con nection 2 2 Route the brake hose 1 behind the steering knuckle 2 and connect to the caliper 5 16 BRAKES BASE ZH ...

Page 183: ...TIRES WHEELS STANDARD PROCEDURE 5 Lower the vehicle 6 Fill and bleed brake system Manual bleeding Refer to 5 BRAKES STAN DARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE INSTALLATION REAR BRAKE HOSE 1 Connect the brake hose 1 to the brake line connection ZH BRAKES BASE 5 17 ...

Page 184: ...ROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE BRAKE PADS SHOES REMOVAL FRONT DISC BRAKE PADS 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun 4 Bottom the caliper pistons into the caliper by prying the caliper over 5 Remove the caliper support spring 2 by prying the s...

Page 185: ... 3 and then remove the caliper slide pins 2 from the caliper 1 CAUTION Never allow the disc brake caliper to hang from the brake hose Damage to the brake hose will result Provide a suitable support to hang the caliper securely 8 Remove the caliper 1 from the mounting bracket 2 ZH BRAKES BASE 5 19 ...

Page 186: ...DISC BRAKE PADS 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Drain a small amount of fluid from the master cyl inder brake reservoir with a clean suction gun 4 Remove the caliper mounting bolts 1 and remove the caliper from the knuckle 5 20 BRAKES BASE ZH ...

Page 187: ...otating the caliper while holding the brake hose with a line wrench 6 Using a suitable punch 1 knock out the retaining pin 4 that holds the pads in place 7 Remove the anti rattle clip 3 and remove the brake pads from the caliper 2 ZH BRAKES BASE 5 21 ...

Page 188: ...tomed out into the caliper you must do so in order to install the caliper onto the rotor Use a C clamp to bottom out caliper 1 Install the inboard and outboard brake pads 2 and 3 onto the caliper 1 2 Lubricate the slide pins 2 and slide pin caps with silicone grease 5 22 BRAKES BASE ZH ...

Page 189: ...n the caliper mounting bracket 2 4 Install the caliper slide pins 2 Tighten the slide pins to 25 N m 18 ft lbs 5 Install the caliper slide pin caps 3 6 Connect the brake pad wear indicator harness connector ZH BRAKES BASE 5 23 ...

Page 190: ...Top off the brake fluid reservoir with new fluid if necessary and check for leaks INSTALLATION REAR DISC BRAKE PADS Note If the caliper piston is not completely bot tomed out into the caliper you must do so in order to install the caliper onto the rotor Use a C clamp to bottom out caliper piston 1 Install the brake pads into the caliper by sliding them through the hole in the top of the caliper 2 ...

Page 191: ...ll directions This means pres sure exerted against the caliper piston 2 and within the caliper bores 3 will be equal Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad This forces the pad lining 6 against the inner surface of the disc brake rotor At the same time fluid pressure within the piston bores forces the caliper to slide inward on the slide pins This act...

Page 192: ... 1 The front outboard brake pads have electronic wear indicators Which when wear is present the wear indi cator will illuminate a MIL light on the instrument panel telling the operator of the brake pad wear concern REMOVAL FRONT DISC BRAKE CALIPER 1 Raise and support the vehicle 2 Remove the front wheel and tire assembly 3 Drain a small amount of fluid from the master cyl inder brake reservoir wit...

Page 193: ...the retaining bolt 6 Bottom the caliper piston into the caliper by prying the caliper over 7 Remove the caliper support spring 2 by prying the spring out of the caliper 1 8 Remove the caliper slide pin caps 3 and slide pins 2 from the caliper 1 ZH BRAKES BASE 5 27 ...

Page 194: ...es Brake fluid can damage paint 10 Remove the brake hose 4 from the caliper 3 11 Remove the inboard and outboard brake pads 2 and 3 from the caliper 1 12 Disassemble the caliper to clean and inspect for wear and damage Refer to 5 BRAKES HY DRAULIC MECHANICAL DISC BRAKE CALI PERS DISASSEMBLY 5 28 BRAKES BASE ZH ...

Page 195: ... NOT spill the brake fluid on any painted surfaces Brake fluid can damage paint 5 Remove the brake hose 1 by rotating the caliper 2 while holding the brake hose 1 with a wrench 6 Using a suitable punch 1 knock out the retaining pin 4 that holds the pads in place 7 Remove the anti rattle clip 3 and remove the brake pads from the caliper 2 8 Disassemble the caliper to check for wear or dam age Refer...

Page 196: ...E WITH SUSTAINED AIR PRESSURE THIS COULD RESULT IN A CRACKED PISTON 3 Remove the caliper piston 2 by using short bursts of low pressure air with a blow gun 1 through the brake hose port Use only enough air pressure to ease the caliper piston out 4 Remove the piston dust boot 2 with a suitable pry tool 1 and discard CAUTION DO NOT SCRATCH PISTON BORE WHILE REMOVING THE SEALS 5 Remove piston seal 2 ...

Page 197: ...ough shop towel Do not clean piston with a polishing or emery cloth because this will damage the chrome plated surface Replace the piston if the chrome plated surface is damaged Clean anodized aluminum versions piston and housing bore with a soft rag only If the piston is jammed or if the cylinder bores are scored or rusted replace the complete fixed brake caliper and with the floating brake calip...

Page 198: ...ton 3 into the caliper bore and press the piston down to the bottom of the caliper bore by hand or with the handle of a hammer 6 Seat the dust boot 4 in caliper 1 7 Install the new caliper bleed screw 8 Install the caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLA TION INSTALLATION FRONT DISC BRAKE CALIPER 1 Install the inboard and outboard brake pads 2 and 3 onto the cal...

Page 199: ... bracket 2 4 Install the caliper slide pins 2 Tighten the slide pins to 25 N m 18 ft lbs 5 Install the caliper slide pin caps 3 6 Install the brake pad wear indicator 2 onto the caliper Tighten the bolt to 8 N m 6 ft lbs ZH BRAKES BASE 5 33 ...

Page 200: ... out and down under the mounting bracket with a screwdriver CAUTION Verify brake hose is not twisted or kinked before tightening the fitting 11 Connect the brake hose 4 to the caliper 3 12 Fill and bleed brake system Manual bleeding Refer to 5 BRAKES STAN DARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE 13 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD P...

Page 201: ...caliper is installed CAUTION Verify the brake hose is not twisted or kinked before installing the caliper to the knuckle 3 Install the caliper to the knuckle Install the mount ing bolts Tighten to 55 N m 41 ft lbs 4 Fill and bleed the brake system Manual bleeding Refer to 5 BRAKES STANDARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE 5 Install the wheel and tire assembly WARNIN...

Page 202: ... thickness will cause pedal pulsation noise and shudder Measure rotor thickness at a minimum of six points around the rotor face Position the micrometer approximately 3 4 in 19 mm from the rotor outer circumference for each measurement Thickness should not vary by more than 0 0005 in 0 0127 mm from point to point on the rotor Refinish or replace the rotor if necessary REAR ROTOR LATERAL RUNOUT Che...

Page 203: ...each measurement Thickness should not vary by more than 0 0005 in 0 0127 mm from point to point on the rotor Refinish or replace the rotor if necessary Note A hub mounted on vehicle lathe is recom mended This type of lathe trues the rotor to the vehicles hub bearing Front rotors and hub bearings are matched mounted for minimum lateral runout Before removing the rotor mark the rotor and hub bearing...

Page 204: ...rn The lathe must machine both sides of the rotor simulta neously with dual cutter heads The rotor mounting surface must be clean before placing on the lathe Equipment capable of machining only one side at a time may produce a tapered rotor REMOVAL FRONT DISC BRAKE ROTOR 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Disconnect the brake pad wear indicator 4 Remove the cali...

Page 205: ...itable support to hang the caliper securely 5 Remove the retaining bolt and then remove the brake rotor 1 from the wheel hub REMOVAL REAR DISC BRAKE ROTOR 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the caliper mounting bolts 1 and remove the caliper from the knuckle ZH BRAKES BASE 5 39 ...

Page 206: ...n result Provide a suitable support to hang the caliper securely 4 Remove the rotor retaining bolt and remove the rotor 1 from the wheel hub INSTALLATION FRONT DISC BRAKE ROTOR 1 Install the rotor 1 onto the wheel hub 2 Install the retaining bolt Tighten to 10 N m 7 ft lbs 5 40 BRAKES BASE ZH ...

Page 207: ...85 ft lbs 5 Connect the brake pad wear indicator 6 Install the wheel and tire assembly Refer to 22 TIRES WHEELS STANDARD PROCEDURE WARNING DO NOT MOVE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED 7 Lower the vehicle 8 Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved ZH BRAKES BASE 5 41 ...

Page 208: ...s and the brake pads are seated and a firm brake pedal is achieved FLUID DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts Swollen rubber parts indicate the presence of petroleum in the brake fluid To test for contamination put a small amount of drained brake fluid in a clear glass jar If the fluid separates into layers ther...

Page 209: ...will absorb moisture from the air and contaminate the fluid CAUTION Never use any type of a petroleum based fluid in the brake hydraulic system Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system Petroleum based fluids would be items such as engine oil transmission fluid power steering fluid etc Use brake fluid appr...

Page 210: ...g test 1 Start the engine and inspect the booster vacuum hose connections A hissing noise indicates a vacuum leak Correct any vacuum leaks before proceeding 2 Stop the engine and shift the transmission into Neutral 3 Pump the brake pedal until all the vacuum reserve in the booster is depleted 4 Press and hold the brake pedal under a light foot pressure The pedal should hold firm if the pedal falls...

Page 211: ...E TEST 1 Disconnect the vacuum hose from the check valve 2 Remove the check valve 1 and the valve seal 3 from the booster 3 Use a hand operated vacuum pump for this test 4 Apply 51 67 kPa 15 20 in of vacuum at the large end of the check valve 2 5 The vacuum should hold steady If the gauge on the pump indicates a vacuum loss the check valve and seal should be replaced DIAGNOSIS AND TESTING MASTER C...

Page 212: ...ne 1 Mount the master cylinder in a vise with brass jaws 2 Attach the bleed tubes to the cylinder outlet ports Then position each tube end into the bottom of the reservoir 3 Fill the reservoir with fresh brake fluid 4 Press the cylinder pistons inward with the wood dowel Then release the pistons and allow them to return under spring pressure Continue the bleed ing operations until all the air bubb...

Page 213: ...d pressure sensor 4 harness connectors 3 Remove brake lines 3 from master cylinder 5 4 Remove the nuts that attach the master cylinder 5 to the booster 6 studs WARNING DO NOT TILT THE MASTER BRAKE CYLINDER WHEN REMOVING FROM THE BRAKE BOOSTER IF TILTED THE BRAKE ROD CAN BE DISCONNECTED FROM THE MASTER CYLINDER 5 Remove the master cylinder 5 from the booster 6 6 Remove the O ring 7 from the master ...

Page 214: ... Disconnect the master cylinder brake fluid pressure sensor 4 harness connectors 4 Remove brake lines 3 from master cylinder 5 5 Remove the nuts that attach the master cylinder 5 to the booster studs WARNING DO NOT TILT THE MASTER BRAKE CYLINDER WHEN REMOVING FROM THE BRAKE BOOSTER IF TILTED THE BRAKE ROD CAN BE DISCONNECTED FROM THE MASTER CYLINDER 6 Remove the master cylinder 5 from the booster ...

Page 215: ...ster cylinder 5 to the booster 6 Install the mounting nuts Tighten to 20 N m 15 ft lbs 4 Install the brake lines 3 to the master cylinder 5 Tighten to 14 N m 10 ft lbs 5 Connect the fluid level sensor harness connector 2 to the fluid reservoir 1 6 Fill and bleed the brake system Manual bleeding Refer to 5 BRAKES STANDARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE ZH BRAKES BA...

Page 216: ... nuts and tighten to 20 N m 15 ft lbs 3 Install the brake lines 3 to the master cylinder 5 Tighten to 14 N m 10 ft lbs 4 Connect the brake fluid level sensor harness connector 2 to the fluid reservoir 1 5 Connect the negative battery cable 6 Fill and bleed the brake system Manual bleeding Refer to 5 BRAKES STANDARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE 5 50 BRAKES BASE Z...

Page 217: ...d valve 2 or the BAS release switch 6 need to be replaced The BAS diaphragm travel sensor 8 and if necessary the BAS control module NOT SHOWN are the only com ponents that can be serviced 1 BAS BRAKE BOOSTER 2 BAS SOLENOID VALVE 3 AIR FILTER 4 AIR FILTER 5 POPPET VALVE 6 BAS RELEASE SWITCH 7 VACUUM PISTON 8 BAS DIAPHRAGM TRAVEL SENSOR 9 COMPRESSION SPRING 10 OUTPUT ROD 11 CABLE CONNECTOR FOR RELEA...

Page 218: ... the rear of the BAS vacuum powered brake booster 1 The full assistance from the brake booster is transmitted to the master cylinder from the output rod 10 When the brake application is terminated the control module receives a signal from the BAS release switch 6 and the BAS solenoid valve 2 closes again The BAS assistance is terminated 1 BAS BRAKE BOOSTER 2 BAS SOLENOID VALVE 3 AIR FILTER 4 AIR F...

Page 219: ...KES HYDRAULIC MECHANICAL MASTER CYLINDER REMOVAL 2 Disconnect the vacuum hose 1 at the booster check valve 2 3 Remove the brake rod pin retaining clip 4 that holds the boosters push rod 1 to the pedal 3 Then slide the push rod off the pin 2 ZH BRAKES BASE 5 53 ...

Page 220: ...n remove the booster from the engine compartment REMOVAL RHD 1 Disconnect the negative battery cable 2 Remove the master cylinder Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER REMOVAL 3 Disconnect the booster check valve 1 and vac uum hose 4 Disconnect the travel sensor harness connector 3 and the solenoid valve harness connector 2 5 54 BRAKES BASE ZH ...

Page 221: ...ush rod to the pedal 3 Then slide the push rod off the pin 2 6 Remove the booster retaining nuts 2 that attach the booster 1 to the dash panel 7 Slide booster 1 forward tilt the booster upward slightly then remove the booster from the engine compartment ZH BRAKES BASE 5 55 ...

Page 222: ...ket 3 2 Align and position the booster 1 on the dash panel 3 Lubricate the pedal pin with Mopar multi mileage grease 4 Install the booster retaining nuts 2 Tighten to 39 N m 29 ft lbs 5 Install the brake rod pin 2 and retaining clip 4 5 56 BRAKES BASE ZH ...

Page 223: ...NSTALLA TION WARNING THE MASTER CYLINDER INSTALLA TION PROCEDURE MUST BE PERFORMED AS WRITTEN OR DAMAGE TO THE BOOSTER MAS TER CYLINDER MAY OCCUR 8 Fill and bleed the brake system Manual bleeding Refer to 5 BRAKES STAN DARD PROCEDURE Pressure bleeding Refer to 5 BRAKES STANDARD PROCEDURE INSTALLATION RHD 1 Align and position the booster 1 on the dash panel 2 Lubricate the pedal pin with Mopar mult...

Page 224: ...or harness connector 3 and the solenoid valve harness connector 2 WARNING THE MASTER CYLINDER INSTALLA TION PROCEDURE MUST BE PERFORMED AS WRITTEN OR DAMAGE TO THE BOOSTER MAS TER CYLINDER MAY OCCUR 7 Install the master cylinder with a new gasket and retaining nuts Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER INSTALLA TION 8 Connect the negative battery cable 9 Fill and bleed the brake s...

Page 225: ...upport bracket The bracket is attached to the bulkhead OPERATION The brake pedal 3 is attached to the booster push rod 1 When the pedal is depressed the primary booster push rod is depressed which moves the booster secondary rod The booster secondary rod depresses the master cylinder piston ZH BRAKES BASE 5 59 ...

Page 226: ...REMOVAL REMOVAL 1 Remove the instrument panel lower cover 2 from the instrument panel 2 Disconnect the stop lamp switch harness connector from the stop lamp switch 1 5 60 BRAKES BASE ZH ...

Page 227: ...emove the C clip 1 5 Remove the washer 2 6 Remove the bushing 3 7 Remove the brake pedal from the bracket 5 REMOVAL RHD 1 Remove the two screws 2 from the lower I P panel 1 then remove the lower panel from the I P ZH BRAKES BASE 5 61 ...

Page 228: ...e stop lamp harness connector from the stop lamp switch 1 3 Remove the return spring 7 4 Remove the C clip 1 5 Remove the washer 2 6 Remove the bushing 3 7 Remove the brake pedal from the bracket 5 5 62 BRAKES BASE ZH ...

Page 229: ...tall the brake pedal 5 to the bracket 2 Install the bushing 3 3 Install the washer 2 4 Install the C clip 1 5 Install the return spring 7 6 Install the stop lamp switch harness connector 1 to the stop lamp switch ZH BRAKES BASE 5 63 ...

Page 230: ...t panel lower cover 2 to the instrument panel INSTALLATION RHD 1 Install the brake pedal 5 to the bracket 2 Install the bushing 3 3 Install the washer 2 4 Install the C clip 1 5 Install the return spring 7 5 64 BRAKES BASE ZH ...

Page 231: ...6 Install the stop lamp switch electrical connector 1 to the stop lamp switch 7 Install the I P lower panel 1 then install the two screws 2 ZH BRAKES BASE 5 65 ...

Page 232: ...connected to the hand lever and the equalizer A set of drum type brake shoes are used for parking brakes The shoes are mounted to the rear wheel hub The parking brake drum is integrated into the rear disc brake rotor The parking brake system consists of the adjuster 1 upper and lower return springs 2 5 hold down springs 3 and the actuator 4 5 66 BRAKES BASE ZH ...

Page 233: ...e necessary would be to the equalizer tensioning bolt The driver is alerted of the parking brake being applied by the red warning lamp in the dash The parking brake switch will cause the lamp to illuminate only when the parking brakes are applied If the lamp remains on after the parking brake is released the switch or wires are faulty If the red lamp comes on a fault has occurred in the front or r...

Page 234: ...JUSTMENTS ADJUSTMENT Note Adjust the parking brake only if the hand brake lever can be pulled up more than 3 notches without having an adequate solid braking effect 1 Raise and support the vehicle 2 Loosen the parking brake cable tensioning bolt 3 3 Remove one wheel bolt on each rear wheel 4 Rotate the rear wheel 2 until the parking brake adjuster wheel 1 can be seen through the removed rear wheel...

Page 235: ...rmly apply the parking brake several times 8 To fine adjust the parking brake Tighten the park ing brake tensioning bolt 3 until the parking brake lever can be moved one tooth with a moderate effort of approximately 90 120 N m 9 Install the wheel bolt and tighten to 110 N m 81 ft lbs ZH BRAKES BASE 5 69 ...

Page 236: ...Remove the wheel and tire assembly 3 Remove the rear caliper assembly bolts 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 4 Remove the rear brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL 5 70 BRAKES BASE ZH ...

Page 237: ...assembly 1 5 Refer to 5 BRAKES PARKING BRAKE SHOES REMOVAL 6 Loosen the parking brake cable equalizer tensioner bolt 3 7 Remove the front parking brake cable to the park ing brake cable equalizer 1 retaining bolt 5 ZH BRAKES BASE 5 71 ...

Page 238: ...assembly 4 by removing the mounting bolt 1 13 Pull the parking brake cable 2 from the eyelets and remove it from vehicle INSTALLATION 1 Install the parking brake cable through the eyelets 2 Attach the parking brake cable 2 to the rear wheel carrier assembly 4 by installing the mount ing bolt 1 Tighten to 20 N m 15 ft lbs 3 Push the cable pin through the arm 3 attaching the actuator to the cable 2 ...

Page 239: ... parking brake cable equalizer to the front parking brake cable mounting bolt 5 8 Install the parking brake shoe assembly 1 5 Refer to 5 BRAKES PARKING BRAKE SHOES INSTALLATION 9 Install the rear brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION ZH BRAKES BASE 5 73 ...

Page 240: ...y Refer to 22 TIRES WHEELS STANDARD PROCEDURE 13 Lower vehicle and verify parking brake operation If parking brakes need to be adjusted Refer to 5 BRAKES PARKING BRAKE ADJUSTMENTS LEVER REMOVAL 1 Remove the parking brake equalizer return spring 4 2 Loosen the parking brake equalizer tensioning bolt 3 3 Remove the bolt at the parking brake equalizer 1 attaching the front parking brake cable to the ...

Page 241: ...th great force suc tion If necessary cut open with a suitable tool 6 Remove the center console 2 Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 7 Disconnect the parking brake switch harness connector Note The front parking brake cable will come with the parking brake handle as an assembly 8 Remove the mounting bolts 2 and pull out the parking brake lever assembly 1 using a forward motion ZH BRAK...

Page 242: ...s 2 Tighten to 20 N m 15 ft lbs 2 Connect the parking brake switch harness connector 3 Install the center console 2 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 4 Install the rubber handle 1 onto the parking brake lever 5 Install the shifter bezel 1 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 5 76 BRAKES BASE ZH ...

Page 243: ...ront parking brake cable mounting bolts 5 7 Tighten the parking brake equalizer tensioning bolt 3 8 Attach the return spring 4 from the equalizer 1 to the body frame 9 Adjust the parking brake Refer to 5 BRAKES PARKING BRAKE ADJUSTMENTS ZH BRAKES BASE 5 77 ...

Page 244: ...e 2 Remove wheel and tire assembly 3 Remove the caliper assembly bolts 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 4 Remove the disc brake rotor 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL 5 78 BRAKES BASE ZH ...

Page 245: ...6 Remove the parking brake shoe 1 return spring using a hooked pick 2 7 Remove the parking brake shoe 1 hold down spring 3 using a pair of needle nose pliers 2 8 Remove the parking brake shoes 1 by lifting them over rear axle shaft flange ZH BRAKES BASE 5 79 ...

Page 246: ...down spring 4 Expanding lock 5 Lower return spring INSTALLATION Note Coat all bearing and sliding surfaces on the expanding lock with Anti seize 1 Install the parking brake adjuster 1 2 Install the upper return spring 2 3 Install the parking brake shoes by placing the assembly over rear axle shaft flange 4 Install the hold down spring 3 by using a pair of needle nose pliers 2 5 80 BRAKES BASE ZH ...

Page 247: ...ol or needle nose pliers 2 6 Tighten the bolt 3 on the parking brake cable equalizer Refer to 5 BRAKES PARKING BRAKE CABLES INSTALLATION 7 Install the disc brake rotors 1 Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION ZH BRAKES BASE 5 81 ...

Page 248: ...SOR REMOVAL CAUTION Do not spill brake fluid on any painted surfaces Brake fluid can damage painted sur faces Note The brake fluid level sensor cannot be replaced by itself You must replace the fluid res ervoir 1 Disconnect the brake fluid level sensor harness connector 2 Remove the screw attaching the fluid reservoir to the master cylinder 3 Remove the fluid reservoir from the master cylinder 5 8...

Page 249: ...ke fluid level sensor harness con nector 4 Fill the reservoir with MOPART brake fluid to the proper level 5 Bleed the braking system Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER STANDARD PROCEDURE and Refer to 5 BRAKES STANDARD PROCEDURE BRAKE PRESSURE SENSOR REMOVAL 1 Remove the brake pressure sensor 1 from the master cylinder ZH BRAKES BASE 5 83 ...

Page 250: ...PPENS THE BRAKE BOOSTER MUST BE REPLACED 1 Operate the brake pedal several times until the vacuum in the brake booster is reduced 2 Unplug the BAS diaphragm travel sensor harness connector 3 Remove the locking ring 1 by using a suitable pick tool to lift the locking ring up and off the BAS diaphragm travel sensor 4 Pull the BAS diaphragm travel sensor out of the brake booster 5 Remove the O ring f...

Page 251: ... it is correctly seated 2 Rub some soapy water onto the front of the dia phragm travel sensor so that the O ring does not bind when inserted 3 Replace locking ring 1 and ensure that it is cor rectly seated 4 Connect the electrical harness connector to the travel sensor ZH BRAKES BASE 5 85 ...

Page 252: ...GE FROM STEERING ANGLE SENSOR 134 1037 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 140 1038 ERROR MOTRONIC CODING 143 1040 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 144 1041 ESP SENSOR CAN PROTOCOL 147 1042 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 148 1045 CAN ERROR TRANSFER BOX TIMEOUT 151 1046 CAN ERROR EAM CODING TIMEOUT 151 1047 CAN ERROR VARIABLE STEER...

Page 253: ...NSOR PLAUSIBILITY WITH PRESSURE GRADIENT 268 1190 YAW RATE ACCELERATION SENSOR INVALID CALIBRATION VALUES 269 1195 YAW RATE ACCELERATION SENSOR CYCLE TOO LONG 271 1201 BAS RELEASE SWITCH CIRCUIT 273 1202 BAS RELEASE SWITCH PLAUSIBILITY ERROR 281 1210 CAB SYSTEM UNDERVOLTAGE 289 1212 CAB SYSTEM OVERVOLTAGE 292 1310 POWER SUPPLY OR RETURN PUMP 295 1330 BAS SOLENOID VALVE CIRCUIT 296 1331 BAS SOLENOI...

Page 254: ...1000 CAB INTERNAL FAILURE HARDWARE ERROR 5 88 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 255: ...gram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Pe...

Page 256: ...1001 CAB INTERNAL FAILURE SIGNAL ERROR 5 90 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 257: ...ram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Per...

Page 258: ...1002 CAB INTERNAL FAILURE LEFT FRONT INLET VALVE 5 92 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 259: ... Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVA...

Page 260: ...1003 CAB INTERNAL FAILURE LEFT FRONT OUTLET VALVE 5 94 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 261: ...t Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOV...

Page 262: ...1004 CAB INTERNAL FAILURE RIGHT FRONT INLET VALVE 5 96 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 263: ...rcuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace Controller Antilock Brake CAB Module Refer to 5 BRAKES ELECTRICAL FRONT WHEEL SPEED SEN SOR REMOVAL P...

Page 264: ...1005 CAB INTERNAL FAILURE RIGHT FRONT OUTLET VALVE 5 98 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 265: ...t Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOV...

Page 266: ...1006 CAB INTERNAL FAILURE LEFT REAR INLET VALVE 5 100 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 267: ...Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL...

Page 268: ...1007 CAB INTERNAL FAILURE LEFT REAR OUTLET VALVE 5 102 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 269: ... Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVA...

Page 270: ...1008 CAB INTERNAL FAILURE RIGHT REAR INLET VALVE 5 104 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 271: ... Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVA...

Page 272: ...1009 CAB INTERNAL FAILURE RIGHT REAR OUTLET VALVE 5 106 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 273: ... Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVA...

Page 274: ...1010 CAB INTERNAL FAILURE LOW PRESSURE FEED VALVE 1 5 108 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 275: ...t Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOV...

Page 276: ...1011 CAB INTERNAL FAILURE MASTER CYLINDER ISOLATION VALVE 1 5 110 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 277: ...rcuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE R...

Page 278: ...1012 CAB INTERNAL FAILURE LOW PRESSURE FEED VALVE 2 5 112 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 279: ...t Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOV...

Page 280: ...1013 CAB INTERNAL FAILURE MASTER CYLINDER ISOLATION VALVE 2 5 114 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 281: ...rcuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE R...

Page 282: ...1014 VALVE PML This DTC is currently undefined 5 116 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 283: ...1018 CAB INTERNAL FAILURE INTERNAL SHORT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 117 ...

Page 284: ...gram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS 1 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performing road test Did the DTC return Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Pe...

Page 285: ...1020 CAN BUS COMMUNICATION GENERAL MALFUNCTION ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 119 ...

Page 286: ...AKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN C BUS CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the harness connectors of the other modules on the CAN Bus network Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the CAB harness connector to the harness connectors of t...

Page 287: ...ss connector to the harness connectors of the other modules on the CAN Bus network Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the CAN C Bus circuit for an open Perform ABS VERIFICATION TEST ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 121 ...

Page 288: ...1022 NO CAN COMMUNICATIONS WITH PCM 5 122 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 289: ...ke System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN C BUS CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the PCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the CAB harness connector to the PCM harness connector...

Page 290: ... the CAB har ness connector to the PCM harness connector Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the CAN C Bus circuit for an open Perform ABS VERIFICATION TEST 5 124 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 291: ...1023 CAN ERROR MOTRONIC TIMEOUT This DTC is currently undefined 1024 ERROR MOTRONIC ESP TORQUE INTERFACE LOCKED This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 125 ...

Page 292: ...1025 PCM NOT IDENTIFIED OR INCORRECT 5 126 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 293: ...ition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine CAUTION Ensure braking capability is available before road test ing Drive the vehicle above 16 km h 10 MPH for at least 20 seconds Stop the vehicle With the DRB IIIT read DTCs Does the DRB IIIT display a PCM Not Identified or Incorrect DTC Yes Replace the Controller Antilock Brake CAB Module Refer to ...

Page 294: ...1026 NO CAN COMMUNICATIONS WITH TCM 5 128 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 295: ...ake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN C BUS CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the TCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the CAB harness connector to the TCM harness connecto...

Page 296: ... the CAB har ness connector to the TCM harness connector Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the CAN C Bus circuit for an open Perform ABS VERIFICATION TEST 5 130 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 297: ...1027 CAN ERROR GEARBOX PROTOCOL This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 131 ...

Page 298: ...1028 TCM NOT IDENTIFIED OR INCORRECT 5 132 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 299: ...nition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine CAUTION Ensure braking capability is available before road test ing Drive the vehicle above 16 km h 10 MPH for at least 20 seconds Stop the vehicle With the DRB IIIT read DTCs Does the DRB IIIT display a TCM Not Identified or Incorrect DTC Yes Replace the Controller Antilock Brake CAB Module Refer to...

Page 300: ...1035 CAN COMMUNICATIONS NO MESSAGE FROM STEERING ANGLE SENSOR 5 134 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 301: ...CCELERATION SENSOR For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Note This DTC will possibly set if the battery has been disconnected Before performing any diagnostics confirm that the steering angle sensor is calibrated correctly If the DTC is current and the battery has been previously disconnected perform the following procedure to...

Page 302: ...ion to the full left position Note It may be helpful to raise the front wheels off the ground and support the vehicle using appropriate safety measures Does the voltage vary between 7 0 and 9 5 volts Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Go to 2 2 MEASURE STEERING ANGL...

Page 303: ...n open Perform ABS VERIFICATION TEST 4 MEASURE THE STEERING ANGLE SENSOR SIGNAL CIRCUIT RESISTANCE Turn the ignition off Disconnect the Yaw Rate Acceleration sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Steering Angle Sensor Signal circuit from the Yaw Rate Acceleration sensor harness connector to the Steering Angle Sensor harness connector...

Page 304: ...e Steering Angle Sensor Signal circuit for a short to ground Perform ABS VERIFICATION TEST No Go to 6 6 MEASURE THE VOLTAGE OF THE STEERING ANGLE SENSOR SIGNAL CIRCUIT Turn the ignition on Measure the voltage of the Steering Angle Sensor Signal circuit at the Steering Angle Sensor harness connector Is the voltage below 1 0 volt Yes Go to 7 No Repair the Steering Angle Sensor Signal circuit for a s...

Page 305: ...off Measure the resistance between ground and the Sensor Ground cir cuit Is the resistance below 5 0 ohms Yes Replace the Steering Angle Sensor Refer to 5 BRAKES ELECTRICAL STEERING ANGLE SENSOR REMOVAL Perform ABS VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform ABS VERIFICATION TEST ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 139 ...

Page 306: ...1037 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 5 140 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 307: ...S Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE S CAN CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the Yaw Rate Acceleration sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the S CAN circuit from the CAB harness connector to the Yaw Rate Acceler...

Page 308: ...the CAB harness connector to the Yaw Rate Acceleration sensor harness connector Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the S CAN circuit for an open Perform ABS VERIFICATION TEST 5 142 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 309: ...1038 ERROR MOTRONIC CODING This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 143 ...

Page 310: ...1040 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 5 144 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 311: ...S Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE S CAN CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the Yaw Rate Acceleration sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the S CAN circuit from the CAB harness connector to the Yaw Rate Acceler...

Page 312: ...the CAB harness connector to the Yaw Rate Acceleration sensor harness connector Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the S CAN circuit for an open Perform ABS VERIFICATION TEST 5 146 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 313: ...1041 ESP SENSOR CAN PROTOCOL This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 147 ...

Page 314: ...1042 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 5 148 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 315: ...S Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE S CAN CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the Yaw Rate Acceleration sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the S CAN circuit from the CAB harness connector to the Yaw Rate Acceler...

Page 316: ...the CAB harness connector to the Yaw Rate Acceleration sensor harness connector Is the resistance below 1 0 ohm Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the S CAN circuit for an open Perform ABS VERIFICATION TEST 5 150 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 317: ...IMEOUT This DTC is currently undefined 1046 CAN ERROR EAM CODING TIMEOUT This DTC is currently undefined 1047 CAN ERROR VARIABLE STEERING TRANS RATIO CODING This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 151 ...

Page 318: ...1100 LEFT FRONT WHEEL SPEED SENSOR CIRCUIT 5 152 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 319: ...The DTC can also set if the Signal is missing or erratic POSSIBLE CAUSES LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE LEFT FR...

Page 320: ...Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Left Front Wheel Speed Sensor 12 Volt Supply circuit at the Left Front Wheel Speed Sensor harness connec tor Is the voltage above 10 volts Yes Go to 8 No Go to 4 4 MEASURE THE VOLTAGE OF THE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT Turn the ignition off Measure the v...

Page 321: ... Perform ABS VERIFICATION TEST No Repair the Left Front Wheel Speed Sensor 12 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST 6 MEASURE THE RESISTANCE BETWEEN GROUND AND THE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and...

Page 322: ...ensor harness connector Is the resistance below 5 0 ohms Yes Go to 8 No Repair the Left Front Wheel Speed Sensor 12 Volt Supply circuit for an open Perform ABS VERIFICATION TEST 8 MEASURE THE RESISTANCE OF THE LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Reconnect the CAB harness connector Measure the resistance between ground and the Left Front Wheel Speed Sensor Signal circ...

Page 323: ...PEED SENSOR REMOVAL Perform ABS VERIFICATION TEST 10 MEASURE THE RESISTANCE OF THE LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Left Front Wheel Speed Sensor Signal circuit from the CAB harness connector to the Left Front Wheel Speed Sensor harness connector Is t...

Page 324: ...Go to 12 12 MEASURE THE RESISTANCE BETWEEN THE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT AND THE SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the Left Front Wheel Speed Sensor 12 Volt Supply circuit and the Left Front Wheel Speed Sensor Signal circuit at the CAB harness connector Is the resistance below 100k ohms Yes Repair the Left Front Wheel Speed Sensor...

Page 325: ...heel concerns as necessary Perform ABS VERIFICATION TEST No Go to 14 14 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accelerate as straight as possible from a stop to 24 km h 15 MPH Is the Left Front Wheel Speed Sensor Signal 0 or differing from others by more th...

Page 326: ...1101 LEFT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL 5 160 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 327: ...pushed out or corroded terminals Visually inspect the Left Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs St...

Page 328: ...1102 LEFT FRONT WHEEL SPEED SENSOR LOW SIGNAL 5 162 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 329: ...shed out or corroded terminals Visually inspect the Left Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Star...

Page 330: ...1103 LEFT FRONT WHEEL SPEED SENSOR LONG GAP 5 164 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 331: ...out or corroded terminals Visually inspect the Left Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the...

Page 332: ...1104 LEFT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR 5 166 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 333: ...el for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accel...

Page 334: ...1105 LEFT FRONT WHEEL SPEED SENSOR DOUBLE FREQUENCY This DTC is currently undefined 5 168 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 335: ...1110 RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 169 ...

Page 336: ... DTC can also set if the Signal is missing or erratic POSSIBLE CAUSES RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE RIGHT...

Page 337: ... Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Right Front Wheel Speed Sensor 12 Volt Supply circuit at the Right Front Wheel Speed Sensor harness con nector Is the voltage above 10 volts Yes Go to 8 No Go to 4 4 MEASURE THE VOLTAGE OF THE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT Turn the ignition off Measure t...

Page 338: ...Perform ABS VERIFICATION TEST No Repair the Right Front Wheel Speed Sensor 12 Volt Sup ply circuit for a short to voltage Perform ABS VERIFICATION TEST 6 MEASURE THE RESISTANCE BETWEEN GROUND AND THE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground a...

Page 339: ...ensor harness connector Is the resistance below 5 0 ohms Yes Go to 8 No Repair the Right Front Wheel Speed Sensor 12 Volt Sup ply circuit for an open Perform ABS VERIFICATION TEST 8 MEASURE THE RESISTANCE OF THE RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Reconnect the CAB harness connector Measure the resistance between ground and the Right Front Wheel Speed Sensor Signal ...

Page 340: ...EED SEN SOR REMOVAL Perform ABS VERIFICATION TEST 10 MEASURE THE RESISTANCE OF THE RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Right Front Wheel Speed Sensor Signal circuit from the CAB harness connector to the Right Front Wheel Speed Sensor harness connector I...

Page 341: ... to 12 12 MEASURE THE RESISTANCE BETWEEN THE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT AND THE SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the Right Front Wheel Speed Sensor 12 Volt Supply circuit and the Right Front Wheel Speed Sensor Signal circuit at the CAB harness connector Is the resistance below 100k ohms Yes Repair the Right Front Wheel Speed Sens...

Page 342: ...heel concerns as necessary Perform ABS VERIFICATION TEST No Go to 14 14 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accelerate as straight as possible from a stop to 24 km h 15 MPH Is the Right Front Wheel Speed Sensor Signal 0 or differing from others by more t...

Page 343: ...1111 RIGHT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 177 ...

Page 344: ...shed out or corroded terminals Visually inspect the Right Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Sta...

Page 345: ...1112 RIGHT FRONT WHEEL SPEED SENSOR LOW SIGNAL ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 179 ...

Page 346: ...ed out or corroded terminals Visually inspect the Right Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start...

Page 347: ...1113 RIGHT FRONT WHEEL SPEED SENSOR LONG GAP ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 181 ...

Page 348: ...t or corroded terminals Visually inspect the Right Front Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the ...

Page 349: ...1114 RIGHT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 183 ...

Page 350: ...l for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accele...

Page 351: ...1115 RIGHT FRONT WHEEL SPEED SENSOR DOUBLE FREQUENCY This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 185 ...

Page 352: ...1120 LEFT REAR WHEEL SPEED SENSOR CIRCUIT 5 186 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 353: ...et The DTC can also set if the Signal is missing or erratic POSSIBLE CAUSES LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE LEFT REAR...

Page 354: ...Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Left Rear Wheel Speed Sensor 12 Volt Supply circuit at the Left Rear Wheel Speed Sensor harness connec tor Is the voltage above 10 volts Yes Go to 8 No Go to 4 4 MEASURE THE VOLTAGE OF THE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT Turn the ignition off Measure the volt...

Page 355: ...L Perform ABS VERIFICATION TEST No Repair the Left Rear Wheel Speed Sensor 12 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST 6 MEASURE THE RESISTANCE BETWEEN GROUND AND THE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and ...

Page 356: ...nsor harness connector Is the resistance below 5 0 ohms Yes Go to 8 No Repair the Left Rear Wheel Speed Sensor 12 Volt Supply circuit for an open Perform ABS VERIFICATION TEST 8 MEASURE THE RESISTANCE OF THE LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Reconnect the CAB harness connector Measure the resistance between ground and the Left Rear Wheel Speed Sensor Signal circuit ...

Page 357: ...EED SENSOR REMOVAL Perform ABS VERIFICATION TEST 10 MEASURE THE RESISTANCE OF THE LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Left Rear Wheel Speed Sensor Signal circuit from the CAB harness connector to the Left Rear Wheel Speed Sensor harness connector Is the r...

Page 358: ...Go to 12 12 MEASURE THE RESISTANCE BETWEEN THE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT AND THE SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the Left Rear Wheel Speed Sensor 12 Volt Supply circuit and the Left Rear Wheel Speed Sensor Signal circuit at the CAB harness connector Is the resistance below 100k ohms Yes Repair the Left Rear Wheel Speed Sensor 12 ...

Page 359: ...wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 14 14 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accelerate as straight as possible from a stop to 24 km h 15 MPH Is the Left Rear Wheel Speed Sensor Signal 0 or differing from others by more th...

Page 360: ...1121 LEFT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL 5 194 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 361: ... pushed out or corroded terminals Visually inspect the Left Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs St...

Page 362: ...1122 LEFT REAR WHEEL SPEED SENSOR LOW SIGNAL 5 196 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 363: ...ushed out or corroded terminals Visually inspect the Left Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Star...

Page 364: ...1123 LEFT REAR WHEEL SPEED SENSOR LONG GAP 5 198 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 365: ... out or corroded terminals Visually inspect the Left Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the...

Page 366: ...1124 LEFT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR 5 200 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 367: ...el for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accel...

Page 368: ...1125 LEFT REAR WHEEL SPEED SENSOR DOUBLE FREQUENCY This DTC is currently undefined 5 202 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 369: ...1130 RIGHT REAR WHEEL SPEED SENSOR CIRCUIT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 203 ...

Page 370: ...The DTC can also set if the Signal is missing or erratic POSSIBLE CAUSES RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE RIGHT R...

Page 371: ...Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Right Rear Wheel Speed Sensor 12 Volt Supply circuit at the Right Rear Wheel Speed Sensor harness connec tor Is the voltage above 10 volts Yes Go to 8 No Go to 4 4 MEASURE THE VOLTAGE OF THE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT Turn the ignition off Measure the v...

Page 372: ...Perform ABS VERIFICATION TEST No Repair the Right Rear Wheel Speed Sensor 12 Volt Sup ply circuit for a short to voltage Perform ABS VERIFICATION TEST 6 MEASURE THE RESISTANCE BETWEEN GROUND AND THE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and...

Page 373: ...nsor harness connector Is the resistance below 5 0 ohms Yes Go to 8 No Repair the Right Rear Wheel Speed Sensor 12 Volt Sup ply circuit for an open Perform ABS VERIFICATION TEST 8 MEASURE THE RESISTANCE OF THE RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Reconnect the CAB harness connector Measure the resistance between ground and the Right Rear Wheel Speed Sensor Signal circ...

Page 374: ...EED SENSOR REMOVAL Perform ABS VERIFICATION TEST 10 MEASURE THE RESISTANCE OF THE RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Right Rear Wheel Speed Sensor Signal circuit from the CAB harness connector to the Right Rear Wheel Speed Sensor harness connector Is th...

Page 375: ...o to 12 12 MEASURE THE RESISTANCE BETWEEN THE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT AND THE SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the Right Rear Wheel Speed Sensor 12 Volt Supply circuit and the Right Rear Wheel Speed Sensor Signal circuit at the CAB harness connector Is the resistance below 100k ohms Yes Repair the Right Rear Wheel Speed Sensor ...

Page 376: ...wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 14 14 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accelerate as straight as possible from a stop to 24 km h 15 MPH Is the Right Rear Wheel Speed Sensor Signal 0 or differing from others by more t...

Page 377: ...1131 RIGHT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 211 ...

Page 378: ...ushed out or corroded terminals Visually inspect the Right Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Sta...

Page 379: ...1132 RIGHT REAR WHEEL SPEED SENSOR LOW SIGNAL ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 213 ...

Page 380: ...hed out or corroded terminals Visually inspect the Right Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start...

Page 381: ...1133 RIGHT REAR WHEEL SPEED SENSOR LONG GAP ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 215 ...

Page 382: ...ut or corroded terminals Visually inspect the Right Rear Wheel Speed Sensor connector and tone wheel for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the ...

Page 383: ...1134 RIGHT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 217 ...

Page 384: ...l for damage and correct installation Are there any visible Sensor connector or tone wheel concerns Yes Correct the sensor connector or tone wheel concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor all wheel speed sensors Slowly accele...

Page 385: ...1135 RIGHT REAR WHEEL SPEED SENSOR DOUBLE FREQUENCY This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 219 ...

Page 386: ...1140 ESP BRAKE PRESSURE SENSOR 1 CIRCUIT 5 220 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 387: ...IRCUIT SHORT TO GROUND BRAKE PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND BRAKE PRESSURE SENSOR GROUND CIRCUIT OPEN BRAKE PRESSURE SENSOR CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE VOLTAGE OF THE ESP BRAKE PRESSURE SENSOR 1 SIGNAL CIRCUIT Turn the ignition ...

Page 388: ...Repair the ESP Brake Pressure Sensor 1 Signal circuit for a short to the 5 Volt Supply circuit Perform ABS VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE OF THE ESP BRAKE PRESSURE SENSOR 1 SIGNAL CIRCUIT With the ignition off Measure the resistance of the ESP Brake Pressure Sensor 1 Signal circuit from the CAB harness connector to the ESP Brake Pressure Sensor 1 harness connector Is the res...

Page 389: ...s con nector Is the resistance below 5 0 ohms Yes Go to 5 No Repair the Sensor Ground circuit for an open Perform ABS VERIFICATION TEST 5 MEASURE THE VOLTAGE OF THE 5 VOLT SUPPLY CIRCUIT With the ignition off Reconnect the CAB harness connector Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the ESP Brake Pressure Sensor 1 harness connector Is the voltage between 4 5 and 5...

Page 390: ...ensor 1 Signal circuit and the Sensor Ground circuit in the ESP Brake Pres sure Sensor 1 harness connector Is the resistance below 100k ohms Yes Repair the ESP Brake Pressure Sensor 1 Signal circuit for a short to the Sensor Ground circuit Perform ABS VERIFICATION TEST No Replace the ESP Brake Pressure Sensor 1 Refer to 5 BRAKES ELECTRICAL PRESSURE SENSOR REMOVAL Perform ABS VERIFICATION TEST 8 CH...

Page 391: ...low 100k ohms Yes Repair the 5 Volt Supply circuit for a short to the Sensor Ground circuit Perform ABS VERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE BETWEEN GROUND AND THE ESP BRAKE PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT With the ignition off Measure the resistance between ground and the 5 Volt Supply circuit Is the resistance below 100k ohms Yes Repair the 5 Volt Supply circuit for a sh...

Page 392: ... Brake Pressure Sensor 1 harness connector to the CAB harness con nector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the ESP Brake Pressure Sensor 5 Volt Supply cir cuit for an open Perform ABS VERIFICATION TEST 5 226 BRAKES ABS ELECTR...

Page 393: ...1141 ESP BRAKE PRESSURE SENSOR 1 PLAUSIBILITY WITH RELEASE SWITCH ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 227 ...

Page 394: ...GE AND CORRECT INSTALLATION Visually inspect the ESP Brake Pressure Sensor 1 for damage and correct installation Are there any visible Brake Pressure Sensor 1 concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB m...

Page 395: ...1142 ESP BRAKE PRESSURE SENSOR 1 PLAUSIBILITY WITH TRAVEL SENSOR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 229 ...

Page 396: ...E AND CORRECT INSTALLATION Visually inspect the ESP Brake Pressure Sensor 1 for damage and correct installation Are there any visible Brake Pressure Sensor 1 concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mo...

Page 397: ...1143 ESP BRAKE PRESSURE SENSOR 1 PLAUSIBILITY WITH BOOSTER DISTANCE GRADIENT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 231 ...

Page 398: ... DAMAGE AND CORRECT INSTALLATION Visually inspect the ESP Brake Pressure Sensor 1 for damage and correct installation Are there any visible Brake Pressure Sensor 1 concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the ...

Page 399: ...1145 ESP BRAKE PRESSURE SENSOR 1 INVALID OFFSET ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 233 ...

Page 400: ...RRECT INSTALLATION Visually inspect the ESP Brake Pressure Sensor 1 for damage and correct installation Are there any visible Brake Pressure Sensor 1 concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DT...

Page 401: ...1150 LATERAL ACCELERATION CIRCUIT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 235 ...

Page 402: ... DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs...

Page 403: ...1151 YAW RATE ACCELERATION SENSOR PLAUSIBILITY ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 237 ...

Page 404: ...RAMS 1 VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Yaw Rate Acceleration Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assista...

Page 405: ...1152 YAW RATE ACCELERATION SENSOR INVALID OFFSET ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 239 ...

Page 406: ...NTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod u...

Page 407: ...1160 YAW RATE ACCELERATION SENSOR YAW MALFUNCTION ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 241 ...

Page 408: ...ENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ...

Page 409: ...1161 YAW RATE ACCELERATION SENSOR PLAUSIBILITY ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 243 ...

Page 410: ...RAMS 1 VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Yaw Rate Acceleration Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assista...

Page 411: ...1162 YAW RATE ACCELERATION SENSOR INVALID OFFSET ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 245 ...

Page 412: ...NTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod u...

Page 413: ...1170 STEERING ANGLE SENSOR INVALID OFFSET ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 247 ...

Page 414: ...ECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Steering Angle Sensor for damage and correct installation Are there any visible Steering Angle Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to mo...

Page 415: ...1172 STEERING ANGLE SENSOR INTERNAL ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 249 ...

Page 416: ...ND CORRECT INSTALLATION Visually inspect the Steering Angle Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB mod ule DTCs while performin...

Page 417: ...1173 STEERING ANGLE SENSOR PLAUSIBILITY ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 251 ...

Page 418: ...T COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Steering Angle Sensor for damage and correct installation Are there any visible Steering Angle Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT ...

Page 419: ...1174 STEERING ANGLE SENSOR NOT INITIALIZED ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 253 ...

Page 420: ...llowing procedure to recalibrate the steering angle sensor Turn the ignition switch on Rotate the steering wheel to the center position Rotate the steering wheel to the full left stop Rotate the steering wheel to the full right stop Rotate the steering wheel back to the center position Sensor recalibration is now complete and the ESP BAS light should be off If the light is still on continue to Ste...

Page 421: ...ts Yes Go to 3 No Repair the Fused Ignition Switch Output circuit for an open Perform ABS VERIFICATION TEST 3 VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Steering Angle Sensor for damage and correct installation Are there any visible Steering Angle Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Replace the Stee...

Page 422: ...IZED This DTC is currently undefined 1179 STEERING ANGLE SENSOR STEERING ANGLE OVERFLOW This DTC is currently undefined 1181 STEERING ANGLE SENSOR STEERING ANGLE GRADIENT ERROR This DTC is currently undefined 5 256 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 423: ...1185 BAS TRAVEL SENSOR CIRCUIT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 257 ...

Page 424: ...OLT SUPPLY CIRCUIT SHORT TO GROUND BAS TRAVEL SENSOR 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT BAS TRAVEL SENSOR GROUND CIRCUIT OPEN BAS TRAVEL SENSOR CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE VOLTAGE OF THE BAS TRAVEL SENSOR SIGNAL CIRCUIT Turn the ignition of...

Page 425: ...ss connector Is the resistance above 100k ohms Yes Go to 3 No Repair the BAS Travel Sensor Signal circuit for a short to the 5 Volt Supply circuit Perform ABS VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE BAS TRAVEL SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance of the BAS Travel Sensor Signal circuit from the CAB harness connector to the BAS Brake Booster C1 harness connec...

Page 426: ...resistance below 5 0 ohms Yes Go to 5 No Repair the BAS Travel Sensor Ground circuit for an open Perform ABS VERIFICATION TEST 5 MEASURE THE VOLTAGE OF THE 5 VOLT SUPPLY CIRCUIT With the ignition off Reconnect the CAB harness connector Turn the ignition on Measure the voltage of the BAS Travel Sensor 5 Volt Supply circuit at the BAS Brake Booster C1 harness connector Is the voltage between 4 5 and...

Page 427: ...BS VERIFICATION TEST 7 MEASURE THE RESISTANCE BETWEEN THE BAS TRAVEL SENSOR SIGNAL CIRCUIT AND THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the BAS Travel Sensor Signal circuit and the BAS Travel Sensor Ground circuit at the BAS Brake Booster C1 harness connector Is the resistance above 100k ohms Yes Replace the BAS Brake Booster Refer to 5 BRAKES HYDRAULIC MECHAN...

Page 428: ... the voltage below 1 0 volt Yes Go to 9 No Repair the 5 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST 9 MEASURE THE RESISTANCE BETWEEN THE BAS TRAVEL SENSOR 5 VOLT SUPPLY CIRCUIT AND THE SENSOR GROUND CIRCUIT Turn the ignition off Measure the resistance between the 5 Volt Supply circuit and the Sen sor Ground circuit Is the resistance above 100k ohms Yes Go to 10 No Repa...

Page 429: ...to ground Perform ABS VERIFICATION TEST 11 MEASURE THE RESISTANCE OF THE BAS TRAVEL SENSOR 5 VOLT SUPPLY CIRCUIT With the ignition off Measure the resistance of the 5 Volt Supply circuit from the BAS Brake Booster C1 harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES C...

Page 430: ...1186 BAS TRAVEL SENSOR PLAUSIBILITY ERROR 5 264 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 431: ...TS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the BAS Travel Sensor for damage and correct installation Are there any visible BAS Travel Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB...

Page 432: ...1187 BAS TRAVEL SENSOR PLAUSIBILITY ERROR 5 266 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 433: ...TS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the BAS Travel Sensor for damage and correct installation Are there any visible BAS Travel Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB...

Page 434: ...1188 BAS TRAVEL SENSOR PLAUSIBILITY WITH PRESSURE GRADIENT This DTC is currently undefined 5 268 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 435: ...1190 YAW RATE ACCELERATION SENSOR INVALID CALIBRATION VALUES ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 269 ...

Page 436: ...INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to...

Page 437: ...1195 YAW RATE ACCELERATION SENSOR CYCLE TOO LONG ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 271 ...

Page 438: ...OMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor ...

Page 439: ...1201 BAS RELEASE SWITCH CIRCUIT ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 273 ...

Page 440: ...EASE SWITCH SENSE APPLIED CIRCUIT OPEN BAS RELEASE SWITCH SENSE APPLIED CIRCUIT SHORT TO GROUND BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT OPEN BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND BAS RELEASE SWITCH CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE VOLTAGE OF...

Page 441: ...UIT AND ALL OTHER CAB VOLTAGE CIRCUITS Turn the ignition off Measure the resistance between the BAS Release Switch Sensor Applied circuit and the Sensor Released circuit in the BAS Brake Booster C2 harness connector Measure the resistance between the BAS Release Switch Sensor Applied circuit and all 5 and 12 volt circuits in the CAB harness con nector Is the resistance for all measurements above 1...

Page 442: ...at the BAS Brake Booster C2 harness connector Is the voltage above 10 volts Yes Go to 5 No Go to 6 5 MEASURE THE VOLTAGE OF THE BAS RELEASE SWITCH SENSOR RELEASED CIRCUIT With the ignition on Measure the voltage of the BAS Release Switch Sensor Released circuit at the BAS Brake Booster C2 harness connector Is the voltage above 10 volts Yes Go to 10 No Go to 8 5 276 BRAKES ABS ELECTRICAL DIAGNOSTIC...

Page 443: ...Volt Supply circuit for a short to ground Perform ABS VERIFICATION TEST 7 MEASURE THE RESISTANCE OF THE 12 VOLT SUPPLY CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch 12 Volt Supply cir cuit from the BAS Brake Booster C2 harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELEC...

Page 444: ...sor Released circuit for a short to ground Perform ABS VERIFICATION TEST 9 MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH SENSOR RELEASED CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch Sensor Released circuit from the BAS Brake Booster C2 harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB M...

Page 445: ...e resistance above 100k ohms Yes Go to 11 No Repair the BAS Release Switch Sensor Applied circuit for a short to ground Perform ABS VERIFICATION TEST 11 MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH SENSOR APPLIED CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch Sensor Applied circuit from the BAS Brake Booster C2 harness connector to the CAB harness connector Is t...

Page 446: ...ase Switch Sensor Applied circuit at the BAS Brake Booster C2 harness connec tor Is the resistance 6 5 7 0k ohms Yes Replace the BAS Release Switch Brake Booster Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL Perform ABS VERIFICATION TEST No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perfor...

Page 447: ...1202 BAS RELEASE SWITCH PLAUSIBILITY ERROR ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 281 ...

Page 448: ...AS RELEASE SWITCH SENSE APPLIED CIRCUIT OPEN BAS RELEASE SWITCH SENSE APPLIED CIRCUIT SHORT TO GROUND BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT OPEN BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND BAS RELEASE SWITCH CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE VOLT...

Page 449: ... CIRCUIT AND ALL OTHER CAB VOLTAGE CIRCUITS Turn the ignition off Measure the resistance between the BAS Release Switch Sensor Applied circuit and the Sensor Released circuit in the BAS Brake Booster C2 harness connector Measure the resistance between the BAS Release Switch Sensor Applied circuit and all 5 and 12 volt circuits in the CAB harness con nector Is the resistance for all measurements ab...

Page 450: ...rcuit at the BAS Brake Booster C2 harness connector Is the voltage above 10 volts Yes Go to 5 No Go to 6 5 MEASURE THE VOLTAGE OF THE BAS RELEASE SWITCH SENSOR RELEASED CIRCUIT With the ignition on Measure the voltage of the BAS Release Switch Sensor Released circuit at the BAS Brake Booster C2 harness connector Is the voltage above 10 volts Yes Go to 10 No Go to 8 5 284 BRAKES ABS ELECTRICAL DIAG...

Page 451: ...h 12 Volt Supply circuit for a short to ground Perform ABS VERIFICATION TEST 7 MEASURE THE RESISTANCE OF THE 12 VOLT SUPPLY CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch 12 Volt Supply cir cuit from the BAS Brake Booster C2 harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8...

Page 452: ...h Sensor Released circuit for a short to ground Perform ABS VERIFICATION TEST 9 MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH SENSOR RELEASED CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch Sensor Released circuit from the BAS Brake Booster C2 harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake ...

Page 453: ...Is the resistance above 100k ohms Yes Go to 11 No Repair the BAS Release Switch Sensor Applied circuit for a short to ground Perform ABS VERIFICATION TEST 11 MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH SENSOR APPLIED CIRCUIT With the ignition off Measure the resistance of the BAS Release Switch Sensor Applied circuit from the BAS Brake Booster C2 harness connector to the CAB harness connector...

Page 454: ... Release Switch Sensor Applied circuit at the BAS Brake Booster C2 harness connec tor Is the resistance 6 5 7 0k ohms Yes Replace the BAS Release Switch Brake Booster Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL Perform ABS VERIFICATION TEST No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL P...

Page 455: ...1210 CAB SYSTEM UNDERVOLTAGE ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 289 ...

Page 456: ...B IIIT READ DTCs Turn the ignition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine Drive the vehicle above 16 km h 10 MPH for at least 20 seconds Stop the vehicle With the DRB IIIT read DTCs Does the DRB IIIT display a System Undervoltage DTC Yes Go to 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harn...

Page 457: ...o 4 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST 4 MEASURE THE VOLTAGE OF THE FUSED B CIRCUIT With the ignition on Measure the voltage of the Fused B circuit at the CAB harness con nector Is the voltage above 10 volts Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFIC...

Page 458: ...1212 CAB SYSTEM OVERVOLTAGE 5 292 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 459: ... DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Turn the ignition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine With the DRB IIIT read DTCs Does the DRB IIIT display a System Overvoltage DTC Yes Go to 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition ...

Page 460: ... Ground circuit for an open Perform ABS VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE GROUND CIRCUIT With the ignition off Measure the resistance between ground and the Ground circuit at of the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS...

Page 461: ...1310 POWER SUPPLY OR RETURN PUMP This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 295 ...

Page 462: ...1330 BAS SOLENOID VALVE CIRCUIT 5 296 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 463: ...T OPEN BAS SOLENOID VALVE BRAKE BOOSTER CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the BAS Brake Booster C2 harness connector Note Check connect...

Page 464: ...elow 5 0 ohms Yes Go to 3 No Repair the BAS Solenoid Valve Control circuit for an open Perform ABS VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CIRCUITS With the ignition off Measure the resistance between the BAS Solenoid Valve circuits at the BAS Brake Booster C2 harness connector Is the resistance above 100k ohms Yes Go to 4 No Repair the BAS Solenoid Valve circuits for ...

Page 465: ...5 No Repair the BAS Solenoid Valve 5 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST 5 MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition on Measure the voltage of the BAS Solenoid Valve Control circuit at the BAS Brake Booster C2 harness connector Is the voltage below 1 0 volt Yes Go to 6 No Repair the BAS Solenoid Valve Control circuit for a ...

Page 466: ... 7 No Repair the BAS Solenoid Valve 5 Volt Supply circuit for a short to ground Perform ABS VERIFICATION TEST 7 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off Measure the resistance between ground and the BAS Solenoid Valve Control circuit Is the resistance above 100k ohms Yes Go to 8 No Repair the BAS Solenoid Valve Control circuit for a short to ground Per...

Page 467: ...een ground and the BAS Solenoid Valve Control circuit Is the resistance 23 5 24 5k ohms Yes Replace the BAS Brake Booster Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 301 ...

Page 468: ...1331 BAS SOLENOID VALVE RESISTANCE TOO HIGH 5 302 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 469: ...E CONTROL CIRCUIT OPEN BAS SOLENOID VALVE BRAKE BOOSTER CONTROLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the CAB harness connector Disconnect the BAS Brake Booster C2 harness connector No...

Page 470: ...ance below 5 0 ohms Yes Go to 3 No Repair the BAS Solenoid Valve Control circuit for an open Perform ABS VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CIRCUITS With the ignition off Measure the resistance between the BAS Solenoid Valve circuits at the BAS Brake Booster C2 harness connector Is the resistance above 100k ohms Yes Go to 4 No Repair the BAS Solenoid Valve circuit...

Page 471: ...Go to 5 No Repair the BAS Solenoid Valve 5 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST 5 MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition on Measure the voltage of the BAS Solenoid Valve Control circuit at the BAS Brake Booster C2 harness connector Is the voltage below 1 0 volt Yes Go to 6 No Repair the BAS Solenoid Valve Control circuit ...

Page 472: ... Go to 7 No Repair the BAS Solenoid Valve 5 Volt Supply circuit for a short to ground Perform ABS VERIFICATION TEST 7 MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off Measure the resistance between ground and the BAS Solenoid Valve Control circuit Is the resistance above 100k ohms Yes Go to 8 No Repair the BAS Solenoid Valve Control circuit for a short to grou...

Page 473: ...e between ground and the BAS Solenoid Valve Control circuit Is the resistance 23 5 24 5k ohms Yes Replace the BAS Brake Booster Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 3...

Page 474: ...1350 YAW RATE ACCELERATION SENSOR HARDWARE ERROR 5 308 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 475: ... FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the Yaw Rate Acceleration Sensor for damage and correct installation Are there any visible Sensor concerns Yes Correct the sensor concerns as necessary Perform ABS VERIFICATION TEST No Go to 2 2 MONITOR THE CAB MODULE WITH THE DRB IIIT With the DRB IIIT erase DTCs Start the engine With an assistant to drive use the DRB IIIT to monitor the CAB m...

Page 476: ...1351 YAW RATE ACCELERATION SENSOR UNDERVOLTAGE 5 310 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 477: ...OLLER ANTILOCK BRAKE CAB For a complete Antilock Brake System ABS Circuit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE YAW RATE ACCELERATION SENSOR 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the Yaw Rate Acceleration Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Yaw ...

Page 478: ...100k ohms Yes Repair the 5 Volt Supply circuit for a short to ground Perform ABS VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE BETWEEN THE SENSOR GROUND CIRCUIT AND THE YAW RATE ACCELERATION SENSOR 5 VOLT SUPPLY CIRCUIT With the ignition off Measure the resistance between the 5 Volt Supply circuit and Sensor Ground circuit at the Yaw Rate Acceleration Sensor harness connec tor Is the resis...

Page 479: ...Yaw Rate Acceleration Sensor harness connector to the CAB harness connector Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the Yaw Rate Acceleration Sensor 5 Volt Supply circuit for an open Perform ABS VERIFICATION TEST ZH BRAKES ABS ELEC...

Page 480: ...1352 YAW RATE ACCELERATION SENSOR OVERVOLTAGE 5 314 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 481: ...am Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE YAW RATE ACCELERATION SENSOR 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the Yaw Rate Acceleration Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Yaw Rate Acceleration Sensor 5 Volt Sup ply circuit at the Yaw Rate Acceleration Se...

Page 482: ... as necessary Measure the voltage of the Yaw Rate Acceleration Sensor 5 Volt Sup ply circuit at the Yaw Rate Acceleration Sensor harness connector Is the voltage above 5 0 volts Yes Repair the 5 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOV...

Page 483: ...W RATE ACCELERATION SENSOR INITIALIZATION TO RUN TIME This DTC is currently undefined 1354 YAW RATE ACCELERATION SENSOR WRONG VERSION This DTC is currently undefined ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 317 ...

Page 484: ...1355 YAW RATE ACCELERATION SENSOR SHORT TO VOLTAGE 5 318 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 485: ...uit Diagram Refer to 5 BRAKES ELECTRICAL SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE YAW RATE ACCELERATION SENSOR 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the Yaw Rate Acceleration Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Yaw Rate Acceleration Sensor 5 Volt Sup ply circuit at the Yaw Rate Accele...

Page 486: ...air as necessary Measure the voltage of the Yaw Rate Acceleration Sensor 5 Volt Sup ply circuit at the Yaw Rate Acceleration Sensor harness connector Is the voltage above 5 0 volts Yes Repair the 5 Volt Supply circuit for a short to voltage Perform ABS VERIFICATION TEST No Replace the Controller Antilock Brake CAB Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE RE...

Page 487: ...ION DURING DRIVE This DTC is currently undefined 1413 DRIVE TEST NOT SUCCESSFUL This DTC is currently undefined 1416 DRIVE TEST PRESSURE SENSOR SIGNAL This DTC is currently undefined 1450 ROLLER DYNAMOMETER ACTIVE This DTC is currently undefined 1500 PRESSURE REGULATOR TARGET PERFORMANCE COMPARISON This DTC is currently undefined 1501 PRESSURE REGULATOR PRESSURE SIGNAL TO BOOSTER PLAUSIBILITY This...

Page 488: ...ng capability is available before road testing Note For sensor signal and pump motor faults the CAB must sense all 4 wheels at 25 km h 15 MPH before the CAB will extinguish the indicator lamp Road test the vehicle for a minimum of 5 minutes Perform several antilock braking stops Again with the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If there are n...

Page 489: ...SCHEMATICS AND DIAGRAMS ANTILOCK BRAKE CIRCUIT DIAGRAM 1 OF 3 ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 323 ...

Page 490: ...ANTILOCK BRAKE CIRCUIT DIAGRAM 2 OF 3 5 324 BRAKES ABS ELECTRICAL DIAGNOSTICS ZH ...

Page 491: ...ANTILOCK BRAKE CIRCUIT DIAGRAM 3 OF 3 ZH BRAKES ABS ELECTRICAL DIAGNOSTICS 5 325 ...

Page 492: ...39 OPERATION 339 REMOVAL 340 INSTALLATION 341 YAW RATE LATERAL ACCELERATION SENSOR DESCRIPTION 342 OPERATION 343 REMOVAL 343 INSTALLATION 344 BRAKE PRESSURE SENSOR DESCRIPTION 344 OPERATION 344 REMOVAL 344 INSTALLATION 345 TRAVEL SENSOR DESCRIPTION 345 OPERATION 346 REMOVAL 346 INSTALLATION 346 SOLENOID VALVE DESCRIPTION 347 OPERATION 347 REMOVAL 347 INSTALLATION 347 RELEASE SWITCH DESCRIPTION 348...

Page 493: ...ty and some steering capability This allows the driver to retain greater control of the vehicle during braking The ABS system features the following components Refer to the proper repair procedures for further diagnosis Master brake cylinder Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER DESCRIP TION Front wheel speed sensors Refer to 5 BRAKES ELECTRICAL FRONT WHEEL SPEED SENSOR DESCRIPTIO...

Page 494: ...ssure at each wheel depending on signals generated by the wheel speed sensors WSS at each wheel and received at the controller antilock brake CAB NOISE AND BRAKE PEDAL FEEL During ABS braking some brake pedal movement may be felt In addition ABS braking will create a ticking pop ping or groaning noises heard by the driver This is normal and is due to the pressurized fluid being transferred between...

Page 495: ...ock warning indicator lamp in the instrument cluster When the ignition is switched on ignition switch in position 929 the antilock warning indicator lamp in the instrument cluster illuminates this is referred to as a bulb check the antilock warning indicator lamp then goes out after the engine is started If the antilock warning indicator lamp illumi nates when the engine is running there may be a ...

Page 496: ... Codes DTCs If any DTCs are present refer to the appropriate diag nostic information Note Diagnostic Trouble Codes DTCs are kept in the controller s memory until either erased by the tech nician using the DRB IIIT or erased automatically after 3500 miles or 255 ignition key cycles whichever occurs first DTCs are retained by the controller even if the ignition is turned off or the battery is discon...

Page 497: ...es out at any time drive the vehicle a short distance Accelerate the vehicle to a speed of at least 40 mph 64 km h Bring the vehicle to a complete stop braking hard enough to cause the ABS to cycle Repeat this action several times Using the DRB IIIT read and record any Diagnostic Trouble Codes DTCs If any DTCs are present refer to the Appropriate Diagnostic Information SPECIFICATIONS TORQUE CHART ...

Page 498: ...or has an internal magneto resistance bridge that alters the voltage and amperage of the signal circuit This voltage and amperage is changed by magnetic induction when the toothed tone wheel passes by the wheel speed sensor head This digital signal is sent to the CAB The CAB measures the voltage and amperage of the digital signal for each wheel The magnetic field of the wheel speed sensor is inter...

Page 499: ...the flange to the steering knuckle 2 Remove the wheel speed sensor 1 from the steering knuckle 3 Disconnect the wheel speed brake wear indicator wire harness connector 2 from the body mount connector 1 ZH BRAKES ABS SERVICE INFORMATION 5 333 ...

Page 500: ...ndi cator wire harness connector 2 to the body mount connector 1 2 Install the wheel speed sensor 1 to the steering knuckle 3 Install the bolts 2 attaching the flange to the steering knuckle Tighten to 12 N m 106 in lbs 5 334 BRAKES ABS SERVICE INFORMATION ZH ...

Page 501: ...ital signal The CAB sends 12 volts to the sensors The sensor has an internal magneto resistance bridge that alters the voltage and amperage of the signal circuit This voltage and amperage is changed by magnetic induction when the toothed tone wheel passes the wheel speed sensor This digital signal is sent to the CAB The CAB measures the voltage and amperage of the digital signal for each wheel ZH ...

Page 502: ...he wheel speed sensor to the rear knuckle 2 Remove the rear wheel speed sensor 2 from the knuckle 3 Pull the rubber grommet 1 out of the body Unhook the wheel speed sensor wire harness from the mount 2 5 336 BRAKES ABS SERVICE INFORMATION ZH ...

Page 503: ...4 Disconnect the wheel speed sensor harness con nector 1 INSTALLATION 1 Connect the wheel speed sensor wire harness con nector 1 ZH BRAKES ABS SERVICE INFORMATION 5 337 ...

Page 504: ...then hook the wheel speed sensor wire harness to the mount 2 3 Install the wheel speed sensor 2 to the knuckle 4 Install the bolt 1 attaching the wheel speed sen sor to the knuckle Tighten to 12 N m 106 in lbs 5 338 BRAKES ABS SERVICE INFORMATION ZH ...

Page 505: ...e barrier blades to detect the rotation and position of the steering wheel With the steering wheel in the center position the eight blades assume a defined position in relation to the nine LED s This center position is recorded by the processor in the steering angle sensor When the steering wheel is turned the position of the blades change in relation to the LED s light dark A distinct signal patt...

Page 506: ...WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY Note Before starting this procedure be certain to turn 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 clockspring from the steering column ...

Page 507: ...nd align the alignment points on the com ponent housings 1 2 Install the steering angle sensor to the clockspring 3 Snap the steering angle sensor retaining tabs 1 onto the clockspring ZH BRAKES ABS SERVICE INFORMATION 5 341 ...

Page 508: ...SCRIPTION The Mark 25T Braking System uses a combined Yaw Rate and Acceleration Sensor The Yaw Rate Lateral Accel eration Sensor is a combined sensor and is located under the center console behind the gear shifter assembly The yaw rate portion of the sensor is used to detect any swerving motion of the vehicle 5 342 BRAKES ABS SERVICE INFORMATION ZH ...

Page 509: ...measures the amount of lateral acceleration during cornering This sensor uses a spring mass type element to measure the amount of lateral acceleration The lateral acceleration that occurs during cornering causes the spring mass element to move from its normal position to a position correspond ing to the magnitude of the lateral acceleration Every change in the spring mass element position changes ...

Page 510: ...Brake Pressure Sensor 2 incorporated into the master cylinder 1 on this vehicle The sensor is used to monitor brake pressure for the hydraulic brake system The sensor is used as an input to the Controller Antilock Brake CAB module OPERATION These sensors are used to measure brake fluid pressure within the master cylinder The sensors send an analog voltage signal to the ESP BAS control module REMOV...

Page 511: ...RICAL BRAKE PRESSURE SWITCH INSTALLATION TRAVEL SENSOR DESCRIPTION The BAS travel sensor 2 is a device used to detect an emergency stop The BAS travel sensor is located on the power brake booster 1 ZH BRAKES ABS SERVICE INFORMATION 5 345 ...

Page 512: ...ake booster 1 and the sensor rod moves proportionally to the travel of the brake pedal The travel sensor is used as an input to the CAB to determine the amount of driver braking effort REMOVAL 1 For the travel sensor removal procedure Refer to 5 BRAKES ELECTRICAL PEDAL POSITION SENSOR REMOVAL INSTALLATION 1 For the travel sensor installation procedure Refer to 5 BRAKES ELECTRICAL PEDAL POSITION SE...

Page 513: ...ed a poppet valve opens and allows atmospheric pressure to enter the rear of the power brake booster diaphragm and increases the brake pressure REMOVAL The solenoid valve is part of the brake booster assembly Refer to the brake booster removal procedure Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL INSTALLATION The solenoid valve is part of the brake booster assembly Refer to ...

Page 514: ...roller Antilock Brake CAB Module REMOVAL The release switch is part of the brake booster assembly Refer to the brake booster removal procedure Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL INSTALLATION The release switch is part of the brake booster assembly Refer to the brake booster installation procedure Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER INSTALLATIO...

Page 515: ...el spin or slip situation the vehicle builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle The hydraulic shuttle valve internal to the ICU closes with every brake pedal application so pressure is not created at the inlet to the pump motor and the vehicle stops normally ABS BRAKING FUNCTION During a stop where one wheel is slipping because the driver is attempting...

Page 516: ...arked before disassembly 2 Remove the hydraulic lines from the HCU Seal off the hydraulic lines and connections with suitable plugs Right rear wheel 1 Master cylinder front 2 Right front wheel 3 Left front wheel 4 Left rear wheel 5 Master cylinder rear 6 3 Disconnect the hydraulic controller unit harness connector 1 from the CAB 4 Remove the HCU upwards by carefully pushing the hydraulic lines to ...

Page 517: ...e lines 1 6 Pay very close atten tion to the locations when installing the hydraulic lines DO NOT cross thread Right rear wheel 1 Master cylinder front 2 Right front wheel 3 Left front wheel 4 Left rear wheel 5 Master cylinder rear 6 3 Connect the hydraulic control unit harness connec tor 1 to the CAB 4 Bleed the brake system Refer to 5 BRAKES STANDARD PROCEDURE 5 Connect the DRB IIIT and read any...

Page 518: ......

Page 519: ...T BEARING REMOVAL 22 INSTALLATION 22 CLUTCH PEDAL REMOVAL 23 INSTALLATION 24 CLUTCH DESCRIPTION The clutch mechanism consists of a flywheel a single dry type disc and a diaphragm style clutch cover A hydraulic linkage is used to operate the clutch release bearing The flywheel is bolted to the rear flange of the crankshaft The clutch cover is bolted to the fly wheel with the clutch disc located bet...

Page 520: ... AND DISPOSAL OF PRODUCTS CON TAINING ASBESTOS DIAGNOSIS AND TESTING CLUTCH SYSTEM Drive the vehicle at normal speeds Shift the transmission through all gear ranges and observe clutch action If the clutch chatters grabs slips or does not release properly remove and inspect the clutch components If the problem is noise or hard shifting further diagnosis may be needed as the transmission or another ...

Page 521: ... whenever misalignment is suspected Flywheel runout should not exceed 0 08 mm 0 003 in Measure runout at the outer edge of the flywheel face with a dial indicator Common causes of runout are Heat warpage Improper machining Incorrect bolt tightening Improper seating on crankshaft flange shoulder Foreign material on crankshaft flange Flywheel machining is not recommended The flywheel clutch surface ...

Page 522: ...ce the release bearing slave cylinder and transmission front bearing retainer as necessary FLYWHEEL BELOW MINIMUM THICKNESS SPECIFICATION 1 Improper flywheel machining Flywheel has excessive taper or excessive material removal 1 Replace flywheel CLUTCH DISC COVER AND OR DIAPHRAGM SPRING WARPED OR DISTORTED 1 Rough handling Impact bent cover spring or disc 1 Replace disc or cover as necessary 2 Imp...

Page 523: ...orrect as necessary Install and lubricate a new bearing CLUTCH WILL NOT DISENGAGE PROPERLY 1 Low hydraulic clutch fluid level 1 Replace hydraulic clutch components as necessary 2 Clutch cover loose 2 Follow proper bolt tightening procedure 3 Clutch disc bent or distorted 3 Replace clutch disc 4 Clutch cover diaphragm spring bent or warped 4 Replace clutch cover 5 Clutch disc installed backwards 5 ...

Page 524: ...position incorrect 1 Replace clutch disc and cover 2 Clutch cover spring or release fingers bent or distorted 2 Replace clutch disc and cover 3 Clutch disc damaged or distorted 2 Replace clutch disc 4 Clutch misalignment 4 Check alignment and runout of flywheel disc and clutch cover Correct as necessary STANDARD PROCEDURE MASTER CYLINDER BLEEDING WARNING RISK OF POISONING DUE TO SWAL LOWING BRAKE ...

Page 525: ... is clear 8 Close the bleeder screw 9 Install the bleeder screw rubber cap 10 Install the bleeder screw rubber access plug 11 Lower the vehicle 12 Disconnect the pressure bleeder 13 Install the brake master cylinder reservoir cap 14 Check the operation of the clutch SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Flywheel Bolts 45 33 398 Slave Cylinder Bolts 10 7 89 Clutc...

Page 526: ...SPECIAL TOOLS 9102 FLYWHEEL LOCKING TOOL 6 8 CLUTCH ZH ...

Page 527: ...UAL REMOVAL Note Gradually remove the clutch cover bolts 1 to 1 1 2 turns at a time 2 Loosen the bolts 1 on the clutch cover 3 Mark the relation of the clutch cover to the fly wheel 4 Remove the bolts 1 on the clutch cover 5 Remove the clutch cover 1 and the clutch disc 2 ZH CLUTCH 6 9 ...

Page 528: ...required on the clutch disc Use an old release bearing or a length of pipe to release diaphragm pressure Set the adjusting ring to the mark as shown 2 Position the clutch disc and clutch cover on the fly wheel 3 Loosely install the clutch cover bolts 1 6 10 CLUTCH ZH ...

Page 529: ...y tighten the clutch cover bolts 1 to 1 1 2 turns at a time 6 Tighten the clutch cover bolts 1 until all bolts are fully seated Tighten the bolts to 25 N m 18 ft lbs 7 Remove the clutch alignment tool 1 8 Install the transmission Refer to 21 TRANSMIS SION TRANSAXLE MANUAL INSTALLATION ZH CLUTCH 6 11 ...

Page 530: ...nst the flywheel When the release bearing is depressed the pressure exerted on the clutch disc by the clutch cover spring is decreased As additional force is applied to the release bearing the bearing presses the diaphragm spring fingers 2 inward on the fulcrums This action moves the clutch cover 1 rearward relieving the clamped force on the disc The clutch disc is disengaged and freewheeling at t...

Page 531: ...e clutch cover 3 Mark the relation of the clutch cover to the fly wheel Note Gradually remove the clutch cover bolts 1 to 1 1 2 turns at a time 4 Remove the bolts 1 on the clutch cover 5 Remove the clutch cover 1 ZH CLUTCH 6 13 ...

Page 532: ...tment is required Use an old release bearing or a length of pipe to release diaphragm pressure Set the adjust ing ring to the mark as shown 2 Position the clutch disc and clutch cover on the fly wheel 3 Loosely install the clutch cover bolts 1 6 14 CLUTCH ZH ...

Page 533: ...ighten the clutch cover bolts 1 to 1 1 2 turns at a time 6 Tighten the clutch cover bolts 1 until all bolts are fully seated Tighten to 25 N m 18 ft lbs 7 Remove the clutch alignment tool 1 8 Install the transmission Refer to 21 TRANSMIS SION TRANSAXLE MANUAL INSTALLATION ZH CLUTCH 6 15 ...

Page 534: ... safety glasses when handling brake fluid 1 Remove the lower driver side instrument panel 5 Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 2 Remove the illumination control module 4 CAUTION Avoid contamination of interior trim and carpet with brake fluid 3 Clamp off the clutch master cylinder supply hose 1 from the brake master cylinder reservoir 4 Disconnect the clutch maste...

Page 535: ...WAL LOWING BRAKE FLUID RISK OF INJURY DUE TO BRAKE FLUID COMING INTO CONTACT WITH THE SKIN AND EYES Note Only pour brake fluid into suitable appropri ately marked containers Wear protective clothing and safety glasses when handling brake fluid 1 Position the clutch master cylinder on the pedal and pivot it clockwise 2 Install the retaining nuts 2 on the bracket assem bly Tighten nuts to 10 N m 89 ...

Page 536: ...rom the clutch master cylinder supply hose 8 Install the illumination control module 4 9 Install the lower drivers side instrument panel 5 Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY INSTALLATION 10 Bleed the hydraulic clutch system Refer to 6 CLUTCH STANDARD PROCEDURE 11 Check for proper clutch actuation 6 18 CLUTCH ZH ...

Page 537: ... by a slave cylinder in the clutch housing The slave cylinder force causes the release bearing to move into contact with the diaphragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward on the fulcrums This action moves the pressure plate rearward relieving clamp ing force on the clutch disc Releasing pedal pressure removes clutch hydraulic pressure The r...

Page 538: ...he bolts to 10 N m 89 in lbs 3 Install the transmission Refer to 21 TRANSMIS SION TRANSAXLE MANUAL INSTALLATION 4 Bleed the hydraulic clutch system Refer to 6 CLUTCH STANDARD PROCEDURE FLYWHEEL DESCRIPTION The flywheel is a heavy plate bolted to the rear of the crankshaft The flywheel incorporates the ring gear around the outer circumference to mesh with the starter to permit engine cranking The r...

Page 539: ...oper machining Incorrect bolt tightening Improper seating on crankshaft flange shoulder Foreign material on crankshaft flange REMOVAL 1 Remove the clutch Refer to 6 CLUTCH CLUTCH DISC REMOVAL 2 Install Special Tool 9102 1 Flywheel Locking Tool 3 Remove and discard the flywheel bolts 1 4 Remove the flywheel spacer 2 and the flywheel 3 5 Inspect the flywheel for wear or cracking 6 Inspect the starte...

Page 540: ...H DISC INSTALLATION 6 Remove Special Tool 9102 Flywheel Locking Tool 7 Install the transmission Refer to 21 TRANSMIS SION TRANSAXLE MANUAL INSTALLATION PILOT BEARING REMOVAL 1 Remove the transmission Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL 2 Remove the clutch cover and clutch disc Refer to 6 CLUTCH PRESSURE PLATE REMOVAL 3 Remove the pilot bearing with an internal blind hole puller INSTA...

Page 541: ...NSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 2 Remove the driver side upper instrument panel 1 Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 3 Disconnect the clutch master cylinder fluid pressure line 1 Refer to 6 CLUTCH MASTER CYLINDER REMOVAL ZH CLUTCH 6 23 ...

Page 542: ...turn spring 3 6 Remove the clutch pedal from the pivot 1 INSTALLATION 1 Install the clutch pedal on the pivot 1 2 Install the return spring 3 and the circlip 2 3 Install the clutch master cylinder fluid pressure line 1 Refer to 6 CLUTCH MASTER CYLINDER INSTALLATION 6 24 CLUTCH ZH ...

Page 543: ...r instrument panel 1 Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY INSTALLATION 5 Install the driver side lower instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY INSTALLATION ZH CLUTCH 6 25 ...

Page 544: ......

Page 545: ...y for the cooling fan circuit The module is mounted to the inner fender The Powertrain Control Module acts as the input to the module to com mand the fan operation The radiator cooling fan is made up of a multiple bladed fan The cooling fan motor is a high speed DC type OPERATION The Radiator Cooling Fan is designed to keep the cooling system operating at a set temperature The cooling fan operates...

Page 546: ... RADIATOR COOLING FAN INOPERATIVE 7 2 COOLING ELECTRICAL DIAGNOSTICS ZH ...

Page 547: ...ng Fan operating Yes Replace the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 3 No Go to 2 2 CHECKING THE PCM FOR AN OPEN Turn the ignition off Disconnect the Powertrain Control Module C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Connect a jumper wi...

Page 548: ...t the Radiator Fan Control Module harness connector Is the voltage above 11 volts Yes Go to 4 No Repair the Fused B circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 3 4 CHECKING THE GROUND CIRCUIT Turn the ignition off Measure the resistance between ground and the module Ground cir cuit Is the resistance below 5 0 ohms Yes Go to 5 No Repair the module Ground circuit for an open Perform...

Page 549: ...adiator Fan Control circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 3 6 CHECKING THE RADIATOR FAN CONTROL MODULE OUTPUT CIRCUIT With the ignition off Disconnect the Radiator Fan Motor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Radiator Fan Control Module Output cir cuit from the Radiator Fan Control Module harness connector to the R...

Page 550: ...air the Radiator Fan Control Module Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 3 8 CHECKING THE RADIATOR FAN MOTOR With the ignition off Measure the resistance of the Radiator Fan Motor Is the resistance below 5 0 ohms Yes Replace the Radiator Fan Control Module Refer to 7 COOLING ENGINE PWM FAN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 3 No Replace t...

Page 551: ... RADIATOR COOLING FAN ALWAYS ON ZH COOLING ELECTRICAL DIAGNOSTICS 7 7 ...

Page 552: ...ck the status of the A C Switch Does the DRB IIIT display Air Conditioning ON Yes Repair the A C Switch circuit Perform POWERTRAIN VERIFICATION TEST VER 3 No Go to 2 2 CHECKING THE RADIATOR FAN CONTROL MODULE OUTPUT CIRCUIT Turn the ignition off Disconnect the Radiator Fan Control Module harness connector Disconnect the Radiator Fan Motor harness connector Note Check connectors Clean repair as nec...

Page 553: ...FICATION TEST VER 3 4 CHECKING THE POWERTRAIN CONTROL MODULE With the ignition off Reconnect the PCM C4 harness connector Measure the resistance between ground and the Radiator Fan Control circuit at the Radiator Fan Control Module harness connector Is the resistance above 100 kohms Yes Replace the Radiator Fan Control Module Refer to 7 COOLING ENGINE PWM FAN CONTROL MODULE REMOVAL Perform POWERTR...

Page 554: ...o this repair With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If this test is being performed after a No Trouble Code test verify the symptom is no longer present If the symptom is still present or any other symptom or DTC is present refer to the appropriate category and per form the corresponding symptom Refer to any Technical Service Bulletins ...

Page 555: ...SCHEMATICS AND DIAGRAMS ZH COOLING ELECTRICAL DIAGNOSTICS 7 11 ...

Page 556: ...gine The Coolant Recovery Reservoir 1 is equipped with a Coolant Level Sensor The Coolant Level Sensor in the Coolant Recovery Reservoir notifies the driver if there is insufficient coolant in the system by illuminating the low engine coolant warning lamp in the Instrument Cluster An Electric Cooling Fan 2 is activated by the Radiator Fan Control Module The cooling system is also equipped with an ...

Page 557: ...ler Radiator The pump is used to circulate coolant between the Charge Air Cooler and the Charge Air Cooler Radiator It operates independently from the engine cooling system The only common link is the Coolant Recovery Reservoir Both systems use the Coolant Recovery Reservoir as their source of coolant OPERATION CAUTION The cooling system is designed to function with a 50 50 mixture of MoparT Antif...

Page 558: ...ure in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions It also provides hot coolant for heater and cooling for automatic transmission fluid It does this by transferring heat from engine metal to coolant moving this heated coolant to the radiator and then transferring this heat to the ambient air The cooling system is also equipped...

Page 559: ...nt DIAGNOSIS AND TESTING PRELIMINARY CHECKS Determine what driving conditions caused the complaint One or more of the following conditions may be the cause of the complaint Prolonged Idle Very High Ambient Temperature Slow Traffic Traffic Jams High Speed Steep Grades Driving techniques to help avoid overheating are Idle with A C off when the temperature gauge is at the end of the normal range 1 RE...

Page 560: ...EASED TO A SAFE PRESSURE POINT NEVER PERMIT PRESSURE TO EXCEED 138 kPa 20 psi If the needle on the dial does not fluctuate race the engine a few times If an abnormal amount of coolant or steam is emitted from the tail pipe it may indicate a faulty head gasket cracked engine block or cylinder head There may be internal leaks which can be determined by removing the oil dipstick If water globules app...

Page 561: ...covery Reservoir Nuts 5 44 Idler Pulley Screw 10 89 Transmission Cooler Line Nuts 20 15 Transmission Cooler Line Banjo Bolts 20 15 Transmission Cooler Line Retainer Bolts 10 89 Water Outlet Housing Bolts 10 89 Water Pump Pulley Bolts 10 89 Water Pump M6 Bolts 10 89 Water Pump M8 Bolts 35 26 ZH COOLING SERVICE INFORMATION 7 17 ...

Page 562: ...SPECIAL TOOLS PRESSURE TESTER ADAPTER 9107 REFRACTOMETER 8286 7 18 COOLING SERVICE INFORMATION ZH ...

Page 563: ...EMOVAL 37 REMOVAL SRT 37 INSTALLATION INSTALLATION 38 INSTALLATION SRT 38 ENGINE COOLANT TEMPERATURE SENSOR OPERATION 39 REMOVAL REMOVAL 39 REMOVAL SRT 40 INSTALLATION INSTALLATION 43 INSTALLATION SRT 45 RADIATOR DESCRIPTION 48 REMOVAL 49 CLEANING 51 INSPECTION 51 INSTALLATION 52 RADIATOR PRESSURE CAP DESCRIPTION 55 OPERATION 55 WARNING 55 CLEANING 56 WATER PUMP DESCRIPTION 56 OPERATION 56 REMOVAL...

Page 564: ...coolant solution CAUTION Mixing of coolants other than specified non HOAT or other HOAT may result in decreased cor rosion protection and engine damage could result The subsequent engine damage may not be covered under the new vehicle warranty COOLANT PERFORMANCE The required ethylene glycol antifreeze and water mixture depends upon the climate and the vehicle operating conditions The coolant perf...

Page 565: ...e checked when any additional coolant is added to the cooling system or after a coolant drain flush and refill The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of 37 C 34 F to 46 C 50 F The use of a hydrometer or a refractometer can be used to test coolant concentration A hydrometer will test the amount of glycol in a mixture by measur...

Page 566: ... facing to rear of vehicle 2 Attach one end of a hose to the draincock 2 Put the other end into a clean container Open draincock and drain the coolant from the radiator This will also empty the coolant recovery reservoir 1 When the tank is empty remove the pressure cap and continue draining the cooling system REFILLING 1 Tighten the radiator draincock and the cylinder block drain plug s if removed...

Page 567: ...it into a clean container Allow the coolant to drain into the container until emptied Reconnect the overflow hose to radi ator REVERSE FLUSHING CAUTION The cooling system normally operates at 97 110 kPa 14 16 psi pressure Exceeding this pres sure may damage the radiator or hoses Reverse flushing of the cooling system is the forcing of water through the cooling system in the reverse direction of no...

Page 568: ...r until it snaps into place 3 Connect the coolant level sensor harness connec tor 2 4 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 5 Start the engine and check for coolant leaks 6 Recheck the coolant level and adjust as necessary ENGINE COOLANT THERMOSTAT DESCRIPTION CAUTION Do not operate an engine without a thermostat except for servicing or testing A pellet typ...

Page 569: ...sting Operating the engine without a thermostat can cause the follow ing problems Longer engine warm up time Unreliable warm up performance Increased exhaust emissions Crankcase condensation This condensation can result in sludge formation OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat When heated the pellet expands overcoming closing spring tension a...

Page 570: ...ters the struc ture of the metal 3 Heat the container and thermostat Note The rate of increase should not be more than 1 C to 2 C min from about 8 C below the start of open ing of the coolant thermostat 4 Measure the temperature of the water 5 Heat the water to the temperature specified on the thermostat Allow the thermostat to fully open and then mea sure the distance of the stroke 6 If the speci...

Page 571: ...d as an assembly The thermostat cannot be serviced separately 4 Remove the thermostat housing retaining bolts and remove the thermostat and housing from the engine INSTALLATION 1 Install the thermostat housing with a new O ring Tighten the bolts to 10 N m 89 in lbs 2 Connect the upper radiator hose 3 Fill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Start the engine an...

Page 572: ...ery in case of an overheat REMOVAL REMOVAL 1 Disconnect the negative battery cable 2 Partially drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE 3 Disconnect the small coolant hose at the coolant recovery reservoir 4 4 Disconnect the large coolant hose at the bottom of the coolant recovery reservoir 3 5 Disconnect the coolant level sensor harness con nector 2 at the co...

Page 573: ...sconnect the small coolant hose at the coolant recovery reservoir 4 4 Disconnect the large coolant hose at the bottom of the coolant recovery reservoir 3 5 Disconnect the coolant level sensor harness con nector 2 at the coolant recovery reservoir 6 Disconnect the charge air cooler coolant hose 2 from the coolant recovery reservoir 1 ZH ENGINE 7 29 ...

Page 574: ...ift the cool ant recovery reservoir from the engine compartment INSTALLATION INSTALLATION 1 Position the coolant recovery reservoir in the engine compartment 2 Install the two retaining nuts 2 Tighten the nuts to 5 N m 44 in lbs 3 Connect the coolant overflow hose 1 7 30 ENGINE ZH ...

Page 575: ...recovery reservoir 7 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 8 Connect the negative battery cable 9 Start the engine and check for coolant leaks 10 Recheck the coolant level INSTALLATION SRT 1 Position the coolant recovery reservoir in the engine compartment 2 Install the two retaining nuts 2 Tighten the nuts to 5 N m 44 in lbs 3 Connect the coolant overflow ...

Page 576: ...rge coolant hose 3 to the bottom of the coolant recovery reservoir 7 Connect the charge air cooler coolant hose 2 to the bottom of the coolant recovery reservoir 1 8 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 9 Connect the negative battery cable 10 Start the engine and check for coolant leaks 11 Recheck the coolant level 7 32 ENGINE ZH ...

Page 577: ...RADIATOR FAN REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the radiator fan harness connector 1 3 Remove the coolant return hose 1 from the mounting bracket 2 ZH ENGINE 7 33 ...

Page 578: ...ator fan hold down clamps 2 and pull up to remove the clamps from the mounting holes 5 Carefully pry the upper radiator hose and return hoses away from the cooling fan 6 Gently lift the radiator fan up and out of the vehicle 7 34 ENGINE ZH ...

Page 579: ...bottom of the radiator fan prior to installation 1 Gently lower the radiator fan into the vehicle 2 Carefully pry the upper radiator hose and return hoses away from the cooling fan 3 Install the radiator fan locating studs 1 into the lower rubber mounts ZH ENGINE 7 35 ...

Page 580: ... the radiator fan hold down clamps 1 5 Route the coolant return hose 1 through the bracket 2 on the radiator fan 6 Connect the radiator fan harness connector 1 7 Connect the negative battery cable 7 36 ENGINE ZH ...

Page 581: ...ooling fan module 1 4 Remove the cooling fan module from the engine compartment REMOVAL SRT 1 Disconnect the negative battery cable 2 Disconnect the radiator fan control module harness connector located next to the air pump in the left front of the vehicle 3 Remove the retaining nuts at the top and bottom of the cooling fan module 1 4 Remove the cooling fan module from the engine compartment ZH EN...

Page 582: ... radiator fan control module harness connector 4 Connect the negative battery cable INSTALLATION SRT 1 Position the radiator fan control module 1 on the inner fender well studs next to the air pump 2 2 Install the upper and lower retaining nuts Tighten the nuts to 10 N m 89 in lbs 3 Connect the radiator fan control module 1 har ness connector 4 Connect the negative battery cable 7 38 ENGINE ZH ...

Page 583: ...l demand slightly richer air fuel mixtures and higher idle speeds until normal operating temperatures are reached The engine coolant sensor input also determines operation of the radiator fan REMOVAL REMOVAL 1 Disconnect the negative battery cable 2 Partially drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE 3 Remove the engine cover 1 Grasp both corners of the engine ...

Page 584: ...ing 6 Remove the engine coolant temperature sensor from the engine REMOVAL SRT 1 Disconnect the negative battery cable 2 Partially drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE 3 Remove the engine cover Grasp both corners of the engine cover and pull up firmly Refer to 9 ENGINE REMOVAL 7 40 ENGINE ZH ...

Page 585: ...e air pump tube assembly from the engine 1 Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE REMOVAL 6 Release the tension on the accessory drive belt 7 Remove the accessory drive belt from the acces sory drive belt idler pulley ZH ENGINE 7 41 ...

Page 586: ...1 and lower retaining bolt 2 9 Remove the supercharger idler pulley 10 Remove the accessory drive belt idler pulley 2 to gain access to the engine coolant temperature sensor 1 11 Disconnect the engine coolant temperature sensor 1 harness connector 7 42 ENGINE ZH ...

Page 587: ...g 13 Remove the engine coolant temperature sensor from the engine INSTALLATION INSTALLATION 1 Clean any debris or corrosion from the engine cool ant temperature sensor mounting surface 2 Use a small amount of petroleum jelly to lubricate the sensor seal 3 Install the engine coolant temperature sensor and retaining clip 1 ZH ENGINE 7 43 ...

Page 588: ...s to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 6 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 7 Connect the negative battery cable 7 44 ENGINE ZH ...

Page 589: ... cool ant temperature sensor mounting surface 2 Use a small amount of petroleum jelly to lubricate the sensor seal 3 Install the engine coolant temperature sensor and retaining clip 1 4 Connect the engine coolant temperature sensor harness connector 1 ZH ENGINE 7 45 ...

Page 590: ...dler pulley Tighten the accessory drive belt idler pulley bolt 2 to 20 N m 15 ft lbs 6 Install the supercharger idler pulley upper mounting bolt 1 and the lower mounting bolt 2 Tighten the mounting bolts to 20 N m 15 ft lbs 7 46 ENGINE ZH ...

Page 591: ...he accessory drive belt pulley Refer to 7 COOLING ACCES SORY DRIVE OPERATION 8 Install the air pump tube assembly 1 and install the retaining bolts 2 Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE INSTALLATION ZH ENGINE 7 47 ...

Page 592: ...allation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 10 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCE DURE 11 Connect the negative battery cable RADIATOR DESCRIPTION The Crossfire has a cross flow type radiator 4 The main radiator core is made of aluminum and the side tanks are made of plastic 3 7 48 ENGINE ZH ...

Page 593: ...age REMOVAL 1 Disconnect the negative battery cable 2 Remove the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 3 Drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Remove the air cleaner inlet tubes 5 Disconnect the upper radiator hose 1 ZH ENGINE 7 49 ...

Page 594: ...nnect the transmission cooler line 3 located on the right side of the radiator automatic trans mission only Refer to 7 COOLING TRANSMIS SION TRANS COOLER LINES REMOVAL 9 Disconnect the transmission cooler line 1 located in the middle front of the vehicle automatic trans mission only 7 50 ENGINE ZH ...

Page 595: ...aning of the radiator fins can be accomplished by applying cold water and compressed air to the back engine side of the radiator This method will help to flush the radiator of any trapped debris INSPECTION The radiator cooling fins should be checked for damage or deterioration Inspect cooling fins to make sure they are not bent or crushed these areas result in reduced heat exchange causing the coo...

Page 596: ...he vehicle 2 Connect the lower radiator hose 2 3 Connect the coolant recovery reservoir hose 1 4 Install the transmission cooler line 3 automatic transmission only Tighten the line to 10 N m 89 in lbs 5 Connect the upper radiator hose 1 7 52 ENGINE ZH ...

Page 597: ...oler line 1 located in the middle front of the vehicle automatic transmis sion only Refer to 7 COOLING TRANSMIS SION TRANS COOLER LINES INSTALLATION 7 Using a suitable tool 1 install the radiator retain ing clamps 2 ZH ENGINE 7 53 ...

Page 598: ...all the radiator fan Refer to 7 COOLING EN GINE RADIATOR FAN INSTALLATION 10 Install the air inlet tubes 11 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 12 Connect the negative battery cable 13 Start the engine and check for coolant leaks 14 Recheck the coolant level 7 54 ENGINE ZH ...

Page 599: ...to its normally closed position With the engine not operating the pressure cap must allow the cooling system to loose pressure and recover engine coolant This recovery is accomplished through the use of a lighter spring in the pressure cap As the hot engine coolant cools it creates a vacuum in the cooling system As this vacuum is created it pulls the vacuum valve open and allows engine coolant to ...

Page 600: ...mp seals are lubricated by the engine coolant OPERATION A centrifugal water pump circulates coolant through the water jackets passages intake manifold radiator cooling system hoses and heater core The coolant absorbs the heat generated when the engine is operating The water pump is driven by the crankshaft via the serpentine drive belt REMOVAL REMOVAL 1 Disconnect the negative battery cable 2 Drai...

Page 601: ... to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 7 Remove the belt tensioner Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS REMOVAL ZH ENGINE 7 57 ...

Page 602: ... coolant by pass hose 1 10 Remove the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR REMOVAL 11 Remove the water pump pulley 2 12 Remove the accessory drive belt idler pulley 1 13 Remove the water pump retaining bolts and the water pump 7 58 ENGINE ZH ...

Page 603: ... cover Grasp both corners of the engine cover and pull up firmly 2 Drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL ZH ENGINE 7 59 ...

Page 604: ... 1 Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE REMOVAL 6 Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt 7 Remove the accessory drive belt from the pulleys 8 Carefully release the wrench tension on the belt tensioner 7 60 ENGINE ZH ...

Page 605: ...bolt 1 and lower retaining bolt 2 10 Remove the supercharger idler pulley 11 Remove the accessory drive belt from the engine 12 Remove the belt tensioner pulley and the belt ten sioner Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS REMOVAL ZH ENGINE 7 61 ...

Page 606: ... CAL CHARGING GENERATOR REMOVAL 16 Remove the water pump pulley 2 17 Remove the accessory drive belt idler pulley 1 18 Relocate the oil cooler hose 3 clamp 19 Remove the water pump retaining bolts 20 Remove the water pump from the engine Remove the oil cooler hose 3 from the water pump to the oil cooler tube 7 62 ENGINE ZH ...

Page 607: ...nd pump must be replaced Be sure to perform a thorough analysis before replacing water pump Inspect and replace the water pump if it has any of the following defects 1 Damage or cracks on the pump body 1 2 Coolant leaks if the seal is leaking this will be evident by traces of thick deposits of dried coolant draining from the pump weep hole A thin black stain below pump weep hole passage is conside...

Page 608: ...the timing chain cover 3 Install the water pump bolts in the correct positions Tighten the bolts to 35 N m 26 ft lbs 4 Install the generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 5 Install the belt tensioner Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS INSTALLATION 7 64 ENGINE ZH ...

Page 609: ...2 and bolts Tighten the water pump pulley bolts to 10 N m 89 in lbs 7 Install the idler pulley 1 and bolt Tighten the idler pulley bolt to 10 N m 89 in lbs 8 Connect the lower radiator hose 2 and coolant by pass hose 1 ZH ENGINE 7 65 ...

Page 610: ...retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 13 Install the air cleaner inlet tubes 2 14 Connect the negative battery cable 15 Fill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCE DURE 16 Start the engine and...

Page 611: ...lts in the correct positions Tighten the bolts to 35 N m 26 ft lbs 4 Install the oil cooler hose 3 to the water pump 5 Install the hose clamp 6 Install the water pump pulley 2 and bolts Tighten the water pump pulley bolts to 10 N m 89 in lbs 7 Install the idler pulley 1 and bolt Tighten the idler pulley bolt to 10 N m 89 in lbs ZH ENGINE 7 67 ...

Page 612: ...ant by pass hose 1 9 Install the generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 10 Rotate the belt tensioner counterclockwise and install the accessory drive belt 11 Release the belt tensioner and remove the wrench 7 68 ENGINE ZH ...

Page 613: ...he air pump tube assembly 1 to the engine Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE INSTALLATION 13 Install the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION ZH ENGINE 7 69 ...

Page 614: ...17 Start the engine and check for coolant leaks 18 Recheck the coolant level RADIATOR CHARGE AIR COOLER DESCRIPTION On vehicles equipped with a supercharger there is an additional radiator used in the cooling system The charge air cooler radiator is a conventional cross flow aluminum core radiator The charge air cooler radiator mounts in front of the A C condenser and behind the front fascia The c...

Page 615: ...oolant is then circulated through the radiator where it is cooled The coolant leaves the radiator and is then pumped back to the charge air cooler REMOVAL 1 Remove the front fascia from the vehicle Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA REMOVAL 2 Remove the nuts from the charge air cooler radia tor 1 left and right mounting bracket studs 3 Tilt the charge air cooler radiator away from the ...

Page 616: ... the charge air cooler radiator 2 to hang from the cooling hoses 1 7 Remove the drain plug 1 from the charge air cooler radiator 8 Drain the coolant out of the charge air cooler cool ing system 7 72 ENGINE ZH ...

Page 617: ...e outlet coolant hose 1 from the charge air cooler radiator 10 Remove the charge air cooler radiator from the vehicle INSTALLATION 1 Locate the upper mounting studs 1 and the lower rubber mounts 2 for the charge air cooler radiator ZH ENGINE 7 73 ...

Page 618: ...nts 3 Tilt the charge air cooler radiator inward and install the radiator onto the upper mounting studs 4 Install the left and right charge air cooler radiator retaining nuts Tighten the nuts to 10 N m 89 in lbs 5 Connect the inlet and outlet coolant hoses 6 Refill the cooling system 7 74 ENGINE ZH ...

Page 619: ...harger OPERATION The purpose of the charge air cooler is to reduce the air inlet temperature thereby increasing air density thus pro ducing an increase in engine efficiency The charge air cooler operates as an air to water heat exchanger The charge air cooler extracts heat from the incoming compressed air leaving the supercharger Transfering the heat in the air to the to the coolant in the charge ...

Page 620: ...HARGER REMOVAL 2 Remove the four charge air cooler flange bolts 2 from the supercharger housing 3 Remove the two mounting bolts 4 from the super charger housing 4 Separate the charge air cooler from the super charger 5 Remove the charge air cooler flange gasket 1 7 76 ENGINE ZH ...

Page 621: ...6 Remove the MAP sensor 1 from the charge air cooler INSTALLATION 1 Install the MAP sensor to the charge air cooler ZH ENGINE 7 77 ...

Page 622: ...er Tighten the charge air cooler mounting bolts 2 to 25 N m 18 ft lbs 4 Install the charge air cooler rear mounting bolts Tighten the charge air cooler rear mounting bolts 4 to 20 N m 15 ft lbs 5 Install the supercharger on the engine Refer to 9 ENGINE MANIFOLDS SUPERCHARGER INSTALLATION 7 78 ENGINE ZH ...

Page 623: ...oolant between the charge air cooler radiator and the charge air cooler The pump is a positive dis placement pump that operates on a pulsed 12 volt signal OPERATION The charge air cooler circulation pump operates independently of the engine cooling system The only common link is the coolant reservoir The circulation pump is operated by a pulsed 12 volt signal ZH ENGINE 7 79 ...

Page 624: ...harge air cooler circulation pump inlet hose 2 3 Remove the charge air cooler circulation pump out let hose 1 4 Disconnect the charge air cooler circulation pump harness connector 2 5 Remove the charge air cooler circulation pump mounting bolt 1 6 Remove the charge air cooler circulation pump from the mounting bracket 7 80 ENGINE ZH ...

Page 625: ...ect the charge air cooler circulation pump harness connector 2 4 Reconnect the charge air cooler circulation pump inlet hose 2 5 Reconnect the charge air cooler circulation pump outlet hose 1 6 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 7 Start the engine and check for coolant leaks 8 Install the right side inner fender lining 9 Recheck the coolant level ZH ENGI...

Page 626: ...UPERCHARGER IDLER SRT 101 INSTALLATION INSTALLATION 103 INSTALLATION IDLER PULLEY SRT 105 INSTALLATION SUPERCHARGER IDLER SRT 106 ACCESSORY DRIVE DESCRIPTION A single serpentine style belt drives all of the engine accessories The accessory drive includes an automatic ten sioner making adjustments unnecessary for the life of the belt OPERATION OPERATION The accessory drive belt provides the link be...

Page 627: ...rn 2 Replace the belt BELT SQUEAL WHEN ACCELERATING ENGINE 1 Belt too loose 1 Check engine accessories and replace belt tensioner as necessary 2 Belt glazed 2 Replace belt BELT CHIRP AT IDLE 1 Belt too loose 1 Check engine accessories and replace belt tensioner as necessary 2 Foreign material imbedded in belt 2 Replace belt 3 Non uniform belt 3 Replace belt 4 Misaligned pulley s 4 Align accessorie...

Page 628: ...s 25 18 BELT TENSIONER REMOVAL REMOVAL 1 Remove the engine cover 1 Grasp both corners of the engine cover and pull up firmly 2 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Remove the pulley from the accessory drive belt tensioner 7 84 ACCESSORY DRIVE ZH ...

Page 629: ...4 Remove the belt tensioner retaining bolts 1 and the belt tensioner 2 REMOVAL SRT 1 Remove the engine cover 1 Grasp both corners of the engine cover and pull up firmly ZH ACCESSORY DRIVE 7 85 ...

Page 630: ... Remove the air pump tube assembly 1 from the engine 5 Release the tension on the accessory drive belt by attaching a wrench and pulling up on the tensioner and relocating the accessory drive belt 6 Remove the accessory drive belt tensioner pulley by holding the stud with a wrench and removing the nut 7 86 ACCESSORY DRIVE ZH ...

Page 631: ...lts 1 8 Remove the accessory drive belt tensioner from the engine INSTALLATION INSTALLATION 1 Position the belt tensioner 2 on the timing chain cover 2 Install the belt tensioner bolts 1 Tighten the bolts to 20 N m 15 ft lbs ZH ACCESSORY DRIVE 7 87 ...

Page 632: ...Install the engine cover 1 Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 6 Start the engine and verify the accessory drive belt is properly routed and seated 7 88 ACCESSORY DRIVE ZH ...

Page 633: ... mounting bolts 1 Tighten the mounting bolts to 20 N m 15 ft lbs 2 Install the accessory drive belt tensioner pulley to the stud Tighten the pulley nut to 20 N m 15 ft lbs 3 Release the tension on the tensioner and install the accessory drive belt ZH ACCESSORY DRIVE 7 89 ...

Page 634: ...ver 1 Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 6 Start the engine and verify the accessory drive belt is properly routed and seated 7 90 ACCESSORY DRIVE ZH ...

Page 635: ... on the accessory drive belt 3 Remove the accessory drive belt from the pulleys 4 Carefully release the wrench tension on the belt tensioner 5 Inspect the accessory drive belt Refer to damage patterns Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSPECTION 6 Inspect the pulleys for wear or damage 7 Replace the accessory drive belt or pulleys as necessary ZH ACCESSORY DRIVE 7 91 ...

Page 636: ... both corners of the engine cover and pull up firmly 2 Remove the air pump tube retaining bolts 2 3 Remove the air pump tube assembly from the engine 1 Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE REMOVAL 7 92 ACCESSORY DRIVE ZH ...

Page 637: ... bolt 2 8 Remove the supercharger idler pulley 9 Remove the accessory drive belt from the engine 10 Inspect the accessory drive belt Refer to damage patterns Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSPECTION 11 Inspect the pulleys for wear or damage 12 Replace the accessory drive belt or pulleys as necessary CLEANING Clean all foreign debris from the belt pulley grooves The belt pulleys mu...

Page 638: ... across the ribbed side 1 due to reverse bending These minor cracks are considered normal and acceptable Parallel cracks 2 are not considered nor mal and should be cause for belt replacement Note Do not use any type of belt dressing or restorer on the accessory drive belt INSTALLATION INSTALLATION 1 Route the accessory drive belt onto the engine pulleys 7 94 ACCESSORY DRIVE ZH ...

Page 639: ...l the engine cover 1 Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 5 Start the engine and verify the accessory drive belt is properly routed and seated ZH ACCESSORY DRIVE 7 95 ...

Page 640: ...SRT 1 Route the accessory drive belt onto the engine pulleys 2 Install the supercharger idler pulley upper mounting bolt 1 and the lower mounting bolt 2 Tighten the bolts to 20 N m 15 ft lbs 7 96 ACCESSORY DRIVE ZH ...

Page 641: ...l the accessory drive belt over the tensioner pulley 4 Release the belt tensioner and remove the wrench 5 Install the air pump tube assembly 1 to the engine Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE INSTALLATION ZH ACCESSORY DRIVE 7 97 ...

Page 642: ... of lubricant to the engine cover rubber mounts 7 Start the engine and verify the accessory drive belt is properly routed and seated IDLER PULLEY REMOVAL REMOVAL Note A small dowel rod can be inserted into the accessory drive belt tensioner to hold the ten sioner in place while performing repairs 1 Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt 7 98 ...

Page 643: ...elt away from the idler pulley 4 3 Remove the idler pulley bolt cover 1 4 Remove the bolt 1 and the idler pulley 2 from the engine 5 Check the pulley bearing for any wear looseness or noise Replace if necessary ZH ACCESSORY DRIVE 7 99 ...

Page 644: ...e accessory drive belt tensioner to hold the ten sioner in place while performing repairs 1 Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt 2 Slide the accessory drive belt away from the idler pulley 8 7 100 ACCESSORY DRIVE ZH ...

Page 645: ...pulley from the engine 4 Check the pulley bearing for looseness and noise Replace if necessary REMOVAL SUPERCHARGER IDLER SRT 1 Remove the engine cover 1 Grasp both corners of the engine cover and pull up firmly ZH ACCESSORY DRIVE 7 101 ...

Page 646: ...air tube assembly 1 by removing the retaining bolts 2 3 Release the tension on the accessory drive belt 4 Remove the supercharger idler pulley retainer bolts 1 and 2 and the pulley assembly 7 102 ACCESSORY DRIVE ZH ...

Page 647: ...NSTALLATION INSTALLATION 1 Position the idler pulley 2 on the engine 2 Install the idler pulley bolt 1 Tighten to 20 N m 15 ft lbs 3 Install the bolt cover 1 on the idler pulley ZH ACCESSORY DRIVE 7 103 ...

Page 648: ... Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley 5 Carefully release the belt tensioner and remove the wrench 6 Install and properly route the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE OPERATION 7 104 ACCESSORY DRIVE ZH ...

Page 649: ...he idler pul ley bolt to 20 N m 15 ft lbs 3 Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley Note If a dowel rod was inserted into the acces sory drive belt tensioner remove rod 4 Carefully release the belt tensioner and remove the wrench ZH ACCESSORY DRIVE 7 105 ...

Page 650: ...er to 7 COOLING ACCESSORY DRIVE OPERATION INSTALLATION SUPERCHARGER IDLER SRT 1 Install the supercharger idler pulley retainer bolts 1 and 2 and the pulley assembly Tighten bolts to 20 N m 15 ft lbs 2 Install the accessory drive belt 7 106 ACCESSORY DRIVE ZH ...

Page 651: ... the engine cover 1 Align engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts ZH ACCESSORY DRIVE 7 107 ...

Page 652: ...rvice the front copper transmission cooler lines 5 the radiator must be removed Refer to 7 COOLING ENGINE RADIATOR REMOVAL 1 Raise and support the vehicle 2 Remove the lower splash shield 3 Disconnect the fittings at either end of the line being serviced 4 Remove the line retainers 1 and the cooler line s as necessary 7 108 TRANSMISSION ZH ...

Page 653: ...removed 3 Tighten the cooler line fittings or banjo bolts to 20 N m 15 ft lbs 4 Tighten the transmission cooler line retaining bolts to 10 N m 89 in lbs 5 Lower the vehicle 6 Install the radiator if removed Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 7 Check the transmission fluid level Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 FLUID STANDARD PROCEDURE ZH TRANSMISSION 7 109 ...

Page 654: ......

Page 655: ...O ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING RADIO INOPERATIVE 2 NO SOUND FROM ALL SPEAKERS 5 NO SOUND FROM LEFT DOOR SPEAKERS 8 NO SOUND FROM RIGHT DOOR SPEAKERS 10 NO SOUND FROM LEFT REAR SPEAKER 12 NO SOUND FROM RIGHT REAR SPEAKER 15 BODY VERIFICATION TEST 18 SCHEMATICS AND DIAGRAMS 19 AUDIO ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH AUDIO VIDEO 8A 1 ...

Page 656: ... RADIO INOPERATIVE 8A 2 AUDIO ELECTRICAL DIAGNOSTICS ZH ...

Page 657: ...ff Disconnect the Radio harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the Radio harness connector cavity 7 connector A Is the voltage above 10 volts Yes Go to 2 No Repair the Radio Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE RADIO FUSED B CIRCUIT ...

Page 658: ... ground and the Ground circuit at cav ity 8 connector A of the Radio harness connector Is the resistance below 5 0 ohms Yes Replace the Radio Refer to 8 ELECTRICAL AUDIO RA DIO REMOVAL Perform BODY VERIFICATION TEST No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST 8A 4 AUDIO ELECTRICAL DIAGNOSTICS ZH ...

Page 659: ... NO SOUND FROM ALL SPEAKERS ZH AUDIO ELECTRICAL DIAGNOSTICS 8A 5 ...

Page 660: ...onnector Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the Power Amplifier harness connector cavity 1 connector B Is the voltage above 10 volts Yes Go to 2 No Repair the Power Amplifier Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE POWER AMPLIFIER FUSED IGNITION SWITCH OUTPUT CIRCUIT VOL...

Page 661: ...nd circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE POWER AMPLIFIER GROUND CIRCUIT RESISTANCE With the ignition off Measure the resistance between ground and the Ground circuit at cav ity 4 connector A of the Power Amplifier harness connector Is the resistance below 5 0 ohms Yes Replace the Power Amplifier Refer to 8 ELECTRICAL AUDIO AMPLIFIER REMOVAL Perform BODY VERIFICATION TEST No ...

Page 662: ... NO SOUND FROM LEFT DOOR SPEAKERS 8A 8 AUDIO ELECTRICAL DIAGNOSTICS ZH ...

Page 663: ...tors Clean repair as necessary Disconnect the Left Door Speaker harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of inline harness connector C229 Measure the resistance between cavity 8 connector B and cavity 18 connector B of the Power Amplifier harness connector Is the resistance below 5 0 ohms Yes Replace the Power Amplifier R...

Page 664: ... NO SOUND FROM RIGHT DOOR SPEAKERS 8A 10 AUDIO ELECTRICAL DIAGNOSTICS ZH ...

Page 665: ...tors Clean repair as necessary Disconnect the Right Door Speaker harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of inline harness connector C231 Measure the resistance between cavity 7 connector B and cavity 17 connector B of the Power Amplifier harness connector Is the resistance below 5 0 ohms Yes Replace the Power Amplifier ...

Page 666: ... NO SOUND FROM LEFT REAR SPEAKER 8A 12 AUDIO ELECTRICAL DIAGNOSTICS ZH ...

Page 667: ...n the ignition off Disconnect the Power Amplifier harness connector Note Check connectors Clean repair as necessary Disconnect the Left Rear Speaker harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Left Rear Speaker harness connector Measure the resistance between cavity 6 connector B and cavity 16 connector B of the Power...

Page 668: ...sure the resistance between cavity 12 connector B and cavity 4 connector B of the Power Amplifier harness connector Is the resistance below 5 0 ohms Yes Replace the Left Rear Speaker Refer to 8 ELECTRI CAL AUDIO SPEAKER REMOVAL Perform BODY VERIFICATION TEST No Repair the Left Rear Speaker Ground circuit or Supply Voltage circuit for an open Perform BODY VERIFICATION TEST 8A 14 AUDIO ELECTRICAL DI...

Page 669: ... NO SOUND FROM RIGHT REAR SPEAKER ZH AUDIO ELECTRICAL DIAGNOSTICS 8A 15 ...

Page 670: ...urn the ignition off Disconnect the Power Amplifier harness connector Note Check connectors Clean repair as necessary Disconnect the Right Rear Speaker harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Right Rear Speaker harness connector Measure the resistance between cavity 5 connector B and cavity 15 connector B of the P...

Page 671: ...sure the resistance between cavity 14 connector B and cavity 13 connector B of the Power Amplifier harness connector Is the resistance below 5 0 ohms Yes Replace the Right Rear Speaker Refer to 8 ELECTRI CAL AUDIO SPEAKER REMOVAL Perform BODY VERIFICATION TEST No Repair the Right Rear Speaker Ground circuit or Supply Voltage circuit for an open Perform BODY VERIFICATION TEST ZH AUDIO ELECTRICAL DI...

Page 672: ...ransmitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT...

Page 673: ...SCHEMATICS AND DIAGRAMS ZH AUDIO ELECTRICAL DIAGNOSTICS 8A 19 ...

Page 674: ...RATION 29 DIAGNOSIS AND TESTING ANTENNA BODY AND CABLE 29 REMOVAL 31 INSTALLATION 31 REAR WINDOW ANTENNA MODULE REMOVAL 32 INSTALLATION 32 REAR WINDOW ANTENNA DESCRIPTION 33 STANDARD PROCEDURE ANTENNA GRID REPAIR 33 REMOVAL 34 INSTALLATION 35 RADIO REMOVAL 35 INSTALLATION 36 SPEAKER REMOVAL LOWER DOOR SPEAKER 36 REMOVAL REAR PANEL SPEAKER 37 REMOVAL TWEETER SPEAKER 38 INSTALLATION LOWER DOOR SPEAK...

Page 675: ...itions The audio system includes the following components Antenna Rear Window Antenna Module Power Amplifier Radio Receiver Speakers OPERATION For detailed operation instructions for the factory installed audio system refer to the Understanding Your Instrument Panel section in the Owner s Manual DIAGNOSIS AND TESTING AUDIO SYSTEM For complete audio system diagnosis see audio electrical diagnostics...

Page 676: ...SPECIAL TOOLS Radio Removal Tool 9241 8A 22 AUDIO SERVICE INFORMATION ZH ...

Page 677: ...l and fold the carpet down to expose the foam insu lation 3 Remove the foam insulating panel Note It is not necessary to remove the electrical connectors to rotate the base plate in the passen ger footwell 4 Remove the plastic retaining nuts 1 from the floor panel and rotate the base plate exposing the amplifier ZH AUDIO SERVICE INFORMATION 8A 23 ...

Page 678: ...nector 6 Remove the amplifier from the base plate REMOVAL RHD 1 Un snap and remove the carpeted floor mat from the passenger footwell 2 Un tuck the carpeting in the passenger footwell and fold the carpet down to expose the foam insu lation 3 Remove the foam insulating panel 8A 24 AUDIO SERVICE INFORMATION ZH ...

Page 679: ...otwell 4 Remove the plastic retaining nuts 1 from the floor panel and rotate the base plate exposing the amplifier 5 Remove the four amplifier retaining screws 1 from the base plate and disconnect the amplifier har ness connector 6 Remove the amplifier from the vehicle ZH AUDIO SERVICE INFORMATION 8A 25 ...

Page 680: ...ws 1 2 Rotate the base plate and install it over the mount ing studs on the floor panel Note Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to the floor mounting studs 3 Install the plastic retaining nuts 1 and secure the base plate to the vehicle floor 8A 26 AUDIO SERVICE INFORMATION ZH ...

Page 681: ...the carpeting in the passenger footwell 6 Install the floor mat to the carpet INSTALLATION RHD 1 Connect the amplifier harness connector and attach the amplifier to the base plate with the four retaining screws 1 ZH AUDIO SERVICE INFORMATION 8A 27 ...

Page 682: ...the base plate to the vehicle floor 4 Install the foam insulating panel 5 Install the carpeting in the passenger footwell 6 Install the floor mat to the carpet ANTENNA BODY CABLE CONVERTIBLE DESCRIPTION The antenna body and cable are secured below the quarter panel by the antenna cap nut through a mounting hole in the left rear quarter panel 1 The coaxial cable is then routed behind the instrument...

Page 683: ... test WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNO SIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS...

Page 684: ...the battery Disconnect and isolate both battery cables negative cable first 2 Reconnect the battery negative cable 3 Touch one ohmmeter test lead to a good clean ground point on the vehicle rear quarter panel Touch the other test lead to the battery negative terminal post Check the ohmmeter reading for continuity 4 There should be continuity The ohmmeter should register less than one ohm resistanc...

Page 685: ...mmet 6 Unplug antenna lead from base of antenna body INSTALLATION 1 Insert antenna lead to base of antenna body 2 Push antenna body down through the rubber grom met 3 Install the nut onto the mounting bracket and tighten 4 Install antenna mast 1 Tighten to 12 N m 106 in lbs Ensure that the antenna mast is fully seated on antenna base and that there is no gap between the mast and base 5 Install tru...

Page 686: ... module from the vehicle INSTALLATION 1 Install the rear window antenna module to the lift gate and attach with the retaining screw 3 and secure 2 Install the rear window antenna module harness connectors 2 Note Use care when routing harnesses and allow sufficient clearance near trim panel pinch points 3 Install the liftgate interior trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM...

Page 687: ... WATER FOR CONTACT WITH THE EYES FLUSH WITH PLENTY OF WATER DO NOT TAKE INTER NALLY IF TAKEN INTERNALLY INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY USE WITH ADE QUATE VENTILATION DO NOT USE NEAR FIRE OR FLAME CONTAINS FLAMMABLE SOLVENTS KEEP OUT OF THE REACH OF CHILDREN 1 Mask the repair area 3 on the inside of the rear glass so that the conductive epoxy can be applied neatly Extend the epoxy...

Page 688: ...nce levels REMOVAL WARNING DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF REAR WINDOW GLASS INSTALLATION IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE IF IT IS NOT CURED THE REAR WINDOW GLASS MAY NOT PERFORM PROPERLY IN AN ACCIDENT BE SURE TO REFER TO THE URE THANE MANUFACTURE S DIRECTIONS FOR CURING TIME SPECIFICATIONS AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE CAUTION Open the d...

Page 689: ... PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG NOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Record customer de...

Page 690: ...PEAKER WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG NOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG S...

Page 691: ...SPEAKER 1 Move the seats and tilt the seat back to the full for ward position 2 Remove the door sill molding 3 Remove the edge plate and the door edge mold ing CAUTION The speaker grille is plastic and may break if excessive force is applied in one place 4 Using a trim stick remove the speaker grille 3 from the back panel carpet 5 Fold the back panel carpet to one side enough to see the retaining ...

Page 692: ...ONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG NOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect the negative batte...

Page 693: ...FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG NOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Install the lower door speaker together with the plastic frame 1 and the speaker cover 2 2 Connect the lower door speaker harness connec...

Page 694: ... the door sill molding 8 Move the seats back to their normal driving position INSTALLATION TWEETER SPEAKER WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHAR...

Page 695: ...door interior trim panel 2 2 Connect the tweeter speaker harness connector 3 3 Install the door interior trim panel 2 Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 4 Connect the negative battery cable ZH AUDIO SERVICE INFORMATION 8A 41 ...

Page 696: ......

Page 697: ...DESCRIPTION 1 SCHEMATICS AND DIAGRAMS 2 CHIME BUZZER ELECTRICAL DIAGNOSTICS DESCRIPTION The electrical diagnostic information for the Chime Buzzer can be found in the appropriate diagnostic section The Chime Buzzer diagnostic section only contains the circuit diagram for a quick system overview For complete electrical diagnostics refer to the Instrument Cluster Electrical Diagnostics section ZH CH...

Page 698: ...SCHEMATICS AND DIAGRAMS 8B 2 CHIME BUZZER ELECTRICAL DIAGNOSTICS ZH ...

Page 699: ...s a single chime tone generator that is integral to the Instrument Cluster to provide an audible indication of vehicle conditions that may require the attention of the vehicle operator The chime warning system includes the following major components Headlamp Switch Door Ajar Switch Seat Belt Switch Ignition Switch Instrument Cluster Coolant Level Sensor Fuel Level Sensor Washer Fluid Level Sensor ...

Page 700: ...ELT WARNING CHIME WITH SEAT BELT UNBUCKLED BUT OTHER CHIME FEATURES OK 1 Seat belt switch ground circuit open 1 Check for continuity between the ground circuit of the wire harness connector for the seat belt switch and a good ground Repair the ground circuit if required 2 Seat belt switch sense circuit open 2 Check for continuity between the seat belt switch sense circuit of the wire harness conne...

Page 701: ...he ignition lock cylinder Replace the faulty ignition switch if required NO CHIMES AT ALL TIMES 1 Faulty Instrument Cluster 1 Use a DRB IIIT scan tool and refer to the appropriate diagnostic information Replace the faulty Instrument Cluster if required OPERATION The chime warning system components operate on battery voltage received through fuse 35 in the Underhood Accessory Fuse Block on a non sw...

Page 702: ...le features in the chime warning system The Instrument Cluster relies upon message inputs received from other modules over the Controller Area Network CAN data bus network to provide chime tones for all of the remaining chime warning system features The internal programming of the Instrument Cluster determines the priority of each chime tone request input that is received as well as the rate and d...

Page 703: ... FROM OCCUPANT RESTRAINT CONTROLLER 14 NO RESPONSE FROM INSTRUMENT CLUSTER 18 NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER TIRE PRESSURE MONITOR 24 NO RESPONSE FROM A C HEATER CONTROL MODULE 29 NO RESPONSE FROM POWER TOP CONTROL MODULE 35 NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 39 NO RESPONSE FROM SHIFT LEVER ASSEMBLY 45 NO RESPONSE FROM TRANSMISSION CONTROL MODULE 50 NO RESPONSE FROM BODY CON...

Page 704: ... DRB IIIT DOES NOT POWER UP 8E 2 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 705: ...e vehicle or other devices and the vehicle battery is fully charged an inoperative DRB IIIT may be the result of a faulty cable Turn the ignition off Measure the voltage of the Fused B circuit at cavity 16 of the Data Link Connector Is the voltage above 11 volts Yes Go to 2 No System voltage must be above 11 volts Check Fuse 14 in the Underhood Accessory Fuse Block Repair the voltage concern as ne...

Page 706: ... NO RESPONSE FROM ALL MODULES 8E 4 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 707: ...connect the PCM C4 harness connector Turn the ignition on Attempt to communicate with any module with the DRB IIIT Does the DRB IIIT communicate with the module selected Yes The repair is complete Perform POWERTRAIN VERIFICATION TEST VER 2 No Go to 2 2 DISCONNECT THE FUEL TANK PRESSURE SENSOR Turn the ignition off Disconnect the Fuel Tank Pressure Sensor harness connector Attempt to communicate wi...

Page 708: ...ss connector Note Check connector Clean repair as necessary Measure the resistance of the Sensor Ground circuit from PCM C4 harness connector cavity 10 to DLC cavity 5 Is the resistance below 5 0 ohms Yes Replace the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground ci...

Page 709: ...gnition on Measure the voltage of the Sensor Ground circuit at DLC cavity 5 Is the voltage below 0 5 volt Yes Replace the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ELECTRONIC CONTROL M...

Page 710: ... NO RESPONSE FROM POWERTRAIN CONTROL MODULE 8E 8 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 711: ...EMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with any other module Is the DRB IIIT able to communicate with the module selected Yes Go to 2 No Perform Symptom No Response From All Modules 2 FUSED B CIRCUIT OPEN Turn the ignition off Disconnect the PCM C5 harness connector Note Check connector Clean repa...

Page 712: ... 4 No Repair the Fused Engine Control Relay Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 4 PCM GROUND CIRCUITS OPEN Turn the ignition off Measure the resistance of the Ground circuits from the PCM C5 har ness connector to ground Is the resistance below 5 0 ohms on each ground circuit Yes Go to 5 No Repair the Ground circuit s for an open Perform POWERTRAIN VERIFICATION TES...

Page 713: ...he DLC Is the resistance below 5 0 ohms Yes Go to 6 No Repair the PCM SCI Receive circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 SCI RECEIVE CIRCUIT SHORTED TO GROUND With the ignition off Measure the resistance between ground and the PCM SCI Receive circuit Is the resistance above 100 kohms Yes Go to 7 No Repair the PCM SCI Receive circuit for a short to ground Perform POWERTRAI...

Page 714: ... PCM SCI Receive circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 8 SCI TRANSMIT CIRCUIT OPEN Turn the ignition off Measure the resistance of the PCM SCI Transmit circuit from the PCM harness connector to the DLC Is the resistance below 5 0 ohms Yes Go to 9 No Repair the PCM SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8E 12 ELECTRONIC CONTRO...

Page 715: ...N VERIFICATION TEST VER 2 10 SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ignition on Measure the voltage of the PCM SCI Transmit circuit at the DLC Is the voltage below 0 5 volt Yes Replace the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the PCM SCI Transmit circuit for a sho...

Page 716: ... NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER 8E 14 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 717: ... Yes Go to 2 No Perform Symptom No Response From All Modules 2 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Turn the ignition off Disconnect the Occupant Restraint Controller ORC harness connec tor Note Check connector Clean repair as necessary Reconnect the battery Turn the ignition on Measure the voltage of...

Page 718: ... ORC har ness connector to the DLC Is the resistance below 5 0 ohms Yes Go to 5 No Repair the SCI Transmit circuit for an open WARNING WHEN RECONNECTING AIRBAG SYSTEM COMPO NENTS THE IGNITION MUST BE TURNED OFF AND THE BAT TERY MUST BE DISCONNECTED FOR TWO MINUTES Perform AIRBAG VERIFICATION TEST 5 SCI TRANSMIT CIRCUIT SHORTED TO GROUND With the ignition off Measure the resistance between ground a...

Page 719: ...NING IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED AT ANY TIME IT MUST BE REPLACED WARNING WHEN RECONNECTING AIRBAG SYSTEM COMPO NENTS THE IGNITION MUST BE TURNED OFF AND THE BAT TERY MUST BE DISCONNECTED FOR TWO MINUTES Perform AIRBAG VERIFICATION TEST No Repair the SCI Transmit circuit for a short to voltage WARNING WHEN RECONNECTING AIRBAG SYSTEM COMPONENTS THE IGNITION MUST BE TURNED OFF AND...

Page 720: ... NO RESPONSE FROM INSTRUMENT CLUSTER 8E 18 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 721: ... ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attempt to communicate ...

Page 722: ...used B circuit for an open Perform BODY VERIFICATION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT S OPEN Turn the ignition off Disconnect the IC C2 harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuits at the IC C1 and C2 harness connectors Is the voltage above 10 volts Yes Go to 5 No Repair the Fused I...

Page 723: ...open Perform BODY VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the IC C1 har ness connector to the DLC Is the resistance below 5 0 ohms Yes Replace the Instrument Cluster Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER REMOVAL Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for an open Perform BODY VERIFICAT...

Page 724: ...tion off Disconnect each of the modules noted above one at a time Turn the ignition on Using the DRB IIIT attempt to communicate with any of the three modules still connected Is the DRB IIIT able to communicate with the module selected Yes Replace the module that was disconnected when communication was restored to the other two mod ules Perform BODY VERIFICATION TEST No Go to 8 8 SCI TRANSMIT CIRC...

Page 725: ...sure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ground Perform BODY VERIFICATION TEST ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 23 ...

Page 726: ... NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER TIRE PRESSURE MONITOR 8E 24 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 727: ...RONIC CONTROL MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attemp...

Page 728: ...TION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN With the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the UGDO TPM harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST 5 GROUND CIRCUIT OPEN Turn the ignition off Measure the resistance of the Ground circuit fr...

Page 729: ...he SCI Transmit circuit at DLC cavity 15 to communicate with the DRB IIIT If one of these modules keeps the SCI Transmit circuit artificially high or low the DRB IIIT will not be able to communicate with any of the four modules Note Perform the following steps for each of the modules until communication is restored with the other modules or until each of the modules has been eliminated as the caus...

Page 730: ...M harness connector Is the voltage below 0 5 volt Yes Go to 9 No Repair the SCI Transmit circuit for a short to voltage Perform BODY VERIFICATION TEST 9 SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TES...

Page 731: ... NO RESPONSE FROM A C HEATER CONTROL MODULE ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 29 ...

Page 732: ...L MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attempt to communi...

Page 733: ...ess connector Is the voltage above 10 volts Yes Go to 4 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT S OPEN With the ignition on Measure the voltage of the Fused Ignition Switch Output circuits at the A C Heater Control Module harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Fused Ignition Switch Output cir...

Page 734: ...m BODY VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the A C Heater Control Module harness connector to the DLC Is the resistance below 5 0 ohms Yes Replace the A C Heater Control Module Refer to 24 HEATING AIR CONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit ...

Page 735: ... Disconnect each of the modules noted above one at a time Turn the ignition on Using the DRB IIIT attempt to communicate with any of the three modules still connected Is the DRB IIIT able to communicate with the module selected Yes Replace the module that was disconnected when communication was restored to the other two mod ules Perform BODY VERIFICATION TEST No Go to 8 8 SCI TRANSMIT CIRCUIT SHOR...

Page 736: ...Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ground Perform BODY VERIFICATION TEST 8E 34 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 737: ... NO RESPONSE FROM POWER TOP CONTROL MODULE ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 35 ...

Page 738: ...ECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attempt to communicate with either the Instrument Cluster A C Heater Cont...

Page 739: ...t the Power Top Control Module harness connector Is the voltage above 10 volts Yes Go to 4 No Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST 4 GROUND CIRCUIT OPEN Turn the ignition off Measure the resistance of the Ground circuit from the Power Top Con trol Module harness connector to ground Is the resistance below 5 0 ohms Yes Go to 5 No Repair the Grou...

Page 740: ... BODY VERIFICATION TEST No Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short ...

Page 741: ... NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 39 ...

Page 742: ...TRONIC CONTROL MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attem...

Page 743: ...nector Is the voltage above 10 volts Yes Go to 4 No Repair the Fused B circuit s for an open Perform ABS VERIFICATION TEST 4 TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN With the ignition on Measure the voltage of the Traction System Relay Output circuit at the CAB harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Traction System Relay Output circuit for an open Perform ABS VE...

Page 744: ... VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the CAB har ness connector to the DLC Is the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODULES CONTROL LER ANTILOCK BRAKE REMOVAL Perform ABS VERIFICATION TEST No Repair the SCI Transmit circuit for an open ...

Page 745: ...connect each of the modules noted above one at a time Turn the ignition on Using the DRB IIIT attempt to communicate with the other module still connected Is the DRB IIIT able to communicate with the other module Yes Replace the module that was disconnected when communication was restored to the other module Perform BODY VERIFICATION TEST No Go to 8 8 SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn t...

Page 746: ...Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ground Perform BODY VERIFICATION TEST 8E 44 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 747: ... NO RESPONSE FROM SHIFT LEVER ASSEMBLY ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 45 ...

Page 748: ...NIC CONTROL MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attempt ...

Page 749: ... VERIFICATION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN With the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the SLA harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Fused Ignition Switch Output circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 GROUND CIRCUIT OPEN Turn the ignition off Measure the resistance of the ...

Page 750: ... to communicate with the DRB IIIT If one of these modules keeps the SCI Transmit circuit artificially high or low the DRB IIIT will not be able to com municate with any of the modules Note Perform the following steps for each of the modules until communication is restored with the other module or until each of the modules has been eliminated as the cause of the fault Turn the ignition off Disconne...

Page 751: ...age below 0 5 volt Yes Go to 9 No Repair the SCI Transmit circuit for a short to voltage Perform BODY VERIFICATION TEST 9 SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit ci...

Page 752: ... NO RESPONSE FROM TRANSMISSION CONTROL MODULE 8E 50 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 753: ...tion on Using the DRB IIIT attempt to communicate with any other module Is the DRB IIIT able to communicate with the module selected Yes Go to 2 No Perform Symptom No Response From All Modules 2 TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN Turn the ignition off Disconnect the TCM harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the Traction ...

Page 754: ...to 4 No Repair the Ground circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 4 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the TCM har ness connector to the DLC Is the resistance below 5 0 ohms Yes Go to 5 No Repair the SCI Transmit circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 8E 52 ELECTRONIC CONTROL MODUL...

Page 755: ...ISSION VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ignition on Measure the voltage of the SCI Transmit circuit at the DLC Is the voltage below 0 5 volt Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ...

Page 756: ... NO RESPONSE FROM BODY CONTROL MODULE 8E 54 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 757: ... MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attempt to communic...

Page 758: ... Is the voltage above 10 volts Yes Go to 4 No Repair the Fused B circuit s for an open Perform BODY VERIFICATION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT S OPEN With the ignition on Measure the voltage of the Fused Ignition Switch Output circuits at the BCM C4 harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Fused Ignition Switch Output circuit s for an open Perform BOD...

Page 759: ...RIFICATION TEST 6 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the BCM C4 harness connector to the DLC Is the resistance below 5 0 ohms Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for an open...

Page 760: ...nect each of the modules noted above one at a time Turn the ignition on Using the DRB IIIT attempt to communicate with the other module still connected Is the DRB IIIT able to communicate with the other module Yes Replace the module that was disconnected when communication was restored to the other module Perform BODY VERIFICATION TEST No Go to 8 8 SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ...

Page 761: ...sure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ground Perform BODY VERIFICATION TEST ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 59 ...

Page 762: ... NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE 8E 60 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 763: ...TRONIC CONTROL MOD ULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK COMMUNICATION WITH OTHER MODULES Turn the ignition on Using the DRB IIIT attempt to communicate with the PCM Is the DRB IIIT able to communicate with the PCM Yes Go to 2 No Perform Symptom No Response From All Modules 2 CHECK COMMUNICATION WITH OTHER MODULES ON SCI TRANSMIT CIRCUIT With the ignition on Using the DRB IIIT attem...

Page 764: ... connector Is the voltage above 10 volts Yes Go to 4 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 4 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN With the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the SKREEM C1 harness connector Is the voltage above 10 volts Yes Go to 5 No Repair the Fused Ignition Switch Output circuit for an open Perfo...

Page 765: ...VERIFICATION TEST 6 SCI TRANSMIT CIRCUIT OPEN With the ignition off Measure the resistance of the SCI Transmit circuit from the SKREEM C1 harness connector to the DLC Is the resistance below 5 0 ohms Yes Replace the Sentry Key Remote Entry Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES EN TRY MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for an open Perf...

Page 766: ...Disconnect each of the modules noted above one at a time Turn the ignition on Using the DRB IIIT attempt to communicate with the other module still connected Is the DRB IIIT able to communicate with the other module Yes Replace the module that was disconnected when communication was restored to the other module Perform BODY VERIFICATION TEST No Go to 8 8 SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Tur...

Page 767: ...ff Measure the resistance between ground and the SCI Transmit circuit Is the resistance above 100 kohms Yes Repair the SCI Transmit circuit for an open Perform BODY VERIFICATION TEST No Repair the SCI Transmit circuit for a short to ground Perform BODY VERIFICATION TEST ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 65 ...

Page 768: ...s and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTCs...

Page 769: ...SCHEMATICS AND DIAGRAMS ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 67 ...

Page 770: ...8E 68 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 771: ...ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 69 ...

Page 772: ...DATA LINK CONNECTOR CIRCUIT DIAGRAM 8E 70 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 773: ...ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 71 ...

Page 774: ...8E 72 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS ZH ...

Page 775: ...ZH ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 73 ...

Page 776: ...VAL 108 INSTALLATION 109 COMMUNICATION DESCRIPTION The Controller Area Network CAN data bus system is a multiplex system used for vehicle communications Mul tiplexing is a system that enables the transmission of several messages over a single channel or circuit Many of the control modules in a vehicle require information from the same sensing device Multiplexing reduces wire harness complexity sen...

Page 777: ...em and the Body Control Module is the dominant node for the CAN B Interior Data Bus System The CAN bus uses low and high voltage levels to generate signals The voltage on the bus varies between zero and two and one half volts The low and high voltage levels are generated by means of variable pulse width mod ulation to form signals of varying length When a module is transmitting on the bus it is re...

Page 778: ...amming of the Powertrain Control Module allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the CAN data bus The Powertrain Control Module for this model is serviced only as a complete unit A Powertrain Control Module can only be rep...

Page 779: ...e referred to as Powertrain Control Module outputs The sensors and switches that provide inputs to the Powertrain Control Module are considered Powertrain Control Module inputs The Powertrain Control Module adjusts ignition timing based upon inputs it receives from sensors that react to engine rpm manifold absolute pressure engine coolant temperature throttle position transmission gear selection a...

Page 780: ...ntry Key Remote Entry Module it cannot be changed and the Sentry Key Remote Entry Module must be replaced 1 Program ignition keys to the Sentry Key Remote Entry Module Note If the PCM and the Sentry Key Remote Entry Module are replaced at the same time all vehicle ignition keys will need to be replaced and programmed to the new Sentry Key Remote Entry Module PROGRAMMING IGNITION KEYS TO THE SENTRY...

Page 781: ...module retain ing clip 1 back pull the powertrain control module up and out of the control module box 4 Disconnect the electrical connectors 1 and remove the powertrain control module 2 ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 79 ...

Page 782: ...module box cover 1 3 Holding the metal powertrain control module retaining clip back pull the powertrain control module 2 up and out of the control module box 5 4 Disconnect the PCM harness electrical connector and remove the powertrain control module 2 8E 80 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 783: ...rs 1 to the power train control module 2 2 Install the powertrain control module into the con trol module box 3 Push the powertrain control module into the metal powertrain control module retaining clip 1 ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 81 ...

Page 784: ...ON RHD 1 Connect the PCM harness electrical connector to the powertrain control module 2 2 Install the powertrain control module into the control module box 5 3 Install the plastic control module box cover 1 and slide the clips rearward to lock the cover 4 Connect the negative battery cable 8E 82 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 785: ...ansmission Control Module Indirect inputs originate from other components modules and are shared with the Transmission Control Module via the vehicle Controller Area Network CAN bus Some examples of direct inputs to the Transmission Control Module are Traction System Relay Output voltage Trans Temp Sensor P N Switch N2 and N3 Speed Sensors Some examples of indirect inputs to the Transmission Contr...

Page 786: ...re rise to the maximum levels and the torque converter lockup clutch is disarmed In order to preserve the operability of the vehicle to some extent the automatic transmission internal hydraulic control can be used to engage second gear or reverse by stopping the vehicle switching off the engine moving the shift selector lever to Park waiting at least ten seconds starting the engine and moving the ...

Page 787: ... 2 Fold back the carpeting in the passenger footwell to expose the foam insulation panel 3 Remove the foam insulation panel Note It is not necessary to remove the electrical connectors to rotate the base plate in the passen ger footwell 4 Remove the three plastic retaining nuts 1 from the floor panel studs 5 Lift the base plate and rotate the top of the base plate toward the rear of the vehicle to...

Page 788: ...ness connectors 7 Remove the TCM 2 from the base plate REMOVAL 1 Un snap and remove the carpet floor mat 2 Fold back the carpeting in the passenger footwell to expose the foam insulation panel 3 Remove the foam insulation panel 8E 86 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 789: ...etaining nuts 1 from the floor panel studs 5 Lift the base plate and rotate the top of the base plate toward the rear of the vehicle to expose the TCM 6 Remove the two retaining screws 2 from the base plate and disconnect the TCM harness connectors 7 Remove the TCM 1 from the base plate ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 87 ...

Page 790: ...base plate and install it over the mount ing studs on the floor panel Note Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to the floor mounting studs 3 Install the three plastic retaining nuts 1 and secure the base plate to the vehicle floor 8E 88 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 791: ... correctly in the foam insulat ing panel 5 Install the carpeting in the passenger footwell 6 Install the floor mat to the carpet INSTALLATION 1 Connect the TCM harness connectors and attach the TCM to the base plate with the two retaining screws 1 ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 89 ...

Page 792: ...loor mounting studs 3 Install the three plastic retaining nuts 1 and secure the base plate to the vehicle floor 4 Install the foam insulation panel Note Make sure the aligning tabs of the base plate are positioned correctly in the foam insulat ing panel 5 Install the carpeting in the passenger footwell 6 Install the floor mat to the carpet 8E 90 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 793: ...icle Control fluid modulation to the wheel brakes while the system is in an ABS mode Store diagnostic information Provide communication to the DRB IIIT scan tool while in diagnostic mode Illuminate the amber ABS warning indicator lamp Illuminate the brake assist BAS electronic stability program ESP lamp on the instrument panel when a trac tion control event occurs The CAB constantly monitors the A...

Page 794: ...rom the CAB memory by a technician using the DRB IIIT scan tool CAB INPUTS Wheel speed sensors four Brake lamp switch System and pump voltage Ground ESP OFF switch Diagnostic communication CAB OUTPUTS Amber ABS warning indicator lamp actuation via CAN BUS Instrument cluster communication via CAN BUS BAS ESP indicator lamp Diagnostic communication REMOVAL 1 Disconnect the negative battery cable 2 C...

Page 795: ...1 Install the Controller Antilock Brake CAB to the Hydraulic Control Unit HCU with the retaining screws 2 Check the seating and condition of the Integrated Control Unit ICU rubber grommets and replace if necessary 3 Install the ICU to the retaining bracket with the retaining screws CAUTION Do not wrongfully connect hydraulic lines Trace the line routing to the corresponding wheel if necessary 4 In...

Page 796: ...Locking Pump Security System Module 3 uses a combination of electrical wires 2 and air pressure vacuum lines 1 The Central Locking Pump Security System Module is located in the right rear of the luggage compartment underneath the trunk floor covering 4 It is wrapped in a sound deadening material in order to oper ate quietly without disturbing the vehicle operator 8E 94 ELECTRONIC CONTROL MODULES S...

Page 797: ...omplished again only upon reaching the specified speed The logic circuitry for this function is integrated into the CLP SSM The auto matic locking function can be activated or deactivated with the DRB IIIT An alternative is to use the interior power door lock switch with the ignition switched on by pressing and holding the door lock switch for more than 5 seconds in either the lock auto locking sw...

Page 798: ...vehicle is parked the value for the vehicle position is stored If the vehicle is moved with a certain inclination in longitudinal and or lateral direction for a certain time when the anti theft alarm system is activated the Anti Theft Tow Sensor transmits an alarm signal to the CLP SSM In order to allow the vehicle to be towed or transported without sounding the alarm Siren the Anti Theft Tow Sens...

Page 799: ... module INSTALLATION 1 Install the central locking pump security system module 3 into the trunk and connect the air lines 2 and the electrical harness 1 2 Install the central locking pump security system module into sound deadening foam covering and slide it back into place ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 97 ...

Page 800: ... the negative battery cable SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION The Sentry Key Remote Entry Module SKREEM 1 is located underneath the top pad of the instrument panel 2 behind the Instrument Cluster The SKREEM works in conjunction with the vehicle locking unlocking remote control and the Central Locking Pump Security System Module to lock and unlock the vehicle 8E 98 ELECTRONIC CONTROL MODUL...

Page 801: ...ired to the SKREEM If the Sentry Key Antenna Ring is not mounted properly around the ignition lock cylinder housing com munication problems between the SKREEM and the ignition key may arise These communication problems will result in ignition key transponder related faults The SKREEM also communicates over the Controller Area Network CAN data bus with the Powertrain Control Module PCM the Instrume...

Page 802: ... 1 from the SKREEM module 6 Press the retaining tabs apart 7 Remove the SKREEM module from the base plate INSTALLATION 1 Install the SKREEM module to the base plate 2 Connect the 18 pin harness connector and the 2 pin CAN BUS harness connector 1 to the SKREEM module 3 Connect the 2 pin harness connector for the sentry key antenna ring 4 Install the Instrument Cluster Refer to 8 ELEC TRICAL INSTRUM...

Page 803: ...bus The BCM for this model is serviced only as a complete unit A BCM can only be repaired by or replaced through an authorized electronic warranty repair station Refer to the latest version of the Warranty Policies and Procedures manual for a current listing of authorized electronic repair stations CONTROL MODULE COOLING FAN The Control Module Cooling Fan is used to decrease the heat that is gener...

Page 804: ...o control and integrate many of the electronic features and functions of the vehicle The microprocessor based Body Control Module hardware and software monitors many hardwired switch and sensor inputs as well as those resources it shares with other electronic modules in the vehicle through its com munication over the Controller Area Network CAN Bus The internal programming of the Body Control Modu...

Page 805: ...2 Slide the clips forward to remove the plastic control module box cover 1 3 Holding the metal body control module retaining clip 1 back pull the body control module up and out of the control module box ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 103 ...

Page 806: ...sconnect the rest of the body control module electrical con nectors 5 Remove the body control module from the control module box 2 REMOVAL RHD 1 Disconnect the negative battery cable 2 Slide the clips forward to remove the plastic control module box cover 1 3 Holding the metal body control module retaining clip back pull the body control module 6 up and out of the control module box 5 8E 104 ELECT...

Page 807: ...INSTALLATION INSTALLATION 1 Connect the electrical connectors 1 to the body control module and push the metal body control module connector lock down to lock the connector assembly Then connect the windshield wiper elec trical connector to the body control module and slide the grey windshield wiper connector lock to the left to lock it 2 Push the body control module into the control mod ule box un...

Page 808: ...on nector lock down to lock the connector assembly Then connect the windshield wiper electrical connector to the body control module and slide the grey windshield wiper connector lock to the left to lock it 2 Install body control module into the control module box 5 3 Install the plastic control module box cover 1 and slide the clips rearward to lock the cover 4 Connect the negative battery cable ...

Page 809: ...nd raise the power windows when the power top switch is depressed STANDARD PROCEDURE POWER TOP CONTROL MODULE INITIALIZATION 1 Connect the DRB IIIT scan tool to the Data Link Connector 2 Turn the Ignition Switch on and access the DTC Functions screen 3 Select Clear DTCs and clear all DTCs in the new replacement Power Top Control Module PTCM Note The new PTCM must be initialized prior to being put ...

Page 810: ...ners 2 and lifting the left trunk trim panel out of the trunk 3 Disconnect the power top control module harness connectors 2 and 3 4 Remove the power top control module retaining screw 1 5 Remove the power top control module from the hydraulic pump bracket 4 8E 108 ELECTRONIC CONTROL MODULES SERVICE INFORMATION ZH ...

Page 811: ...ctors 2 and 3 4 Install the trunk interior trim panel 1 5 Install the plastic panel retainers 2 6 Connect the negative battery cable 7 Perform the Standard Procedure to complete the installation and programing of the new power top control module Refer to 8 ELECTRICAL ELEC TRONIC CONTROL MODULES POWER TOP CONTROL MODULE STANDARD PROCEDURE ZH ELECTRONIC CONTROL MODULES SERVICE INFORMATION 8E 109 ...

Page 812: ......

Page 813: ... 21 DIAGNOSIS AND TESTING BATTERY CABLES 21 TRAY DESCRIPTION DESCRIPTION 23 DESCRIPTION RHD 24 OPERATION 24 REMOVAL REMOVAL 25 REMOVAL RHD 25 INSTALLATION INSTALLATION 26 INSTALLATION RHD 26 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory installed equipment on this model All of the components of the battery system are located within the engine compartment of the vehicle Th...

Page 814: ...e with one another and must be tested as a com plete 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 thoroughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal ...

Page 815: ...tions are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures 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 Determine the batte...

Page 816: ...g 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 systems in use 8 Advise the vehicle operator as required THE BATTERY WILL NOT ACCEPT A CHARGE 1 The battery is faulty 1 Test the battery using the Micro 420...

Page 817: ...ery hold down hard ware of all corrosion Remove any corrosion using a wire brush and a sodium bicarbonate baking soda and warm water cleaning solution Paint any exposed bare metal 3 If the removed battery 3 is to be reinstalled clean the outside of the battery case and the top cover with a sodium bicarbonate baking soda and warm water cleaning solution 2 using a stiff bristle parts cleaning brush ...

Page 818: ...quipment specification for the vehicle being serviced Battery sizes and ratings are discussed in more detail below Group Size The outside dimensions and terminal placement of the battery conform to standards established by the Battery Council International BCI Each battery is assigned a BCI Group Size number to help identify a correctly sized replacement Cold Cranking Amperage The Cold Cranking Am...

Page 819: ...SPECIAL TOOLS Micro 420 Battery Tester ZH BATTERY SYSTEM 8F 7 ...

Page 820: ...y The battery is not sealed and has a vent 5 The chemical composition of the metal coated plates within the low maintenance battery reduces battery gassing and water loss at normal charge and discharge rates Therefore the battery should not require additional water in normal service If the electrolyte level in this battery does become low distilled water must be added However rapid loss of electro...

Page 821: ...r to Standard Procedure for the proper battery charging procedures Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY STANDARD PRO CEDURE MICRO 420 BATTERY TESTER The Micro 420 automotive battery tester is designed to help dealership technicians diagnose the cause of a defec tive battery Follow the instruction manual supplied with the tester to properly diagnose a vehicle If the instruction manual is no...

Page 822: ...cal system components may result CAUTION Battery electrolyte will bubble inside the battery case during normal battery charging Electrolyte boiling or being discharged from the battery vents indicates a battery overcharging condition Immediately reduce the charging rate or turn off the charger to evaluate the battery condition Damage to the battery may result from overcharging CAUTION The battery ...

Page 823: ... current is measurable during the charging time the battery may be good and the charging should be completed in the normal manner CHARGE RATE Voltage Hours 16 0 volts maximum up to 4 hours 14 0 to 15 9 volts up to 8 hours 13 9 volts or less up to 16 hours CHARGING TIME REQUIRED The time required to charge a battery will vary depending upon the following factors Battery Capacity A completely discha...

Page 824: ...ke certain all of the vehicle accessory loads are OFF including the ignition The preferred test position is at the battery terminal If the battery is not accessible you may test using both the positive and negative jumper posts Select TESTING AT JUMPER POST when connecting to that location 3 Connect the tester to the battery or jumper posts the red clamp to positive and the black clamp to negative...

Page 825: ...es negative cable first 3 Using a voltmeter connected to the battery posts see the instructions provided by the manufacturer of the volt meter measure the open circuit voltage See the Open Circuit Voltage Table This voltage reading will indicate the battery state of charge but will not reveal its cranking capacity If a battery has an open circuit voltage reading of 12 4 volts or greater it may be ...

Page 826: ...ery negative cable terminal clamp and the battery negative terminal post Make sure that the doors remain closed so that the illuminated entry system is not activated The multi meter amperage reading may remain high for up to three minutes or may not give any reading at all while set in the highest amperage scale depending upon the electrical equipment in the vehicle The multi meter leads must be s...

Page 827: ...st milliampere scale of the multi meter to check the low amper age IOD CAUTION Do not open any doors or turn on any electrical accessories with the lowest milliampere scale selected or the multi meter may be damaged 5 Observe the multi meter reading The low amperage IOD should not exceed thirty five milliamperes 0 035 amperes If the current draw exceeds thirty five milliamperes isolate each circui...

Page 828: ... in the battery The elec trolyte should be approximately 1 centimeter above the battery plates or until the lip 2 inside the bat tery cap holes is covered 3 Add only distilled water until the electrolyte level is approximately one centimeter above the plates 8F 16 BATTERY SYSTEM ZH ...

Page 829: ...1 Disconnect the negative battery cable 4 If necessary use a battery terminal puller to remove the terminal clamp from the battery post 2 Remove the protective plastic cap 1 3 Disconnect the positive battery cable 2 If necessary use a battery terminal puller to remove the terminal clamp from the battery post 4 Remove the battery hold down nut 3 and strap from the battery 5 Remove the battery 5 fro...

Page 830: ...negative battery cable 3 If necessary use a battery terminal puller to remove the terminal clamp from the battery post 2 Remove the positive battery cable protective plastic cap 2 3 Disconnect the positive battery cable 1 If necessary use a battery terminal puller to remove the terminal clamp from the battery post 4 Remove the battery hold down nut 5 and strap from the battery 5 Remove the battery...

Page 831: ...he hold down nut 3 Tighten the battery hold down nut to 8 N m 71 in lbs CAUTION Be certain that the battery cable terminal clamps are connected to the correct battery terminal posts Reverse battery polarity may damage electrical components of the vehicle 4 Clean the battery cable terminal clamps and the battery terminal posts 5 Connect the positive battery cable 2 Tighten the terminal clamp pinch ...

Page 832: ...sitive battery terminal plastic cap 2 7 Connect the negative battery cable 3 Tighten the terminal clamp pinch bolt hex nut to 7 N m 60 in lbs CABLES DESCRIPTION The battery cables are large gauge stranded copper wires sheathed within a heavy plastic or synthetic rubber insu lating jacket The wire used in the battery cables combines excellent flexibility and reliability with high electrical cur ren...

Page 833: ...ions or the battery cable If excessive resistance is found in the battery cable connections the connection point should be dis assembled cleaned of all corrosion or foreign material then reassembled Following reassembly check the voltage drop for the battery cable connection and the battery cable again to confirm repair When performing the voltage drop test it is important to remember that the vol...

Page 834: ...attery 2 positive cable terminal clamp Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor connection between the battery positive cable ter minal clamp and the battery positive terminal post 3 Connect the voltmeter 2 to measure between the battery 1 positive cable terminal clamp and the starter solenoid 3 B terminal stud Rotate a...

Page 835: ... negative cable eyelet terminal connection to the engine block Repeat the test If the reading is still above 0 2 volt replace the faulty battery negative cable TRAY DESCRIPTION DESCRIPTION The battery is mounted in a battery tray 1 located in the right rear corner of the engine compartment The battery tray and support unit is secured at the front with a bolt 2 on the front wheelhouse inner panel a...

Page 836: ...OPERATION The battery tray provides a secure mounting location and supports the battery The battery tray also provides the anchor points for the battery hold down hardware The battery tray and the battery hold down hardware combine to secure and stabilize the battery in the engine compartment which prevents battery movement during vehicle oper ation Unrestrained battery movement during vehicle ope...

Page 837: ... BATTERY REMOVAL 2 Remove the battery tray 1 retaining bolts 2 3 Remove the battery tray 1 REMOVAL RHD 1 Remove the battery Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY REMOVAL 2 Remove the battery tray 1 retaining bolts 2 3 Remove the battery tray 1 ZH BATTERY SYSTEM 8F 25 ...

Page 838: ... m 11 ft lbs 3 Install the battery Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY INSTALLATION INSTALLATION RHD 1 Install the battery tray 1 2 Install the battery tray 1 retaining bolts 2 Tighten the bolts to 15 N m 11 ft lbs 3 Install the battery Refer to 8 ELECTRICAL BAT TERY SYSTEM BATTERY INSTALLATION 8F 26 BATTERY SYSTEM ZH ...

Page 839: ...e three gauges The lamp is located on the instrument panel Refer to Instrument Cluster for additional information Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER DESCRIPTION DIAGNOSIS AND TESTING CHARGING SYSTEM The following procedures may be used to diagnose the charging system if the check gauges lamp is illuminated with the engine running an undercharged or overcharged battery condition occurs Remem...

Page 840: ...r replace as required 4 Inspect generator mounting bolts for tightness Replace or tighten bolts if required 5 Inspect accessory drive belt condition and tension Tighten or replace belt as required 6 Inspect the automatic belt tensioner 7 Inspect generator electrical connections at generator field battery output and ground terminal Also check gen erator ground wire connection at engine They should ...

Page 841: ...SCHEMATICS AND DIAGRAMS ZH CHARGING SYSTEM 8F 29 ...

Page 842: ... energized rotor begins to rotate within the generator the spinning magnetic field induces a current into the windings of the stator coil Once the generator begins producing sufficient current it also provides the current needed to energize the rotor The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rec tification From the diodes rectified...

Page 843: ...ull the tensioning pulley in a counter clockwise direction Lock the tensioning pulley with a pin or slowly release the pulley after the belt is free from the area 4 Remove the upper generator bolt 2 5 Remove the lower generator bolt 3 and reposition the generator to access the generator harness connectors 6 Remove the protective plastic cap from the generator B cable retaining nut 5 7 Disconnect t...

Page 844: ...B cable nut 5 3 Install the generator 1 into the mounting bracket 4 Install the upper and lower generator mounting bolts Tighten the generator mounting bolts to 42 N m 31 ft lbs CAUTION Be sure to check proper installation on all pulleys 5 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 6 Install the right side air inlet tube 7 Connect the negative batt...

Page 845: ...lacement is necessary the voltage regulator can be replaced separately from the generator OPERATION OPERATION The amount of DC current produced by the generator is controlled by the voltage regulator circuitry This circuitry is connected in series with the generators second rotor field terminal and its ground ZH CHARGING SYSTEM 8F 33 ...

Page 846: ...e generator 4 Remove the voltage regulator 2 INSTALLATION 1 Insert the voltage regulator 2 ensure that the ground lug is making contact to the voltage regulator 2 Install the screws 3 attaching the voltage regulator to the generator 3 Install the plastic voltage regulator cover 4 with the clips 4 Install the generator 1 Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 8F 34 CHARGING SYSTEM ZH...

Page 847: ...ECTRICAL IGNITION CONTROL DESCRIPTION Refer to 8 ELECTRICAL STARTING STARTER MOTOR OPERATION for complete service information and circuit diagrams for the starting system wiring components Group 8F Engine Systems covers the Battery Starting Systems and Charging System We have combined these systems to make it easier to locate the information you are seeking within this Service Manual However when ...

Page 848: ...the starter motor is automatically disengaged by the PCM through the pulse module The pulse module further prevents starter motor damage by not allowing the starter motor to be engaged if the engine is already running DIAGNOSIS AND TESTING STARTING SYSTEM The battery starting and charging systems operate with one another and must be tested as a complete system In order for the vehicle to start and...

Page 849: ...uits test OK replace the starter motor assembly INSPECTION For complete wiring diagrams refer to Starting System in the Contents of Group 8W Wiring Diagrams Before removing any unit from the starting system for repair or diagnosis perform the following inspections WARNING ON VEHICLES EQUIPPED WITH AIRBAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING CO...

Page 850: ...ltage reads above 9 6 volts and the current amperage draw reads below specifications refer to Feed Circuit Test in this section c If the voltage reads 12 5 volts or greater and the starter motor does not turn refer to Control Circuit Test ing in this section d If the voltage reads 12 5 volts or greater and the starter motor turns very slowly refer to Feed Circuit Test in this section Note A cold e...

Page 851: ...ositive lead of the voltmeter 1 to the battery 2 negative terminal post Connect the negative lead of the voltmeter 1 to the battery 2 negative cable clamp Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor contact between the cable clamp and the terminal post 2 Connect the positive lead of the voltmeter 1 to the battery 2 positiv...

Page 852: ...ost and a good clean ground on the engine block 3 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 negative cable attachment on the engine block Repeat the test If the reading is still above 0 2 volt replace the faulty battery negative cable 5 Connect the positive lead of the voltmeter 3 to the starter 1 ...

Page 853: ...ter Motor in the Diagnosis and Testing section of Group 8F Engine Systems for the procedures Refer to 8 ELECTRICAL STARTING STARTER MOTOR DIAGNOSIS AND TESTING Ignition Switch Refer to Ignition Switch and Key Lock Cylinder in the Diagnosis and Testing section of Group 8D Ignition System for the procedures Refer to 8 ELECTRICAL IGNITION CONTROL DESCRIP TION Wire harnesses and connections Refer to S...

Page 854: ...SCHEMATICS AND DIAGRAMS 8F 42 STARTING SYSTEM ZH ...

Page 855: ...bs Starter Motor B Terminal 14 10 Starter Motor Ground Terminal 6 52 Starter Motor Retaining Bolts 42 31 STARTER MOTOR DESCRIPTION The starter motor 2 is mounted with two bolts to the transmission housing and is located on the right side of the engine The starter motor incorporates several features to create a reliable efficient compact light weight and powerful unit The electric motor of the star...

Page 856: ...OVAL and Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 2 Mount the starter motor securely in a soft jawed bench vise The vise jaws should be clamped on the mounting flange of the starter motor Never clamp on the starter motor by the field frame 3 Connect a suitable volt ampere tester and a 12 volt battery to the starter motor in series and set the ammeter to the 100 ampere scale See th...

Page 857: ...nuity tester 3 There should be continuity If OK go to Step 4 If not OK replace the faulty starter motor assembly 4 Using a continuity tester 3 check for continuity between the solenoid terminal 2 and the solenoid case 1 There should be continuity If not OK replace the faulty starter motor assembly ZH STARTING SYSTEM 8F 45 ...

Page 858: ...exhaust manifold to the rear exhaust system Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 6 Remove the starter bolts 1 and reposition the starter to access the starter electrical cables 7 Remove the starter positive cable protective plastic cap 3 8 Disconnect the starter cables by removing the ground cable nut 2 and the positive cable nut 9 Remove the starter 4 from the vehicle 8F 46 STAR...

Page 859: ...nut 2 to 6 N m 52 in lbs 3 Install the starter positive cable protective plastic cap 3 4 Install the starter bolts 1 Tighten to 42 N m 31 ft lbs 5 Install the right side exhaust pipe Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLA TION 6 Connect the right side O2 sensor 7 Install the lower engine panel 8 Lower the vehicle 9 Connect the negative battery cable ZH STARTING SYSTEM 8F 47 ...

Page 860: ......

Page 861: ...ATED SEATS ELECTRICAL DIAGNOSTICS 28 HEATED SEATS SERVICE INFORMATION 39 HEATED GLASS ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page HEATED GLASS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING REAR DEFOGGER SWITCH SENSE CIRCUIT 2 REAR WINDOW DEFOGGER INOPERATIVE 6 BODY VERIFICATION TEST 10 SCHEMATICS AND DIAGRAMS 11 HEATED GLASS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH HEATED SYSTEMS 8G 1...

Page 862: ...REAR DEFOGGER SWITCH SENSE CIRCUIT 8G 2 HEATED GLASS ELECTRICAL DIAGNOSTICS ZH ...

Page 863: ...FOGGER SWITCH SENSE CIRCUIT OPEN A C HEATER CONTROL MODULE BODY CONTROL MODULE For a complete Heated Glass Circuit Diagram Refer to 8 ELECTRICAL HEATED GLASS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 REAR DEFOGGER SWITCH SENSE SHORTED TO B Turn the ignition off Disconnect the BCM C3 harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the Rea...

Page 864: ... TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Go to 3 3 OPEN REAR DEFOGGER SWITCH SENSE CIRCUIT Turn the ignition off Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Rear Defogger Switch Sense circuit from the BCM C3 harness connector to the A C Heater Control Module harness connector Is the resistance...

Page 865: ...form BODY VERIFICATION TEST 5 REAR DEFOGGER SWITCH SENSE CIRCUIT SHORTED TO B Turn the ignition off Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Defogger Switch Sense circuit at the A C Heater Control Module harness connector Is the voltage above 1 0 volt Yes Repair the Rear Defogger S...

Page 866: ... REAR WINDOW DEFOGGER INOPERATIVE 8G 6 HEATED GLASS ELECTRICAL DIAGNOSTICS ZH ...

Page 867: ...he light stops blinking Once the rear window defogger indicator stops blinking the system will resume normal operation Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE REAR WINDOW DEFOGGER FUSED B CIRCUIT VOLTAGE Note Inspect Fuse 25 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Central ...

Page 868: ...ndow Defogger Ground circuit for an open Perform BODY VERIFICATION TEST No Go to 4 4 MEASURE REAR WINDOW DEFOGGER SUPPLY CIRCUIT VOLTAGE Turn the ignition off Disconnect the Rear Window Defogger Grid harness connector termi nal 2 Note Check connector Clean repair as necessary Turn the ignition on Activate the Rear Window Defogger Measure the voltage at the Rear Window Defogger Grid harness con nec...

Page 869: ...the CLP SSM C2 harness connector to the Rear Window Defogger Grid harness connector terminal 2 Is the resistance below 5 0 ohms Yes Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the Rear Window Defogger Grid Supply circuit for an open Perform BODY VERIFICATION TE...

Page 870: ...smitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT re...

Page 871: ...SCHEMATICS AND DIAGRAMS ZH HEATED GLASS ELECTRICAL DIAGNOSTICS 8G 11 ...

Page 872: ...quipment A push button Rear Window Defogger Switch 2 located in the center console activates the rear window defogger The switch is illuminated with instrumentation lighting for easy night time use An LED 1 in the push button switch illuminates when the rear window defogger is working When energized a grid on the inside of the window heats up to help clear the outside surface of ice snow or fog Th...

Page 873: ...ide surface to clear fog or snow The grid lines comprise a parallel electrical cir cuit and are bonded to the glass permanently Both the horizontal grid lines 1 and the vertical bus bars 2 are highly resistant to abrasion However it is pos sible for an open circuit to occur in an individual grid line resulting in no current flow Care should be taken when cleaning the glass or removing foreign mate...

Page 874: ... RUN position 2 Press the Defogger Switch to the ON position The rear window defogger operation can be checked by feeling the rear window glass and the side view mirrors A distinct difference in temperature between the grid lines and the adjacent clear glass can be detected within three to four minutes of operation 3 Using a 12 volt DC voltmeter contact the rear glass heating grid terminal right s...

Page 875: ... For complete rear window defogger switch installation procedures refer to heater control installation in the Heating and Air Conditioning sec tion of this manual Refer to 24 HEATING AIR CONDITIONING CONTROLS HEATER CONTROL INSTALLATION REAR WINDOW DEFOGGER GRID DIAGNOSIS AND TESTING REAR WINDOW DEFOGGER GRID For complete rear window defogger grid electrical diagnosis with schematics and diagrams ...

Page 876: ...sed STANDARD PROCEDURE REAR GLASS HEATING GRID REPAIR Repair of the rear glass heating grid lines bus bars terminals or pigtail wires can be accomplished using a MoparT Rear Window Defogger Repair Kit Part Number 4267922 or equivalent WARNING MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER WHICH ARE HARMFUL IF SWALLOWED AV...

Page 877: ... the bus bar To prevent the terminal or pigtail wire from moving while the epoxy is curing it must be wedged or clamped 8 Carefully remove the masking tape or template CAUTION Do not allow the glass surface to exceed 204 C 400 F or the glass may fracture 9 Allow the epoxy to cure 24 hours at room temperature or use a heat gun that will not over heat the glass Hold the heat gun approximately 25 cen...

Page 878: ...RORS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING LEFT HEATED MIRROR INOPERATIVE 19 RIGHT HEATED MIRROR INOPERATIVE 21 BODY VERIFICATION TEST 23 SCHEMATICS AND DIAGRAMS 24 HEATED MIRRORS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING 8G 18 HEATED MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 879: ... LEFT HEATED MIRROR INOPERATIVE ZH HEATED MIRRORS ELECTRICAL DIAGNOSTICS 8G 19 ...

Page 880: ...tivate the rear window defogger Measure the voltage of the Fused Heated Mirror Supply circuit at the Left Power Mirror harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused Heated Mirror Supply circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE LEFT MIRROR HEATER ELEMENT GROUND CIRCUIT RESISTANCE Turn the ignition off Measure the resistance between ground and th...

Page 881: ... RIGHT HEATED MIRROR INOPERATIVE ZH HEATED MIRRORS ELECTRICAL DIAGNOSTICS 8G 21 ...

Page 882: ...tivate the rear window defogger Measure the voltage of the Fused Heated Mirror Supply circuit at the Right Power Mirror harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused Heated Mirror Supply circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE RIGHT MIRROR HEATER ELEMENT GROUND CIRCUIT RESISTANCE Turn the ignition off Measure the resistance between ground and ...

Page 883: ...mitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT rea...

Page 884: ...SCHEMATICS AND DIAGRAMS 8G 24 HEATED MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 885: ...fogger is activated the sideview mirror heating elements are powered The heating elements behind each sideview mirror cannot be repaired If faulty or damaged the entire sideview mirror assembly must be replaced For complete sideview mirror removal procedures see Sideview Mirror removal in this section Refer to 8 ELECTRICAL POWER MIRRORS SIDEVIEW MIRROR REMOVAL OPERATION When the Rear Window Defogg...

Page 886: ...ror glass surface refer to Heated Mirror Elec trical Diagnostics in this section Note If the interior dome lamp dims or flickers while opening a door and the defogger is activated inspect the door wire harness section that flexes near the door hinge It is possible to have an intermittent open or short circuit in the fused heated mirror supply or ground circuits when the door is not in a stationary...

Page 887: ...be adjusted or repaired If faulty or damaged the entire sideview mir ror assembly must be replaced as a unit For com plete sideview mirror removal procedures see sideview mirror removal Refer to 8 ELECTRICAL POWER MIRRORS SIDEVIEW MIRROR REMOVAL ZH HEATED MIRRORS SERVICE INFORMATION 8G 27 ...

Page 888: ... DIAGNOSTICS DIAGNOSIS AND TESTING LEFT HEATED SEAT INOPERATIVE 29 RIGHT HEATED SEAT INOPERATIVE 32 BOTH HEATED SEATS INOPERATIVE 35 BODY VERIFICATION TEST 37 SCHEMATICS AND DIAGRAMS 38 HEATED SEATS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING 8G 28 HEATED SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 889: ... LEFT HEATED SEAT INOPERATIVE ZH HEATED SEATS ELECTRICAL DIAGNOSTICS 8G 29 ...

Page 890: ...c Test 1 TEST THE LEFT HEATED SEAT Turn the ignition off Disconnect the Heated Seat Module harness connector Note Check connector Clean repair as necessary Connect a fused jumper wire from B to cavity 3 LHD of the Heated Seat Module harness connector With the jumper wire connected does the Left Heated Seat warm up Yes Replace the Heated Seat Module Refer to 8 ELECTRI CAL HEATED SEATS HEATED SEAT M...

Page 891: ... the resistance below 5 0 ohms Yes Go to 3 No Repair the Left Heated Seat Output circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE LEFT HEATED SEAT GROUND CIRCUIT RESISTANCE Measure the resistance between ground and the Left Heated Seat Ground circuit Is the resistance below 5 0 ohms Yes Replace the Left Heated Seat Back Heated Seat Cushion Element Refer to 8 ELECTRICAL HEATED SEATS HEA...

Page 892: ... RIGHT HEATED SEAT INOPERATIVE 8G 32 HEATED SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 893: ...ic Test 1 TEST THE RIGHT HEATED SEAT Turn the ignition off Disconnect the Heated Seat Module harness connector Note Check connector Clean repair as necessary Connect a fused jumper wire from B to cavity 1 LHD of the Heated Seat Module harness connector With the jumper wire connected does the Right Heated Seat warm up Yes Replace the Heated Seat Module Refer to 8 ELECTRI CAL HEATED SEATS HEATED SEA...

Page 894: ...Is the resistance below 5 0 ohms Yes Go to 3 No Repair the Right Heated Seat Output circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE RIGHT HEATED SEAT GROUND CIRCUIT RESISTANCE Measure the resistance between ground and the Right Heated Seat Ground circuit Is the resistance below 5 0 ohms Yes Replace the Right Heated Seat Back Heated Seat Cushion Element Refer to 8 ELECTRICAL HEATED SEA...

Page 895: ... BOTH HEATED SEATS INOPERATIVE ZH HEATED SEATS ELECTRICAL DIAGNOSTICS 8G 35 ...

Page 896: ...n repair as necessary Measure the voltage of the Fused B circuit at the Heated Seat Mod ule harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Heated Seat Module Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE HEATED SEAT MODULE FUSED IGNITION SWITCH OUTPUT CIRCUIT VOLTAGE Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circu...

Page 897: ...smitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT re...

Page 898: ...SCHEMATICS AND DIAGRAMS 8G 38 HEATED SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 899: ...LE REMOVAL 44 INSTALLATION 45 HEATED SEATS SERVICE INFORMATION DESCRIPTION Electrically Heated Seats are standard equipment on this model Each seat has a separate control switch 1 and 2 located in the Center Console Each seat has individual heating elements one set within the seat cushion and the other within the seat back The heated seat system features two heating stages Each control switch 1 an...

Page 900: ...ced only with their respective assemblies DIAGNOSIS AND TESTING Before testing the individual components of the Heated Seat System ensure the battery is fully charged then check the following If the Heated Seat Switch LED indicators do not illuminate with the Ignition Switch in the ACC or ON RUN position and the switch pressed check Fuse 1 and Fuse 24 in the Underhood Accessory Fuse Block If OK se...

Page 901: ...nec tors 1 4 Press the locking tabs inward and remove the heated seat switches from the interior trim panel INSTALLATION 1 Align the heated seat switch with the center con sole interior trim panel and press together until the locking tabs engage fully 2 Connect the heated seat switch harness connec tors 3 Install the center console interior trim panel Refer to 23 BODY INTERIOR CENTER CONSOLE INSTA...

Page 902: ...d 5 are an integrated part of the seat cushion 4 or seat back cushion 2 The heated seat elements are only serviced with the cushion assemblies The seat covers 6 are serviced separately and are attached to the seat frame 3 8G 42 HEATED SEATS SERVICE INFORMATION ZH ...

Page 903: ... see seat cushion removal in the body section Refer to 23 BODY SEATS SEAT CUSHION REMOVAL REMOVAL HEATED SEAT BACK ELEMENT Note Disconnect the negative battery cable before removing the seat or attempting seat electrical repair The heated seat back element 2 is part of the seat back assembly 3 To access the element the seat must be removed and the seat cover 1 disassem bled For complete seat back ...

Page 904: ...ck element 2 is an integral part of the seat back cushion 3 For complete seat back installation procedures see seat back installation in the body section Refer to 23 BODY SEATS SEAT BACK INSTALLATION HEATED SEAT MODULE REMOVAL WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE...

Page 905: ...Refer to 8 ELECTRICAL HEATED SEATS DRIVER HEATED SEAT SWITCH REMOVAL INSTALLATION The Heated Seat Control Module is integrated within the Heated Seat Switch assembly For complete Heated Seat Control Module installation procedures see Heated Seat Switch installation in this section Refer to 8 ELECTRICAL HEATED SEATS DRIVER HEATED SEAT SWITCH INSTALLATION ZH HEATED SEATS SERVICE INFORMATION 8G 45 ...

Page 906: ......

Page 907: ...CE INFORMATION 9 HORN ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page HORN ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING HORNS INOPERATIVE 2 HORNS ALWAYS ON 5 BODY VERIFICATION TEST 7 SCHEMATICS AND DIAGRAMS 8 HORN ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH HORN 8H 1 ...

Page 908: ... HORNS INOPERATIVE 8H 2 HORN ELECTRICAL DIAGNOSTICS ZH ...

Page 909: ...HE HORNS Note Inspect the Horn Fuse F6 located in the Relay Control Module If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Relay Control Module connector E Note Check connectors Clean repair as necessary Connect a fused jumper wire from cavity 1 of the Relay Control Mod ule connector E to B Did the Horns sound Yes Go to 4 No Go to 2 ZH H...

Page 910: ... ness connector and ground Is the resistance below 5 0 ohms Yes Replace the Horn s Refer to 8 ELECTRICAL HORN HORN REMOVAL Perform BODY VERIFICATION TEST No Repair the Horn Ground circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE THE HORN SWITCH CIRCUIT RESISTANCE Disconnect the Relay Control Module harness connector D Note Check connectors Clean repair as necessary Measure the resistan...

Page 911: ... HORNS ALWAYS ON ZH HORN ELECTRICAL DIAGNOSTICS 8H 5 ...

Page 912: ...r the Horn circuit for a short to voltage Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE THE HORN SWITCH CIRCUIT VOLTAGE Disconnect the Relay Control Module harness connector D Note Check connector Clean repair as necessary Measure the resistance of the Horn Switch circuit between cavity 1 of the Relay Control Module connector D and ground Is the resistance below 5 0 ohms Yes Repair the Horn ...

Page 913: ...transmitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB III...

Page 914: ...SCHEMATICS AND DIAGRAMS 8H 8 HORN ELECTRICAL DIAGNOSTICS ZH ...

Page 915: ...S AND TESTING 13 REMOVAL 14 INSTALLATION 14 HORN RELAY DESCRIPTION 16 REMOVAL 17 INSTALLATION 17 HORN SERVICE INFORMATION DESCRIPTION A dual note electro magnetic Horn System is standard equipment on this model The horn circuit consists of a Horn Switch Fuse Horn Relay and Horns Both high and low note horn units are located behind the front grille ZH HORN SERVICE INFORMATION 8H 9 ...

Page 916: ...e Box 5 When the Horn Switch is depressed it completes the ground circuit to the horn relay The horn relay coil closes a set of contacts which allows current to flow to the Horns SPECIFICATIONS HORN TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs HORN MOUNTING BRACKET BOLT 11 8 100 HORN SWITCH RETAINING NUTS 5 44 8H 10 HORN SERVICE INFORMATION ZH ...

Page 917: ...HORN REMOVAL 1 Disconnect the negative battery cable 2 Remove the front grille Refer to 23 BODY EX TERIOR GRILLE REMOVAL 3 Disconnect the horn harness connector 1 ZH HORN SERVICE INFORMATION 8H 11 ...

Page 918: ...e 1 5 Remove the horn from the vehicle INSTALLATION 1 Position the horn s 1 onto the vehicle core sup port and install the horn bracket mounting bolt Tighten the bolt to 11 N m 100 in lbs 2 Connect the horn harness connector 3 Install the front grille Refer to 23 BODY EXTE RIOR GRILLE INSTALLATION 8H 12 HORN SERVICE INFORMATION ZH ...

Page 919: ...LD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The horn switch is comprised of two separate contact plates suspended by pre loaded springs It may be tested in the following manner 1 Disconnect the negative battery cable 2 Remove the driver airbag Refer to 8 ELECTRI CAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Disconnect the horn switch harness connectors 1 and 2 4 Using an ohmmet...

Page 920: ...onnect the negative battery cable 2 Remove the driver airbag Refer to 8 ELECTRI CAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Disconnect the horn switch harness connector 1 4 Remove the horn switch retaining nuts 2 and remove the horn switch from the steering wheel INSTALLATION WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNO...

Page 921: ...eload springs are centered over the mounting studs 2 2 Press downward evenly on the horn switch and install the horn switch retaining nuts Tighten the nuts to 5 N m 44 in lbs 3 Connect the horn switch harness connector 1 4 Install the airbag Refer to 8 ELECTRICAL RE STRAINTS DRIVER AIRBAG INSTALLATION 5 Connect the negative battery cable 2 ZH HORN SERVICE INFORMATION 8H 15 ...

Page 922: ...trol Module Box 3 on the passenger side of the engine compartment The Relay Control Module also contains the Fuse 2 for the horn relay circuitry The Relay Control Module cannot be adjusted or repaired If faulty or damaged the entire module must be replaced as an assembly 8H 16 HORN SERVICE INFORMATION ZH ...

Page 923: ...e relay control module Refer to 8 ELECTRICAL POWER DISTRIBUTION RELAY REMOVAL INSTALLATION 1 Install the relay control module Refer to 8 ELEC TRICAL POWER DISTRIBUTION RELAY INSTALLATION ZH HORN SERVICE INFORMATION 8H 17 ...

Page 924: ......

Page 925: ...S DESCRIPTION 1 SCHEMATICS AND DIAGRAMS 2 IGNITION SYSTEM ELECTRICAL DIAGNOSTICS DESCRIPTION The electrical diagnostic information for the Ignition System can be found in the appropriate diagnostic section The Ignition System Electrical Diagnostic section only contains the circuit diagram for a quick system overview For complete electrical diagnostics refer to the Engine Electrical Diagnostics sec...

Page 926: ...SCHEMATICS AND DIAGRAMS 8I 2 IGNITION SYSTEM ELECTRICAL DIAGNOSTICS ZH ...

Page 927: ... REMOVAL 7 INSTALLATION 7 IGNITION COIL DESCRIPTION 8 OPERATION 9 REMOVAL REMOVAL 10 REMOVAL SRT 11 INSTALLATION INSTALLATION 13 INSTALLATION SRT 15 KNOCK SENSOR DESCRIPTION 18 OPERATION 18 REMOVAL 19 INSTALLATION 19 SPARK PLUG DESCRIPTION 20 OPERATION 21 DIAGNOSIS AND TESTING SPARK PLUG CONDITIONS 22 REMOVAL 26 INSTALLATION 27 SPARK PLUG CABLE DESCRIPTION 28 OPERATION 29 REMOVAL 29 INSTALLATION 2...

Page 928: ...ck The camshaft position sensor is a hall effect device and the crankshaft position sensor is an inductive device The camshaft position sensor and crankshaft position sensor generate pulses that are inputs to the PCM The PCM determines engine position from these sensors The PCM calculates injector sequence and ignition timing based on crankshaft camshaft position The two spark plugs per cylinder a...

Page 929: ...e sensor 2 wire The Crankshaft Sensor is used to determine the crankshaft position and speed The Crankshaft Position Sensor is mounted on the left rear of the cylinder block Knock Sensors The knock sensors are Piezo type sensors The engine is equipped with two knock sensors The knock sensors monitor vibration of the crankcase and act to control timing on the relevant cylinder The Knock Sensors are...

Page 930: ...ertrain Control Module PCM The sensor generates pulses The PCM determines engine position from the Camshaft Position Sensor and Crankshaft Position Sensor inputs The PCM uses the sensor inputs to determine ignition coil timing and manage fuel injection syn chronization The Camshaft Position Sensor is a hall effect type sensor The Camshaft Position Sensor is used to determine when cylinder 1 is on ...

Page 931: ... retaining bolt 2 4 Remove the camshaft position sensor from the cyl inder head INSTALLATION Note Lubricate the camshaft position sensor O ring with engine oil 1 Inspect the camshaft position sensor O ring 1 for damage 2 Lubricate the camshaft position sensor O ring as necessary ZH IGNITION SYSTEM SERVICE INFORMATION 8I 7 ...

Page 932: ...ft position sensor harness con nector 1 6 Connect the negative battery cable IGNITION COIL DESCRIPTION The Ignition Coils are mounted on the cylinder head covers They are connected to the spark plugs via short spark plug cables The coils are a dual coil type construction Utilizing two separate coils in one coil pack 8I 8 IGNITION SYSTEM SERVICE INFORMATION ZH ...

Page 933: ... primary wind ings collapses The collapsing magnetic field induces a voltage into the secondary windings and creates a high voltage surge that is sent to the spark plug wire Each cylinder has a double coil set and its own ded icated spark plug wire The coils are controlled by the PCM The coils can be fired simultaneously or in phases The coils are phase shift triggered firing plugs A B then B A th...

Page 934: ...AL 1 Disconnect the negative battery cable 2 2 Remove the air cleaner inlet tubes 2 3 Remove the engine cover 1 Grasp both corners of the engine cover and pull up firmly 8I 10 IGNITION SYSTEM SERVICE INFORMATION ZH ...

Page 935: ...5 Disconnect the spark plug cables 4 from the spark plugs 6 Remove the ignition coil retaining bolt 2 7 Remove the ignition coil 3 from the cylinder head cover REMOVAL SRT 1 Disconnect the negative battery cable 2 ZH IGNITION SYSTEM SERVICE INFORMATION 8I 11 ...

Page 936: ...rs of the engine cover and pull up firmly 3 Remove the upper air cleaner housing by removing the inlet tube 2 and the retaining screws 1 Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 8I 12 IGNITION SYSTEM SERVICE INFORMATION ZH ...

Page 937: ...l mounting bolt 1 7 Remove the ignition coil from the engine INSTALLATION INSTALLATION 1 Position the ignition coil 3 on the cylinder head cover 2 Install the ignition coil retaining bolt 2 Tighten the bolt to 8 N m 71 in lbs 3 Connect the ignition coil wire harness connector 1 to the coil pack ZH IGNITION SYSTEM SERVICE INFORMATION 8I 13 ...

Page 938: ...priate spark plug location G K plug side Note Refer to the reference pad cast into the cyl inder head cover to identify proper spark plug spark plug cable orientation Note When installing spark plug cables insure a positive connection is made A snap should be felt when a good connection is made between the spark plug cable and the spark plug 6 Insure a firm connection is made from the spark plug c...

Page 939: ... engine cover apply a small amount of lubricant to the engine cover rubber mounts 8 Connect the negative battery cable INSTALLATION SRT 1 Position the ignition coil 3 on the cylinder head cover 2 Install the ignition coil retaining bolt 2 Tighten the bolt to 8 N m 71 in lbs 3 Connect the ignition coil wire harness connector 1 to the coil pack ZH IGNITION SYSTEM SERVICE INFORMATION 8I 15 ...

Page 940: ...priate spark plug location G K plug side Note Refer to the reference pad cast into the cyl inder head cover to identify proper spark plug spark plug cable orientation Note When installing spark plug cables insure a positive connection is made A snap should be felt when a good connection is made between the spark plug cable and the spark plug 6 Insure a firm connection is made from the spark plug c...

Page 941: ... cover 1 Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 9 Connect the negative battery cable ZH IGNITION SYSTEM SERVICE INFORMATION 8I 17 ...

Page 942: ...sends an input signal to the Powertrain Control Module PCM In response the PCM retards ignition timing for the affected cylinder The voltage signal produced by the knock sensor increases with the amplitude of vibration The PCM receives the knock sensor voltage signal as an input If the signal rises above a predetermined level the PCM will store that value in memory and retard ignition timing to re...

Page 943: ... at the knock sensors 1 3 Remove the retaining bolts 4 Remove the knock sensors from the engine block INSTALLATION Note The knock sensor bolt torque is higher than other sensors If the proper torque is not applied to the knock sensor driveability can be affected 1 Position the knock sensors 1 on the engine block 2 Install the knock sensor retaining bolts Tighten the bolts to 20 N m 15 ft lbs 3 Con...

Page 944: ...l service They have resistance values of 6 000 to 20 000 ohms when checked with at least a 1000 volt tester For spark plug identification and specifications Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS Do not use an ohm meter to check the resistance of the spark plugs This will give an inaccurate reading 8I 20 IGNITION SYSTEM SERVICE INFORMATION ZH ...

Page 945: ...accurate reading Spark plugs using either a single or double platinum tips 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 ser vice life of 75 000 miles for severe driving conditions A thin platinum pad is welded to the center electrode 2 ends Extreme care must be used to prevent spark plug cross thread...

Page 946: ...aused by coolant in the com bustion chamber Spark plug performance may be affected by MMT deposits COLD FOULING CARBON FOULING Cold fouling is sometimes referred to as carbon fouling The deposits that cause cold fouling are basically carbon A dry black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables Cold carbon fouling of the entire set of spark...

Page 947: ...ng may be traced to loose depos its in the combustion chamber These deposits 2 accumulate on the spark plugs during continuous stop and go driving When the engine is suddenly sub jected to a high torque load deposits partially liquefy and bridge the gap between electrodes 3 This short circuits the electrodes Spark plugs with electrode gap bridging 1 should be replaced ZH IGNITION SYSTEM SERVICE IN...

Page 948: ... electrode 1 and shell area may be heavy but the deposits are easily removed Spark plugs with scavenger deposits can be considered normal in con dition and can be cleaned using solvent CHIPPED ELECTRODE INSULATOR A chipped electrode insulator 3 usually results from bending the center electrode 2 while adjusting the spark plug electrode gap Under certain conditions severe detonation can also separa...

Page 949: ...ture of a particular type spark plug Spark plugs are designed to operate within specific temperature ranges This depends upon the thickness and length of the center electrode s porcelain insulator SPARK PLUG OVERHEATING Overheating is indicated by a white or gray center electrode insulator that also appears blistered The increase in electrode gap will be considerably in excess of the normal 0 025 ...

Page 950: ... boots 2 to remove them from the spark plugs Note Avoid allowing debris to fall into the spark plug holes during replacement 2 Clean the cylinder head spark plug recesses 2 using low pressure compressed air CAUTION Do not use power tools to replace spark plugs Damage to the cylinder head can result 3 Use a rubber insulated spark plug socket and a hand ratchet to remove the spark plugs 1 4 Remove t...

Page 951: ...N m 21 ft lbs Note When installing the spark plug cables route the cables correctly Failure to route the cables properly can cause improper spark plug phase shift 4 Install the spark plug cables to the appropriate spark plug location G K plug side Note Refer to the reference pad cast into the cyl inder head cover to identify proper spark plug spark plug cable orientation ZH IGNITION SYSTEM SERVICE...

Page 952: ...lug cables 2 to the spark plugs SPARK PLUG CABLE DESCRIPTION Spark Plug cables often referred to as secondary ignition wires transfer electrical current from the electronic Igni tion Coils to the individual spark plugs at each cylinder The resistive spark plug cables are of nonmetallic construc tion The cables provide suppression of radio frequency emissions from the ignition system 8I 28 IGNITION...

Page 953: ... shifting of the spark plugs Install spark plug insu lators over spark plugs Ensure the top of the spark plug insulator covers the upper end of the spark plug tube then connect the other end to coil pack REMOVAL CAUTION When disconnecting a high tension cable from a spark plug or from the ignition coil twist the rubber boot slightly 1 2 turn to break it loose Grasp the boot not the cable and pull ...

Page 954: ...rientation Note When installing spark plug cables insure a positive connection is made A snap should be felt when a good connection is made between the spark plug cable and the spark plug 3 Insure a firm connection is made from the spark plug cables 2 to the spark plugs 8I 30 IGNITION SYSTEM SERVICE INFORMATION ZH ...

Page 955: ...N FROM INSTRUMENT CLUSTER 17 NO COMMUNICATION TO INSTRUMENT CLUSTER 19 NO CAN COMMUNICATIONS WITH PCM 21 NO CAN COMMUNICATIONS WITH CAB 28 NO CAN COMMUNICATIONS WITH TCM 35 CAN BUS COMMUNICATION GENERAL MALFUNCTION 42 LEFT TURN SIGNAL INDICATOR INOPERATIVE 45 RIGHT TURN SIGNAL INDICATOR INOPERATIVE 47 HIGH BEAM INDICATOR INOPERATIVE 49 BRAKE WARNING INDICATOR INOPERATIVE 52 BATTERY VOLTAGE INDICAT...

Page 956: ...COOLANT LEVEL SENSOR WASHER FLUID LEVEL SWITCH CIRCUIT 8J 2 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 957: ... 8 ELECTRICAL INSTRUMENT CLUSTER STAN DARD PROCEDURE Perform BODY VERIFICATION TEST No Go to 2 2 INSPECT THE LOW WASHER FLUID INDICATOR LAMP With the ignition off Remove the Low Washer Fluid Indicator Lamp from the Instrument Cluster and inspect the lamp for an open fila ment Is the lamp filament open Yes Replace the Low Washer Fluid Indicator Lamp Refer to 8 ELECTRICAL INSTRUMENT CLUSTER STANDARD...

Page 958: ...R FLUID LEVEL SWITCH CIRCUIT RESISTANCE With the ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Coolant Level Sensor harness connector Connect a jumper wire between cavity 1 and cavity 2 of the Washer Fluid Level Switch harness connector Measure the resistance between cav...

Page 959: ...LAMP OUTAGE INDICATOR CIRCUIT ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 5 ...

Page 960: ...UMENT CLUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 THE LAMP OUTAGE INDICATOR LAMP INSTRUMENT CLUSTER Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Lamp Outage Indicator circuit at the Instru ment Cluster C1 harness connector Is the voltage above 10 volts Yes Inspect ...

Page 961: ...e Lamp Outage Indicator circuit from the Illumination Control Module D harness connector to the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms Yes Replace the Illumination Control Module Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST No Repair the Lamp Outage Indicator circuit for an open Perform BODY VERIFICATION TES...

Page 962: ...FUEL LEVEL SENSOR CIRCUIT 8J 8 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 963: ...ENT CLUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 MEASURE FUEL LEVEL SENSOR CIRCUIT VOLTAGE Turn the ignition off Disconnect the Fuel Level Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage between cavity 1 and cavity 2 of the Fuel Level Sensor harness connector Is the voltage approximately 7 of a volt Yes Replace the Fuel Level ...

Page 964: ... Level Sensor harness connector Measure the resistance of the Fuel Level Sensor circuit from cavity D4 to cavity D5 at the Instrument Cluster C2 harness connector Is the resistance below 5 0 ohms Yes Replace the Instrument Cluster Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER DIAGNOSIS AND TEST ING Perform BODY VERIFICATION TEST No Repair the appropriate Fuel Level Sensor circuit for an open Perform B...

Page 965: ...AMBIENT TEMPERATURE SENSOR CIRCUIT ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 11 ...

Page 966: ...LUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Ambient Temperature Sensor voltage Does the DRB IIIT display AMBIENT TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Ambient Temperature Se...

Page 967: ... AIR CONDITIONING CONTROLS AMBIENT TEMP SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Instrument Cluster harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Ambient Temperature Sensor Signal cir cuit from the Instrument Cluster harness connector...

Page 968: ... ELECTRI CAL INSTRUMENT CLUSTER REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Ambient Temperature Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT read the Ambient Temperat...

Page 969: ...Y VERIFICATION TEST No Go to 8 8 READ A C HEATER CONTROL MODULE DTC S WITH DRB IIIT Ensure the Ambient Temperature Sensor is connected at this time Start the engine Turn the A C system on and run for at least five minutes With the DRB IIIT read A C Heater Control Module DTC s Does the DRB IIIT display Ambient Temperature Sensor Failure DTC Yes Replace the Ambient Temperature Sensor Refer to 24 HEA...

Page 970: ...nd Perform BODY VERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE FROM THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance from the Ambient Temperature Sensor Signal circuit to the Sensor Ground circuit at the Ambient Temperature Sen sor connector Is the resistance below 1000 0 ohms Yes Repair the Ambient Temperature Sensor ...

Page 971: ...NO COMMUNICATION FROM INSTRUMENT CLUSTER ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 17 ...

Page 972: ...THE SERIAL COMMUNICATION K1 CIRCUIT Turn the ignition off Disconnect the Instrument Cluster harness connector Disconnect the A C Heater Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Serial Communication K1 circuit from the Instrument Cluster harness connector to the A C Heater Control Module harness connector Is the resistance below ...

Page 973: ...NO COMMUNICATION TO INSTRUMENT CLUSTER ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 19 ...

Page 974: ...HE SERIAL COMMUNICATION K2 CIRCUIT Turn the ignition off Disconnect the Instrument Cluster harness connector Disconnect the A C Heater Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Serial Communication K2 circuit from the Instrument Cluster harness connector to the A C Heater Control Module harness connector Is the resistance below 5...

Page 975: ...NO CAN COMMUNICATIONS WITH PCM ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 21 ...

Page 976: ...AIN CONTROL MODULE For a complete Instrument Cluster Circuit Diagram Refer to 8 ELECTRICAL INSTRUMENT CLUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF PCM DTCS ARE PRESENT Turn ignition on With the DRB IIIT read PCM DTCs Are any performance or Bus related DTCs present Yes Repair all PCM DTCs before proceeding Perform BODY VERIFICATION TEST No Go To 2 2 VERIFY DTCS With the igniti...

Page 977: ... circuit to the CAN C Bus circuit at the PCM C4 harness connector Is the SKREEM CAN C Bus termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform BODY VERIFICATION TEST No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the SKREEM CAN...

Page 978: ...5 0 ohms Yes Go To 7 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C Bus circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST 8J 24 INSTRUMENT CLU...

Page 979: ...s Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 9 9 CAN C BUS CIRCUIT SHORTED TO VOLTAGE With the ignition on Measure the voltage of the CAN C Bus circuit at the PCM C4 har ness connector Is the voltage above 1 0 volt Yes Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 10 ZH INSTRUMENT CLUSTER ELECTRICAL DIAG...

Page 980: ...he ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the Instru ment Cluster C1 harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C Bus circuit for an open between the PCM C4 harness and the Instrument Cluster C1 harness connecto...

Page 981: ...e Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a po...

Page 982: ...NO CAN COMMUNICATIONS WITH CAB 8J 28 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 983: ...WERTRAIN CONTROL MODULE For a complete Instrument Cluster Circuit Diagram Refer to 8 ELECTRICAL INSTRUMENT CLUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF CAB DTCS ARE PRESENT Turn ignition on With the DRB IIIT read CAB DTCs Are any performance or Bus related DTCs present Yes Repair all CAB DTCs before proceeding Perform BODY VERIFICATION TEST No Go To 2 2 VERIFY DTCS With the i...

Page 984: ... circuit to the CAN C Bus circuit at the PCM C4 harness connector Is the SKREEM CAN C Bus termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform BODY VERIFICATION TEST No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the SKREEM CAN...

Page 985: ...5 0 ohms Yes Go To 7 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C Bus circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST ZH INSTRUMENT CLUSTE...

Page 986: ...s Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 9 9 CAN C BUS CIRCUIT SHORTED TO VOLTAGE With the ignition on Measure the voltage of the CAN C Bus circuit at the PCM C4 har ness connector Is the voltage above 1 0 volt Yes Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 10 8J 32 INSTRUMENT CLUSTER ELECTRICAL D...

Page 987: ...LUSTER With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the CAB har ness connector to the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C Bus circuit for an open between the Instrument Cluster C1 harness and the CAB harness con nector Perform ...

Page 988: ...e Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a po...

Page 989: ...NO CAN COMMUNICATIONS WITH TCM ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 35 ...

Page 990: ...OWERTRAIN CONTROL MODULE For a complete Instrument Cluster Circuit Diagram Refer to 8 ELECTRICAL INSTRUMENT CLUSTER SCHE MATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF TCM DTCS ARE PRESENT Turn ignition on With the DRB IIIT read TCM DTCs Are any performance or Bus related DTCs present Yes Repair all TCM DTCs before proceeding Perform BODY VERIFICATION TEST No Go To 2 2 VERIFY DTCS With the ...

Page 991: ... circuit to the CAN C Bus circuit at the PCM C4 harness connector Is the SKREEM CAN C Bus termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform BODY VERIFICATION TEST No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the SKREEM CAN...

Page 992: ...5 0 ohms Yes Go To 7 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C Bus circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C Bus circuit for an open Perform BODY VERIFICATION TEST 8J 38 INSTRUMENT CLU...

Page 993: ...s Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 9 9 CAN C BUS CIRCUIT SHORTED TO VOLTAGE With the ignition on Measure the voltage of the CAN C Bus circuit at the PCM C4 har ness connector Is the voltage above 1 0 volt Yes Repair the CAN C Bus circuit for a short to voltage Perform BODY VERIFICATION TEST No Go To 10 ZH INSTRUMENT CLUSTER ELECTRICAL DIAG...

Page 994: ...R With the ignition off Disconnect the TCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the TCM C3 harness connector to the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C Bus circuit for an open between the Instrument Cluster C1 harness and the TCM C3 harness connector Perfor...

Page 995: ...e Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a po...

Page 996: ...CAN BUS COMMUNICATION GENERAL MALFUNCTION 8J 42 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 997: ...agnostic Test 1 MEASURE THE RESISTANCE OF THE CAN C BUS CIRCUIT Turn the ignition off Disconnect the Instrument Cluster harness connector Disconnect the harness connectors of the other modules on the CAN Bus network Note Check connectors Clean repair as necessary Measure the resistance of the CAN C Bus circuit from the Instru ment Cluster harness connector to the harness connectors of the other mo...

Page 998: ...e Instru ment Cluster harness connector to the harness connectors of the other modules on the CAN Bus network Is the resistance below 1 0 ohm Yes Replace the Instrument Cluster Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER REMOVAL Perform ABS VERIFICATION TEST No Repair the CAN C Bus circuit for an open Perform ABS VERIFICATION TEST 8J 44 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 999: ... LEFT TURN SIGNAL INDICATOR INOPERATIVE ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 45 ...

Page 1000: ...RD PROCEDURE Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE LEFT TURN SIGNAL INDICATOR DRIVER CIRCUIT RESISTANCE With the ignition off Disconnect the Remote Keyless Entry Relay Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Left Turn Signal Indicator Driver circuit from the RKE Relay harness connector cavity...

Page 1001: ... RIGHT TURN SIGNAL INDICATOR INOPERATIVE ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 47 ...

Page 1002: ...R STANDARD PROCEDURE Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE RIGHT TURN SIGNAL INDICATOR CIRCUIT RESISTANCE With the ignition off Disconnect the Remote Keyless Entry Relay Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Right Turn Signal Indicator circuit from the RKE Relay harness connector cavity 5 t...

Page 1003: ... HIGH BEAM INDICATOR INOPERATIVE ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 49 ...

Page 1004: ...ect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Turn the High Beams on Measure the voltage of the High Beam Indicator Lamp circuit at the Instrument Cluster C1 harness connector Is the voltage above 10 volts Yes Check the High Beam Indicator Lamp If the lamp is OK Replace the Instrument Cluster Refer to 8 ELECTRICAL INSTRUMENT CL...

Page 1005: ...r circuit from the Illu mination Control Module harness connector cavity 7 to the Instrument Cluster C1 harness connector cavity A2 Is the resistance below 5 0 ohms Yes Replace the Illumination Control Module Refer to 8 ELECTRICAL INSTRUMENT CLUSTER REMOVAL Perform BODY VERIFICATION TEST No Repair the High Beam Indicator circuit for an open Perform BODY VERIFICATION TEST ZH INSTRUMENT CLUSTER ELEC...

Page 1006: ... BRAKE WARNING INDICATOR INOPERATIVE 8J 52 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 1007: ...CATOR SWITCH Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Brake Fluid Level Switch harness connector Turn the ignition on Is the Brake Warning Indicator lamp on Yes Replace the Brake Fluid Level Switch Refer to 5 BRAKES ELECTRICAL BRAKE FLUID LEVEL SWITCH RE...

Page 1008: ...2 of the Brake Fluid Level Switch harness connector Measure the resistance between ground and the Brake Warning Indi cator circuit Is the resistance below 5 0 ohms Yes Check the Brake Warning Indicator lamp If the lamp is OK replace the Instrument Cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER REMOVAL Perform BODY VERIFICATION TEST No Repair the Brake Warning Indicator circuit for an open Perfo...

Page 1009: ... BATTERY VOLTAGE INDICATOR INOPERATIVE ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 55 ...

Page 1010: ...f Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Start the engine Measure the voltage of the Battery Voltage Indicator circuit at the Instrument Cluster harness connector Is the voltage above 10 volts Yes Check the Battery Voltage Indicator Lamp If the lamp is OK replace the Instrument Cluster Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER STANDAR...

Page 1011: ... Battery Voltage Indicator circuit from the Generator harness connector to the Instrument Cluster C1 harness connector Is the resistance below 5 0 ohms Yes Replace the Generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL Perform BODY VERIFICATION TEST No Repair the Battery Voltage Indicator circuit for an open Perform BODY VERIFICATION TEST ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 57 ...

Page 1012: ... SEAT BELT INDICATOR INOPERATIVE 8J 58 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 1013: ...n on Is the Seat Belt Indicator Lamp on Yes Replace the Seat Belt Indicator Switch Refer to 8 ELEC TRICAL RESTRAINTS SEAT BELT BUCKLE REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 SEAT BELT INDICATOR CIRCUIT Turn the ignition off Disconnect the Instrument Cluster C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Seat Belt Indic...

Page 1014: ... TELESCOPING WHEEL INDICATOR INOPERATIVE 8J 60 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 1015: ...t the lamp for an open fila ment Is the lamp filament open Yes Replace the Telescoping Wheel Indicator Lamp Refer to 8 ELECTRICAL INSTRUMENT CLUSTER STANDARD PROCEDURE Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE TELESCOPING WHEEL INDICATOR CIRCUIT RESISTANCE With the ignition off Disconnect the Instrument Cluster C2 harness connector Note Check connectors Clean repair as necessary With the...

Page 1016: ...tters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read ...

Page 1017: ...SCHEMATICS AND DIAGRAMS ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 63 ...

Page 1018: ...8J 64 INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS ZH ...

Page 1019: ...ZH INSTRUMENT CLUSTER ELECTRICAL DIAGNOSTICS 8J 65 ...

Page 1020: ...FSS MAINTENANCE INDICATOR AFTER AN OIL CHANGE 103 STANDARD PROCEDURE INSTRUMENT CLUSTER BULBS 106 REMOVAL REMOVAL INSTRUMENT CLUSTER 107 REMOVAL RHD 109 INSTALLATION INSTALLATION INSTRUMENT CLUSTER 110 INSTALLATION RHD 111 INSTRUMENT CLUSTER SERVICE INFORMATION DESCRIPTION DESCRIPTION The Instrument Cluster is used to inform the driver of important vehicle operating conditions and to warn the driv...

Page 1021: ...ure indicator lamp Left turn signal indicator lamp Right turn signal indicator lamp High beam indicator lamp Low fuel level indicator lamp Low washer fluid indicator lamp Low coolant level indicator lamp Battery voltage indicator lamp Seat belt indicator lamp Lamp outage indicator lamp Malfunction Indicator Lamp MIL Brake Assist System BAS MIL Electronic Stability Program ESP warning lamp Suppleme...

Page 1022: ...ing distance 1 or the remaining time 1 and the tool symbol 2 are displayed The FSS indicator 2 has its own microprocessor in the Instrument Cluster The FSS indicator 2 obtains time information from the digital clock integrated into the Instrument Cluster The other data required is obtained via the CAN data bus from the Controller Antilock Brake CAB and the Powertrain Control Module PCM The followi...

Page 1023: ...ectronic Programmable Read Only Memory EEPROM The indicator lamps are listed below according to their type and actuation method hard wired or CAN Bus HARD WIRE ACTUATED INDICATOR LAMPS Left turn signal indicator lamp Right turn signal indicator lamp High beam indicator lamp Low fuel level indicator lamp Low washer fluid indicator lamp Low coolant level indicator lamp Battery voltage indicator lamp...

Page 1024: ...Wheel Speed Sensors WSS signals for calculating vehicle speed and distance from the CAB Coolant temperature from the PCM Engine speed from the PCM Load torque from the PCM OPERATION OPERATION INSTRUMENT CLUSTER GAUGES The Instrument Cluster is made up of four analog gauges Speedometer The speedometer has a 0 160 Miles Per Hour MPH primary scale with Kilometers Per Hour km h on the secondary scale ...

Page 1025: ...achometer The tachometer also contains the digital clock and the transmission range indicator Coolant Temperature The temperature gauge is displayed as C Cold and H Hot There are varying incremental designations between C and H Fuel Level The fuel level gauge is displayed in increments of one quarter marks displaying F Full 1 2 one half tank and E Empty ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J...

Page 1026: ...Pressing the control dial to the left 3 of the speedometer resets the trip odometer One press is used if the ignition switch is in the RUN position two presses with the ignition switch in other positions or with the key removed The trip and cumu lative odometer displays are also used to indicate engine oil level Tachometer The two digital displays integrated in the tachometer will display the tran...

Page 1027: ...o the right of the Tachometer All of the indicator lamps illuminate each time the engine is started to verify system operation and to perform an Instrument Cluster bulb check The following eighteen indica tors are present WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIR BAG SEAT BELT...

Page 1028: ... did not have ABS Battery Voltage Indicator Lamp The Battery voltage indicator lamp illuminates when the charging system falls below current demand caus ing the battery to not receive a full charge during operation Brake Assist System Indicator Lamp BAS Elec tronic Stability Program ESP The BAS ESP indicator lamp illuminates if there is a malfunction in the BAS ESP If the BAS ESP indicator lamp il...

Page 1029: ...ndicator lamp 1 located between the left and right turn signal indica tors illuminates when the ESP system is deactivated ESP deactivation is performed by depressing the ESP button located on the center console The ESP indi cator lamp will also flash if the system is activated and there is a lose of traction When the Electronic Stabil ity Program is activated the ESP indicator lamp will remain off...

Page 1030: ... column Lamp Outage Indicator Lamp The Lamp outage indicator lamp illuminates if there is an exterior lamp failure such as a headlamp or tail lamp failure Low Coolant Indicator Lamp The Low coolant indicator lamp illuminates if the engine coolant drops below its threshold indicating a low engine coolant level 8J 76 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1031: ...cate a low fuel level Low Tire Pressure Indicator Lamp The Low tire pressure indicator lamp illuminates if any tire should experience a drop in pressure or if a tire is over inflated above the recommended pressure Low Washer Fluid Indicator Lamp The Low washer fluid indicator lamp illuminates to indicate a low windshield washer fluid level ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 77 ...

Page 1032: ...ssion Control Mod ule TCM Oil Level Indicator Lamp The Oil level indicator lamp illuminates if the engine oil drops below 4 25 liters 4 5 quarts indicating that the engine oil has dropped by 1 9 liters 2 quarts Seat Belt Indicator Lamp The Seat belt indicator lamp illuminates if the driver s seat belt is not buckled 8J 78 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1033: ... to operate 1 Turn signal indicator Activating the turn signal switch is indicated audibly by the turn signal indicator ticking The driver s attention is brought to a problem in the turn signal system by the turn signal indicator ticking at a higher frequency The turn signal indicator ticking is generated electromagnetically The frequency corresponds to that of the turn signal indi cator lamp 2 Pa...

Page 1034: ...CAB Malfunction Indicator Lamp MIL from the PCM Electronic Stability Program ESP indicator lamp from the CAB The lamp is illuminated if there is a fault in the ESP system or whenever the system is making compensations for driving conditions CAN DATA BUS ACTUATED INSTRUMENTS Odometer 1 the input is transmitted by the Controller Antilock Brake CAB and is deter mined using input from the four wheel s...

Page 1035: ...i vate when a door is opened when the ignition switch is in the ON RUN position or by pressing the lamp intensity adjustment knob when the ignition is off CONTROL BUTTONS The Instrument Cluster has two control dials which are to the left and right of the speedometer face The right control dial 2 is used to adjust the time Refer to the Owner s Manual The left control dial 3 is used to regulate the ...

Page 1036: ... temperatures are displayed after a delay of approx imately 5 minutes At vehicle speeds over 60 km h 37 MPH outside air temperatures are displayed after a delay of approxi mately 2 minutes FLEXIBLE SERVICE SYSTEM FSS MAINTENANCE INDICATOR The FSS maintenance indicator informs the driver when maintenance is due The FSS maintenance indi cator operates based on distance traveled and time between serv...

Page 1037: ...e specified between two FSS maintenance intervals The remaining time means the time remaining until the next FSS maintenance service is due The remaining time is strictly a time criterion The remaining time is reduced by one day each day regardless of the mileage The tool symbol 2 the current remain ing time 1 and 9D9 for days will appear for 10 seconds and automatically with the ignition switch i...

Page 1038: ...ut seen on the Instrument Cluster The Electronic Sta bility Program ESP indicator lamp located between the left and right turn signals in the speed ometer face illuminates when it is activated by the Controller Antilock Brake CAB indicating the need to adjust driving behavior to the prevailing road conditions Also located in the speedometers face are the trip odometer and the Flexible Service Syst...

Page 1039: ...fuel level gauge is displayed in increments of one quarter marks displaying F Full 1 2 one half tank and E Empty The temperature gauge is dis played as H Hot and C Cold The outside ambient air temperature digital display is located in the lower center portion of the coolant tem perature fuel gauge and is calibrated in degrees Centigrade C ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 85 ...

Page 1040: ...and the speedometer resets the digital clock The trip odometer 1 can be reset at anytime The odometer 1 display also shows the distance remain ing to the next regular maintenance service as calcu lated by the FSS Pressing the dial to the left 3 of the speedometer resets the trip odometer One press is used if the ignition switch is in the RUN position two presses with the ignition switch in other p...

Page 1041: ...ine is started to verify system operation and to perform an Instrument Cluster bulb check The following Instrument Cluster indicators are present WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIR BAG SEAT BELT TENSIONER FRONT IMPACT SENSORS SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMP...

Page 1042: ... it did not have ABS 3 Battery Voltage Indicator Lamp The Battery volt age indicator lamp illuminates when the charging system falls below current demand causing the battery to not receive a full charge during operation 4 Brake Assist Indicator Lamp BAS Electronic Stability Program ESP The BAS ESP indicator lamp illuminates if there is a malfunction in the BAS ESP If the BAS ESP indicator lamp ill...

Page 1043: ...luid in the brake fluid reservoir drops below the mini mum level indicated on the side of the brake fluid Reservoir 6 Brake Wear Indicator Lamp The Brake wear indi cator lamp illuminates when the front brake pads reach their replacement threshold ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 89 ...

Page 1044: ...again deactivating the system When the Electronic Stability Program is activated the ESP indicator lamp will illuminate to warn the driver of compensations being made by the ESP system 8 High Beam Indicator Lamp The High beam indi cator lamp illuminates when the high beam lamps are activated by the multifunction switch located in the steering column 9 Lamp Outage Indicator Lamp The Lamp outage ind...

Page 1045: ...ning Lamp The Low fuel warning lamp located on the left side of the cluster illumi nates when the fuel level in the fuel tank reaches approximately 8 liters 2 1 gallons to indicate a low fuel level 12 Low Washer Fluid Indicator Lamp The Low washer fluid indicator lamp illuminates to indicate a low windshield washer fluid level ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 91 ...

Page 1046: ...present in the Powertrain Control Module PCM or Transmission Control Module TCM 14 Oil Level Indicator Lamp The Oil level indicator lamp illuminates if the engine oil drops below 4 25 liters 4 5 quarts indicating that the engine oil has dropped by 1 9 liters 2 quarts 8J 92 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1047: ...vehicle is unoccupied will not trigger this warning Release the parking brake Switch off headlamps Remove the key from the ignition Turn signal indicator ticking activating the turn signal switch is indicated audibly by the turn signal indicator tick ing The driver s attention is brought to a problem in the turn signal system by the turn signal indicator ticking at a higher frequency The turn sign...

Page 1048: ...em or whenever the system is making compensations for driving conditions INSTRUMENTS ACTUATED BY THE CAN DATA BUS Odometer 1 the input is transmitted by the Controller Antilock Brake CAB and is deter mined using input from the four wheel speed sensors Speedometer the input is transmitted by the Controller Antilock Brake CAB and is deter mined using input from the four wheel speed sensors The indiv...

Page 1049: ...N RUN position or by press ing the lamp intensity adjustment knob when the igni tion is off CONTROL BUTTONS The Instrument Cluster has two control dials 2 and 3 which are to the left and right of the speedometer face The right push button 2 is used to adjust the time Refer to the Owner s Manual The left push button 3 is used to regulate the instrument illumination activate the display illumi natio...

Page 1050: ...icle speeds over 60 km h 37 MPH outside air temperatures are displayed after a delay of approxi mately 2 minutes FLEXIBLE SERVICE SYSTEM FSS MAINTENANCE INDICATOR The FSS maintenance indicator informs the driver when maintenance is due The FSS maintenance indi cator operates based on distance traveled and time between service criteria After exceeding a total dis tance or total time set at the fact...

Page 1051: ...ining time means the time remaining until the next FSS maintenance service is due The remaining time is strictly a time criterion The remaining time is reduced by one day each day regardless of the mileage The tool symbol 2 the current remain ing time 1 and 9D9 for days will appear for 10 seconds and automatically with the ignition switch in the RUN position after 5 seconds or while driving when t...

Page 1052: ... indicator lamps and malfunction indicator lamps illumi nate 2 Start the engine all of the indicator lamps and malfunction indicator lamps extinguish at an engine speed of 480 RPM if the systems are functioning correctly 3 The following indicator lamps and malfunction indicator lamps extinguish independently of the engine running SRS malfunction indicator lamp after approximately 4 seconds and the...

Page 1053: ...auge must indicate according to operating conditions seen with the DRB IIIT WARNING CHIME OPERATIONAL CHECK The light outage indicator lamp parking brake warning key in ignition warning and the seat belt reminder warning chime stays on for approximately 6 seconds The seat belt warning chime will be interrupted as soon as the driver s seat belt is inserted into the seat belt buckle ZH INSTRUMENT CL...

Page 1054: ...tton twice within 1 second The tool symbol 2 will appear and the cur rent remaining distance appear for 10 seconds STANDARD PROCEDURE DISPLAY OF REMAINING FSS MILEAGE AT DRIVER S REQUEST The remaining FSS mileage 1 can be displayed at the request of the driver 8J 100 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1055: ...econd period RESETTING THE FSS MAINTENANCE INDICATOR The FSS maintenance indicator can be reset to the total mileage 1 or total time in two ways 1 Automatically when the odometer 1 is reset to 0 within the first 155 miles The FSS maintenance indicator is reset to the values set at the factory 2 Manually by the driver ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 101 ...

Page 1056: ...ial 3 depressed 2 Simultaneously move the ignition switch to the RUN position 3 3 Continue to hold the control dial 3 down for 10 seconds After the audible tone 15000 km 7 500 miles appears on the display The remaining mile age 1 is displayed again 8J 102 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1057: ...ch to the RUN position 3 2 Within 4 seconds of moving the ignition switch into the RUN position press the reset button for the trip odometer 3 twice within one second The dis play for the FSS service request 1 is activated for 10 seconds ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 103 ...

Page 1058: ...d move the ignition switch to the OFF position 1 The FSS service request will continue to be displayed 4 Press the reset button 3 for the trip odometer 1 and hold 5 Move the ignition switch to the RUN position 3 8J 104 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1059: ...reset button for the trip odometer about 10 seconds until the audible signal sounds and the new start distance appears 1 in the display 7 The tool symbol 2 should disappear at this time ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 105 ...

Page 1060: ...EMOVAL 1 Remove the Instrument Cluster Refer to 8 ELECTRICAL INSTRUMENT CLUSTER REMOVAL 2 To remove the Instrument Cluster bulbs turn the bulb counter clockwise and remove it from the back of the Instrument Cluster housing 8J 106 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1061: ...bs place the bulb into the Instrument Cluster housing back and then turn the bulb clockwise until it locks 2 Install the Instrument Cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER INSTALLATION REMOVAL REMOVAL INSTRUMENT CLUSTER ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 107 ...

Page 1062: ...Instrument Clus ter outer bezel carefully pry the bezel from the top edge to disengage the retaining tabs from the Instrument Panel 5 Remove the retaining screws from Instrument Clus ter 6 Rotate the Instrument Cluster away from the Instru ment Panel 7 Disconnect the Instrument Cluster harness connec tors from the back of the Instrument Cluster 8 Remove the Instrument Cluster from the vehicle 8J 1...

Page 1063: ...REMOVAL 4 Remove the Instrument Cluster bezel 1 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 5 Remove the retaining screws from Instrument Clus ter 6 Move the Instrument Cluster toward the rear of the vehicle 7 Unlock and disconnect the Instrument Cluster har ness connectors from the back of the Instrument Cluster 8 Remove the Instrument Cluster from the vehicle ZH INSTRUMEN...

Page 1064: ... 2 Connect the Instrument Cluster harness connectors 3 Install the retaining screws to the Instrument Cluster 4 Install the Instrument Cluster outer bezel 1 Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY INSTALLATION 8J 110 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1065: ...WHEEL INSTALLA TION 7 Connect the negative battery cable INSTALLATION RHD 1 Install the Instrument Cluster 2 Connect and lock the Instrument Cluster harness connectors 3 Install the retaining screws to the Instrument Clus ter 4 Install the Instrument Cluster bezel 1 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION ZH INSTRUMENT CLUSTER SERVICE INFORMATION 8J 111 ...

Page 1066: ...Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY INSTALLATION 6 Install the steering wheel Refer to 19 STEER ING COLUMN STEERING WHEEL INSTALLA TION 7 Connect the negative battery cable 8J 112 INSTRUMENT CLUSTER SERVICE INFORMATION ZH ...

Page 1067: ...20 LEFT HIGH BEAM HEADLAMP INOPERATIVE 23 RIGHT LOW BEAM HEADLAMP INOPERATIVE 26 RIGHT HIGH BEAM HEADLAMP INOPERATIVE 29 LEFT FRONT SIDE MARKER LAMP INOPERATIVE 32 RIGHT FRONT SIDE MARKER LAMP INOPERATIVE 35 LEFT REAR SIDE MARKER LAMP INOPERATIVE 38 RIGHT REAR SIDE MARKER LAMP INOPERATIVE 41 LEFT TAIL LAMP INOPERATIVE 44 LEFT STOP LAMP INOPERATIVE 47 LEFT BACK UP LAMP INOPERATIVE 50 LEFT REAR TURN...

Page 1068: ... LEFT FOG LAMP INOPERATIVE 8L 2 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1069: ...n filament Is the Bulb filament open Yes Replace the Left Fog Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR FOG LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Fog Lamp harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance of the ...

Page 1070: ...LAMPS LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT FOG LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the fog lamps off Measure the resistance between ground and the Left Fog Lamp har ness connector cavity 1 Is the resistance below 5 0 ohms Yes Ensure that the Left Fog Lamp bulb is installed properly and replace the bulb socket if necessary Pe...

Page 1071: ... RIGHT FOG LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 5 ...

Page 1072: ...or an open filament Is the Bulb filament open Yes Replace the Right Fog Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR FOG LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Fog Lamp harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resista...

Page 1073: ...S LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT FOG LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the fog lamps off Measure the resistance between the Right Fog Lamp harness connec tor cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Fog Lamp bulb is installed properly and replace the bulb socket if necessary Per...

Page 1074: ... LEFT PARK LAMP INOPERATIVE 8L 8 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1075: ...he Left Park Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Park Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR FRONT POSITION LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Park Lamp harness connector Disconnect the Illumination Control Module harness connector Note Check connector...

Page 1076: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT PARK LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the park lamps off Measure the resistance between the Left Park Lamp harness connec tor cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Park Lamp bulb is installed properly and replace the bulb socket if necessary Perform ...

Page 1077: ... LEFT FRONT TURN LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 11 ...

Page 1078: ...mp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Front Turn Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Front Lamp Assembly harness connector Disconnect the Multi Function Switch harness connector Note Check connectors Clean repai...

Page 1079: ... MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT FRONT TURN LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the left turn signal off Measure the resistance between the Left Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Front Turn Lamp bulb is installed properly and replace the bulb socket i...

Page 1080: ... RIGHT PARK LAMP INOPERATIVE 8L 14 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1081: ...ve the Right Park Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Park Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Park Lamp harness connector Disconnect the Illumination Control Module harness connector Note Check connectors...

Page 1082: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT PARK LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the park lamps off Measure the resistance between the Right Park Lamp harness con nector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Park Lamp bulb is installed properly and replace the bulb socket if necessary Perfo...

Page 1083: ... RIGHT FRONT TURN LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 17 ...

Page 1084: ...mp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Front Turn Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Front Lamp Assembly harness connector Disconnect the Multi Function Switch harness connector Note Check connectors Clean rep...

Page 1085: ... MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT FRONT TURN LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the right turn signal off Measure the resistance between the Right Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Front Turn Lamp bulb is installed properly and replace the bulb sock...

Page 1086: ... LEFT LOW BEAM HEADLAMP INOPERATIVE 8L 20 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1087: ...lb filament open Yes Replace the Left Low Beam Headlamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERI OR HEADLAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Front Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance betwee...

Page 1088: ...HTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT LOW BEAM HEADLAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the low beam headlamps off Measure the resistance between the Left Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Low Beam Headlamp bulb is installed properly and replace th...

Page 1089: ... LEFT HIGH BEAM HEADLAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 23 ...

Page 1090: ...ulb filament open Yes Replace the Left High Beam Headlamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERI OR HEADLAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Front Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance betw...

Page 1091: ...HTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT HIGH BEAM HEADLAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the high beam headlamps off Measure the resistance between the Left Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left High Beam Headlamp bulb is installed properly and replace...

Page 1092: ... RIGHT LOW BEAM HEADLAMP INOPERATIVE 8L 26 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1093: ...n filament Is the Bulb filament open Yes Replace the Right Low Beam Headlamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR HEADLAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Front Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure...

Page 1094: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT LOW BEAM HEADLAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the low beam headlamps off Measure the resistance between the Right Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Low Beam Headlamp bulb is installed properly and replace ...

Page 1095: ... RIGHT HIGH BEAM HEADLAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 29 ...

Page 1096: ...and inspect for an open filament Is the Bulb filament open Yes Replace the Right High Beam Headlamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR HEADLAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Front Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repa...

Page 1097: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT HIGH BEAM HEADLAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the high beam headlamps off Measure the resistance between the Right Front Lamp Assembly har ness connector cavity 2 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right High Beam Headlamp bulb is installed properly and repla...

Page 1098: ... LEFT FRONT SIDE MARKER LAMP INOPERATIVE 8L 32 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1099: ...nt Side Marker Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Front Side Marker Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Front Side Marker Lamp harness connector Disconnect the Illumination Control Module harness connector...

Page 1100: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT FRONT SIDE MARKER LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the side marker lamps off Measure the resistance between the Left Front Side Marker Lamp har ness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Front Side Marker Lamp bulb is installed properly and...

Page 1101: ... RIGHT FRONT SIDE MARKER LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 35 ...

Page 1102: ...Front Side Marker Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Front Side Marker Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Front Side Marker Lamp harness connector Disconnect the Illumination Control Module harness conn...

Page 1103: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT FRONT SIDE MARKER LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the side marker lamps off Measure the resistance between the Right Front Side Marker Lamp harness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Front Side Marker Lamp bulb is installed properly a...

Page 1104: ... LEFT REAR SIDE MARKER LAMP INOPERATIVE 8L 38 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1105: ...ar Side Marker Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Rear Side Marker Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Rear Side Marker Lamp harness connector Disconnect the Illumination Control Module harness connector N...

Page 1106: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT REAR SIDE MARKER LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the side marker lamps off Measure the resistance between the Left Rear Side Marker Lamp har ness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Rear Side Marker Lamp bulb is installed properly and re...

Page 1107: ... RIGHT REAR SIDE MARKER LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 41 ...

Page 1108: ... Rear Side Marker Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Rear Side Marker Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTE RIOR MARKER LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Rear Side Marker Lamp harness connector Disconnect the Illumination Control Module harness connec...

Page 1109: ...TING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT REAR SIDE MARKER LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the side marker lamps off Measure the resistance between the Right Rear Side Marker Lamp harness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Rear Side Marker Lamp bulb is installed properly and ...

Page 1110: ... LEFT TAIL LAMP INOPERATIVE 8L 44 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1111: ... Stop Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Tail Stop Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connect...

Page 1112: ...Module Perform BODY VERIFICATION TEST 4 MEASURE LEFT TAIL STOP LAMP GROUND CIRCUIT RESISTANCE Turn the tail lamps off Measure the resistance between the Left Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Tail Stop Lamp bulb is installed prop erly and replace the bulb socket if necessary Perform BODY VERIFICATION TEST No Repair the Left R...

Page 1113: ... LEFT STOP LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 47 ...

Page 1114: ...ent Is the Bulb filament open Yes Replace the Left Tail Stop Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the res...

Page 1115: ...Module Perform BODY VERIFICATION TEST 4 MEASURE LEFT TAIL STOP LAMP GROUND CIRCUIT RESISTANCE Release the brake pedal Measure the resistance between the Left Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Tail Stop Lamp bulb is installed prop erly and replace the bulb socket if necessary Perform BODY VERIFICATION TEST No Repair the Left R...

Page 1116: ... LEFT BACK UP LAMP INOPERATIVE 8L 50 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1117: ...spect for an open filament Is the Bulb filament open Yes Replace the Left Back Up Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BACKUP LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessa...

Page 1118: ...dule Perform BODY VERIFICATION TEST 4 MEASURE LEFT BACK UP LAMP GROUND CIRCUIT RESISTANCE Move the transmission shift lever into park Turn the ignition off Measure the resistance between the Left Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Back Up Lamp bulb is installed prop erly and replace the bulb socket if necessary Perform BODY VE...

Page 1119: ... LEFT REAR TURN LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 53 ...

Page 1120: ...p bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Left Rear Turn Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Left Rear Lamp Assembly harness connector Disconnect the Multi Function Switch harness connector Note Check connectors Clean repai...

Page 1121: ...R MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LEFT REAR TURN LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the left turn signal off Measure the resistance between the Left Rear Lamp Assembly har ness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Left Rear Turn Lamp bulb is installed properly and replace the bulb socket if ...

Page 1122: ... RIGHT TAIL LAMP INOPERATIVE 8L 56 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1123: ...il Stop Lamp bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Tail Stop Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check con...

Page 1124: ...Module Perform BODY VERIFICATION TEST 4 MEASURE RIGHT TAIL STOP LAMP GROUND CIRCUIT RESISTANCE Turn the tail lamps off Measure the resistance between the Right Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Tail Stop Lamp bulb is installed properly and replace the bulb socket if necessary Perform BODY VERIFICATION TEST No Repair the Righ...

Page 1125: ... RIGHT STOP LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 59 ...

Page 1126: ...ent Is the Bulb filament open Yes Replace the Right Tail Stop Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the r...

Page 1127: ...Module Perform BODY VERIFICATION TEST 4 MEASURE RIGHT TAIL STOP LAMP GROUND CIRCUIT RESISTANCE Release the brake pedal Measure the resistance between the Right Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Tail Stop Lamp bulb is installed properly and replace the bulb socket if necessary Perform BODY VERIFICATION TEST No Repair the Righ...

Page 1128: ... RIGHT BACK UP LAMP INOPERATIVE 8L 62 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1129: ...spect for an open filament Is the Bulb filament open Yes Replace the Right Back Up Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BACKUP LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Rear Lamp Assembly harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as neces...

Page 1130: ...dule Perform BODY VERIFICATION TEST 4 MEASURE RIGHT BACK UP LAMP GROUND CIRCUIT RESISTANCE Move the transmission shift lever into park Turn the ignition off Measure the resistance between the Right Rear Lamp Assembly har ness connector and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Back Up Lamp bulb is installed properly and replace the bulb socket if necessary Perform BODY ...

Page 1131: ... RIGHT REAR TURN LAMP INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 65 ...

Page 1132: ...p bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Right Rear Turn Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Right Rear Lamp Assembly harness connector Disconnect the Multi Function Switch harness connector Note Check connectors Clean rep...

Page 1133: ... MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE RIGHT REAR TURN LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the right turn signal off Measure the resistance between the Right Rear Lamp Assembly har ness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Right Rear Turn Lamp bulb is installed properly and replace the bulb socket ...

Page 1134: ... CENTER HIGH MOUNTED STOP LAMP INOPERATIVE 8L 68 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1135: ...ectors Clean repair as necessary Measure the resistance between the Center High Mounted Stop Lamp harness connector and the Illumination Control Module harness con nector Is the resistance below 5 0 ohms Yes Go to 2 No Repair the Fused B circuit for an open between the Center High Mounted Stop Lamp and the Illumination Con trol Module Perform BODY VERIFICATION TEST 2 MEASURE CENTER HIGH MOUNTED ST...

Page 1136: ...Stop Lamp harness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Replace the Center High Mounted Stop Lamp Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR CENTER HIGH MOUNTED STOP LAMP REMOVAL Perform BODY VERIFICATION TEST No Repair the Center High Mounted Stop Lamp ground circuit for an open Perform BODY VERIFICATION TEST 8L 70 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1137: ... LICENSE LAMP NO 1 INOPERATIVE ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 71 ...

Page 1138: ...ilament Is the Bulb filament open Yes Replace the License Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR LICENSE PLATE LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the License Lamp No 1 harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistan...

Page 1139: ...MPS LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LICENSE LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the license lamps off Measure the resistance between the License Lamp No 1 harness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the License Lamp bulb is installed properly and replace the bulb socket if necessary...

Page 1140: ... LICENSE LAMP NO 2 INOPERATIVE 8L 74 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1141: ...ilament Is the Bulb filament open Yes Replace the License Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR LICENSE PLATE LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the License Lamp No 2 harness connector Disconnect the Illumination Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistan...

Page 1142: ...MPS LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE LICENSE LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the license lamps off Measure the resistance between the License Lamp No 2 harness connector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the License Lamp bulb is installed properly and replace the bulb socket if necessary...

Page 1143: ...rs and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTC...

Page 1144: ...SCHEMATICS AND DIAGRAMS 8L 78 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1145: ...ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 79 ...

Page 1146: ...8L 80 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1147: ...ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 81 ...

Page 1148: ...8L 82 LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1149: ...ZH LAMPS LIGHTING EXTERIOR ELECTRICAL DIAGNOSTICS 8L 83 ...

Page 1150: ...ON 102 REMOVAL 102 INSTALLATION 103 HEADLAMP DESCRIPTION 104 OPERATION 104 REMOVAL LOW BEAM BULB 104 REMOVAL HIGH BEAM BULB 105 INSTALLATION LOW BEAM BULB 106 INSTALLATION HIGH BEAM BULB 106 HEADLAMP LEVELING MOTOR EXPORT DESCRIPTION 106 OPERATION 107 DIAGNOSIS AND TESTING HEADLAMP LEVELING MOTOR EXPORT 107 HEADLAMP LEVELING SYSTEM 108 REMOVAL 108 INSTALLATION 108 HEADLAMP LEVELING SWITCH EXPORT D...

Page 1151: ...rrosion If a socket has become corroded clean the socket and bulb base with an abrasive fiber sanding pad or metallic bristle brush Replace sockets and bulbs that are deformed from corrosion that could prevent a continuous body ground Wire connectors can make intermittent contact or become corroded Before coupling wire connectors inspect the terminals inside the connector Male terminals should not...

Page 1152: ...wire connectors multifunction switch and headlamp switch Each vehicle is equipped with various lamp assemblies 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 bulbs check the socket for loose pin connections and or evidence of corrosion Repair as neces sary...

Page 1153: ...1 Test and repair charging system 2 Both headlamp bulbs defective 2 Replace both headlamp bulbs HEADLAMPS FLASH RANDOMLY 1 Faulty headlamp switch 1 Replace headlamp switch 2 Loose or corroded terminals or splices in circuit 2 Inspect and repair all connectors and splices HEADLAMPS DO NOT ILLUMINATE 1 No voltage to headlamps 1 Check fuse If good repair open headlamp circuit 2 No ground at headlamps...

Page 1154: ...ull it from the rear lamp unit 4 Remove the bulb from backup lamp socket INSTALLATION 1 Install the bulb 2 into the backup lamp socket 1 2 Insert the backup lamp socket 1 into the rear lamp unit 4 and rotate clockwise to lock 3 Install the access panel onto the interior trim panel 4 Connect the negative battery cable 8L 88 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION ZH ...

Page 1155: ...N TRANSAXLE MANUAL BACKUP LAMP SWITCH REMOVAL BACKUP LAMP SWITCH Automatic Transmission The Backup Lamp Switch for automatic transmission models is an integrated component of the shifter mechanism 4 and cannot be adjusted or repaired If faulty worn or damaged the entire shifter mechanism assembly must be replaced For complete Backup Lamp Switch removal procedures refer to Shifter Mechanism removal...

Page 1156: ...he coil windings The field draws the moveable relay contact point away from its normal resting position and holds it against the contact point The brake lamp relay terminals are connected to the vehicles electrical system through a connector recepta cle in the Underhood Accessory Fuse Block REMOVAL 1 Disconnect the negative battery cable 2 Remove the underhood accessory fuse block cover and relay ...

Page 1157: ...ws the brake lamps and Center High Mounted Stop Lamp to illuminate When the brake pedal is released the plunger returns to its rested position and the brake lamp relay is de energized As the relay is de energized the brake lamps are again returned to their off state REMOVAL The Brake Switch BAS Solenoid Valve is part of the Brake Booster Assembly Refer to the Power Brake Booster removal procedure ...

Page 1158: ...trical diagnostics in this section REMOVAL REMOVAL COUPE 1 Disconnect the negative battery cable 2 Remove the liftgate interior trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 3 Remove the retaining screws 2 from the liftgate 4 Disconnect the Center High Mounted Stop Lamp CHMSL harness connector 3 5 Slide the CHMSL assembly 1 outward and remove from the liftgate REMO...

Page 1159: ... and remove the sup port bracket 1 from the decklid 7 Disconnect the Center High Mounted Stop Lamp CHMSL harness connector 1 8 Remove the attaching screws 2 for the Center High Mounted Stop Lamp CHMSL harness con nector 1 9 Remove the Center High Mounted Stop Lamp CHMSL from the vehicle ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 93 ...

Page 1160: ...r 3 Install the liftgate interior trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 4 Connect the negative battery cable INSTALLATION ROADSTER 1 Insert the Center High Mounted Stop Lamp CHMSL assembly into the decklid install the retaining screws 2 and tighten 2 Connect the CHMSL harness connector 1 8L 94 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION ZH ...

Page 1161: ...ATE TAILGATE TRIM PANEL INSTALLATION 5 Connect the negative battery cable FOG LAMP REMOVAL 1 Disconnect the negative battery cable 2 Raise and support the vehicle 3 Rotate the steering wheel fully in one direction and open the access panel 1 in the front inner fender liner ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 95 ...

Page 1162: ...he fog lamp bulb 2 counterclockwise and remove from the fog lamp unit 3 INSTALLATION 1 Insert and rotate the fog lamp bulb 2 clockwise into the fog lamp unit 3 2 Connect the fog lamp harness connector 1 to the fog lamp bulb 2 8L 96 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION ZH ...

Page 1163: ...hicle 5 Connect the negative battery cable FOG LAMP UNIT REMOVAL 1 Disconnect the negative battery cable 2 Raise and support the vehicle 3 Remove the lower engine splash shield retaining nuts 1 and remove the splash shield ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 97 ...

Page 1164: ...rom the front fascia panel INSTALLATION 1 Position the fog lamp unit into the front fascia panel 2 Insert the fog lamp unit attachment bolts 1 and secure 3 Connect the fog lamp harness connector to the fog lamp bulb 2 4 Install the lower engine splash shield 5 Connect the negative battery cable 8L 98 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION ZH ...

Page 1165: ...re turned on or off with the headlamp switch These lamps function in the same way that parking lamps do The bulbs for the Front Position Lamps are serviceable when the headlamp unit is removed however they cannot be adjusted If the housing is faulty worn or damaged the entire headlamp unit must be replaced REMOVAL 1 Disconnect the negative battery cable 2 Remove the headlamp unit Refer to 8 ELECTR...

Page 1166: ...HEADLAMP INSTALLATION 3 Connect the negative battery cable FRONT TURN SIGNAL LAMP REMOVAL 1 Disconnect the negative battery cable 2 Remove the headlamp unit Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR HEADLAMP REMOVAL 3 Rotate the turn signal bulb housing 1 counter clockwise and remove from the headlamp unit 2 4 Remove the bulb from the bulb housing 8L 100 LAMPS LIGHTING EXTERIOR SERVICE INFORM...

Page 1167: ...tive battery cable HAZARD FLASHER DESCRIPTION The Hazard Flasher 1 is integrated within the Hazard Switch Assembly 2 and cannot be adjusted or repaired If faulty worn or damaged the entire Haz ard Switch Assembly must be replaced For complete Hazard Switch removal procedures refer to Hazard Switch removal in this section Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR HAZARD SWITCH REMOVAL ZH LAMPS...

Page 1168: ... OFF position REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT ING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNO SIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS...

Page 1169: ...g tabs and remove the hazard switch 2 from the center console cover 1 INSTALLATION 1 Insert the hazard switch 1 into the center console cover 2 and press to engage the locking tabs ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 103 ...

Page 1170: ...mp Front Position Lamp Front Turn Signal Lamp OPERATION The headlamps and front position lamps are controlled by the Illumination Control Module which contains a dedi cated headlamp switch The turn signal lamps are controlled by the Multifunction Switch and Hazard Flasher The headlamps are serviced separately For complete Exterior Lamp replacement procedures refer to Exterior Lamps Lighting remova...

Page 1171: ...OVAL HIGH BEAM BULB 1 Disconnect the negative battery cable 2 Remove the headlamp unit Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEADLAMP REMOVAL 3 Remove the headlamp bulb access plug 4 Disconnect the headlamp bulb harness connector 1 5 Disengage the bulb retaining clip 2 and remove the bulb 3 from the headlamp unit ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 105 ...

Page 1172: ...bs 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 Damage to lamp and or Illumination Control Module can result Do not use fuses circuit break ers or relays having greater amperage value than indicated on the fuse panel or in the Owner s Man ual 1 Install the headlamp bulb 3 into the headlamp unit a...

Page 1173: ...r wire and connector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness con nectors splices and grounds HEADLAMP LEVELING MOTOR The Headlamp Leveling Motors move the headlamp and beam pattern according to the signal received from the Headlamp Leveling Switch With the vehicles headlamps ON a signal voltage is...

Page 1174: ...h with a protective surface under the lens to prevent damage 4 Grasp the leveling motor and rotate approximately 45 degrees to unlatch it from the lamp housing 5 Using an appropriate prying tool place the edge of tool between leveling motor gasket and headlamp unit Pry the leveling motor up and out Note Significant force will be required to unsnap the leveling motor pushrod from the headlamp refle...

Page 1175: ...retention connector pin out information and location views for the various wire harness connec tors splices and grounds DIAGNOSIS AND TESTING HEADLAMP LEVELING SWITCH 1 Disconnect the negative battery cable 2 Remove the headlamp leveling switch from the instrument panel Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEADLAMP SWITCH REMOVAL 3 Using an Ohm meter and the table below check the resistan...

Page 1176: ...s are activated by pulling rear ward on the Headlamp Switch knob REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT ING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIA...

Page 1177: ...E AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the headlamp switch into the lower instru ment panel 1 2 Install the headlamp switch attachment screws 1 and 2 and secure 3 Install the headlamp switch interior trim panel 4 Connect the harness connectors at the rear of the headlamp switch and lock to secure 5...

Page 1178: ...s mounted onto the front of the core support structure and aimed with built in adjustment screws 4 STANDARD PROCEDURE STANDARD PROCEDURE HEADLAMP UNIT ALIGNMENT HEADLAMP ALIGNMENT PREPARATION 1 Verify headlamp dimmer switch and high beam indicator operation 2 Inspect and correct damaged or defective components that could interfere with proper headlamp alignment 3 Verify proper tire inflation 4 Cle...

Page 1179: ... down adjustment reference 6 Measure distance from the center line of the vehicle to the center of each headlamp being aligned Transfer measurements to screen with tape to each side of vehicle center line HEADLAMP ADJUSTMENT A properly aimed left and right low beam headlamp will project the center of the low beam hot spot on the alignment screen below the horizontal center line and 152 mm 6 in to ...

Page 1180: ...unce front suspension three times by pushing downward on front bumper and releasing 5 Measure the distance from the center of headlamp lens to the ground Transfer measurement to the alignment screen with tape Use this line for up down adjustment reference 6 Measure distance from the center line of the vehicle to the center of each headlamp being aligned Transfer measurements to screen with tape to...

Page 1181: ...ctor and the front posi tion lamp socket INSTALLATION 1 Install the front position lamp socket and the head lamp unit harness connector 2 Position the headlamp unit into the fascia area 3 Install the upper retaining bolts 1 finger tight 4 Install the lower retaining bolts finger tight 5 Tighten all retaining bolts to torque specification 6 Close the access panel in the inner fender well 7 Connect ...

Page 1182: ... negative battery cable 2 Open the liftgate and remove the license plate lamp lens attachment screws 3 3 Remove the license plate lamp lens 2 and pull the bulb 1 outward from the lamp socket 8L 116 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION ZH ...

Page 1183: ...he negative battery cable MARKER LAMP REMOVAL REMOVAL REAR MARKER LAMP 1 Disconnect the negative battery cable 2 Insert a trim stick 2 at the front edge of the rear marker lamp lens 1 gently depress rearward and lift out from the fascia 3 Rotate the socket counterclockwise and remove the rear marker lamp bulb from the socket ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 117 ...

Page 1184: ...clockwise and remove the front marker lamp bulb from the socket INSTALLATION INSTALLATION REAR MARKER LAMP 1 Insert the rear marker bulb into the socket 1 and rotate clockwise into the rear marker lamp lens 2 2 Install the back edge of the rear marker lamp lens first into the fascia 3 then press the forward edge in at the front 3 Connect the negative battery cable 8L 118 LAMPS LIGHTING EXTERIOR SE...

Page 1185: ...DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect the negative battery cable 2 Remove the steering wheel Refer to 19 STEER ING COLUMN STEERING WHEEL REMOVAL 3 Remove the clockspring Refer to 8 ELECTRI CAL RESTRAINTS CLOCKSPRING REMO...

Page 1186: ...n switch harness connec tors 4 Install the screws 2 attaching the multifunction switch to the steering column 5 Install the bracket on the top of the multifunction switch 6 Install the screw 1 attaching the speed control switch to the multifunction switch 7 Install the lower instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 8 Install the clockspring Refer to...

Page 1187: ...om the tail lamp unit 1 4 Remove the bulb from tail stop lamp socket 2 REMOVAL TURN SIGNAL LAMP 1 Disconnect the negative battery cable 2 Remove the access panel from the cargo area inte rior trim panel 3 Rotate the turn signal lamp socket 2 counter clockwise and pull it from the tail lamp unit 1 4 Remove the bulb from turn signal lamp socket 2 ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 121...

Page 1188: ...r cargo area interior trim panel 3 Connect the negative battery cable INSTALLATION TAIL STOP LAMP 1 Install the bulb 2 into the tail stop lamp socket 1 2 Insert the tail stop lamp socket 1 into the tail lamp unit 3 and rotate clockwise to lock 3 Install the access panel into the cargo area interior trim panel 4 Connect the negative battery cable 8L 122 LAMPS LIGHTING EXTERIOR SERVICE INFORMATION Z...

Page 1189: ...nal lamp socket 1 2 Insert the turn signal lamp socket 1 into the tail lamp unit 3 and rotate clockwise to lock 3 Install the access panel into the cargo area interior trim panel 4 Connect the negative battery cable ZH LAMPS LIGHTING EXTERIOR SERVICE INFORMATION 8L 123 ...

Page 1190: ... AND TESTING HAZARD SWITCH CIRCUIT 125 DOME LAMP CIRCUIT 128 CARGO LAMP INOPERATIVE 131 GLOVE BOX LAMP INOPERATIVE 134 ASH RECEIVER LAMP INOPERATIVE 137 BODY VERIFICATION TEST 140 SCHEMATICS AND DIAGRAMS 141 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING 8L 124 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1191: ...HAZARD SWITCH CIRCUIT ZH LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS 8L 125 ...

Page 1192: ...am Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR SCHE MATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE HAZARD SWITCH CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the Console Switch Group harness connector Note Check connector Clean repair as necessary Measure the resistance of the Hazard Switch circuit between the BCM harness connector and the Co...

Page 1193: ...to 3 3 MEASURE THE RESISTANCE OF THE HAZARD SWITCH CIRCUIT Turn the ignition off Measure the resistance of the Hazard Switch circuit between the Con sole Switch Group harness connector and ground Is the resistance below 10K ohms Yes Repair the Hazard Switch circuit for a short to ground Perform BODY VERIFICATION TEST No Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODU...

Page 1194: ...DOME LAMP CIRCUIT 8L 128 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1195: ...t Diagram Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR SCHE MATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE DOME LAMP CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the Dome Lamp harness connector Note Check connector Clean repair as necessary Measure the resistance of the Dome Lamp circuit between the BCM harness connector and the Dome Lamp harn...

Page 1196: ... 3 3 MEASURE THE RESISTANCE OF THE DOME LAMP CIRCUIT Turn the ignition off Measure the resistance of the Dome Lamp circuit between the Dome Lamp harness connector and ground Is the resistance below 10K ohms Yes Repair the Dome Lamp circuit for a short to ground Perform BODY VERIFICATION TEST No Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL ...

Page 1197: ... CARGO LAMP INOPERATIVE ZH LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS 8L 131 ...

Page 1198: ...amp Bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Cargo Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR CARGO LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE CARGO LAMP VOLTAGE Disconnect the Cargo Lamp harness connector Note Check connector Clean repair as necessary Measure the voltage between ground and the Cargo Lamp harness connector c...

Page 1199: ...the Cargo Lamp harness connector cav ity 1 to the Dome Lamp harness connector cavity 1 Is the resistance below 5 0 ohms Yes Replace the Dome Lamp Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR COURTESY LAMP REMOVAL Perform BODY VERIFICATION TEST No Repair the open circuit between the Cargo Lamp and the Dome Lamp Perform BODY VERIFICATION TEST ZH LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS 8L 133...

Page 1200: ... GLOVE BOX LAMP INOPERATIVE 8L 134 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1201: ...fuse before continuing Turn the ignition off Remove the Glove Box Lamp Bulb and inspect for an open filament Is the Bulb filament open Yes Replace the Glove Box Lamp bulb Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR GLOVE BOX LAMP REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE GLOVE BOX LAMP VOLTAGE Disconnect the Glove Box Lamp harness connector Note Check connector Clean repair as ...

Page 1202: ...the Glove Box Lamp har ness connector cavity 1 Is the resistance below 5 0 ohms Yes Replace the Glove Box Lamp Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR GLOVE BOX LAMP REMOVAL Perform BODY VERIFICATION TEST No Repair the Glove Box Lamp ground circuit for an open Perform BODY VERIFICATION TEST 8L 136 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1203: ... ASH RECEIVER LAMP INOPERATIVE ZH LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS 8L 137 ...

Page 1204: ...d inspect for an open filament Is the Bulb filament open Yes Replace the Ash Receiver Lamp bulb Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE FUSED B CIRCUIT RESISTANCE Disconnect the Ash Receiver Lamp harness connector Disconnect the Illumination Control Module harness connector Note Check connector Clean repair as necessary Measure the resis...

Page 1205: ...LIGHTING EXTERIOR HEAD LAMP SWITCH REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE ASH RECEIVER LAMP GROUND CIRCUIT RESISTANCE Turn the ignition off Turn the parking lamps off Measure the resistance between the Ash Receiver Lamp harness con nector cavity 1 and ground Is the resistance below 5 0 ohms Yes Ensure that the Ash Receiver Lamp bulb is installed prop erly and replace the bulb socket if n...

Page 1206: ...rs and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTC...

Page 1207: ...SCHEMATICS AND DIAGRAMS ZH LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS 8L 141 ...

Page 1208: ...8L 142 LAMPS LIGHTING INTERIOR ELECTRICAL DIAGNOSTICS ZH ...

Page 1209: ...ICE INFORMATION DIAGNOSIS AND TESTING LAMPS LIGHTING INTERIOR WARNING EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS PERSONAL INJURY CAN RESULT CAUTION Do not use bulbs other than those indicated in the Bulb Application table Damage to lamp and or Illumination Control Module can result Do not use fuses circuit breakers or relays having greater amperage value than indicated on the fu...

Page 1210: ...ers or captured edges are not holding the component in place For additional interior lamp diagnosis refer to Interior Lamp Diagnostics in this section SPECIFICATIONS INTERIOR LAMPS CAUTION Do not use bulbs other than those listed in the Bulb Application Table Damage to lamp can result BULB APPLICATION TABLE LAMP BULB Cargo Lamp C5W Cluster Illumination 12 2W 1K 12 1 5W Courtesy Lamp C5W Glove Box ...

Page 1211: ...e bulb 1 into the cargo lamp unit 2 2 Install the cargo lamp unit 2 to the cargo area interior trim panel 3 Refer to 8 ELECTRICAL LAMPS LIGHTING INTERIOR CARGO LAMP UNIT INSTALLATION 3 Connect the negative battery cable ZH LAMPS LIGHTING INTERIOR SERVICE INFORMATION 8L 145 ...

Page 1212: ...e negative battery cable 2 Gently pry the cargo lamp unit 1 away from the cargo area interior trim panel 2 3 Disconnect the cargo lamp unit harness connector 1 and remove from the vehicle 8L 146 LAMPS LIGHTING INTERIOR SERVICE INFORMATION ZH ...

Page 1213: ...gative battery cable COURTESY LAMP REMOVAL 1 Remove the courtesy lamp switch unit from the roof frame Refer to 8 ELECTRICAL LAMPS LIGHT ING INTERIOR COURTESY LAMP SWITCH REMOVAL 2 Rotate the lamp socket 1 counterclockwise in the courtesy lamp switch unit and remove 3 Remove the bulb from the lamp socket ZH LAMPS LIGHTING INTERIOR SERVICE INFORMATION 8L 147 ...

Page 1214: ...sition the courtesy lamps illluminate when the doors are opened then fade to off approximately 8 seconds after the last door is closed unless the courtesy lamp switch is depressed If a door remains unclosed the lamps will remain on for approximately 5 minutes At this time the Body Control Module will interrupt the ground path to conserve battery power The courtesy lamp defeat switch is an integrat...

Page 1215: ...e Block and ground is provided by the Body Control Module Regardless of the ignition switch position the courtesy lamps illuminate when either door is opened if the courtesy lamp defeat switch is in the position or the courtesy lamp switch is pressed The courtesy lamps will fade off approximately 8 seconds after the last door is closed If a door remains unclosed the lamps will remain on for approx...

Page 1216: ...witch unit harness connector and remove from the vehicle INSTALLATION 1 Connect the courtesy lamp switch unit harness connector 1 and align into the headliner opening 2 Install the retaining screws and secure 3 Install the lens cover into the courtesy lamp switch unit body 4 Connect the negative battery cable 8L 150 LAMPS LIGHTING INTERIOR SERVICE INFORMATION ZH ...

Page 1217: ...r plate and the liftgate switch is integral to the liftgate latch assembly A door or body harness connector with a service loop connects each switch to the vehicle electrical system The door ajar switches cannot be adjusted or repaired and if faulty or damaged the switch itself or the liftgate latch must be replaced as an assembly For complete door ajar switch removal procedures see the appropriat...

Page 1218: ... switch harness connector REMOVAL LIFTGATE AJAR SWITCH The liftgate ajar switch 1 is an integral part of the lift gate handle assembly and cannot be adjusted or repaired If faulty worn or damaged the entire liftgate handle assembly must be replaced For complete lift gate handle removal procedures see liftgate handle removal in the body section Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE EXTER...

Page 1219: ...es see liftgate handle installation in the body section of this manual Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE EXTERIOR HANDLE INSTALLATION GLOVE BOX LAMP REMOVAL WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT A...

Page 1220: ...NENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER SONAL INJURY 1 Press the bulb retaining arm 2 aside and install the bulb 1 into the glove box lamp switch assem bly 2 Install the glove box lamp switch assembly Refer to 8 ELECTRICAL LAMPS LIGHTING INTERI OR GLOVE BOX LAMP SWITCH INSTALLA TION 8L 154 LAMPS LIGHTING INTERIO...

Page 1221: ...x is opened Neither of these switches can be adjusted or repaired If faulty worn or damaged the entire Glove Box Lamp Switch assembly must be replaced For complete Glove Box Lamp Switch removal procedures refer to the Glove Box Lamp Switch removal procedure in this section REMOVAL WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPON...

Page 1222: ...nect the negative battery cable HEATER SWITCH ILLUMINATION DESCRIPTION The Heater Switch 3 is illuminated with LEDs when ever the headlamps or marker lamps are on The lamp brightness is adjustable with the dimmer switch located in the Instrument Cluster The heater switch LEDs cannot be adjusted or repaired If faulty or dam aged the entire Heater Switch Assembly must be replaced as a unit For compl...

Page 1223: ... adjusted or repaired If faulty or damaged the entire transmission range indicator assembly must be replaced as a unit For complete transmission range indicator removal procedures see shift mechanism removal in the auto matic transmission section Refer to 21 TRANSMIS SION TRANSAXLE AUTOMATIC NAG1 SHIFT MECHANISM REMOVAL ASH RECEIVER LAMP REMOVAL 1 Remove the cover on the center console Refer to 23...

Page 1224: ...the ashtray housing 1 to the left and remove it toward the right arrows 4 Disconnect the ashtray harness connector for the courtesy lamp on the back of the ashtray 1 5 Remove the ashtray lamp from the ashtray harness connector 8L 158 LAMPS LIGHTING INTERIOR SERVICE INFORMATION ZH ...

Page 1225: ... lamp into the ashtray lamp har ness connector 2 Connect the ashtray lamp harness connector to the ashtray 1 3 Install the ashtray housing 1 to the right and push it toward the left ZH LAMPS LIGHTING INTERIOR SERVICE INFORMATION 8L 159 ...

Page 1226: ...the screws 1 3 attaching the ashtray 2 to the center console 5 Install the cover 1 on the center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 8L 160 LAMPS LIGHTING INTERIOR SERVICE INFORMATION ZH ...

Page 1227: ...re Pressure Monitor ing TPM System utilizes a control module to monitor and operate the system The control module also has a Universal Garage Door Opener integrated along with it The Tire Pressure Monitoring System utilizes transmit ters that are located in the valve stem 1 of each tire 2 to communicate the tire pressure condition to the module If a tire has low air pressure an indicator light on ...

Page 1228: ...een LED does not light replace the battery 2 Hold the RF detector within one inch of the TRAINED Universal Transmitter and press any one of the transmitter 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 4 If a RF signal is not detected replace the Universal Transmitter and reprogram as instructed in the Owner s M...

Page 1229: ...e Pressure Monitor module away from the headliner 3 Disconnect the Universal Garage Door Opener Tire Pressure Monitor module harness connector INSTALLATION 1 Connect the harness connector to the Universal Garage Door Opener Tire Pressure Monitor mod ule 2 Install the Universal Garage Door Opener Tire Pressure Monitor module by snapping it into the headliner 3 Connect the negative battery cable ZH ...

Page 1230: ......

Page 1231: ...S ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE 2 FUEL DOOR LOCK ACTUATOR SLOW RESPONSE 4 PASSENGER DOOR LIFTGATE LOCK ACTUATOR SLOW RESPONSE 6 BODY CONTROL MODULE INTERNAL FAILURE 8 CLP SSM SYSTEM UNDERVOLTAGE 11 CLP SSM SYSTEM OVERVOLTAGE 14 NO COMMUNICATION WITH BODY CONTROL MODULE AND CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE 17 DOOR LOCK DOOR UNLOCK SW...

Page 1232: ...DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE 8N 2 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1233: ...efer to 8 ELECTRICAL POWER LOCKS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK DRIVER DOOR LOCK ACTUATOR PNEUMATIC LINE FOR A PRESSURE VACUUM LEAK Turn the ignition off Disconnect the Fuel Door Lock Actuator Pneumatic line and the Driver Door Lock Actuator at the CLP SSM Install the Drivers Door Lock Actuator Pneumatic line onto the Fuel Door Actuator connector Lock and unlock the doors with the...

Page 1234: ...FUEL DOOR LOCK ACTUATOR SLOW RESPONSE 8N 4 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1235: ...CTRICAL POWER LOCKS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK FUEL DOOR LOCK ACTUATOR PNEUMATIC LINE FOR A PRESSURE VACUUM LEAK Turn the ignition off Disconnect the Fuel Door Lock Actuator Pneumatic line and the Driver Door Lock Actuator at the CLP SSM Install the Fuel Door Actuator Pneumatic line onto the Drivers Door Lock Actuator connector Lock and unlock the doors with the remote control...

Page 1236: ...PASSENGER DOOR LIFTGATE LOCK ACTUATOR SLOW RESPONSE 8N 6 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1237: ...LOCKS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK PASSENGER DOOR LIFT GATE LOCK ACTUATOR PNEUMATIC LINE FOR A PRESSURE VACUUM LEAK Turn the ignition off Disconnect the Fuel Door Lock Actuator Pneumatic line and the Passenger Door Liftgate Lock Actuator at the CLP SSM Install the Passenger Door Liftgate Lock Actuator Pneumatic line onto the Fuel Door Lock Actuator connector Lock and unlock the ...

Page 1238: ...BODY CONTROL MODULE INTERNAL FAILURE 8N 8 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1239: ... BCM POWER CIRCUIT Turn the ignition off Disconnect the BCM harness connector Note Check connectors Clean repair as necessary Measure the voltage of the Fused B circuit cavity 75 at the BCM C4 harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE THE VOLTAGE OF THE BCM POWER CIRCUIT Measure the voltage of the ...

Page 1240: ...ty 4 at the BCM C4 harness connector Is the voltage above 10 volts Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 8N 10 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1241: ...CLP SSM SYSTEM UNDERVOLTAGE ZH POWER LOCKS ELECTRICAL DIAGNOSTICS 8N 11 ...

Page 1242: ... DRB IIIT READ DTCs Turn the ignition on With the DRBIIIT read and record the Central Locking Pump Security System Module DTCs With the DRB IIIT erase the Central Locking Pump Security System Module DTCs Start the engine With the DRB IIIT read DTCs Does the DRB IIIT display a System Undervoltage DTC Yes Go To 2 No Go To 5 The condition that caused this DTC to set is currently not present Inspect t...

Page 1243: ...NTRY MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the Fused B circuit for open Perform BODY VERIFICATION TEST 5 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTC s Note Ch...

Page 1244: ...CLP SSM SYSTEM OVERVOLTAGE 8N 14 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1245: ...DRB IIIT READ DTCs Turn the ignition on With the DRBIIIT read and record the Central Locking Pump Security System Module DTCs With the DRB IIIT erase the Central Locking Pump Security System Module DTCs Start the engine With the DRB IIIT read DTCs Does the DRB IIIT display a System Overvoltage DTC Yes Go To 2 No Go To 4 2 MEASURE THE BATTERY VOLTAGE Turn the ignition off Disconnect the CLP SSM har...

Page 1246: ...that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTC s Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires...

Page 1247: ...NO COMMUNICATION WITH BODY CONTROL MODULE AND CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE ZH POWER LOCKS ELECTRICAL DIAGNOSTICS 8N 17 ...

Page 1248: ...TERNAL FAILURE For a complete Power Locks Circuit Diagram Refer to 8 ELECTRICAL POWER LOCKS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Disconnect the CLP SSM C1 harness connector Disconnect the BCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the CLP SSM C1...

Page 1249: ...it from the CLP SSM C1 harness connector to the BCM harness connector Is the resistance below 1 0 ohm Yes Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the CAN B Bus circuit for an open Perform BODY VERIFICATION TEST ZH POWER LOCKS ELECTRICAL DIAGNOSTICS 8N 19 ...

Page 1250: ...DOOR LOCK DOOR UNLOCK SWITCH SENSE CIRCUIT 8N 20 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1251: ...ENSE CIRCUIT SHORTED TO GROUND DOOR LOCK UNLOCK SWITCH SENSE CIRCUIT OPEN BODY CONTROL MODULE INTERNAL FAILURE For a complete Power Locks Circuit Diagram Refer to 8 ELECTRICAL POWER LOCKS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE DOOR LOCK SWITCH SENSE CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the SKREEM C1 harness connector Note Ch...

Page 1252: ...ms Yes Go to 3 No Repair the Door Unlock Switch Sense circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE DOOR LOCK UNLOCK SWITCH SENSE CIRCUITS Measure the resistance between the Door Lock Unlock Switch Sense circuits at the SKREEM harness connector Is the resistance below 10K ohms Yes Repair the Door Lock Unlock Switch Sense circuits for a short together Perform BO...

Page 1253: ...1 0 volts Yes Repair the Door Lock Switch Sense circuit for a short to B Perform BODY VERIFICATION TEST No Go to 5 5 MEASURE THE VOLTAGE OF THE DOOR UNLOCK SWITCH SENSE CIRCUIT Measure the voltage of the Door Unlock Switch Sense circuit at the SKREEM C1 harness connector Is voltage above 1 0 volts Yes Repair the Door Unlock Switch Sense circuit for a short to B Perform BODY VERIFICATION TEST No Go...

Page 1254: ...form BODY VERIFICATION TEST No Go to 7 7 MEASURE THE RESISTANCE OF THE DOOR UNLOCK SWITCH SENSE CIRCUIT Measure the resistance between ground and the Door Unlock Switch Sense circuit at the SKREEM C1 harness connector Is the resistance below 10K ohms Yes Repair the Door Unlock Switch Sense circuit for a short to ground Perform BODY VERIFICATION TEST No Replace the Body Control Module Refer to 8 EL...

Page 1255: ...CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE INTERNAL FAILURE ZH POWER LOCKS ELECTRICAL DIAGNOSTICS 8N 25 ...

Page 1256: ...he ignition off Disconnect the CLP SSM C2 harness connector Measure the voltage of the Fused B circuit cavity 2 at the CLP SSM C2 harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE THE VOLTAGE OF THE CLP SSM B CIRCUIT Measure the voltage of the Fused B circuit cavity 4 at the CLP SSM C2 harness connector Is...

Page 1257: ...smitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT re...

Page 1258: ...SCHEMATICS AND DIAGRAMS 8N 28 POWER LOCKS ELECTRICAL DIAGNOSTICS ZH ...

Page 1259: ...E KEYLESS ENTRY RELAY 47 INSTALLATION INSTALLATION 49 INSTALLATION REMOTE KEYLESS ENTRY RELAY 49 POWER LOCKS SERVICE INFORMATION DESCRIPTION Power Locks are standard equipment Two ignition keys with integral Remote Keyless Entry RKE trans mitters are supplied with the vehicle They operate the ignition and the locks in the driver s door and glove box The driver s door lock cylinder is the only exte...

Page 1260: ... the Central Locking Pump Security System Module via the Controller Area Network CAN bus The Central Locking Pump Security System Module incorporates a pump to supply pressure or vacuum and valves which direct the supply via pneumatic supply lines to the Power Lock System component For additional information about the BCM SKREEM or Central Locking Pump Security System Module functions as they rela...

Page 1261: ...from any of the following An open door signal The key in the ignition sense The power lock switch signal The rear liftgate signal Automatic Locking The power lock switch in the center console operates the automatic locking feature With the ignition switch in the ON RUN position pressing and holding the upper portion of the power lock switch for at least five seconds activates automatic locking Wit...

Page 1262: ...Locks Electrical Diag nostics in this section PNEUMATIC SUPPLY LINES The Power Lock Actuators are controlled by pneumatic supply lines that transfer either vacuum or pressure from the Central Locking Pump Security System Module to the component through distributors When trouble shooting prob lems related to the pneumatic portion of the power lock system a preliminary inspection should be performed...

Page 1263: ...ic supply line STANDARD PROCEDURE TOGGLING CUSTOMER PREFERENCES Automatic Locking The automatic locking function can be activated or deactivated with the DRB IIIT The interior power door lock switch may also be used with the ignition switched on by pressing and holding the power door lock switch for more than 5 seconds in either the lock auto locking switched on or unlock auto locking switched off...

Page 1264: ...s with line at 300 mbar 8 9 in Hg vacuum in 1 minute 25 mbar 74 in Hg TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs DOOR LOCK ATTACHMENT SCREWS 8 70 CENTRAL LOCKING PUMP DESCRIPTION The Central Locking Pump Security System Module 3 is the pressure vacuum supply pump for the power lock system It is located in the right rear quarter panel area beneath the floor covering For complete Central Lo...

Page 1265: ...nd 12 in 30 5 cm for all others To test position the transmitter as shown Press any transmitter button then test each button individually The tool will beep if a radio signal strength that lights five or more LEDs is detected Repeat this test three times If transmitter fails any of the tests refer to the Electrical Diagnostic portion of this section STANDARD PROCEDURE TRANSMITTER PROGRAMMING The R...

Page 1266: ...ter the batteries are replaced TRANSMITTER RANGE Operation range is within 20 meters 66 feet of the module receiver POWER LOCK SWITCH DESCRIPTION The mounting arrangement of the power lock switch is unique and integrated with additional switches within the trim panel on the center console The power lock switch is not serviceable separately When replacement is necessary the service part includes ad...

Page 1267: ...ESP harness connectors 1 4 Press the locking tabs inward and remove the outer gang of switches 5 Press the locking tabs inward and remove the power lock hazard and ESP switch from the trim panel INSTALLATION 1 Align the power lock switch with the center console interior trim panel and press together until the lock ing tabs engage fully ZH POWER LOCKS SERVICE INFORMATION 8N 37 ...

Page 1268: ...TEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER SONAL INJURY Refer to 8 ELECTRICAL RESTRAINTS WARNING 1 Remove the door interior trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Remove the door lock cylinder Refer to 23 BODY DOOR ...

Page 1269: ...rail through the installation opening 6 Remove the inside handle release cable 8 and the driver door latch assembly harness connector 7 Disconnect the pneumatic supply line 2 from the lock actuator on the door latch assembly 8 Remove the door latch assembly attachment screws 1 9 Remove the door latch assembly 3 from the door through the installation opening ZH POWER LOCKS SERVICE INFORMATION 8N 39...

Page 1270: ...ation opening and install the attachment bolts 2 Install the lower cover plug 3 Note Inspect the door watershield for damage and replace if necessary 6 Install the door watershield 1 7 Install the door lock cylinder Refer to 23 BODY DOOR FRONT LOCK CYLINDER INSTALLA TION 8 Install the door interior trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION DRIVER DOOR LOCK SWITCH REMOVAL WARNI...

Page 1271: ...or lock actuator 6 Disconnect the remaining door harness connectors and remove the driver door lock switch INSTALLATION Note Ensure the harness is routed and secured in its original position to avoid potential interference with moving parts 1 Install the door harness assembly into the door 2 Install the driver door lock switch into the door latch assembly 1 3 Install the door watershield 4 Install...

Page 1272: ...on the fuel door lock actuator 2 and pull back to remove the actuator from the fuel door latch located next to the gas cap Note Use caution when removing fragile pneu matic supply line fitting 3 Remove the pneumatic supply line 1 from the fuel door lock actuator 8N 42 POWER LOCKS SERVICE INFORMATION ZH ...

Page 1273: ...e fuel door latch 1 90 5 Remove the fuel door latch from the vehicle INSTALLATION 1 Install the fuel door latch into the access hole 1 and rotate it 90 to lock it in place ZH POWER LOCKS SERVICE INFORMATION 8N 43 ...

Page 1274: ...o the fuel door lock actuator 3 Insert the fuel door lock actuator 2 into the fuel door latch and press together firmly until locking tab is seated fully 4 Install the right side interior trim panel 4 8N 44 POWER LOCKS SERVICE INFORMATION ZH ...

Page 1275: ...h assembly For complete liftgate latch installation procedures refer to Liftgate Latch installation in the Body Section Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE LATCH INSTALLATION LIFTGATE LOCK ACTUATOR REMOVAL The liftgate lock actuator 2 is serviced with the lift gate exterior handle assembly For complete liftgate exterior handle removal procedures refer to Liftgate Exterior Handle remov...

Page 1276: ... 2 DIAGNOSIS AND TESTING WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER SONAL INJURY Refer to 8 ELECTRICAL RESTRAINTS WARNING When troubleshooting problems related to the pneumatic portion of the Power L...

Page 1277: ...onnector 1 from the SKREEM module 4 Disconnect the 2 pin harness connector for the sentry key antenna ring 5 Disconnect the 18 pin harness connector 1 from the SKREEM module 6 Press the retaining tabs apart 7 Remove the SKREEM module from the base plate REMOVAL REMOTE KEYLESS ENTRY RELAY 1 Remove the underhood accessory fuse block lid 1 ZH POWER LOCKS SERVICE INFORMATION 8N 47 ...

Page 1278: ...2 Carefully release the four tabs 1 to remove the underhood accessory fuse block cover panel 2 3 Remove the remote keyless entry relay 1 8N 48 POWER LOCKS SERVICE INFORMATION ZH ...

Page 1279: ...ctor 1 to the SKREEM module 3 Connect the 2 pin harness connector for the sentry key antenna ring 4 Install the Instrument Cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER INSTALLA TION 5 Connect the negative battery cable INSTALLATION REMOTE KEYLESS ENTRY RELAY 1 Install the remote keyless entry relay 1 ZH POWER LOCKS SERVICE INFORMATION 8N 49 ...

Page 1280: ...nstall the underhood accessory fuse block cover panel 2 and secure it by snapping the retention tabs 1 into place 3 Install the underhood accessory fuse block lid 1 8N 50 POWER LOCKS SERVICE INFORMATION ZH ...

Page 1281: ... AND TESTING LEFT POWER MIRROR INOPERATIVE 52 RIGHT POWER MIRROR INOPERATIVE 55 BOTH POWER MIRRORS INOPERATIVE 58 AUTOMATIC DAY NIGHT MIRROR INOPERATIVE 60 BODY VERIFICATION TEST 63 SCHEMATICS AND DIAGRAMS 64 POWER MIRRORS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH POWER MIRRORS ELECTRICAL DIAGNOSTICS 8N 51 ...

Page 1282: ... LEFT POWER MIRROR INOPERATIVE 8N 52 POWER MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 1283: ...or Turn the ignition on Connect a jumper wire between cavity 6 and cavity 7 of the Power Mirror Switch harness connector With the jumper wires connected does the Left Power Mirror Horizontal Motor Run Yes Go To 2 No Go To 3 2 TEST THE LEFT POWER MIRROR VERTICAL MOTOR With the ignition on With the jumper wire between cavity 3 and ground of the Power Mirror Switch harness connector still connected D...

Page 1284: ... No Repair the Left Power Mirror Horizontal Motor circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE LEFT POWER MIRROR VERTICAL MOTOR CIRCUIT RESISTANCE Turn the ignition off Disconnect all jumper wires Disconnect the Left Power Mirror pigtail harness connector Note The Power Mirror pigtail harness connector can be accessed by removing the small square access panel located at the top fro...

Page 1285: ... RIGHT POWER MIRROR INOPERATIVE ZH POWER MIRRORS ELECTRICAL DIAGNOSTICS 8N 55 ...

Page 1286: ...ition on Connect a jumper wire between cavity 6 and cavity 8 of the Power Mirror Switch harness connector With the jumper wires connected does the Right Power Mirror Horizontal Motor Run Yes Go To 2 Perform BODY VERIFICATION TEST No Go to 3 2 TEST THE RIGHT POWER MIRROR VERTICAL MOTOR With the ignition on With the jumper wire between cavity 4 and ground of the Power Mirror Switch harness connector...

Page 1287: ...No Repair the Right Power Mirror Horizontal Motor circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE RIGHT POWER MIRROR VERTICAL MOTOR CIRCUIT RESISTANCE Turn the ignition off Disconnect all jumper wires Disconnect the Right Power Mirror pigtail harness connector Note The Power Mirror pigtail harness connector can be accessed by removing the small square access panel located at the top f...

Page 1288: ... BOTH POWER MIRRORS INOPERATIVE 8N 58 POWER MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 1289: ... necessary Turn the ignition on Measure the voltage of the Fused B circuit at the Power Mirror Switch harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Power Mirror Switch Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE POWER MIRROR SWITCH GROUND CIRCUIT RESISTANCE Turn the ignition off Measure the resistance between ground and the Power Mirror Switch h...

Page 1290: ... AUTOMATIC DAY NIGHT MIRROR INOPERATIVE 8N 60 POWER MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 1291: ...f Disconnect the Automatic Day Night Mirror harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused B circuit at the Automatic Day Night Mirror harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Automatic Day Night Mirror Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE AUTOMATIC DAY NIGHT MI...

Page 1292: ...e manual transmission gear shift lever into Reverse Measure the voltage of the Backup Lamp Feed circuit at the Automatic Day Night Mirror harness connector Is battery voltage present Yes Repair the Automatic Day Night Mirror Backup Lamp Feed circuit for a short to voltage Perform BODY VERIFICATION TEST No Replace the Automatic Day Night Mirror Refer to 8 ELECTRICAL POWER MIRRORS AUTOMATIC DAY NIGH...

Page 1293: ...mitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT rea...

Page 1294: ...SCHEMATICS AND DIAGRAMS POWER HEATED MIRRORS CIRCUIT DIAGRAM 8N 64 POWER MIRRORS ELECTRICAL DIAGNOSTICS ZH ...

Page 1295: ...ZH POWER MIRRORS ELECTRICAL DIAGNOSTICS 8N 65 ...

Page 1296: ...position switch located in the Center Console An inside Automatic Day Night Rear View Mirror is also standard equipment It is located in the traditional location at the top and center of the windshield The automatic day night mirror position is manually adjustable however the automatic dimming feature of the mirror is not OPERATION Both Sideview Mirrors are heated and each housing can manually fol...

Page 1297: ...t SIDEVIEW MIRROR S VERTICAL OR HORIZONTAL MOVEMENT SLUGGISH OR INOPERATIVE 1 Faulty or worn motor 1 Replace Mirror Assembly 2 Poor connection at mirror harness connector 2 Secure connector 3 Faulty switch assembly 3 Refer to Power Mirrors Electrical Diagnostics in this section 4 Mirror ground circuit fault 4 Repair ground circuit SIDEVIEW MIRROR S DO NOT CLEAR IN COLD WEATHER 1 Faulty fuse 1 Repl...

Page 1298: ...e rear view mirror to protect the driver from the unwanted headlight glare of trailing vehicles while driving at night The self dimming feature is defeated if the interior lights are switched on or the system senses the backup light circuit is energized whenever the transmission is shifted into reverse REMOVAL 1 Disconnect the negative battery cable 2 Insert a 5 mm metal dowel into the hole on the...

Page 1299: ...r to 8 ELECTRI CAL LAMPS LIGHTING INTERIOR COURTESY LAMP SWITCH INSTALLATION 3 Position the mirror base over the mounting plate so that it is flush with the windshield surface 4 Rotate the mirror base approximately 90 degrees until the hole is positioned downward 5 Connect the negative battery cable ZH POWER MIRRORS SERVICE INFORMATION 8N 69 ...

Page 1300: ...after the adhesive accelerator has been applied 5 Apply adhesive accelerator to the bracket contact surface on the windshield glass Allow the adhesive accelerator to dry for one minute Do not touch the glass contact surface after the adhesive accelerator has been applied Note The adhesive will cure very rapidly Insure the mirror mounting bracket is correctly aligned before applying to windshield 6...

Page 1301: ...e retaining clip using a suitable tool 1 and remove the power mirror switch from the cen ter console INSTALLATION 1 Install the power mirror switch into the center console 2 Install the center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 3 Connect the negative battery cable SIDEVIEW MIRROR REMOVAL WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING...

Page 1302: ... attaching screws 5 Remove the two screws attaching the mirror to the door and remove the mirror INSTALLATION 1 Install the two screws 1 attaching the mirror to the door 2 Connect the sideview mirror harness connector 3 Install the door interior trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 4 Rotate the mirror back to its rest position 5 Connect the negative battery cable 8N 72 P...

Page 1303: ... RECLINER MOTOR INOPERATIVE 81 DRIVER POWER SEAT HORIZONTAL MOTOR INOPERATIVE 83 DRIVER POWER SEAT FRONT RISER MOTOR INOPERATIVE 85 DRIVER POWER SEAT REAR RISER MOTOR INOPERATIVE 87 PASSENGER POWER SEAT RECLINER MOTOR INOPERATIVE 89 PASSENGER POWER SEAT HORIZONTAL MOTOR INOPERATIVE 91 BODY VERIFICATION TEST 93 SCHEMATICS AND DIAGRAMS 94 POWER SEATS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH P...

Page 1304: ... DRIVER POWER SEAT INOPERATIVE 8N 74 POWER SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 1305: ...onnector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused B circuit at the Driver Power Seat Switch harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE DRIVER POWER SEAT SWITCH GROUND CIRCUIT RESISTANCE Turn the ignition off Measure the resistance between ...

Page 1306: ... PASSENGER POWER SEAT INOPERATIVE 8N 76 POWER SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 1307: ...connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused B circuit at the Passenger Power Seat Switch harness connector Is the voltage above 10 volts Yes Go to 2 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE PASSENGER POWER SEAT SWITCH GROUND CIRCUIT RESISTANCE Turn the ignition off Measure the resistance b...

Page 1308: ... BOTH POWER SEATS INOPERATIVE 8N 78 POWER SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 1309: ...f Disconnect the Power Seat Relay Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 8 and cavity 2 of the Power Seat Relay harness connector Actuate the Driver and Passenger Power Seat Switches Did the Driver and Passenger Power Seats move Yes Replace the Power Seat Relay Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE POWER SEAT RELAY FUSED B CIRCUIT VOLTAGE...

Page 1310: ...rcuit Is the resistance below 5 0 ohms Yes Repair the open circuit between the Power Seat Relay harness connector and the Underhood Accessory Fuse Block Perform BODY VERIFICATION TEST No Repair the open Ground circuit between the Power Seat Relay harness connector and ground Perform BODY VERIFICATION TEST 8N 80 POWER SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 1311: ... DRIVER POWER SEAT RECLINER MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 81 ...

Page 1312: ...necessary Connect a jumper wire from B to one cavity of the Driver Power Seat Recliner Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Driver Power Seat Recliner Motor connector motor side Note recliner movement if no recliner movement is noted reverse the jumper wires at the Recliner Motor connector Did the Driver Power Seat Recliner move backward or...

Page 1313: ... DRIVER POWER SEAT HORIZONTAL MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 83 ...

Page 1314: ...per wire from B to one cavity of the Driver Power Seat Horizontal Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Driver Power Seat Horizontal Motor connector motor side Note seat movement if no seat movement is noted reverse the jumper wires at the Horizontal Motor connector Did the Driver Power Seat move backward or forward Yes Replace the Driver Po...

Page 1315: ... DRIVER POWER SEAT FRONT RISER MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 85 ...

Page 1316: ...vity of the Driver Power Seat Front Riser Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Driver Power Seat Front Riser Motor connector motor side Note seat movement if no seat front riser movement is noted reverse the jumper wires at the Front Riser Motor connector Did the Driver Seat Front Riser move up or down Yes Replace the Driver Power Seat Swit...

Page 1317: ... DRIVER POWER SEAT REAR RISER MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 87 ...

Page 1318: ...cavity of the Driver Power Seat Rear Riser Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Driver Power Seat Rear Riser Motor connector motor side Note seat movement if no seat rear riser movement is noted reverse the jumper wires at the Rear Riser Motor connector Did the Driver Seat Rear Riser move up or down Yes Replace the Driver Power Seat Switch ...

Page 1319: ... PASSENGER POWER SEAT RECLINER MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 89 ...

Page 1320: ...from B to one cavity of the Passenger Power Seat Recliner Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Passenger Power Seat Recliner Motor connector motor side Note seat movement if no recliner movement is noted reverse the jumper wires at the Recliner Motor connector Did the Passenger Power Seat Recliner move backward or for ward Yes Replace the P...

Page 1321: ... PASSENGER POWER SEAT HORIZONTAL MOTOR INOPERATIVE ZH POWER SEATS ELECTRICAL DIAGNOSTICS 8N 91 ...

Page 1322: ...r wire from B to one cavity of the Passenger Power Seat Horizontal Motor connector motor side Connect a second jumper wire from ground to the other cavity of the Passenger Power Seat Horizontal Motor connector motor side Note seat movement if no seat movement is noted reverse the jumper wires at the Horizontal Motor connector Did the Passenger Power Seat move backward or forward Yes Replace the Pa...

Page 1323: ...smitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT re...

Page 1324: ...SCHEMATICS AND DIAGRAMS POWER SEATS CIRCUIT DIAGRAM 8N 94 POWER SEATS ELECTRICAL DIAGNOSTICS ZH ...

Page 1325: ... equipment Each seat contains a lower 1 and a rear 2 power adjustment switch located on the lower outboard seat trim panel between the seat base and the door The driver s seat features 8 way adjustment while the passenger s seat is 4 way adjustable OPERATION The power seat lower switch adjusts the bottom portion of the seat forward and backward as well as tilting upward and downward both in the fr...

Page 1326: ... behind the seat for binding or obstructions 4 If the dome lamp does not dim proceed with testing of the individual power seat system components and cir cuits For complete power seat system diagnosis refer to Power Seats Electrical Diagnostics in this section SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Front Riser Motor Attachment Screw 4 35 Horizontal Motor Attachment Screw...

Page 1327: ...ard and downward to remove 4 Disconnect the power seat switch harness connec tors 1 and 2 5 Separate the cable straps and expose the wiring harness 6 Remove the side panel with switches from the seat base ZH POWER SEATS SERVICE INFORMATION 8N 97 ...

Page 1328: ...ch wiring harness in its original location 2 Connect the power seat switch harness connectors 1 and 2 3 Position the side panel with the switches as one part on the seat base then install the side panel attaching screw 1 4 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 5 Connect the negative battery cable 8N 98 POWER SEATS SERVICE INFORMATION ZH ...

Page 1329: ...Refer to 23 BODY SEATS SEAT REMOVAL Note Only disconnect the harness connector for the defective motor 2 Disconnect the rear riser motor harness connector 7 3 Remove the rear riser motor rear attachment bolt 1 ZH POWER SEATS SERVICE INFORMATION 8N 99 ...

Page 1330: ...move the rear riser motor INSTALLATION 1 Position the rear riser motor between the front and rear attachment brackets 2 Install the rear riser motor rear attachment bolt 1 Tighten the motor bolt to 4 N m 35 in lbs 8N 100 POWER SEATS SERVICE INFORMATION ZH ...

Page 1331: ... original position to avoid potential interference with moving parts 5 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 6 Connect the negative battery cable HORIZONTAL AND FRONT RISER MOTORS REMOVAL REMOVAL HORIZONTAL MOTOR 1 Remove the front seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Disconnect the horizontal motor harness connector 1 ZH POWER SEATS SERVICE INFORMATION 8N 101 ...

Page 1332: ...attachment screws 1 4 Remove the horizontal motor REMOVAL FRONT RISER MOTOR 1 Remove the front seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Disconnect the front riser motor harness connector 2 8N 102 POWER SEATS SERVICE INFORMATION ZH ...

Page 1333: ...rizontal motor so that the notch 3 is aligned as shown 2 Install the horizontal motor attachment screws 1 Tighten the motor screws to 4 N m 35 in lbs 3 Connect the horizontal motor harness connector 4 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 5 Connect the negative battery cable ZH POWER SEATS SERVICE INFORMATION 8N 103 ...

Page 1334: ...tor 4 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 5 Connect the negative battery cable RECLINER MOTOR REMOVAL 1 Disconnect the negative battery cable 2 Remove the seat back cover enough to expose the recliner motor Refer to 23 BODY SEATS SEAT BACK COVER REMOVAL 3 Remove the bolt 1 attaching the recliner motor to the seat back frame 4 Disconnect the recliner motor harness connec...

Page 1335: ...STALLATION Note Insure the rubber mount for the attachment bolt is seated properly 1 Install the shaft 2 to the seat back frame 1 and install the snap ring Note Insure the harness is routed and secured in its original position to avoid potential interference with moving parts ZH POWER SEATS SERVICE INFORMATION 8N 105 ...

Page 1336: ... 5 Connect the negative battery cable POWER SEAT TRACK REMOVAL 1 Remove the front seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Remove the power seat switch assembly Refer to 8 ELECTRICAL POWER SEATS DRIVER SEAT SWITCH REMOVAL 3 Remove the power seat track rear inboard and out board attachment bolts 1 4 Tilt the rear track mechanism outward then remove the power seat track front inboard and outboard ...

Page 1337: ...N Note Insure wire harnesses are routed and secured in their original position to avoid potential interference with moving parts 1 Position the power seat track assembly over the seat cushion and align the mounting points 2 Install the power seat track power harness connec tor 8 ZH POWER SEATS SERVICE INFORMATION 8N 107 ...

Page 1338: ...echanism inward and install the power seat track rear inboard and out board attachment bolts 1 5 Install the power seat switch assembly Refer to 8 ELECTRICAL POWER SEATS DRIVER SEAT SWITCH INSTALLATION 6 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 8N 108 POWER SEATS SERVICE INFORMATION ZH ...

Page 1339: ...CS DIAGNOSIS AND TESTING LEFT FRONT POWER WINDOW INOPERATIVE 110 RIGHT FRONT POWER WINDOW INOPERATIVE 114 BOTH POWER WINDOWS INOPERATIVE 118 BODY VERIFICATION TEST 120 SCHEMATICS AND DIAGRAMS 121 POWER WINDOWS ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH POWER WINDOWS ELECTRICAL DIAGNOSTICS 8N 109 ...

Page 1340: ... LEFT FRONT POWER WINDOW INOPERATIVE 8N 110 POWER WINDOWS ELECTRICAL DIAGNOSTICS ZH ...

Page 1341: ... measure the voltage of the Left Power Window Switch Sense circuit by backprobing the Left Front Power Window Switch harness connec tor Is the voltage between 8 0 9 0 volts rolling the window down and between 4 0 5 0 volts rolling the window up Yes Go to 5 No Go to 2 2 MEASURE THE VOLTAGE OF THE LEFT POWER WINDOW SWITCH SENSE CIRCUIT Release the Left Power Window Switch Turn the ignition off Disco...

Page 1342: ...MER MODUL REMOVAL Perform BODY VERIFICATION TEST No Repair the Left Power Window Switch Sense circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE GROUND CIRCUIT RESISTANCE Turn the ignition off Disconnect the Body Control Module BCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Ground circuit from the Left Front Power Window Switch harness...

Page 1343: ...efer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Go to 6 6 MEASURE LEFT FRONT POWER WINDOW DRIVER CIRCUITS RESISTANCE With the ignition off Disconnect the Left Front Power Window Motor harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Left Front Pow...

Page 1344: ... RIGHT FRONT POWER WINDOW INOPERATIVE 8N 114 POWER WINDOWS ELECTRICAL DIAGNOSTICS ZH ...

Page 1345: ...he voltage of the Right Power Window Switch Sense cir cuit by backprobing the Right Front Power Window Switch harness connector Is the voltage between 8 0 9 0 volts rolling the window down and between 4 0 5 0 volts rolling the window up Yes Go to 5 Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE THE VOLTAGE OF THE RIGHT POWER WINDOW SWITCH SENSE CIRCUIT Release the Right Power Window Switch Tu...

Page 1346: ...IMER MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the Right Power Window Switch Sense circuit for an open Perform BODY VERIFICATION TEST 4 MEASURE GROUND CIRCUIT RESISTANCE Turn the ignition off Disconnect the Body Control Module BCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Ground circuit from the Right Front Power Window Switch har...

Page 1347: ... to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODULE REMOVAL Perform BODY VERIFICATION TEST No Go to 6 6 MEASURE RIGHT FRONT POWER WINDOW DRIVER MOTOR CIRCUIT RESISTANCE With the ignition off Disconnect the Right Front Power Window Motor harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 and cavity 2 of the Right Fron...

Page 1348: ... BOTH POWER WINDOWS INOPERATIVE 8N 118 POWER WINDOWS ELECTRICAL DIAGNOSTICS ZH ...

Page 1349: ...he voltage at the BCM C4 harness connector Fused B circuit Is the voltage above 10 volts Yes Go to 2 No Repair the BCM Fused B circuit for an open Perform BODY VERIFICATION TEST 2 MEASURE THE GROUND CIRCUIT RESISTANCE Turn the ignition off Disconnect the Left Front Power Window Switch harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Ground circuit fro...

Page 1350: ...mitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT rea...

Page 1351: ...SCHEMATICS AND DIAGRAMS ZH POWER WINDOWS ELECTRICAL DIAGNOSTICS 8N 121 ...

Page 1352: ...PLOYMENT AND POSSIBLE PER SONAL INJURY Refer to 8 ELECTRICAL RESTRAINTS WARNING Before any testing of the Power Window System is performed the battery should be fully charged All the wiring harness connectors should be inspected and cleaned if necessary to ensure good connections 1 If both of the power windows are inoperative check Fuse 19 in the Underhood Accessory Fuse Block 2 With the dome lamp...

Page 1353: ... enough to expose the power window motor attach ment rivets and harness connector Note Use caution to properly support the power window motor before drilling rivets 4 Disconnect the power window motor harness con nector 1 5 Drill out the three power window motor attaching rivets 2 6 Remove the power window motor from the door ZH POWER WINDOWS SERVICE INFORMATION 8N 123 ...

Page 1354: ...tor 1 4 Install the door watershield 1 5 Install the door interior trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 6 Connect the negative battery cable POWER WINDOW SWITCH REMOVAL WARNING REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR SEAT STEERING WHEEL STEER ING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDE...

Page 1355: ...the clips together and remove the power window switch from the shifter cover trim panel INSTALLATION 1 Install the power window switch to the shifter cover trim panel 2 Connect the power window switch harness connec tor 1 3 Install the shifter cover trim panel Refer to 23 BODY INTERIOR CENTER CONSOLE INSTAL LATION 4 Connect the negative battery cable ZH POWER WINDOWS SERVICE INFORMATION 8N 125 ...

Page 1356: ......

Page 1357: ...T 17 PASSENGER AIRBAG SQUIB CIRCUIT 23 LEFT SIDE AIRBAG SQUIB CIRCUIT 29 RIGHT SIDE AIRBAG SQUIB CIRCUIT 35 PROGRAMMING DOES NOT CORRESPOND TO THE VEHICLE EQUIPMENT 41 ORC SYSTEM UNDERVOLTAGE 43 AIRBAG WARNING INDICATOR CIRCUIT 46 PASSENGER AIRBAG ON OFF SWITCH SIGNAL CIRCUIT 49 DRIVER SEAT BELT SWITCH CIRCUIT 53 PASSENGER SEAT BELT SWITCH CIRCUIT 57 LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT 61 RIGHT...

Page 1358: ...ORC INTERNAL FAILURE 8O 2 RESTRAINTS ELECTRICAL DIAGNOSTICS ZH ...

Page 1359: ...the battery must be disconnected WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the ORC harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the ORC harness connector Is the voltage above 10 volts Yes Replace the Occupant Restraint Controller...

Page 1360: ...DRIVER AIRBAG SQUIB CIRCUIT 8O 4 RESTRAINTS ELECTRICAL DIAGNOSTICS ZH ...

Page 1361: ...UIB CIRCUIT S SHORT TO VOLTAGE DRIVER SQUIB CIRCUIT S SHORT TO GROUND DRIVER SQUIB CIRCUITS SHORT TO EACH OTHER DRIVER AIRBAG SQUIB OCCUPANT RESTRAINT CONTROLLER For a complete Restraints System Circuit Diagram Refer to 8 ELECTRICAL RESTRAINTS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System components the ignition must be turned off an...

Page 1362: ... Driver Airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL Perform AIRBAG VERIFICATION TEST 3 WITH THE DRB IIIT READ ACTIVE DTCs WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Load Tool from the Driver Airbag connector Disconnect the Clockspring connector C232 red 2 wire connector located at the base of the steering column Not...

Page 1363: ...r the Driver Squib Line 1 circuit for an open Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected 5 MEASURE THE RESISTANCE OF THE DRIVER SQUIB LINE 2 CIRCUIT WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Measure the resistance of the Driver Squib Line...

Page 1364: ...T TWO MINUTES BEFORE PROCEEDING WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY Measure the voltage of the Driver Squib Line 1 circuit at the Clock spring 2 wire connector Is voltage present Yes Repair the Driver Squib Line 1 circuit for a short to volt age Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery m...

Page 1365: ... RESISTANCE OF THE DRIVER SQUIB LINE 2 CIRCUIT With the ignition on Measure the resistance between ground and the Driver Squib Line 2 circuit Is the resistance below 10K ohms Yes Repair the Driver Squib Line 2 circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Rep...

Page 1366: ...g system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspect related wire harness connectors Look for broken bent pushed out spread corroded or con tam...

Page 1367: ...DRIVER SEAT BELT TENSIONER SQUIB CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 11 ...

Page 1368: ...T BELT SQUIB CIRCUIT S SHORT TO VOLTAGE DRIVER SEAT BELT SQUIB CIRCUIT S SHORT TO GROUND DRIVER SEAT BELT SQUIB CIRCUITS SHORT TO EACH OTHER DRIVER SEAT BELT TENSIONER SQUIB OCCUPANT RESTRAINT CONTROLLER For a complete Restraints System Circuit Diagram Refer to 8 ELECTRICAL RESTRAINTS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System com...

Page 1369: ...TS DIAGNOSIS AND TESTING 3 MEASURE THE RESISTANCE OF THE DRIVER SEAT BELT SQUIB LINE 1 CIRCUIT WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the ORC harness connector Note Check connectors Clean repair as necessary Connect the appropriate harness adapter to the ORC connector Disconnect the Load Tool from the Driver Seat Belt Tensioner Squib...

Page 1370: ... Seat Belt Squib Line 2 circuit at the Driver Seat Belt Tensioner Squib connector Is the resistance below 10K ohms Yes Repair the Driver Seat Belt Squib circuits for a short to each other Perform AIRBAG VERIFICATION TEST Refer to 8 ELECTRICAL RESTRAINTS DIAGNOSIS AND TEST ING Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No...

Page 1371: ...cuit for a short to ground Perform AIRBAG VERIFICATION TEST Refer to 8 ELECTRICAL RESTRAINTS DIAGNOSIS AND TEST ING Note When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected No Go to 9 9 MEASURE THE RESISTANCE OF THE DRIVER SEAT BELT SQUIB LINE 2 CIRCUIT With the ignition off Measure the resistance between ground and the Driver Seat Belt S...

Page 1372: ...iggle the wiring harness and connectors of the appropriate airbag system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspect related wire harness conne...

Page 1373: ...PASSENGER SEAT BELT TENSIONER SQUIB CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 17 ...

Page 1374: ... Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Note Ensure the battery is fully charged Turn the ignition on With the DRB IIIT select ACTIVE or STORED DTCs Is the DTC ACTIVE Yes Go to 2 No Go to 10 2 WITH THE DRB IIIT READ ACTIVE DTCs WARNING TURN THE IGNITION OFF DISCONNECT THE...

Page 1375: ...istance below 1 0 ohm Yes Go to 4 No Repair the Passenger Seat Belt Squib Line 1 circuit for an open Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected 4 MEASURE THE RESISTANCE OF THE PASSENGER SEAT BELT SQUIB LINE 2 CIRCUIT With the ignition off Measure the resistance of the Passenger Seat Belt ...

Page 1376: ...E IGNITION ON THEN RECONNECT THE BATTERY Measure the voltage of the Passenger Seat Belt Squib Line 1 circuit at the Squib connector Is voltage present Yes Repair the Passenger Seat Belt Squib Line 1 circuit for a short to voltage Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 7 7 MEA...

Page 1377: ...t be disconnected No Go to 9 9 MEASURE THE RESISTANCE OF THE PASSENGER SEAT BELT SQUIB LINE 2 CIRCUIT With the ignition off Measure the resistance between ground and the Passenger Seat Belt Squib Line 2 circuit Is the resistance below 10K ohms Yes Repair the Passenger Seat Belt Squib Line 2 circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System comp...

Page 1378: ...ch in both switch positions Wiggle the wiring harness and connectors of the appropriate airbag system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspe...

Page 1379: ...PASSENGER AIRBAG SQUIB CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 23 ...

Page 1380: ... SQUIB CIRCUIT S SHORT TO VOLTAGE PASSENGER SQUIB CIRCUIT S SHORT TO GROUND PASSENGER SQUIB CIRCUITS SHORT TO EACH OTHER PASSENGER AIRBAG SQUIB OCCUPANT RESTRAINT CONTROLLER For a complete Restraints System Circuit Diagram Refer to 8 ELECTRICAL RESTRAINTS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System components the ignition must be t...

Page 1381: ...e Passenger Airbag Refer to 8 ELECTRICAL RESTRAINTS PASSENGER AIRBAG REMOVAL Perform AIRBAG VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE PASSENGER SQUIB LINE 1 CIRCUIT WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the ORC harness connector Note Check connectors Clean repair as necessary Connect the appropriate harness adapter to the OR...

Page 1382: ...rcuit and the Passenger Squib Line 2 circuit at the Passenger Airbag Squib connector Is the resistance below 10K ohms Yes Repair the Passenger Squib circuits for a short to each other Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 6 6 MEASURE THE VOLTAGE OF THE PASSENGER SQUIB LINE 1...

Page 1383: ...s Yes Repair the Passenger Squib Line 1 circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 9 9 MEASURE THE RESISTANCE OF THE PASSENGER SQUIB LINE 2 CIRCUIT With the igntion off Measure the resistance between ground and the Passenger Squib Line 2 circuit Is t...

Page 1384: ...ag system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspect related wire harness connectors Look for broken bent pushed out spread corroded or con ta...

Page 1385: ...LEFT SIDE AIRBAG SQUIB CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 29 ...

Page 1386: ... SHORT TO VOLTAGE LEFT SIDE SQUIB CIRCUIT S SHORT TO GROUND LEFT SIDE SQUIB CIRCUITS SHORT TO EACH OTHER LEFT SIDE AIRBAG SQUIB OCCUPANT RESTRAINT CONTROLLER For a complete Restraints System Circuit Diagram Refer to 8 ELECTRICAL RESTRAINTS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System components the ignition must be turned off and th...

Page 1387: ...ide Airbag Refer to 8 ELECTRICAL RESTRAINTS SIDE IMPACT AIRBAG CON TROL MOD REMOVAL Perform AIRBAG VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE LEFT SIDE SQUIB LINE 1 CIRCUIT WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the ORC harness connector Note Check connectors Clean repair as necessary Connect the appropriate harness adapter to...

Page 1388: ...rcuit and the Left Side Squib Line 2 circuit at the Left Side Airbag Squib con nector Is the resistance below 10K ohms Yes Repair the Left Side Squib circuits for a short to each other Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 6 6 MEASURE THE VOLTAGE OF THE LEFT SIDE SQUIB LINE ...

Page 1389: ...s Repair the Left Side Squib Line 1 circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 9 9 MEASURE THE RESISTANCE OF THE LEFT SIDE SQUIB LINE 2 CIRCUIT With the ignition off Measure the resistance between ground and the Left Side Squib Line 2 circuit Is the ...

Page 1390: ...ag system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspect related wire harness connectors Look for broken bent pushed out spread corroded or con ta...

Page 1391: ...RIGHT SIDE AIRBAG SQUIB CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 35 ...

Page 1392: ...S SHORT TO VOLTAGE RIGHT SIDE SQUIB CIRCUIT S SHORT TO GROUND RIGHT SIDE SQUIB CIRCUITS SHORT TO EACH OTHER RIGHT SIDE AIRBAG SQUIB OCCUPANT RESTRAINT CONTROLLER For a complete Restraints System Circuit Diagram Refer to 8 ELECTRICAL RESTRAINTS SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Note When reconnecting the Airbag System components the ignition must be turned off an...

Page 1393: ...Side Airbag Refer to 8 ELECTRICAL RESTRAINTS SIDE IMPACT AIRBAG CON TROL MOD REMOVAL Perform AIRBAG VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE RIGHT SIDE SQUIB LINE 1 CIRCUIT WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the ORC harness connector Note Check connectors Clean repair as necessary Connect the appropriate harness adapter ...

Page 1394: ...circuit and the Right Side Squib Line 2 circuit at the Right Side Airbag Squib connector Is the resistance below 10K ohms Yes Repair the Right Side Squib circuits for a short to each other Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 6 6 MEASURE THE VOLTAGE OF THE RIGHT SIDE SQUIB ...

Page 1395: ...s Repair the Right Side Squib Line 1 circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected No Go to 9 9 MEASURE THE RESISTANCE OF THE RIGHT SIDE SQUIB LINE 2 CIRCUIT With the ignition off Measure the resistance between ground and the Right Side Squib Line 2 circuit Is t...

Page 1396: ...bag system and rotate the steering wheel from stop to stop Note Check connectors Clean repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identifying a possible intermittent problem Visually inspect related wire harness connectors Look for broken bent pushed out spread corroded or con t...

Page 1397: ...PROGRAMMING DOES NOT CORRESPOND TO THE VEHICLE EQUIPMENT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 41 ...

Page 1398: ...gram the side airbag equipment to YES On the parts control modules menu program the seat belt buckle equipment to YES On the parts control modules menu program the seat occupied recognition equipment to YES Set the front passenger airbag to YES Turn the ignition off Turn the ignition on Erase DTCs the Airbag Warning Indicator Light should flash to indi cate that the programming procedure was succe...

Page 1399: ...ORC SYSTEM UNDERVOLTAGE ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 43 ...

Page 1400: ...bag System components the ignition must be turned off and the battery must be disconnected Turn the ignition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine Leave the vehicle running for at least 20 seconds With the DRB IIIT read DTCs Does the DRB IIIT display a System Undervoltage DTC Yes Go to 2 No The condition that caused this DTC to set is currently...

Page 1401: ...sure the voltage of the Fused Ignition Switch Output circuit at the ORC harness connector Is the voltage above 10 volts Yes Replace the Occupant Restraint Controller Refer to 8 ELECTRICAL RESTRAINTS OCCUPANT RESTRAINT CONTROLLER REMOVAL WARNING IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED AT ANY TIME IT MUST BE REPLACED Perform AIRBAG VERIFICATION TEST No Repair the Fused Ignition Switch Output...

Page 1402: ...AIRBAG WARNING INDICATOR CIRCUIT 8O 46 RESTRAINTS ELECTRICAL DIAGNOSTICS ZH ...

Page 1403: ...the fuse is open repair the cause of the open first before continuing Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Turn the ignition off Remove the Airbag Warning Indicator Lamp Bulb from the Instrument Cluster and inspect for an open filament Is the Bulb filament open Yes Replace the Airbag Warning Indicator Lamp bulb Ref...

Page 1404: ...turned off and the battery must be disconnected 4 MEASURE THE VOLTAGE AT THE ORC WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Reconnect the Instrument Cluster harness connector WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY Connect a jumper wire to ground at the ORC harness connector Did the Airbag Warning Indicator Light illuminate Yes Repl...

Page 1405: ...PASSENGER AIRBAG ON OFF SWITCH SIGNAL CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 49 ...

Page 1406: ... Test 1 MEASURE FUSED B CIRCUIT VOLTAGE Note Inspect Fuse 2 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open first before continuing Note The Passenger Seat Occupant Simulator is located behind the passenger footwell near the Power Amplifier Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disc...

Page 1407: ...NAL CIRCUIT RESISTANCE With the ignition off Measure the resistance between ground and the Passenger Airbag On Off Switch Signal circuit Is the resistance below 10K ohms Yes Repair the Passenger Airbag On Off Switch Signal circuit for a short to ground Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be discon...

Page 1408: ...pant Simulator Ground circuit Is the resistance below 5 0 ohms Yes Replace the Passenger Seat Occupant Simulator Refer to 8 ELECTRICAL RESTRAINTS ON OFF SWITCH INDICATOR MODULE REMOVAL Perform AIRBAG VERIFICATION TEST No Repair the Passenger Seat Occupant Simulator Ground circuit for an open Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be t...

Page 1409: ...DRIVER SEAT BELT SWITCH CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 53 ...

Page 1410: ...Test 1 READ DTCs WITH THE DRB IIIT Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Note Ensure the battery is fully charged WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Switch harness connector Note Check connectors Clean repair as necessary Conne...

Page 1411: ...ense circuit at the Driver Seat Belt Switch harness connector Is voltage present Yes Repair the Driver Seat Belt Switch Sense circuit for a short to voltage Perform AIRBAG VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE OF THE DRIVER SEAT BELT SWITCH SENSE CIRCUIT Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Measure ...

Page 1412: ...d circuit at the Driver Seat Belt Switch harness connector Is the resistance below 5 0 ohms Yes Replace the Occupant Restraint Controller Refer to 8 ELECTRICAL RESTRAINTS OCCUPANT RESTRAINT CONTROLLER REMOVAL WARNING IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED AT ANY TIME IT MUST BE REPLACED Perform AIRBAG VERIFICATION TEST No Repair the Driver Seat Belt Switch ground circuit for an open Perfo...

Page 1413: ...PASSENGER SEAT BELT SWITCH CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 57 ...

Page 1414: ... Diagnostic Test 1 READ DTCs WITH THE DRB IIIT Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Note Ensure the battery is fully charged WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Switch connector Note Check connectors Clean repair as necessar...

Page 1415: ...circuit at the Passenger Seat Belt Switch harness connector Is voltage present Yes Repair the Passenger Seat Belt Switch Sense circuit for a short to voltage Perform AIRBAG VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE OF THE PASSENGER SEAT BELT SWITCH SENSE CIRCUIT Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected Meas...

Page 1416: ...d circuit at the Passenger Seat Belt Switch harness connector Is the resistance below 5 0 ohms Yes Replace the Occupant Restraint Controller Refer to 8 ELECTRICAL RESTRAINTS OCCUPANT RESTRAINT CONTROLLER REMOVAL WARNING IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED AT ANY TIME IT MUST BE REPLACED Perform AIRBAG VERIFICATION TEST No Repair the Passenger Seat Belt Switch ground circuit for an open...

Page 1417: ...LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 61 ...

Page 1418: ...IDE IMPACT SENSOR FUSED IGNITION SWITCH OUTPUT VOLTAGE Note Inspect Fuse 2 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open first before continuing Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PRO...

Page 1419: ...the Left Side Impact Sensor Signal circuit for an open Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected 3 MEASURE THE LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT RESISTANCE With the ignition off Measure the resistance between ground and the Left Side Impact Sensor Signal circuit Is the resistance be...

Page 1420: ...nd the battery must be disconnected No Go to 5 5 MEASURE THE LEFT SIDE IMPACT SENSOR GROUND CIRCUIT RESISTANCE WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Measure the resistance between ground and the Left Side Impact Sensor Ground circuit Is the resistance below 1 0 ohm Yes Replace the Left Side Impact Sensor Refer to 8 ELEC TRICAL RESTRAINTS IMPAC...

Page 1421: ...RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 65 ...

Page 1422: ...HT SIDE IMPACT SENSOR FUSED IGNITION SWITCH OUTPUT VOLTAGE Note Inspect Fuse 2 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open first before continuing Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE...

Page 1423: ...the Right Side Impact Sensor Signal circuit for an open Perform AIRBAG VERIFICATION TEST Note When reconnecting the Airbag System components the ignition must be turned off and the battery must be disconnected 3 MEASURE THE RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT RESISTANCE With the ignition off Measure the resistance between ground and the Right Side Impact Sensor Signal circuit Is the resistance...

Page 1424: ...and the battery must be disconnected No Go to 5 5 MEASURE THE RIGHT SIDE IMPACT SENSOR GROUND CIRCUIT RESISTANCE WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING Measure the resistance between ground and the Right Side Impact Sensor Ground circuit Is the resistance below 1 0 ohm Yes Replace the Right Side Impact Sensor Refer to 8 ELECTRICAL RESTRAINTS IM...

Page 1425: ...ase all Diagnostic Trouble Codes DTCs from the airbag system module Turn the ignition off and wait 15 seconds Turn the ignition on and with the DRB IIIT confirm that no DTCs are present and that all components are func tioning properly If there are no DTCs present and all components are functioning properly the repair is complete Are any DTCs present YES Repair is not complete refer to appropriate...

Page 1426: ...SCHEMATICS AND DIAGRAMS 8O 70 RESTRAINTS ELECTRICAL DIAGNOSTICS ZH ...

Page 1427: ...ZH RESTRAINTS ELECTRICAL DIAGNOSTICS 8O 71 ...

Page 1428: ... LEFT SIDE 113 REMOVAL RIGHT SIDE 115 INSTALLATION INSTALLATION LEFT SIDE 118 INSTALLATION RIGHT SIDE 120 SIDE IMPACT AIRBAG DESCRIPTION 123 OPERATION 124 REMOVAL 125 INSTALLATION 125 SEAT BELT BUCKLE DESCRIPTION 127 REMOVAL 127 INSTALLATION 129 SEAT BELT SEAT BELT TENSIONER DESCRIPTION 130 OPERATION 130 REMOVAL 133 INSPECTION 136 INSTALLATION 136 RESTRAINTS SERVICE INFORMATION DESCRIPTION Occupan...

Page 1429: ...ting the engine the seat belt warning indicator flashes briefly as an added precaution Child Restraint Anchors The front passenger seat includes a LATCH Lower Anchors and Tether for Children child seat anchorage system LATCH compatible child seats are those engineered for retention by direct attachment to the vehicle s seat structure rather than with the vehicle s seat belts The child seat s lower...

Page 1430: ...at belt is not fastened the system will not recognize the belt and not trigger the SBT But if the impact is severe enough the airbags will be triggered even if the seat belts are not fastened Impacts that exceed the higher threshold always trigger the airbags The driver and passenger SRS systems operate independently of one another based on seat belt use SBT actuation occurs only if the seat belts...

Page 1431: ... front of the driver Clockspring The clockspring is located at the top of the steering column directly beneath the steering wheel where it is attached to the column by two screws 1 Driver Front Airbag The driver front airbag 1 is located in the center of the steering wheel as part of the steering wheel trim cover ZH RESTRAINTS SERVICE INFORMATION 8O 75 ...

Page 1432: ...on key to turn the switch 1 to the OFF posi tion This will illuminate the passenger airbag OFF warning lamp on the center console This indicates that the passenger front airbag is deactivated The passenger front airbag will not be activated until the switch is turned to the ON position and the passenger airbag OFF warning lamp goes out The passenger airbag off warning lamp 1 in the cen ter console...

Page 1433: ...onents to each other through the electrical system of the vehi cle These hard wired circuits are integral to several wire harnesses which are routed throughout the vehicle and retained by many different methods These circuits may be connected to each other to the vehicle electrical system and to the SRS components through the use of a combination of soldered splices splice block connectors and man...

Page 1434: ...ned to the ON or RUN position and then goes out after approxi mately six seconds An error or malfunction is indicated in the SRS by the airbag warning indicator not illuminating when the igni tion switch is turned to the ON or RUN position or not going out after six seconds Errors and malfunctions not endangering occupant protection are indicated by the airbag warning indica tor illuminating for a...

Page 1435: ...ll stay illuminated as long as the Passenger Airbag On Off Switch is in the Off position FRONT END MEDIUM SEVERE HEAD ON COLLISION SRS OPERATION Only the seat belt tensioners SBT are triggered The ORC registers medium deceleration stage one threshold due to a collision The triggering pulse is transferred only to the SBT squibs because the restraint function of the seat belts in com bination with t...

Page 1436: ...hreshold The ORC recognizes the vehicles rapid deceleration due to a collision The ORC routes the triggering pulse to the driver and passenger airbag squibs At the same time the driver and passenger SBTs are also triggered 8O 80 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1437: ...hold value a check is made to deter mine which front seat belts are fastened The ORC then activates only the SBTs which have fastened seat belts The driver passenger airbags are not activated unless a frontal collision which exceeds the stage two threshold is detected ZH RESTRAINTS SERVICE INFORMATION 8O 81 ...

Page 1438: ...it indicates that there is a concern in the SRS electrical circuits Such a problem may cause airbags to not deploy when required or to deploy when not required Deployment of the driver and passenger airbags depends upon the angle and severity of an impact Deployment is not based upon vehicle speed rather deployment is based upon the rate of deceleration as measured by the forces of gravity G force...

Page 1439: ... ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPL...

Page 1440: ...NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF A NON DEPLOYED AIRBAG WHEN CARRYING A NON DEPLOYED AIRBAG THE TRIM COVER OR AIRBAG CUSHION SIDE OF THE UNIT SHOULD BE POINTED AWAY FROM THE BODY TO MIN IMIZE INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT IF THE AIRBAG UNIT IS PLACED ON A BENCH OR ANY OTHER SURFACE THE TRIM COVER OR AIRBAG CUSHION SIDE OF THE U...

Page 1441: ...t is possible for only one initiator to be used due to an airbag system fault therefore it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials The following procedure should be per formed using a DRBIIIT scan tool to verify the status of both airbag squibs before either deploye...

Page 1442: ...leanup by using a vacuum cleaner to remove any residual powder from the vehicle inte rior Clean from outside the vehicle and work your way inside so that you avoid kneeling or sitting on a non cleaned area 2 Be certain to vacuum the heater and air condition ing outlets as well Run the heater and air condi tioner blower on the lowest speed setting and vacuum any powder expelled from the outlets 3 N...

Page 1443: ... be certain that there are no occupants in the vehicle then reconnect the battery negative cable 6 Using the DRBIIIT read and record any active current Diagnostic Trouble Code DTC data 7 Next use the DRBIIIT to read and record any stored historical DTC data 8 If any DTCs are found refer to the appropriate diagnostic information 9 Use the DRBIIIT to erase any stored DTC data 10 Turn the ignition sw...

Page 1444: ...it must be replaced OPERATION The microprocessor in the Occupant Restraint Controller ORC contains the Supplemental Restraint System SRS logic circuits and controls all of the SRS components The Occupant Restraint Controller ORC uses On Board Diagnostics OBD and Controller Area Network CAN to communicate with other electronic modules in the vehicle as well as with the DRBIIIT scan tool The Occupan...

Page 1445: ...c accelerometer sensor within the Occupant Restraint Controller ORC that pro vides an additional logic input to the Occupant Restraint Controller ORC microprocessor The safing sensor is used to verify the need for a Supplemental Restraint System SRS deployment by detecting the impact energy of a collision The impact energy must exceed the safing threshold in order for the airbags to deploy Pre pro...

Page 1446: ... ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS NEVER STRIKE OR DROP THE OCCUPANT RESTRAINT CONTROLLER AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALI BRATION IF AN OCCUPANT RESTRAINT CONTROLLER IS ACCIDENTALLY DROPPED DURING SERVICE THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL INCOMPLETE OR IMPROPER SUPPLEMENTA...

Page 1447: ...NTROLLER IS ACCIDENTALLY DROPPED DURING SERVICE THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL INCOMPLETE OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES 1 Carefully position the occupant restraint controller on the mount that is welded onto the top of the floor panel transmission tunnel The arrow on ...

Page 1448: ... replaced OPERATION The clockspring is used to provide continuous electrical continuity between the instrument panel and the electrical components mounted on or in the steering wheel The clockspring case is secured to the top of the steering column The connector receptacle on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through a single four pin c...

Page 1449: ...if the steering column is disconnected from the steering gear the clockspring tape can change position relative to the other steering components The clockspring must then be re centered following completion of such service or the clockspring tape may be damaged WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN D...

Page 1450: ...TEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER SONAL INJURY Note Before starting this procedure be certain to turn the steering wheel until the front wheels are in the straight ahead position 1 Place t...

Page 1451: ...fer to 19 STEER ING COLUMN STEERING WHEEL REMOVAL 6 Remove the two screws 1 that secure the clock spring to the steering column upper housing 7 Remove the clockspring 8 Separate the clockspring from the steering angle sensor Refer to 5 BRAKES ELECTRICAL STEERING ANGLE SENSOR REMOVAL ZH RESTRAINTS SERVICE INFORMATION 8O 95 ...

Page 1452: ...Refer to 5 BRAKES ELECTRICAL STEERING ANGLE SENSOR INSTALLATION Note If the clockspring is being reused be certain to remove anything securing the clockspring rotor to the clockspring case that was used to maintain clockspring centering until reinstallation on the steering column If clockspring centering was not maintained the clockspring must be centered again before it is installed Refer to 8 EL...

Page 1453: ...ews 1 to the steer ing wheel Refer to 8 ELECTRICAL RE STRAINTS DRIVER AIRBAG INSTALLATION 6 Do not reconnect the negative battery cable at this time Perform the Supplemental Restraint System verification test procedure after servicing any Sup plemental Restraint System component Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE ZH RESTRAINTS SERVICE INFORMATION 8O 97 ...

Page 1454: ...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 ARE IRRITATED MOVE TO ANOTHER AREA WHERE THERE IS PLENTY OF CLEAN FRESH AIR TO BREATH IF THE IRRITATION IS NOT ALLEVIATED BY THESE ACTIONS CONTACT A PHYSICIAN The airbag used in this model is a multistage Next Generation type that compl...

Page 1455: ... the Seat Belt Tensioner SBT and Occupant Restraint Controller ORC 2 The squib ignites the solid fuel in the gas genera tor The solid fuel combusts developing a gas which explodes under high pressure into the airbag through a filter 3 The airbag inflates and tears open the steering wheel cushion cover at a predetermined breaking point ZH RESTRAINTS SERVICE INFORMATION 8O 99 ...

Page 1456: ... DRIVER AIRBAG PASSENGER AIR BAG FRONT IMPACT SENSOR SIDE IMPACT SENSOR SIDE IMPACT AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PRO...

Page 1457: ...for the horn switch 6 Disconnect the clockspring driver airbag pigtail harness connectors CAUTION Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators 7 Re...

Page 1458: ...s or connector insulators can result in damage to the airbag circuits or connector insulators 3 Carefully position the driver airbag in the steering wheel Note Be certain that the clockspring wires and horn switch harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel 4 From the underside of the steering wheel install and tighten the two screws 1 th...

Page 1459: ... be replaced If inspection reveals that the passenger airbag mounting points on the instrument panel structural duct have been cracked or damaged by the deployment event the instrument panel structural duct assembly must also be replaced OPERATION The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller ORC through the passenger airbag squib ...

Page 1460: ...he improper disposal of potentially live pyrotechnic materials REMOVAL 1 Before attempting any service to the airbag system refer to the warnings in this section Refer to 8 ELEC TRICAL RESTRAINTS WARNING 2 Disconnect the negative battery cable 2 Wait two minutes for the system capacitor to discharge before further service 3 Remove the upper section 1 of instrument panel Refer to 23 BODY INSTRUMENT...

Page 1461: ...tor receptacle Improper removal of the squib wires and their connector insulators can result in damage to the airbag circuits or connec tor insulators 5 Remove the four bolts 1 that secure the airbag to the instrument panel 6 Remove the passenger airbag as a unit WARNING DO NOT PLACE AN INTACT UNDE PLOYED AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLO...

Page 1462: ...uct must be replaced INSTALLATION 1 Verify the negative battery cable 2 is discon nected before proceeding Wait two minutes for the system capacitor to discharge before fur ther service 2 Carefully position the passenger airbag unit onto the instrument panel 3 Install the four bolts 1 that secure the passenger airbag to the instrument panel Tighten to 35 N m 26 ft lbs 8O 106 RESTRAINTS SERVICE INF...

Page 1463: ...PTION The passenger seat occupant simulator is located on the front side of the passenger floor access panel The mod ule is attached to the access panel with a plastic wire tie The multiplexed DC voltage signal received from the passenger airbag switch is converted into a digital signal andsent to the occupant restraint controller OPERATION The passenger seat occupant simulator receives a multiple...

Page 1464: ...ystem capacitor to discharge before further service 2 Un snap and remove the carpeted floor mat 3 Un tuck the carpeting in the passenger footwell and fold the carpet down to expose the foam insu lation 4 Remove the foam insulating panel 8O 108 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1465: ... Remove the plastic retaining nuts 1 from the floor panel and rotate the base plate exposing the pas senger seat occupant simulator 6 Remove the plastic tie and disconnect the passen ger seat occupant simulator harness connector Remove the passenger seat occupant simulator 1 ZH RESTRAINTS SERVICE INFORMATION 8O 109 ...

Page 1466: ...ding Wait two minutes for the system capacitor to discharge before fur ther service 2 Connect the passenger seat occupant simulator harness connector and attach the passenger seat occupant simulator 1 to the base plate with a plastic wire tie 8O 110 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1467: ... and secure the base plate to the vehicle floor 5 Install the foam insulating panel 6 Install the carpeting in the passenger footwell 7 Install the floor mat to the carpet 8 Do not reconnect the negative battery cable at this time Perform the Supplemental Restraint System verification test procedure after servicing any Sup plemental Restraint System component Refer to 8 ELECTRICAL RESTRAINTS STAND...

Page 1468: ...eleration which provides verification of the direction and severity of an impact Each sensor also contains an electronic com munication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller ORC The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to de...

Page 1469: ...eginning of this section Refer to 8 ELECTRICAL RESTRAINTS WARNING 2 Remove the door sill plate 1 Note Pull straight up on the sill plate to release it from the retaining clips 3 Move the seat to the full rearward position 4 Remove the seat track front bolts 1 ZH RESTRAINTS SERVICE INFORMATION 8O 113 ...

Page 1470: ...em capacitor to discharge before further service 9 Tilt the seat back to gain access to the bottom of the seat 10 Disconnect the power seat harness connectors 11 Carefully remove the seat from the vehicle 12 Remove the carpet retainer button 3 at the pas senger compartment rear wall 1 Note Do not pry on the carpet retainer button the button will unscrew from the fastener 13 Fold back the carpet ne...

Page 1471: ...of the connector can result in damage to the airbag circuits or con nector insulator 15 Remove the two bolts attaching the side impact sensor 1 to the body cross brace 16 Remove the side impact sensor from the vehicle REMOVAL RIGHT SIDE 1 Before attempting any service procedures refer to the warnings in the beginning of this section Refer to 8 ELECTRICAL RESTRAINTS WARNING 2 Remove the door sill p...

Page 1472: ...at track rear bolts are easily accessed when the seat back is tilted fully forward 6 Remove the seat track rear bolts 1 7 Remove the seat belt bolt 2 holding the seat belt to the seat 8 Disconnect the negative battery cable Wait two minutes for the system capacitor to discharge before further service 8O 116 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1473: ... side impact sensor Note The carpet is firmly molded and will need to be propped up while servicing the impact sensor 14 Disconnect the side impact sensor harness con nector 2 CAUTION Use caution when disconnecting the squib connector Do not pry on the connector insulator to disengage the connector from the side impact sensor Improper removal of the connector can result in damage to the airbag cir...

Page 1474: ... brace 3 Install the bolts attaching the side impact sensor to the body cross brace Tighten the side impact sen sor bolts to 12 N m 106 in lbs CAUTION Use caution when connecting the squib harness connector to the side impact sensor receptacle Improper assembly of these connec tors can result in damage to the airbag circuits or connector insulators 4 Connect the side impact sensor harness connecto...

Page 1475: ...s connectors 9 Install the seat belt bolt 2 Tighten the seat belt bolt to 35 N m 26 ft lbs 10 Install the seat track rear bolts 1 Tighten the rear bolts to 50 N m 37 ft lbs 11 Temporarily reconnect the negative battery cable 12 Move the seat to the full rearward position 13 Disconnect the negative battery cable again 14 Install the seat track front bolts 1 Tighten the front bolts to 50 N m 37 ft l...

Page 1476: ...upplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component Refer to 8 ELECTRICAL RESTRAINTS STAN DARD PROCEDURE INSTALLATION RIGHT SIDE 1 Verify the negative battery cable 2 is discon nected before proceeding Wait two minutes for the system capacitor to discharge before fur ther service 8O 120 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1477: ...ge to the airbag circuits or connector insulators 4 Connect the side impact sensor harness connector 5 Reposition the carpet to the floor Note The carpet is firmly molded and will need to be properly seated to the contours of the vehicle floor 6 Install the carpet hold down button 1 7 Install the front seat 8 Reconnect the power seat harness connectors 9 Install the seat belt bolt 2 Tighten the se...

Page 1478: ...o 50 N m 37 ft lbs 15 Install the door sill plate by pushing it firmly down onto the retaining clips 16 Install the ignition key 17 Do not reconnect the negative battery cable at this time Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component Refer to 8 ELECTRICAL RESTRAINTS STAN DARD PROCEDURE 8O 122 RESTRAINTS SERVICE IN...

Page 1479: ...nds to form a protective cushion between the passenger and the door Thus the impact on the passenger s thorax and the ejecting motion of the head which might otherwise cause serious injuries are reduced The ORC and the IC each contain a central processing unit and programming that allow them to communicate with each other using the Controller Area Network CAN This method of communication is used b...

Page 1480: ... rapidly and produce the pressure necessary to rupture a con tainment disk in the inert gas canister The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded airbag cushion causing the cushion to inflate As the airbag cushion inflates it will rip open a predetermined area in the driver or passenger door to form a...

Page 1481: ...rcuits or connec tor insulators 6 Drill out the mounting rivets 1 for the side impact airbag 7 Remove the side impact airbag from the door WARNING DO NOT PLACE AN INTACT UNDE PLOYED AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED INSTALLATION WARNING DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVE...

Page 1482: ...n when connecting the squib harness connector to the side impact airbag receptacle Improper assembly of these connec tors can result in damage to the airbag circuits or connector insulators 5 Install the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION 6 Install the ignition key 7 Do not reconnect the negative battery cable at this time Perform the Supplemental Restraint System ...

Page 1483: ...l buckle design with a release button on the top to free the seat belt The left and right front seat belt buckle restraint system monitors the status of the driver s and passenger s seat belt switch The airbag unit can be ignited if the seat belt is not fastened during the initial triggering threshold REMOVAL 1 Move the seat to the full rearward position 2 Remove the seat track front bolts 1 ZH RE...

Page 1484: ...s 1 5 Remove the seat belt bolt 2 holding the seat belt to the seat 6 Tilt the seat back to gain access to the bottom of the seat 7 Disconnect the power seat harness connectors 8 Carefully remove the seat from the vehicle 9 Disconnect the seat belt buckle harness connector and remove the bolt 1 attaching the belt buckle to the seat 8O 128 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1485: ...ckle Tighten to 35 N m 26 ft lbs 4 Connect the seat belt buckle harness connector 5 Install the front seat 6 Reconnect the power seat harness connectors 7 Install the seat belt bolt 2 Tighten the seat belt bolt to 35 N m 26 ft lbs 8 Install the seat track rear bolts 1 Tighten the rear bolts to 50 N m 37 ft lbs ZH RESTRAINTS SERVICE INFORMATION 8O 129 ...

Page 1486: ...nel OPERATION The front seat belt system incorporates both driver and passenger Seat Belt Tensioner SBT retractors At the onset of an impact event each tensioner uses a pyrotechnic device which is triggered simultaneously with the front air bags to rapidly retract the seat belts With the slack removed the occupant s forward motion in an impact will be reduced as well the likelihood of contacting i...

Page 1487: ...lay The Squib in the gas generator is triggered and the resulting combustion gas moves the piston 2 in the gas generator cylinder 3 up at high speed The pull cable 4 connected to the piston is tensioned causing the cable pulley 5 to turn Inertia and centrifugal force cause the pawls 7 in the cable pulley 5 to engage in the teeth in the toothed ring 6 A positive connection is then present between t...

Page 1488: ...uses the tor sion rod 6 to arrest on one side The torsion rod 6 forms the heart of the retractor shaft and therefore takes up the tension forces acting on the seat belt As soon as the force on the seat belt exceeds 4 kN the torsion rod 6 deforms counteracting a further increase in the load and limiting the force As soon as the force on the seat belt decreases the locking pawls in the toothed ring ...

Page 1489: ...ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG WARNING NEVER DISASSEMBLE THE SEAT BELT TENSIONERS CAUTION Never attempt to eliminate noises by lubricating with oil or grease 1 Before attempting any service procedur...

Page 1490: ...ic cover 3 to the door opening 7 Remove the plastic cover 3 8 Remove the door edge guard 2 9 Remove the bolt 1 attaching the belt guide to the vehicle 10 Fold back the carpet 1 in the upper corner area 8O 134 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1491: ... gage the connector from the inflator connector receptacle Improper removal of the squib wires and their connector insulators can result in dam age to the airbag circuits or connector insulators 12 Remove the bolt 1 attaching the seat belt ten sioner to the vehicle 13 Remove the seat belt tensioner from the vehicle ZH RESTRAINTS SERVICE INFORMATION 8O 135 ...

Page 1492: ...sioner squib status 1 Red Pin 1 is visible All squibs have been fired 2 Red Pin 1 is not visible All squibs have not been fired INSTALLATION 1 Verify the negative battery cable 2 is discon nected before proceeding Wait two minutes for the system capacitor to discharge before fur ther service 8O 136 RESTRAINTS SERVICE INFORMATION ZH ...

Page 1493: ...oner squib harness con nector 1 CAUTION Use caution when connecting the squib harness connector to the inflator connector recep tacle Improper assembly of these wires and their connector insulators can result in damage to the airbag circuits or connector insulators 5 Install the bolt 1 on the upper belt guide Tighten to 35 N m 26 ft lbs ZH RESTRAINTS SERVICE INFORMATION 8O 137 ...

Page 1494: ...e bolt 1 on the belt end attaching it to the seat Tighten to 35 N m 26 ft lbs 11 Install the plastic bolt cover over the seat belt bolt 12 Do not reconnect the negative battery cable at this time Perform the Supplemental Restraint System verification test procedure after servicing any Supplemental Restraint System component Refer to 8 ELECTRICAL RESTRAINTS STAN DARD PROCEDURE 8O 138 RESTRAINTS SER...

Page 1495: ...N 9 SPEED CONTROL ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page SPEED CONTROL ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING P0575 SPEED CONTROL SWITCH INPUT CIRCUIT 2 POWERTRAIN VERIFICATION TEST VER 5 7 SCHEMATICS AND DIAGRAMS 8 SPEED CONTROL ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING ZH SPEED CONTROL 8P 1 ...

Page 1496: ... P0575 SPEED CONTROL SWITCH INPUT CIRCUIT 8P 2 SPEED CONTROL ELECTRICAL DIAGNOSTICS ZH ...

Page 1497: ...erminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If the PCM detects and stores a DTC the PCM also stores the engi...

Page 1498: ...ECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 SPEED CONTROL OFF SIGNAL CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the Speed Control Switch harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Speed Control Off Signal circuit Is the resistance abov...

Page 1499: ...circuit open Perform POWERTRAIN VERIFICATION TEST VER 5 6 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the Speed Control Switch harness connector Is the voltage above 10 volts Yes Replace the Speed Control Switch Refer to 8 ELECTRI CAL SPEED CONTROL SWITCH REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 5 No Repa...

Page 1500: ...tors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagrams as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Test Comple...

Page 1501: ...ol problems and then return to the symptom list Using caution press and release the brake pedal If the speed control did not disengage the repair is not complete Check for TSBs that pertain to speed control problems and then return to the symptom list Bring the vehicle speed back up to 35 mph Press the RESUME switch If the speed control did not resume the previously set speed the repair is not com...

Page 1502: ...SCHEMATICS AND DIAGRAMS 8P 8 SPEED CONTROL ELECTRICAL DIAGNOSTICS ZH ...

Page 1503: ...ion Sensor Kickdown Switch Automatic Trans mission Throttle Body and the Clutch Pedal Position Switch Manual Transmission The Speed Control System is designed to operate at speeds above 25 MPH 40 km h OPERATION When speed control operation is requested by the Speed Control Switch The Powertrain Control Module allows a set speed to be stored in its memory for speed control To store a set speed pres...

Page 1504: ...ry switch activation of the ACCEL SET switch position A tap down feature is used to decelerate without dis engaging the Speed Control System To decelerate from an existing recorded target speed momentarily push the speed control switch downward into the DECEL SET switch position For each switch activa tion speed will be lowered approximately 1 MPH SWITCH REMOVAL WARNING REFER TO RESTRAINTS BEFORE ...

Page 1505: ...ifunction switch 4 Install the lower instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 5 Install the clockspring Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING INSTALLATION 6 Install the steering wheel Refer to 19 STEER ING COLUMN STEERING WHEEL INSTALLA TION 7 Connect the negative battery cable ZH SPEED CONTROL SERVICE INFORMATION 8P 11 ...

Page 1506: ......

Page 1507: ...ITY SYSTEM MODULE 8 CAN B BUS CIRCUIT FAILURE 11 CAN B BUS CIRCUIT FAILURE 14 DOOR LOCK SWITCH SENSE CIRCUIT 17 DOOR UNLOCK SWITCH SENSE CIRCUIT 20 ANTI THEFT TOW SENSOR SIGNAL CIRCUIT 23 NO CAN COMMUNICATIONS WITH PCM 26 SIREN SIGNAL OUTPUT CIRCUIT 29 CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE INTERNAL FAILURE 32 ALARM TRIPS ON ITS OWN 34 VTSS VERIFICATION TEST 35 SENTRY KEY REMOTE ENTRY MODULE ...

Page 1508: ...CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE SYSTEM UNDERVOLTAGE 8Q 2 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1509: ...ICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Turn the ignition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine With the DRB IIIT read DTCs Does the DRB IIIT display a System Undervoltage DTC Yes Go to 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness fo...

Page 1510: ...s Yes Go to 4 No Repair the Fused B circuit for high resistance Perform VTSS VERIFICATION TEST 4 MEASURE THE VOLTAGE OF THE FUSED B CIRCUIT Measure the voltage of the Fused B circuit cavity 4 at the CLP SSM C2 harness connector Is the voltage above 11 volts Yes Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REMOTE ENTRY MODULE REMO...

Page 1511: ...CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE SYSTEM OVERVOLTAGE ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 5 ...

Page 1512: ... DRB IIIT READ DTCs Turn the ignition on With the DRB IIIT erase DTCs Turn the ignition off Turn the ignition on Start the engine With the DRB IIIT read DTCs Does the DRB IIIT display a System Overvoltage DTC Yes Go to 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition 2 MEASURE THE BATTERY VOLTAGE Turn t...

Page 1513: ...ween ground and the Ground circuit Is the resistance below 1 0 ohm Yes Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL Perform VTSS VERIFICATION TEST No Repair the Ground circuit for an open Perform VTSS VERIFICATION TEST ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 7 ...

Page 1514: ...NO COMMUNICATION WITH BCM AND CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE 8Q 8 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1515: ... complete Vehicle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Disconnect the CLP SSM harness connector Disconnect the BCM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the CLP...

Page 1516: ... the CLP SSM harness connector to the BCM harness connector Is the resistance below 1 0 ohm Yes Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL Perform VTSS VERIFICATION TEST No Repair the CAN B Bus circuit for an open Perform VTSS VERIFICATION TEST 8Q 10 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1517: ...CAN B BUS CIRCUIT FAILURE ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 11 ...

Page 1518: ...icle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the CLP SSM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the BCM harness conn...

Page 1519: ...E THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Measure the resistance between ground and the CAN B Bus circuit at the CLP SSM harness connector Is the resistance below 10K ohms Yes Repair the CAN B Bus circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REM...

Page 1520: ...CAN B BUS CIRCUIT FAILURE 8Q 14 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1521: ...icle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the CLP SSM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the BCM harness conn...

Page 1522: ...E THE RESISTANCE OF THE CAN B BUS CIRCUIT Turn the ignition off Measure the resistance between ground and the CAN B Bus circuit at the CLP SSM harness connector Is the resistance below 10K ohms Yes Repair the CAN B Bus circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Central Locking Pump Security System Mod ule Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SENTRY KEY REM...

Page 1523: ...DOOR LOCK SWITCH SENSE CIRCUIT ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 17 ...

Page 1524: ...ehicle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE DOOR LOCK SWITCH SENSE CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the SKREEM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Door Lock Switch Sense circui...

Page 1525: ... 3 MEASURE THE RESISTANCE OF THE DOOR LOCK SWITCH SENSE CIRCUIT Turn the ignition off Measure the resistance between ground and the Door Lock Switch Sense circuit at the SKREEM harness connector Is the resistance below 10K ohms Yes Repair the Door Lock Switch Sense circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Sentry Key Remote Entry Module Refer to 8 ELECTRICAL VEHIC...

Page 1526: ...DOOR UNLOCK SWITCH SENSE CIRCUIT 8Q 20 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1527: ... Vehicle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE DOOR UNLOCK SWITCH SENSE CIRCUIT Turn the ignition off Disconnect the BCM harness connector Disconnect the SKREEM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Door Unlock Switch Sense ...

Page 1528: ...3 3 MEASURE THE RESISTANCE OF THE DOOR UNLOCK SWITCH SENSE CIRCUIT Turn the ignition off Measure the resistance between ground and the Door Unlock Switch Sense circuit at the SKREEM harness connector Is the resistance below 10K ohms Yes Repair the Door Unlock Switch Sense circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Sentry Key Remote Entry Module Refer to 8 ELECTRICA...

Page 1529: ...ANTI THEFT TOW SENSOR SIGNAL CIRCUIT ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 23 ...

Page 1530: ...ft Security System circuit diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE ANTI THEFT TOW SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the CLP SSM harness connector Disconnect the Anti Theft Tow Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Anti Theft Tow...

Page 1531: ... No Go to 3 3 MEASURE THE RESISTANCE OF THE ANTI THEFT TOW SENSOR SIGNAL CIRCUIT Turn the ignition off Measure the resistance between ground and the Anti Theft Tow Sen sor Signal circuit at the Anti Theft Tow Sensor harness connector Is the resistance below 10K ohms Yes Repair the Anti Theft Tow Sensor Signal circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Anti Theft To...

Page 1532: ...NO CAN COMMUNICATIONS WITH PCM 8Q 26 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1533: ...rity System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE CAN C BUS CIRCUIT Turn the ignition off Disconnect the SKREEM harness connector Disconnect the PCM harness connector Measure the resistance of the CAN C Bus circuit from the SKREEM harness connector to the PCM harness connector Is the resistance below 1 ...

Page 1534: ... connector and the PCM harness connector Is the resistance below 1 0 ohm Yes Replace the Sentry Key Remote Entry Module Refer to 8 ELECTRICAL VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL Perform VTSS VERIFICATION TEST No Repair the CAN C Bus circuit for an open Perform VTSS VERIFICATION TEST 8Q 28 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1535: ...SIREN SIGNAL OUTPUT CIRCUIT ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 29 ...

Page 1536: ...cle Theft Security System Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECU RITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE SIREN SIGNAL OUTPUT CIRCUIT Turn the ignition off Disconnect the CLP SSM harness connector Disconnect the Siren harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Siren Signal Output circuit from...

Page 1537: ... to volt age Perform VTSS VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE OF THE SIREN SIGNAL OUTPUT CIRCUIT Turn the ignition off Measure the resistance between ground and the Siren Signal Output circuit at the Siren harness connector Is the resistance below 10K ohms Yes Repair the Siren Signal Output circuit for a short to ground Perform VTSS VERIFICATION TEST No Replace the Siren Perform ...

Page 1538: ...CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE INTERNAL FAILURE 8Q 32 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1539: ...M harness connector Measure the voltage of the Fused B circuit cavity 2 at the CLP SSM C2 harness connector Is the voltage between 12 and 16 volts Yes Go to 2 No System voltage must be between 12 and 16 volts Repair the voltage concern as necessary Perform VTSS VERIFICATION TEST 2 MEASURE THE VOLTAGE OF THE CLP SSM POWER CIRCUIT Measure the voltage of the Fused B circuit cavity 4 at the CLP SSM C2...

Page 1540: ...ICLE THEFT SECURITY SYSTEM WITH THE DRB IIIT Note If any vehicle theft DTCs are set diagnose them first before continuing With the DRB IIIT in Inputs Outputs read the Central Locking Pump Security System Module last cause state Were there any causes displayed Yes Check for a possible intermittent condition with the circuit indicated by the DRB IIIT Perform VTSS VERIFICATION TEST No The condition t...

Page 1541: ...arm Switch fails to flash there is a problem with the system Select the appropriate VTSS symp tom to troubleshoot the failure With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Operate all functions of the sys tem that caused the original complaint Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTCs from ALL modules Are any DTCs pr...

Page 1542: ...SENTRY KEY REMOTE ENTRY MODULE INTERNAL FAILURE 8Q 36 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1543: ...THEFT SECURITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE VOLTAGE OF THE SKREEM POWER CIRCUIT Turn the ignition off Disconnect the SKREEM harness connector Note Check connectors Clean repair as necessary Measure the voltage of the Fused B circuit cavity 18 at the SKREEM C1 harness connector Is the voltage between 12 and 16 volts Yes Replace the Sentry Key Remote Entry Module Perform SEN...

Page 1544: ...INVALID TRANSMITTER 8Q 38 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1545: ...CHEMATICS AND DIAGRAMS Diagnostic Test 1 WITH THE DRB IIIT READ DTCs Turn the ignition on With the DRB IIIT record and erase DTCs Turn the ignition off Turn the ignition on With the DRB IIIT read DTCs Does the DRB IIIT display an Invalid Transmitter DTC Yes Replace the Ignition Key Perform SENTRY KEY VERIFICATION TEST No The condition that caused this DTC to set is currently not present Inspect th...

Page 1546: ...SENTRY KEY ANTENNA CIRCUIT 8Q 40 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1547: ...LE THEFT SECURITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE SENTRY KEY ANTENNA CIRCUIT Disconnect the Sentry Key Antenna Ring connector from the SKREEM Turn the ignition on Measure the resistance of the Sentry Key Antenna circuit from cavity 1 to cavity 2 of the connector Is the resistance between 4 and 6 ohms Yes Replace the Sentry Key Remote Entry Module Perform SEN...

Page 1548: ...REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT 8Q 42 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1549: ... Key Remote Entry SKREEM Circuit Diagram Refer to 8 ELECTRICAL VEHICLE THEFT SECURITY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 MEASURE THE RESISTANCE OF THE REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT Turn the ignition off Disconnect the SKREEM harness connector Remove the Remote Keyless Entry Relay Note Check connectors Clean repair as necessary Measure the resistance of the Remote Keyless Entry ...

Page 1550: ...Perform SENTRY KEY VERIFICATION TEST No Go to 3 3 MEASURE THE RESISTANCE OF THE REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT Turn the ignition off Measure the resistance between ground and the Remote Keyless Entry Relay Control circuit at the Remote Keyless Entry Relay harness connector Is the resistance below 10K ohms Yes Repair the Remote Keyless Entry Relay Control circuit for a short to ground P...

Page 1551: ...tic Trouble Codes DTCs from ALL modules Operate all functions of the sys tem that caused the original complaint Perform 5 ignition key cycles leaving the key on for at least 90 seconds per cycle Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTCs from ALL modules Are any DTCs present or is the original complaint still present Are any DTCs present YES Repa...

Page 1552: ...SCHEMATICS AND DIAGRAMS VEHICLE THEFT SECURITY SYSTEM CIRCUIT DIAGRAM 8Q 46 VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS ZH ...

Page 1553: ...ZH VEHICLE THEFT SECURITY ELECTRICAL DIAGNOSTICS 8Q 47 ...

Page 1554: ...E DESCRIPTION 55 OPERATION 56 REMOVAL REMOVAL SENTRY KEY REMOTE ENTRY MODULE 57 REMOVAL SENTRY KEY ANTENNA RING 57 INSTALLATION INSTALLATION SENTRY KEY REMOTE ENTRY MODULE 58 INSTALLATION SENTRY KEY ANTENNA RING 59 DOOR CYLINDER LOCK SWITCH REMOVAL 60 INSTALLATION DRIVER CYLINDER LOCK SWITCH 60 ANTI THEFT TOW SENSOR REMOVAL 60 INSTALLATION 61 TOW AWAY ALARM SWITCH REMOVAL 62 INSTALLATION 63 UK SEC...

Page 1555: ...d When a pressure threshold is reached in the system the pump is switched off by an internal pressure switch The pressure in the system is then released by the CLP SSM and the unlocking operation is completed The locking procedure is accomplished in a fashion opposite to the unlocking operation However the next time the remote control button is pressed the CLP SSM is also actuated by connecting it...

Page 1556: ...the power door lock actua tors The vehicle security alarm is also activated by the relocking function ANTI THEFT SYSTEM Once the anti theft alarm system is set the anti theft alarm can be triggered if The Doors Hood or Liftgate Decklid is opened The Radio is removed disconnected electrically The Ignition is jumped The Glove Box is opened The Anti theft Tow Sensor is tripped The Alarm Siren is trip...

Page 1557: ...im panel 1 5 Remove the rear interior trim panel 2 6 Remove the right half of the floor covering 3 7 Remove the sound deadening foam material from the central locking pump security system module 8 Disconnect the air lines 2 and the electrical har ness 1 from the central locking pump security system module 3 and remove the module ZH VEHICLE THEFT SECURITY SERVICE INFORMATION 8Q 51 ...

Page 1558: ...rity system module into sound deadening foam covering and slide it back into place 3 Install the right half of the trunk floor covering 3 4 Install the rear interior trim panel 2 5 Install the right side interior trim panel 4 6 Install the right upper trim panel 1 7 Install the trunk floor carpet 8 Connect the negative battery cable 8Q 52 VEHICLE THEFT SECURITY SERVICE INFORMATION ZH ...

Page 1559: ...placed Refer to 23 BODY HOOD LATCH REMOVAL INSTALLATION The Hood Ajar Switch is an integral part of the hood latch assembly For installation procedures refer to the Body Section Refer to 23 BODY HOOD LATCH INSTALLATION SIREN REMOVAL 1 Remove the cowl grille Refer to 23 BODY EX TERIOR COWL GRILLE REMOVAL 2 Remove the bolt 1 from the siren bracket ZH VEHICLE THEFT SECURITY SERVICE INFORMATION 8Q 53 ...

Page 1560: ...3 Disconnect the siren electrical connector 1 INSTALLATION 1 Connect the siren electrical connector 1 8Q 54 VEHICLE THEFT SECURITY SERVICE INFORMATION ZH ...

Page 1561: ...IPTION The Sentry Key Remote Entry Module SKREEM 1 is located underneath the top pad of the instrument panel 2 behind the Instrument Cluster The SKREEM works in conjunction with the vehicle locking unlocking remote control and the Central Locking Pump Security System Module to lock and unlock the vehicle ZH VEHICLE THEFT SECURITY SERVICE INFORMATION 8Q 55 ...

Page 1562: ... wired to the SKREEM If the Sentry Key Antenna Ring is not mounted properly around the ignition lock cylinder housing com munication problems between the SKREEM and the ignition key may arise These communication problems will result in ignition key transponder related faults The SKREEM also communicates over the Controller Area Network CAN data bus with the Powertrain Control Module PCM the Instru...

Page 1563: ...18 pin electrical connector 1 from the SKREEM 4 Disconnect the 2 pin connector for the sentry key antenna ring 5 Press the retaining tabs apart 6 Remove the SKREEM from the base plate REMOVAL SENTRY KEY ANTENNA RING 1 Remove the instrument cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER REMOVAL 2 Disconnect the sentry key antenna ring electrical connector 1 from the sentry key remote entry modul...

Page 1564: ...EY REMOTE ENTRY MODULE 1 Install the SKREEM module to the base plate 2 Connect the 18 pin electrical connector and the 2 pin CAN bus connector 1 to the SKREEM 3 Connect the 2 pin connector for the sentry key antenna ring 4 Install the instrument cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER INSTALLA TION 5 Connect the negative battery cable 8Q 58 VEHICLE THEFT SECURITY SERVICE INFORMATION ZH ...

Page 1565: ...o the ignition switch key cylinder 2 2 Install the sentry key antenna ring electrical con nector 1 to the sentry key remote entry module 2 3 Install the instrument cluster Refer to 8 ELEC TRICAL INSTRUMENT CLUSTER INSTALLA TION ZH VEHICLE THEFT SECURITY SERVICE INFORMATION 8Q 59 ...

Page 1566: ...DER LOCK SWITCH The Driver Cylinder Lock Switch is an integral part of the Driver Door Lock Actuator assembly and cannot be adjusted or repaired If faulty worn or damaged the entire assembly must be replaced For installation procedures refer to the Body Section Refer to 8 ELECTRICAL POWER LOCKS DRIVER DOOR LATCH SWITCH INSTALLATION ANTI THEFT TOW SENSOR REMOVAL 1 Remove the right side trunk inner ...

Page 1567: ... sensor electrical con nector 1 INSTALLATION Note Install the anti theft tow sensor with the UP mark properly positioned 1 Connect the anti theft tow sensor electrical connec tor 1 ZH VEHICLE THEFT SECURITY SERVICE INFORMATION 8Q 61 ...

Page 1568: ...de trunk inner trim panel TOW AWAY ALARM SWITCH REMOVAL 1 Remove the heated seat switches Refer to 8 ELECTRICAL HEATED SEATS DRIVER HEATED SEAT SWITCH REMOVAL 2 Carefully depress tabs 1 inward to remove the tow away alarm switch 2 8Q 62 VEHICLE THEFT SECURITY SERVICE INFORMATION ZH ...

Page 1569: ...ese sensors are connected to an interface module that is located above the courtesy lamp assembly in the head liner A defeat switch in the courtesy lamp assembly can disable the intrusion sensing function in the event that the vehicle is parked for a short time with a pet child or object which could cause false alarms if left in the vehicle The interface module is connected to the standard alarm m...

Page 1570: ......

Page 1571: ...ING VOLTAGE SUPPLY CIRCUIT OPEN 2 HEATED WASHER NOZZLES INOPERATIVE 4 WASHERS INOPERATIVE 7 WASHERS RUN CONTINUOUSLY WITH IGNITION ON 10 WIPERS INOPERATIVE 13 WIPERS HIGH SPEED INOPERATIVE 17 WIPERS LOW SPEED INOPERATIVE 20 WIPERS INTERMITTENT SPEED INOPERATIVE 23 WIPERS RUN CONTINUOUSLY WITH IGNITION ON 25 BODY VERIFICATION TEST 27 SCHEMATICS AND DIAGRAMS 28 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ...

Page 1572: ...VOLTAGE SUPPLY CIRCUIT OPEN 8R 2 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1573: ...UIT Note Inspect Fuse 4 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Disconnect the BCM harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the BCM C4 harness connector Is the voltage between 12 and 16 volts Yes Replace the B...

Page 1574: ... HEATED WASHER NOZZLES INOPERATIVE 8R 4 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1575: ...zle harness connector Note Check connectors Clean repair as necessary Turn the ignition on Connect a test light between cavity 1 and 2 of the washer nozzle har ness connector Did the test light illuminate Yes Go to 2 No Go to 3 2 TEST BOTH HEATED NOZZLES Disconnect the right and left heated nozzle connectors and the nozzle connector to the thermoswitch Measure the resistance across each heated noz...

Page 1576: ...ROUND CIRCUIT Connect a test light from B to cavity 1 of the harness connector Did the test light illuminate Yes Repair the Fused B circuit for an open No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST 8R 6 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1577: ... WASHERS INOPERATIVE ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 7 ...

Page 1578: ... Depress the washer switch and measure the voltage between the ground circuit and the Washer Pump Motor Control circuit at the Washer Pump Motor harness connector Is the voltage 12 16 Volts Yes Replace the Washer Pump Motor Refer to 8 ELECTRI CAL WIPERS WASHERS WASHER PUMP MOTOR REMOVAL Perform BODY VERIFICATION TEST No Go to 2 2 MEASURE MULTI FUNCTION SWITCH VOLTAGE Turn the ignition on Depress t...

Page 1579: ...an repair as necessary Depress the washer switch and measure the resistance between cav ity 8 and cavity 11 of the Multi Function Switch Is the resistance below 5 0 ohms Yes Repair the Washer Pump Motor Control circuit for an open Perform BODY VERIFICATION TEST No Replace the Multi Function Switch Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATIO...

Page 1580: ... WASHERS RUN CONTINUOUSLY WITH IGNITION ON 8R 10 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1581: ...Cs are set diagnose them first before con tinuing Disconnect the BCM harness connector Note Check connectors Clean repair as necessary Disconnect the Multi Function Switch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Washer Pump Motor Control circuit at cav ity 8 of the Multi Function Switch harness connector Is voltage present Y...

Page 1582: ...witch between cavity 8 and cavity 11 While measuring the resistance depress the washer switch once and release Did the resistance reading go from infinite to less than 5 ohms to infinite Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Replace the Multi Function Switch Refer to 8 ELECTR...

Page 1583: ... WIPERS INOPERATIVE ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 13 ...

Page 1584: ...he Body Control Module BCM C2 harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 of the BCM C2 harness con nector and B Connect a jumper wire between cavity 41 of the BCM C2 harness con nector and ground With the jumper wires connected does the Wiper Motor move Yes Go to 2 No Replace the Wiper Motor Refer to 8 ELECTRICAL WIP ERS WASHERS FRONT W...

Page 1585: ...LES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Go to 3 3 MEASURE WIPER WASHER FUSED B CIRCUIT VOLTAGE Note Inspect Fuse 32 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Multi Function Switch harness connector Note Check connectors Clean repair as necessary T...

Page 1586: ...itch in intermittent then low then high positions Are the resistance readings below 1K ohms Yes Repair the Wiper Switch Mux circuit for an open Perform BODY VERIFICATION TEST No Replace the Multi Function Switch Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 8R 16 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1587: ... WIPERS HIGH SPEED INOPERATIVE ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 17 ...

Page 1588: ...rn the ignition off Disconnect the Body Control Module BCM C2 harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 1 of the BCM C2 harness con nector and B Connect a jumper wire between cavity 41 of the BCM C2 harness con nector and ground With the jumper wires connected does the Wiper Motor move Yes Go to 2 No Replace the Wiper Motor Refer to 8 EL...

Page 1589: ... Switch in the High position Is the voltage approximately 12 volts Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Replace the Multi Function Switch Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST ZH WIPERS WASHERS ELECTRICAL ...

Page 1590: ... WIPERS LOW SPEED INOPERATIVE 8R 20 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1591: ...rn the ignition off Disconnect the Body Control Module BCM C2 harness connector Note Check connectors Clean repair as necessary Connect a jumper wire between cavity 2 of the BCM C2 harness con nector and B Connect a jumper wire between cavity 41 of the BCM C2 harness con nector and ground With the jumper wires connected does the Wiper Motor move Yes Go to 2 No Replace the Wiper Motor Refer to 8 EL...

Page 1592: ... Switch in the Low position Is the voltage approximately 12 volts Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Replace the Multi Function Switch Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL Perform BODY VERIFICATION TEST 8R 22 WIPERS WASHERS ELECTRICA...

Page 1593: ... WIPERS INTERMITTENT SPEED INOPERATIVE ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 23 ...

Page 1594: ...e Body Control Module BCM connector Turn the ignition on Measure the BCM C3 harness connector cavity 65 for voltage with the Wiper Switch in the Intermittent position Is the voltage approximately 12 volts Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST No Replace the Multi Function Switch...

Page 1595: ... WIPERS RUN CONTINUOUSLY WITH IGNITION ON ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 25 ...

Page 1596: ...oltage present Yes Go to 2 No Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform BODY VERIFICATION TEST 2 MEASURE MULTI FUNCTION SWITCH VOLTAGE Turn the ignition off Disconnect the Multi Function Switch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Wi...

Page 1597: ...mitters and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT rea...

Page 1598: ...SCHEMATICS AND DIAGRAMS WIPERS WASHERS CIRCUIT DIAGRAM 1 of 2 8R 28 WIPERS WASHERS ELECTRICAL DIAGNOSTICS ZH ...

Page 1599: ...HEATED WASHER NOZZLES 2 of 2 ZH WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 29 ...

Page 1600: ...38 OPERATION 38 STANDARD PROCEDURE WASHER NOZZLE AIMING 39 REMOVAL 40 INSTALLATION 42 WASHER PUMP MOTOR REMOVAL 44 INSTALLATION 44 WASHER RESERVOIR REMOVAL 45 INSTALLATION 46 WIPER ARMS DESCRIPTION 46 REMOVAL 47 INSTALLATION 48 WIPER BLADES STANDARD PROCEDURE WINDSHIELD WIPER BLADE ALIGNMENT 49 REMOVAL 51 CLEANING 53 INSTALLATION 53 WIPER LINKAGE DESCRIPTION 55 WIPER MODULE DESCRIPTION 56 REMOVAL ...

Page 1601: ... located in the washer fluid reservoir behind the right front inner fender liner Washer Nozzles Two heated washer nozzles 4 are secured into dedicated openings within the cowl grille at the base of the windshield Washer Plumbing The plumbing for the washer system consists of rubber hoses and molded plastic fittings The plumbing is routed from behind the right front inner fender liner through the r...

Page 1602: ...d inward momentarily then released the Wiper System will only cycle once A mist and wash function is also available if the multifunction switch lever is pressed inward past the point of resistance momentarily This will oper ate the washers and cycle the Wiper System twice then return the wipers to the park position The most reliable efficient and accurate means to diagnose the BCM inputs and outpu...

Page 1603: ...arm clearance See procedure in this section Reinspect 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 attachment 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 pivot shaft or both DRIVER AND OR ...

Page 1604: ...her hose is not partially pinched If not OK properly route hose 2 Reverse polarity to pump 2 Check for crossed circuity to pump If not OK repair circuit 3 Nozzle or nozzle hose plugged by contamination 3 Clean nozzle hose of contamination Determine source of contamination inspect reservoir and clean system as required COWL GRILLE NOZZLE STREAM OVERSHOOTS WINDSHIELD 1 Nozzle not seated in cowl gril...

Page 1605: ...e when the ignition switch is turned to the ACC or ON RUN positions Fuse 32 in the Underhood Accessory Fuse Block protect the circuitry of the Wiper System and the vehicle The Wiper System in addition to HI 1 and LO 2 speeds has an intermittent delay 3 mode The wip ers will return to the park position when the wiper por tion of the switch is rotated to the OFF position A mist function can be opera...

Page 1606: ...m the rubber grommet 3 3 Remove the washer fluid level switch 2 from the washer reservoir 1 INSTALLATION 1 Insert the washer fluid level switch 2 into the rub ber grommet 3 at the rear of the washer reservoir 1 2 Press the washer fluid level switch inward until fully seated 3 Install the washer reservoir Refer to 8 ELECTRI CAL WIPERS WASHERS WASHER RESERVOIR INSTALLATION 8R 36 WIPERS WASHERS SERVI...

Page 1607: ...pump motor 2 3 Remove the cowl grille Refer to 23 BODY EX TERIOR COWL GRILLE REMOVAL 4 From the underside of the cowl grille remove the washer hose attachment clamps 2 and release the two washer hose retaining clips 5 Remove the washer hose 1 from the washer noz zles 3 6 Pull the washer hose from the cowl opening and remove the washer hose from the vehicle ZH WIPERS WASHERS SERVICE INFORMATION 8R ...

Page 1608: ...all the right front inner fender liner Refer to the body section in this manual WASHER NOZZLE DESCRIPTION This vehicle is equipped with Heated Washer Nozzles The Heated Washer Nozzles eliminate freezing of the noz zles during the colder seasons The Heated Washer Nozzles are located in the cowl area OPERATION The Heated Washer Nozzles are controlled by a thermoswitch that is attached to the undersi...

Page 1609: ...left nozzles are identi cal Both nozzles emit two spray streams onto the windshield wiper sweep pattern To aim perform the following steps 1 Using a safety pin 1 adjust each nozzle jet as required to aim the spray within the wiper sweep pattern 2 Each adjustment of the jet should be checked by actuating the washer system switch from inside the vehicle 3 After adjustment a final check of the spray ...

Page 1610: ...ille Refer to 23 BODY EX TERIOR COWL GRILLE REMOVAL 3 Remove the clamp s 1 attaching the hose to the washer nozzle 2 then remove the hose 4 Pull the thermoswitch off the cowl grille then dis connect the washer nozzle harness connector 1 and or 2 from the thermoswitch 8R 40 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1611: ... grille 5 Disconnect the washer nozzle harness connector 2 from the nozzle 6 Insert a small screwdriver into the slot between the washer nozzle 1 and the cowl grille 2 pressing inward to release the retaining clip 7 Remove the washer nozzle from the cowl grill ZH WIPERS WASHERS SERVICE INFORMATION 8R 41 ...

Page 1612: ... retaining clip is fully seated 2 Slide the washer hose clamps 1 onto the washer hose 2 3 Install the washer hose 2 over the washer nozzle 3 4 Tighten the washer clamps 1 onto the washer nozzle 3 allowing approximately 0 78 inch 20 mm clearance between the washer hoses 8R 42 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1613: ...ime 5 Connect the washer nozzle harness connector 2 6 Connect the washer nozzle harness connector s 1 2 to the thermoswitch Install the thermoswitch into the cowl grill 7 Install the cowl grille Refer to 23 BODY EXTERIOR COWL GRILLE INSTALLATION ZH WIPERS WASHERS SERVICE INFORMATION 8R 43 ...

Page 1614: ...her pump motor 1 and pull it out of the rubber grom met 2 INSTALLATION 1 Insert the washer pump motor 1 into the rubber grommet 2 at the base of the washer reservoir 3 2 Press the washer pump motor downward until fully seated 3 Install the washer reservoir Refer to 8 ELECTRI CAL WIPERS WASHERS WASHER RESERVOIR INSTALLATION 8R 44 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1615: ...r pump motor harness con nector 3 5 Remove the washer pump motor supply hose from the washer pump motor 3 6 Remove the washer fluid filler tube 1 from the washer reservoir 7 Remove the washer reservoir attachment bolt 2 8 Carefully pull the washer reservoir forward to release the rubber mounting grommets 9 Remove the washer reservoir from behind the right front wheel ZH WIPERS WASHERS SERVICE INFO...

Page 1616: ...6 Install the right front inner fender liner 7 Connect the negative battery cable WIPER ARMS DESCRIPTION The Wiper Arms connect the wiper pivots and the wiper blades They feature an over center hinge that allows easy access to the windshield glass for cleaning and service operations A molded black plastic cap fits over the Wiper Arm attachment nut for protection The Wiper Arm cannot be adjusted or...

Page 1617: ...over center position 3 Carefully pry the plastic nut cap 5 off of the pivot end of the wiper arm 2 4 Remove the wiper arm attachment nut 4 from the wiper pivot shaft 3 5 Use a suitable battery terminal puller to disengage the wiper arm from the wiper pivot shaft tapered splines Corrosion between the wiper arm and the pivot shaft may cause this to be difficult Use caution so as to not damage the pi...

Page 1618: ...chment nut 1 finger tight 3 Carefully set the wiper arm down so the wiper blade touches the glass surface 4 Align the center of the wiper blade 2 with the top of the dot matrix 1 on the bottom of the wind shield Torque the wiper arm retaining nut to 19 N m 14 ft lbs 8R 48 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1619: ...ower the hood prop outer sleeve 2 then close the hood WIPER BLADES STANDARD PROCEDURE WINDSHIELD WIPER BLADE ALIGNMENT WARNING THE WINDSHIELD WIPER MECHANISM CAN PINCH CRUSH OR IN EXTREME CASES EVEN SEVER EXTREMITIES ALWAYS REMOVE THE IGNITION KEY WHEN WORKING ON WINDSHIELD WIPER MECHANISM ZH WIPERS WASHERS SERVICE INFORMATION 8R 49 ...

Page 1620: ...he LO position for approximately 2 seconds then rotate back to the OFF position Ensure the wiper arm pivots have stopped in the park position 4 Install the wiper arm so the center of the blade 2 is aligned with the top of the dot matrix 1 on the bottom of the windshield and secure Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARMS INSTALLATION 8R 50 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1621: ... wiper arm to the service position 2 Squeeze the release tab 1 and slide the wiper blade 2 away from the wiper arm 3 Using a small screwdriver 1 gently push the two retainer springs 2 out of their retention slots ZH WIPERS WASHERS SERVICE INFORMATION 8R 51 ...

Page 1622: ...emove the retainer springs 1 by pulling the springs from the opposite end of the wiper blade 5 Unhook the wiper element 1 from the wiper blade retention slots 2 8R 52 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1623: ...cumulation of salt and road film The wiper blades arms and windshield should be cleaned with a sponge or cloth and a mild detergent or non abrasive cleaner If the wiper blades continue to streak or smear they should be replaced INSTALLATION 1 Install the wiper element 1 onto the wiper blade by sliding the element through the guides ZH WIPERS WASHERS SERVICE INFORMATION 8R 53 ...

Page 1624: ...2 Index the wiper element 1 into the wiper blade retention slots 2 3 Install the retainer springs 1 by sliding the springs onto the edges of the wiper blade 8R 54 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1625: ...position WIPER LINKAGE DESCRIPTION The wiper linkages are integral parts of the Wiper Module Assembly They cannot be adjusted or repaired If faulty worn or damaged the entire wiper module must be replaced as an assembly For complete Wiper Module Removal procedures refer to Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE REMOVAL ZH WIPERS WASHERS SERVICE INFORMATION 8R 55 ...

Page 1626: ...le on the exterior of the vehicle The Wiper Module consists of the following major components Wiper Pivot Shafts 1 Linkage 2 Module Frame 3 Crank Arm 4 Wiper Motor 5 REMOVAL Note If possible cycle the Wiper System to posi tion the wiper arms and linkage in the park posi tion before removal is attempted 1 Disconnect the negative battery cable 2 Remove the wiper arms Refer to 8 ELECTRI CAL WIPERS WA...

Page 1627: ...the wiper motor harness connector 2 from the Body Control Module BCM 3 6 Remove the wiper motor harness rubber grommet 1 from the control module box 4 7 Remove the wiper motor harness rubber grommet 2 from the cowl ledge 3 ZH WIPERS WASHERS SERVICE INFORMATION 8R 57 ...

Page 1628: ... cowl 9 Remove the lower wiper module attachment bolt 3 under the cowl ledge 2 10 Remove the two upper wiper module attachment nuts 1 CAUTION Do not allow the wiper module to con tact the windshield 11 Remove the wiper module 4 from the vehicle 8R 58 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1629: ...upper attachment nut mounting studs 1 2 Install the two wiper module upper attachment nuts and secure 3 Install the lower wiper module attachment bolt through the hole 2 in the cowl and secure 4 Install the cowl grille drain 1 into the cowl and rotate clockwise to secure Insure the grommet is seated fully ZH WIPERS WASHERS SERVICE INFORMATION 8R 59 ...

Page 1630: ...grom met 1 into the control module box 4 7 Connect the wiper motor harness connector 2 to the Body Control Module BCM 3 and slide the locking tab fully over the connector 2 8 Install the control module box cover 1 9 Install the cowl grille Refer to 23 BODY EXTE RIOR COWL GRILLE INSTALLATION 10 Install the wiper arms Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARMS INSTALLA TION 11 Connect the negat...

Page 1631: ...ion switch to the ON RUN position 5 Rotate the multifunction switch to the low position 6 Rotate the multifunction switch back to the OFF position and wait until the wiper motor stops 7 Turn the ignition switch to the OFF LOCK position 8 Disconnect the negative battery cable 9 Disconnect the wiper motor harness connector from the BCM 10 The new wiper motor should now be in the park position 1 and ...

Page 1632: ...PERS WASHERS WIPER MODULE REMOVAL 3 Remove the crank arm retaining nut 1 from the wiper motor shaft 2 4 Scribe a reference mark 3 on both the wiper mod ule and the crank arm for proper alignment during reassembly 5 Press the crank arm 4 off of the wiper motor shaft 2 8R 62 WIPERS WASHERS SERVICE INFORMATION ZH ...

Page 1633: ...per motor 3 into the wiper motor module 2 2 Install the three wiper motor retaining bolts 1 Tighten bolts to 11 N m 8 ft lbs 3 Align the wiper motor crank arm 1 onto the wiper motor shaft in the park position 3 and press into place 4 Install the wiper motor crank arm retaining nut 2 Tighten retaining nut to 26 N m 19 ft lbs 5 Install the wiper motor module into the vehicle Refer to 8 ELECTRICAL WI...

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Page 1635: ...0 1 HORN CIGAR LIGHTER 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 MESSAGE CENTER 8W 46 1 AUDIO SYSTEM 8W 47 1 REAR WINDOW DEFOGGER 8W 48 1 TIRE PRESSURE MONITOR 8W 49 1 FRONT LIGHTING 8W 50 1 REAR LIGHTING 8W 51 1 TURN SIGNALS 8W 52 1 WIPERS 8W 53 1 POWER WINDOWS 8W 60 1 POWER DOOR LOCKS 8W 61 1 POWER MIRRORS 8W 6...

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Page 1637: ... vehicles it is important to understand all of their features and characteristics 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 All switches components and modules are shown in the at rest position with the doors closed and the key removed from the ignition Components are...

Page 1638: ...8W 01 2 8W 01 WIRING DIAGRAM INFORMATION ZH ...

Page 1639: ...ZH 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 ...

Page 1640: ...8W 01 4 8W 01 WIRING DIAGRAM INFORMATION ZH ...

Page 1641: ...ITH TRACER SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections If a component is most likely found in a particular group it will be shown complete all wires connectors and pins within that group For example 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...

Page 1642: ...n line connectors located in the Instrument Panel area are C200 series numbers In line connectors located in the body are C300 series numbers Jumper harness connectors are C400 series numbers Grounds and ground connectors are identified with a G and follow the same series numbering as the in line connectors Splices are identified with an S and follow the same series numbering as the in line connec...

Page 1643: ...W FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY WARNING ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING DIAGNOSIS AND TESTING WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below Jumper Wire This is a test wire used ...

Page 1644: ...or corrosion on the terminals Any amount of corrosion or dirt could cause an intermittent problem Damaged connector component casing exposing the item to dirt or moisture Wire insulation that has rubbed through causing a short to ground Some or all of the wiring strands broken inside of the insulation Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wirin...

Page 1645: ...er sliding across a seat sitting down from a standing posi tion or walking a distance 2 Avoid touching electrical terminals of the part unless instructed to do so by a written procedure 3 When using a voltmeter be sure to connect the ground lead first 4 Do not remove the part form it s protective packing until it is time to install the part 5 Before removing the part from it s pakage ground the pa...

Page 1646: ...le the wiring harness about six to eight inches apart and watch the voltmeter test lamp 4 If the voltmeter registers voltage or the test lamp glows there is a short to ground in that general area of the wiring harness TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits 2 Replace the blown f...

Page 1647: ...ed 6 Position the connector locking finger away from the terminal using the proper special tool Pull on the wire to remove the terminal from the connector INSTALLATION 1 Insert the removed terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connector being sure that all wires are inserted into the proper cavities For additional connector pin out identificati...

Page 1648: ...attery and test affected systems 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 connector 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 Spli...

Page 1649: ...that needs to be spliced 2 Place a piece of adhesive lined heat shrink tubing on one side of the wire Make sure the tubing will be long enough to cover and seal the entire repair area 3 Place the strands of wire overlapping each other inside of the splice clip 1 4 Using crimping too 1 l Mopar p n 05019912AA crimp the splice clip and wires together ZH 8W 01 WIRING DIAGRAM INFORMATION 8W 01 13 ...

Page 1650: ...type solder 1 only CAUTION DO NOT USE ACID CORE SOLDER 6 Center the heat shrink tubing 2 over the joint and heat using a heat gun Heat the joint until the tub ing is tightly sealed and sealant 1 comes out of both ends of the tubing 8W 01 14 8W 01 WIRING DIAGRAM INFORMATION ZH ...

Page 1651: ...W 44 Door Ajar Switches 8W 61 Door Lock Actuators 8W 61 Door Tweeters 8W 47 EGR Solenoid 8W 30 Component Page Engine Control Relay 8W 30 Engine Coolant Temperature Sensor 8W 30 Engine Fuse Block 8W 10 Engine Fuse Block Fuses 8W 10 Engine Starter Motor 8W 21 ESP Brake Pressure Sensors 8W 35 ESP Off Switch 8W 35 ESP Yaw Rate Lateral Acceleration Sensor 8W 35 EVAP Purge Solenoid 8W 30 EVAPorator Temp...

Page 1652: ... 66 S2 Solenoid 8W 66 S3 Solenoid 8W 66 S4 Solenoid 8W 66 Component Page Seat Belt Switches 8W 43 Seat Belt Tensioner Squibs 8W 43 Seat Occupant Simulator 8W 43 Sentry Key Antenna Ring 8W 61 Sentry Key Remote Entry Module 8W 61 Shift Lever Assembly 8W 31 Short Runner Valve Solenoid 8W 30 Side Impact Sensors 8W 43 Side Marker Lamps 8W 50 51 Siren 8W 39 Speakers 8W 47 Speed Control Switch 8W 33 Spli...

Page 1653: ...n Relay 8W 10 22 Horn No 1 8W 10 22 Horn No 2 8W 10 22 Ignition Switch 8W 10 9 Illumination Control Module 8W 10 14 17 18 19 20 Illumination Control Module Fuses 8W 10 5 Instrument Cluster 8W 10 12 14 16 17 18 19 Intrusion Sensor 8W 10 10 13 Key In Ignition Switch 8W 10 16 Left Fog Lamp 8W 10 19 Left Front Lamp Assembly 8W 10 19 Left Front Power Window Switch 8W 10 14 18 Left Front Side Marker Lam...

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Page 1677: ...W 15 2 Left Power Mirror 8W 15 6 Left Rear Lamp Assembly 8W 15 10 13 Left Rear Side Marker Lamp 8W 15 10 13 Left Side Impact Sensor 8W 15 7 Left Turn Signal Lamp 8W 15 2 License Lamp No 1 8W 15 10 12 License Lamp No 2 8W 15 11 12 Liftgate Lock Switch 8W 15 11 12 Noise Suppressor No 1 8W 15 4 Noise Suppressor No 2 8W 15 4 Occupant Restraint Controller 8W 15 7 Park Brake Switch 8W 15 8 Passenger Pow...

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Page 1691: ...2 G200 8W 18 4 Instrument Cluster 8W 18 3 5 6 Occupant Restraint Controller 8W 18 2 Component Page Power Top Control Module 8W 18 4 7 Powertrain Control Module 8W 18 2 5 6 Relay Control Module 8W 18 2 Sentry Key Remote Entry Module 8W 18 4 5 6 Shift Lever Assembly 8W 18 3 5 Steering Angle Sensor 8W 18 2 Transmission Control Module 8W 18 4 5 Underhood Accessory Fuse Block 8W 18 2 Universal Garage D...

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Page 1699: ...Engine Fuse Block 8W 20 2 Engine Starter Motor 8W 20 2 Fuse 4 8W 20 2 G107 8W 20 2 Component Page Generator 8W 20 2 Instrument Cluster 8W 20 2 Powertrain Control Module 8W 20 2 Pulse Module 8W 20 2 Splice Block 100 8W 20 2 ZH 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Page 1701: ...k Switch 8W 21 2 Engine Fuse Block 8W 21 2 Engine Starter Motor 8W 21 2 Fuse 4 8W 21 2 G107 8W 21 2 Component Page Generator 8W 21 2 Ignition Switch 8W 21 2 Powertrain Control Module 8W 21 2 Pulse Module 8W 21 2 Splice Block 100 8W 21 2 ZH 8W 21 STARTING SYSTEM 8W 21 1 ...

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Page 1703: ...l Tank Pressure Sensor 8W 30 9 Fuse 2 8W 30 7 8 11 Fuse 3 8W 30 4 5 6 Fuse 4 8W 30 7 8 Fuse 5 8W 30 6 Component Page Fuse 10 8W 30 3 Fuse 11 8W 30 2 Fuse 13 8W 30 5 G100 8W 30 3 4 5 8 11 G101 8W 30 2 3 5 G104 8W 30 2 G204 8W 30 6 Generator 8W 30 5 Ignition Switch 8W 30 4 5 Illumination Control Module 8W 30 4 Intake Air Temperature Sensor 8W 30 9 Kickdown Switch 8W 30 3 Left Knock Sensor 8W 30 7 8 ...

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Page 1715: ...1 2 Illumination Control Module 8W 31 3 Kickdown Switch 8W 31 3 Component Page Powertrain Control Module 8W 31 3 Radio 8W 31 3 Relay Control Module 8W 31 2 Shift Lever Assembly 8W 31 2 3 Splice Block 200 8W 31 2 Traction System Relay 8W 31 2 Transmission Control Module 8W 31 2 3 Transmission Solenoid Assembly 8W 31 2 3 Underhood Accessory Fuse Block 8W 31 2 ZH 8W 31 TRANSMISSION CONTROL SYSTEM 8W ...

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Page 1719: ... 2 Clutch Pedal Position Switch 8W 33 2 Fuse 10 8W 33 2 G100 8W 33 2 G101 8W 33 2 Component Page Kickdown Switch 8W 33 2 Powertrain Control Module 8W 33 2 Speed Control Switch 8W 33 2 Throttle Body 8W 33 2 Underhood Accessory Fuse Block 8W 33 2 ZH 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

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Page 1721: ...35 5 G200 8W 35 3 G203 8W 35 4 Component Page Illumination Control Module 8W 35 4 5 Left Front WSS Brake Pad Wear Sensor 8W 35 4 5 Left Rear Wheel Speed Sensor 8W 35 4 Park Brake Switch 8W 35 4 Power Amplifier 8W 35 4 Relay Control Module 8W 35 3 Right Front WSS Brake Pad Wear Sensor 8W 35 4 5 Right Rear Wheel Speed Sensor 8W 35 4 Shift Lever Assembly 8W 35 3 4 Splice Block 100 8W 35 3 Splice Bloc...

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Page 1727: ...tch 8W 39 2 Component Page Hood Ajar Switch 8W 39 3 Illumination Control Module 8W 39 2 Instrument Cluster 8W 39 4 Intrusion Sensor 8W 39 4 Left Door Ajar Switch 8W 39 2 Left Rear Lamp Assembly 8W 39 2 Liftgate Lock Switch 8W 39 2 Power Seat Relay 8W 39 2 Power Top Control Module 8W 39 3 Rear Window Defogger 8W 39 3 Right Door Ajar Switch 8W 39 2 Right Rear Lamp Assembly 8W 39 2 Siren 8W 39 3 Spli...

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Page 1731: ... 4 Fuse 35 8W 40 2 Fuse 37 8W 40 2 G100 8W 40 3 G200 8W 40 2 3 G201 8W 40 4 Component Page G202 8W 40 4 G204 8W 40 4 Generator 8W 40 3 Illumination Control Module 8W 40 2 Instrument Cluster 8W 40 2 3 4 Key In Ignition Switch 8W 40 2 Left Door Ajar Switch 8W 40 4 Occupant Restraint Controller 8W 40 4 Park Brake Switch 8W 40 4 Right Door Ajar Switch 8W 40 4 Splice Block 200 8W 40 2 Telescopic Steeri...

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Page 1735: ...Fuse 6 8W 41 2 Fuse 31 8W 41 2 G100 8W 41 2 G200 8W 41 2 Glove Box Lamp 8W 41 2 Component Page Horn Relay 8W 41 2 Horn Switch 8W 41 2 Horn No 1 8W 41 2 Horn No 2 8W 41 2 Occupant Restraint Controller 8W 41 2 Relay Control Module 8W 41 2 Underhood Accessory Fuse Block 8W 41 2 ZH 8W 41 HORN CIGAR LIGHTER 8W 41 1 ...

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Page 1737: ...ector 8W 42 3 EVAPorator Temperature Sensor 8W 42 2 Fuse 15 8W 42 2 Fuse 33 8W 42 2 Component Page Fuse 34 8W 42 3 Fuse 35 8W 42 3 Fuse 36 8W 42 3 Fuse 37 8W 42 3 G200 8W 42 3 Heater Core Temperature Sensor 8W 42 2 Instrument Cluster 8W 42 3 Recirculated Air Switchover Valve 8W 42 3 Underhood Accessory Fuse Block 8W 42 2 3 Universal Garage Door Opener Tire Pressure Monitor 8W 42 3 ZH 8W 42 AIR CON...

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Page 1739: ...2005 ZH Service Manual Publication No 81 270 05036 05ZH8W 42 3 December 2004 ...

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Page 1741: ...ument Cluster 8W 43 2 Component Page Left Side Airbag Squib 8W 43 3 Left Side Impact Sensor 8W 43 3 Occupant Restraint Controller 8W 43 2 3 4 Passenger Airbag On Off Switch 8W 43 2 Passenger Airbag Squib 8W 43 4 Passenger Seat Belt Switch 8W 43 2 Passenger Seat Belt Tensioner Squib 8W 43 4 Passenger Seat Occupant Simulator 8W 43 2 Powertrain Control Module 8W 43 4 Relay Control Module 8W 43 3 Righ...

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Page 1745: ...4 2 Glove Box Lamp 8W 44 2 Component Page Glove Box Switch 8W 44 2 Illumination Control Module 8W 44 2 3 Instrument Cluster 8W 44 2 3 Left Door Ajar Switch 8W 44 2 Left Front Lamp Assembly 8W 44 3 Left Rear Lamp Assembly 8W 44 3 Liftgate Lock Switch 8W 44 2 Multi Function Switch 8W 44 3 Rear Spoiler Switch 8W 44 3 Remote Keyless Entry Relay 8W 44 3 Right Door Ajar Switch 8W 44 2 Right Front Lamp A...

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Page 1749: ...8W 45 2 G201 8W 45 2 G204 8W 45 2 G206 8W 45 2 Component Page G300 8W 45 4 G301 8W 45 4 Instrument Cluster 8W 45 3 Intrusion Sensor 8W 45 2 Left Front Power Window Motor 8W 45 5 Left Front Power Window Switch 8W 45 4 Liftgate Lock Switch 8W 45 3 Multi Function Switch 8W 45 5 Power Amplifier 8W 45 2 Rear Spoiler Limit Switch 8W 45 4 Rear Spoiler Motor 8W 45 4 Rear Spoiler Switch 8W 45 4 Right Front...

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Page 1755: ... 8W 46 2 3 Fuse 3 8W 46 2 3 Fuse 35 8W 46 2 3 G201 8W 46 2 G204 8W 46 3 Component Page Illumination Control Module 8W 46 2 3 Instrument Cluster 8W 46 2 3 Key In Ignition Switch 8W 46 2 3 Left Door Ajar Switch 8W 46 2 Right Door Ajar Switch 8W 46 3 Underhood Accessory Fuse Block 8W 46 2 3 Washer Fluid Level Switch 8W 46 2 3 ZH 8W 46 MESSAGE CENTER 8W 46 1 ...

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Page 1759: ...rol Module 8W 47 2 Instrument Cluster 8W 47 2 Left Door Speaker 8W 47 4 Component Page Left Door Tweeter 8W 47 4 Left Rear Speaker 8W 47 5 Power Amplifier 8W 47 3 4 5 Power Top Control Module 8W 47 4 Radio 8W 47 2 3 Right Door Speaker 8W 47 4 Right Door Tweeter 8W 47 4 Right Rear Speaker 8W 47 5 Shift Lever Assembly 8W 47 2 Splice Block 200 8W 47 2 Underhood Accessory Fuse Block 8W 47 2 3 ZH 8W 47...

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Page 1765: ...tral Locking Pump Security System Module 8W 48 2 Fuse 4 8W 48 2 Fuse 25 8W 48 2 Fuse 26 8W 48 2 Component Page G205 8W 48 2 G300 8W 48 2 G301 8W 48 2 Left Power Mirror 8W 48 2 Rear Window Defogger 8W 48 2 Right Power Mirror 8W 48 2 Underhood Accessory Fuse Block 8W 48 2 ZH 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Page 1767: ... 2 Heated Seat Module 8W 49 2 Instrument Cluster 8W 49 2 Left Front Tire Pressure Sensor Transmitter 8W 49 2 Component Page Left Rear Tire Pressure Sensor Transmitter 8W 49 2 Right Front Tire Pressure Sensor Transmitter 8W 49 2 Right Rear Tire Pressure Sensor Transmitter 8W 49 2 Siren 8W 49 2 Underhood Accessory Fuse Block 8W 49 2 Universal Garage Door Opener Tire Pressure Monitor 8W 49 2 ZH 8W 49...

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Page 1769: ...mination Control Module 8W 50 2 3 4 5 6 Component Page Instrument Cluster 8W 50 4 Left Fog Lamp 8W 50 5 Left Front Lamp Assembly 8W 50 3 4 Left Front Side Marker Lamp 8W 50 2 Left Headlamp Leveling Motor 8W 50 6 Left Park Lamp 8W 50 2 Multi Function Switch 8W 50 4 Right Fog Lamp 8W 50 5 Right Front Lamp Assembly 8W 50 3 4 Right Front Side Marker Lamp 8W 50 2 Right Headlamp Leveling Motor 8W 50 6 R...

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Page 1775: ...use 7 8W 51 2 3 Fuse 10 8W 51 2 3 Fuse 11 8W 51 2 3 Fuse 12 8W 51 4 Component Page G300 8W 51 2 4 5 G301 8W 51 2 3 4 5 G302 8W 51 3 4 5 Illumination Control Module 8W 51 2 3 4 5 Instrument Cluster 8W 51 2 3 Left Rear Lamp Assembly 8W 51 2 3 4 5 Left Rear Side Marker Lamp 8W 51 2 3 License Lamp No 1 8W 51 2 3 License Lamp No 2 8W 51 2 3 Powertrain Control Module 8W 51 5 Right Rear Lamp Assembly 8W ...

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Page 1781: ... 8W 52 3 G301 8W 52 3 G302 8W 52 3 Component Page Illumination Control Module 8W 52 2 Left Front Lamp Assembly 8W 52 3 Left Rear Lamp Assembly 8W 52 3 Left Turn Signal Lamp 8W 52 3 Multi Function Switch 8W 52 2 Right Front Lamp Assembly 8W 52 3 Right Rear Lamp Assembly 8W 52 3 Right Turn Signal Lamp 8W 52 3 ZH 8W 52 TURN SIGNALS 8W 52 1 ...

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Page 1785: ...8W 53 3 Fuse 20 8W 53 2 Fuse 32 8W 53 2 G100 8W 53 3 G101 8W 53 2 3 Component Page G204 8W 53 2 Heated Washer Nozzles 8W 53 3 Multi Function Switch 8W 53 2 Underhood Accessory Fuse Block 8W 53 2 3 Washer Pump Motor 8W 53 2 Wiper Motor 8W 53 2 ZH 8W 53 WIPERS 8W 53 1 ...

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Page 1789: ... Illumination Control Module 8W 60 3 Left Front Power Window Motor 8W 60 2 3 Component Page Left Front Power Window Switch 8W 60 2 3 Right Front Power Window Motor 8W 60 2 3 Right Front Power Window Switch 8W 60 2 3 Splice Block 200 8W 60 2 Underhood Accessory Fuse Block 8W 60 2 3 ZH 8W 60 POWER WINDOWS 8W 60 1 ...

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Page 1793: ...00 8W 61 4 5 G201 8W 61 2 5 6 G204 8W 61 2 3 5 6 G206 8W 61 2 3 Component Page G301 8W 61 2 3 Instrument Cluster 8W 61 6 Left Door Ajar Switch 8W 61 6 Liftgate Lock Actuator 8W 61 2 3 Liftgate Lock Switch 8W 61 2 3 Passenger Door Lock Actuator 8W 61 2 3 Power Seat Relay 8W 61 6 Power Top Control Module 8W 61 3 Remote Keyless Entry Antenna 8W 61 5 Remote Keyless Entry Relay 8W 61 4 Right Door Ajar ...

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Page 1799: ...8W 62 2 Fuse 6 8W 62 2 Fuse 7 8W 62 3 Fuse 36 8W 62 2 G201 8W 62 2 3 G203 8W 62 2 Component Page G204 8W 62 2 Illumination Control Module 8W 62 3 Intrusion Sensor 8W 62 3 Left Power Mirror 8W 62 2 Power Mirror Switch 8W 62 2 Powertrain Control Module 8W 62 3 Right Power Mirror 8W 62 2 Shift Lever Assembly 8W 62 3 Underhood Accessory Fuse Block 8W 62 2 3 ZH 8W 62 POWER MIRRORS 8W 62 1 ...

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Page 1803: ... 2 Left Door Ajar Switch 8W 63 2 Left Heated Seat Back 8W 63 5 Component Page Left Heated Seat Back Heated Seat Cushion 8W 63 5 Left Heated Seat Cushion 8W 63 5 Passenger Power Seat 8W 63 4 Passenger Power Seat Horizontal Motor 8W 63 4 Passenger Power Seat Recliner Motor 8W 63 4 Power Seat Relay 8W 63 2 Right Door Ajar Switch 8W 63 2 Right Heated Seat Back 8W 63 5 Right Heated Seat Back Heated Sea...

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Page 1809: ... Switch 8W 66 3 Left Rotation Relay 8W 66 5 Power Amplifier 8W 66 3 Component Page Power Top Control Module 8W 66 2 3 4 5 6 Power Top Hydraulic Assembly 8W 66 5 Power Top Switch 8W 66 2 Power Top Travel Sensors 8W 66 2 Rear Bow Switch 8W 66 4 Right Rotation Relay 8W 66 5 Roof Open Switch 8W 66 4 Splice Block 200 8W 66 2 Tonneau Cover Switch 8W 66 4 Tonneau Cover Travel Sensor 8W 66 6 Trunk Latch A...

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Page 1815: ...W 68 2 Fuse 20 8W 68 2 G200 8W 68 2 G300 8W 68 2 G301 8W 68 2 Instrument Cluster 8W 68 2 Component Page Rear Spoiler Limit Switch 8W 68 2 Rear Spoiler Motor 8W 68 2 Rear Spoiler Switch 8W 68 2 Splice Block 200 8W 68 2 Underhood Accessory Fuse Block 8W 68 2 ZH 8W 68 POWER REAR SPOILER 8W 68 1 ...

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Page 1817: ...8 S211 8W 42 2 S212 8W 10 16 S213 8W 45 5 S215 8W 10 14 S217 8W 44 3 S218 8W 61 5 S220 8W 10 12 S221 8W 47 3 Component Page S224 8W 70 2 S225 8W 47 3 S226 8W 47 3 S232 8W 45 4 S233 8W 10 10 S235 8W 47 3 S236 8W 47 3 S239 8W 10 15 S240 8W 70 2 S241 8W 63 5 S242 8W 15 8 S243 8W 63 5 S244 8W 15 8 S246 8W 10 20 S247 8W 10 10 S300 8W 48 2 S301 8W 66 6 S302 8W 66 6 S305 8W 48 2 S330 8W 18 7 S331 8W 18 7...

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Page 1819: ... 80 17 C223 8W 80 17 C224 8W 80 17 Component Page C224 8W 80 17 C226 8W 80 17 C226 8W 80 18 C228 8W 80 18 C228 8W 80 18 C229 8W 80 19 C229 8W 80 19 C230 8W 80 19 C230 8W 80 19 C231 8W 80 20 C231 8W 80 20 C232 8W 80 20 C232 8W 80 20 C300 ZH27 8W 80 20 C300 ZH27 8W 80 21 C301 ZH27 8W 80 21 C301 ZH27 8W 80 21 C302 ZH27 8W 80 21 C302 ZH27 8W 80 22 Camshaft Position Sensor 8W 80 22 Cargo Compartment Di...

Page 1820: ...or 8W 80 40 Component Page Left Front Power Window Switch 8W 80 40 Left Front Side Marker Lamp Except Export 8W 80 41 Left Front WSS Brake Pad Wear Sensor 8W 80 41 Left Headlamp Leveling Motor Export 8W 80 41 Left Heated Seat Back Heated Seat Cushion 8W 80 41 Left Knock Sensor 8W 80 42 Left Park Lamp 8W 80 42 Left Power Mirror 8W 80 42 Left Rear Lamp Assembly 8W 80 42 Left Rear Side Marker Lamp 8W...

Page 1821: ... Knock Sensor 8W 80 63 Right Park Lamp 8W 80 63 Component Page Right Power Mirror 8W 80 63 Right Rear Lamp Assembly 8W 80 63 Right Rear Side Marker Lamp 8W 80 63 Right Rear Speaker 8W 80 64 Right Rear Wheel Speed Sensor 8W 80 64 Right Rotation Relay ZH27 8W 80 64 Right Side Airbag Squib 8W 80 64 Right Side Impact Sensor 8W 80 65 Right Turn Signal Lamp Export 8W 80 65 Roof Open Switch ZH27 8W 80 65...

Page 1822: ...COOLANT CIRCULATION VALVE CONTROL 11 12 16BR GROUND 13 22DG BL REAR DEFOGGER SWITCH SENSE 14 22RD WT A C PRESSURE SENSOR 5 VOLT SUPPLY 15 16 18BR YL RECIRCULATED AIR SWITCHOVER VALVE CONTROL 17 22BK BL SCI TRANSMIT 18 22YL VT SERIAL COMMUNICATION K1 19 20 18BL DG A C COMPRESSOR CLUTCH CONTROL 21 18PK RD BL FUSED IGNITION SWITCH OUTPUT 22 20BK DG FUSED IGNITION SWITCH OUTPUT 23 24 22GY RD EVAPORATO...

Page 1823: ...NSOR GROUND 4 20DG ACCELERATOR PEDAL POSITION SENSOR SIGNAL NO 2 5 20GY ACCELERATOR PEDAL POSITION SENSOR SIGNAL NO 1 6 20BK SENSOR GROUND AIR PUMP EXCEPT SRT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 12RD WT AIR PUMP RELAY OUTPUT 2 14BR GROUND AIR PUMP SRT 2 WAY CAV CIRCUIT FUNCTION 1 12BK AIR PUMP RELAY OUTPUT 2 14BR GROUND AIR PUMP SWITCHOVER SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20GY BR AIR PUM...

Page 1824: ...20BR SENSOR GROUND ANTENNA C1 ZH27 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 2 18BL DG ENABLE SIGNAL TO AMPLIFIER ANTENNA C1 ZH29 BLACK 1 WAY CAV CIRCUIT FUNCTION 1 18BL DG ENABLE SIGNAL TO AMPLIFIER ANTENNA C2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 24BK ANTENNA 2 BK SHIELD ANTI THEFT TOW SENSOR BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 3 4 22DG GY SENSOR GROUND 5 18BR DG ANTI THEFT TOW SENSOR SIGNAL 6 18RD YL FU...

Page 1825: ...TCH OUTPUT 5 6 BACKUP LAMP SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20PK RD FUSED IGNITION SWITCH OUTPUT 2 20GY YL BACKUP LAMP SWITCH OUTPUT BAS BRAKE BOOSTER C1 BLACK 3 WAY CAV CIRCUIT FUNCTION 1 20PK YL 5 VOLT SUPPLY 2 20VT DG BAS TRAVEL SENSOR SIGNAL 3 20YL DG SENSOR GROUND BAS BRAKE BOOSTER C2 BLACK 6 WAY CAV CIRCUIT FUNCTION 1 20GY BAS RELEASE SWITCH SENSOR RELEASED 2 20PK 12 VOLT SUPPLY 3 1...

Page 1826: ...LOW SPEED CONTROL 2 14DG WIPER HIGH SPEED CONTROL 40 14WT WIPER PARK SWITCH SENSE 41 14BK 12 VOLT SUPPLY BODY CONTROL MODULE C3 BLACK 9 WAY CAV CIRCUIT FUNCTION 45 16BK BL TURN SIGNAL MONITORED GROUND 46 16BK YL HAZARD SWITCH SIGNAL 47 22DG BL REAR DEFOGGER SWITCH SENSE 48 22DG BK REAR DEFOGGER INDICATOR DRIVER 49 20WT DG DOOR LOCK SWITCH MUX 63 16GY WASHER PUMP MOTOR CONTROL 64 65 18BL WIPER SWIT...

Page 1827: ... 22 23 24 25 26 27 28 20BR GY EXCEPT SRT SPOILER LIMIT SWITCH SIGNAL UP 29 20BR YL EXCEPT SRT SPOILER LIMIT SWITCH SIGNAL DOWN 30 20BK DG ESP OFF SIGNAL 31 20BL GY ZH29 LIFTGATE LOCK SWITCH SENSE LOCK 32 33 34 20BK WT SCI TRANSMIT 35 36 37 38 20WT BL RIGHT POWER WINDOW SWITCH SENSE 39 20DG YL LEFT POWER WINDOW SWITCH SENSE 42 14BR GROUND 43 14BR EXCEPT SRT GROUND 44 12RD YL FUSED B 51 52 53 54 55 ...

Page 1828: ... FLUID LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR WT BRAKE FLUID LEVEL SWITCH SENSE BRAKE LAMP SWITCH A T BLACK 3 WAY CAV CIRCUIT FUNCTION 1 2 20RD YL TRACTION SYSTEM RELAY OUTPUT 3 20RD BL BTSI FEED C100 ZH27 NATURAL BODY SIDE CAV CIRCUIT 1 18BK WT 1 18BK WT EXPORT 2 18BK DG 2 18BK DG EXPORT 3 22GY BK 4 22GY RD 5 16PK YL DG 6 18PK RD WT 7 20BK YL 8 8W 80 10 8W 80 CONNECTOR...

Page 1829: ...T 7 20BK YL 8 C100 ZH29 BLACK BODY SIDE CAV CIRCUIT 1 18BK WT 1 18BK WT EXPORT 2 18BK DG 2 18BK DG EXPORT 3 22GY BK 4 22GY RD C100 ZH29 BLACK COCKPIT SIDE CAV CIRCUIT 1 18BK WT 2 18BK DG 3 22GY BK 4 22GY RD C105 BLACK BODY SIDE CAV CIRCUIT 1 18BR RD 2 20YL RD 3 20RD YL 4 ZH 8W 80 CONNECTOR PIN OUTS 8W 80 11 ...

Page 1830: ...2 12BK SRT 3 18BL DG 4 16BK YL 5 20BL 6 14VT WT 7 8 C106 BLACK ENGINE SIDE CAV CIRCUIT 1 20BR VT EXCEPT SRT 1 20GY BL SRT 2 12RD WT SRT 3 18BL DG 4 16BK YL 5 18BL 6 14VT 7 8 C200 BLACK COCKPIT SIDE CAV CIRCUIT 1 18BK DG 2 16VT 3 18BK WT 4 22BK BL 4 22BK BL 5 18RD DG 5 18RD DG 6 22RD YL 6 22RD YL 7 8 8W 80 12 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1831: ...8BK WT EUROPE 4 22BK BL 4 20BK BL EXCEPT EXPORT 5 18RD DG 6 20RD YL 7 8 C201 BLACK BODY SIDE CAV CIRCUIT 1 20DG 2 20WT 3 20RD DG 4 20BR 5 20BL YL 6 20BK DG 7 20GY YL M T 8 20BL 9 20BR 10 20YL 11 20BR 12 20BK BL 13 20DG VT 14 20BL DG 15 16 20BK YL 17 22YL 18 20DG BK ZH 8W 80 CONNECTOR PIN OUTS 8W 80 13 ...

Page 1832: ...10 20YL 11 20BR 12 20BK BL 13 20DG VT 14 20BL DG 15 16 20BK YL 17 22YL 18 20DG BK C206 BLACK BODY SIDE CAV CIRCUIT 1 22BK RD 2 20BL 3 20BK 4 20BR GY 5 20BK WT 6 7 22RD YL A T 8 22DG C206 BLACK COCKPIT SIDE CAV CIRCUIT 1 22BK RD 2 20BL 3 20BK 4 20BR GY 5 20BK WT 5 22BK WT 6 7 22RD YL 8 22DG 8W 80 14 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1833: ...SIDE CAV CIRCUIT 1 18RD DG 2 20DG WT 3 22WT 4 22DG C210 BODY SIDE CAV CIRCUIT 1 20BL DG 2 20BR DG C210 RED COCKPIT SIDE CAV CIRCUIT 1 20BL DG 2 20BR DG C211 NATURAL BODY SIDE CAV CIRCUIT 1 20DG WT 2 18BR DG 3 14RD WT 4 18BR WT 5 20BR 5 20BR 6 20YL BK 7 20YL DG 8 18RD DG 8 18RD DG ZH 8W 80 CONNECTOR PIN OUTS 8W 80 15 ...

Page 1834: ...20DG EXCEPT EXPORT 3 18DG WT EXPORT 4 18RD DG EXCEPT EXPORT 5 18BR BL EXCEPT EXPORT 6 20DG VT M T EXCEPT EXPORT 7 8 20BK BL ZH27 C219 BLUE ENGINE COMPARTMENT SIDE CAV CIRCUIT 1 20BK RD EXCEPT EXPORT 2 20BR YL EXCEPT EXPORT 2 20BR YL EXCEPT EXPORT 3 20DG EXCEPT EXPORT 3 18DG WT EXPORT 4 18RD DG EXCEPT EXPORT 5 18BR BL EXCEPT EXPORT 6 20DG VT M T EXCEPT EXPORT 7 8 20BK BL 8W 80 16 8W 80 CONNECTOR PI...

Page 1835: ...LACK BODY SIDE CAV CIRCUIT 1 20BL BK 2 20BL WT C224 YELLOW DOOR SIDE CAV CIRCUIT 1 20BL RD 2 20BL GY C226 COCKPIT SIDE CAV CIRCUIT 1 18GY 2 20BR VT 3 20BR RD 4 20BR DG 5 22BL 6 22RD WT 7 18BL DG 8 22BR YL 9 22BL RD 10 20DG YL 11 20BL YL 12 22YL 13 20RD WT 14 20BR YL 15 16 17 18 ZH 8W 80 CONNECTOR PIN OUTS 8W 80 17 ...

Page 1836: ...18BR YL 9 18BL RD 10 20DG YL 11 20BL YL 12 22YL 13 20RD WT 14 20BR YL 15 16 17 18 C228 BLACK BODY SIDE CAV CIRCUIT 1 18PK RD WT 2 18BR 3 18WT 4 18GY 5 18BK 6 20BR 7 20BL 8 20BK C228 BLACK DOOR SIDE CAV CIRCUIT 1 18PK RD WT 2 18BR 3 18WT 4 18GY 5 18BK 6 20BR 7 20BL 8 20BK 8W 80 18 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1837: ... DOOR SIDE CAV CIRCUIT 1 18BK BL 1 16BK BL 2 18BR DG 2 16BR DG 3 14DG 4 14BK 5 C230 BLACK BODY SIDE CAV CIRCUIT 1 18PK RD WT 2 18BR 3 18WT 4 18GY VT 5 18BK VT 6 7 8 C230 BLACK DOOR SIDE CAV CIRCUIT 1 18PK RD WT 2 18BR 3 18WT 4 18GY 5 18BK 6 7 8 ZH 8W 80 CONNECTOR PIN OUTS 8W 80 19 ...

Page 1838: ...E CAV CIRCUIT 1 16BK BL 1 18BK BL 2 18BR DG 2 16BR DG 3 14DG 4 14BK 5 C232 RED BODY SIDE CAV CIRCUIT 1 20VT 2 20DG C232 RED COCKPIT SIDE CAV CIRCUIT 1 20VT 2 20DG C300 ZH27 NATURAL BODY SIDE CAV CIRCUIT 1 2 20BR BL 3 20BR VT 4 20BK VT 5 16BK DG 6 16RD DG 7 8 8W 80 20 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1839: ... SIDE CAV CIRCUIT 1 14BK 2 20BR BK 3 20BR BL 4 C301 ZH27 BLACK REAR WINDOW DEFOG GER SIDE CAV CIRCUIT 1 14BK 2 20BK 3 20BK 4 C302 ZH27 BLACK BODY SIDE CAV CIRCUIT 1 16RD WT EXCEPT SRT 2 16BR WT EXCEPT SRT 3 20BR GY EXCEPT SRT 4 20BR YL EXCEPT SRT 5 20BK BL 6 18GY VT 7 18GY YL 8 14BR ZH 8W 80 CONNECTOR PIN OUTS 8W 80 21 ...

Page 1840: ...OUND 2 20PK CAMSHAFT POSITION SENSOR SIGNAL 3 20RD BL FUSED ENGINE CONTROL RELAY OUTPUT CARGO COMPARTMENT DIVIDER SWITCH ZH27 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR BK CARGO DIVIDER SENSE CARGO LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18BR YL CARGO LAMP CONTROL 2 18RD GY FUSED B CENTER HIGH MOUNTED STOP LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BK BL BRAKE LAMP RELAY OU...

Page 1841: ...WAY CAV CIRCUIT FUNCTION 1 14BK REAR WINDOW DEFOGGER GRID SUPPLY 2 12RD DG FUSED B 3 14BR GROUND 4 16BK YL WT FUSED B CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE C3 BLACK 18 WAY CAV CIRCUIT FUNCTION 1 2 3 4 22DG GY SENSOR GROUND 5 18BR RD HOOD AJAR SWITCH SENSE 6 20WT DG TOW AWAY ALARM SWITCH SENSE 7 20YL RD SIREN SIGNAL OUTPUT 8 20YL EXPORT INTRUSION SENSOR SIGNAL 9 20BR DG ZH27 TONNEAU COVER SWI...

Page 1842: ...FT TAIL LAMP OUTPUT CHARCOAL CANISTER SHUTOFF VALVE EXCEPT EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18RD DG FUSED ENGINE CONTROL RELAY OUTPUT 2 18BR BL CHARCOAL CANISTER SHUTOFF VALVE CONTROL CHARGE AIR COOLER CIRCULATION PUMP SRT 2 WAY CAV CIRCUIT FUNCTION 1 18RD BL FUSED CHARGE AIR COOLER CIRCULATION PUMP DRIVER 2 18BR GROUND CIGAR LIGHTER BLACK 3 WAY CAV CIRCUIT FUNCTION 1 16BR GROUND 2 3 16BK...

Page 1843: ...ERLOCK SWITCH OUTPUT CLUTCH PEDAL POSITION SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20RD BK CLUTCH PEDAL POSITION SWITCH SIGNAL COIL ON PLUG NO 1 BLACK 3 WAY CAV CIRCUIT FUNCTION 1 18BK COIL ON PLUG DRIVER NO 1 2 18BK DG FUSED IGNITION SWITCH OUTPUT 3 18BK WT COIL ON PLUG DRIVER NO 1 COIL ON PLUG NO 2 BLACK 3 WAY CAV CIRCUIT FUNCTION 1 18YL COIL ON PLUG DRIVER NO 2 2 18BK DG FUSED I...

Page 1844: ...BK YL FUSED IGNITION SWITCH OUTPUT 3 18VT WT COIL ON PLUG DRIVER NO 5 COIL ON PLUG NO 6 BLACK 3 WAY CAV CIRCUIT FUNCTION 1 18GY COIL ON PLUG DRIVER NO 6 2 18BK YL FUSED IGNITION SWITCH OUTPUT 3 18GY WT COIL ON PLUG DRIVER NO 6 CONSOLE SWITCH GROUP BLACK 11 WAY CAV CIRCUIT FUNCTION 1 18BK WT LEFT TURN SIGNAL OUTPUT 2 18BK DG RIGHT TURN SIGNAL OUTPUT 3 16BK BL TURN SIGNAL MONITORED GROUND 4 20BR GRO...

Page 1845: ... 20BR SENSOR GROUND 25 20DG S CAN 26 27 20GY BAS RELEASE SWITCH SENSOR RELEASED 28 20BK VT BAS CONTROL 29 20WT S CAN 30 20PK 12 VOLT SUPPLY 31 18YL VT BAS RELEASE SWITCH SENSOR APPLIED 32 12BK FUSED B 33 20WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 20BR RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 20BL LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 37 20BR LEFT REAR WHEEL SPEED SENSOR SIGNAL...

Page 1846: ...HER LEVEL COMBINATION 2 20BR YL COOLANT WASHER LEVEL SIGNAL CRANKSHAFT POSITION SENSOR NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 20DG CRANKSHAFT POSITION SENSOR SIGNAL 2 2 20DG WT CRANKSHAFT POSITION SENSOR SIGNAL 1 DATA LINK CONNECTOR BLACK 16 WAY CAV CIRCUIT FUNCTION 1 20BK WT SCI TRANSMIT 2 3 20DG YL SCI RECEIVE 4 18BR GROUND 5 20BR YL SENSOR GROUND 6 7 22BL SCI TRANSMIT 8 20RD WT FUSED IGNITION SWI...

Page 1847: ...EXCEPT EUROPE BLACK 3 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BL DRIVER CYLINDER LOCK SWITCH SENSE LOCK 3 20BK DRIVER CYLINDER LOCK SWITCH SENSE UNLOCK DRIVER POWER SEAT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 14RD BK FUSED POWER SEAT RELAY OUTPUT 2 14BR GROUND DRIVER SEAT BELT SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20GY DG DRIVER SEAT BELT SWITCH SENSE 3 20BR GROUND 4 20BR DG DRIVE...

Page 1848: ...NGINE CONTROL RELAY OUTPUT ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20DG RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 2 20BR WT SENSOR GROUND ESP BRAKE PRESSURE SENSOR 1 BLACK 3 WAY CAV CIRCUIT FUNCTION 1 20BR BL SENSOR GROUND 2 20BL WT ESP BRAKE PRESSURE SENSOR 1 SIGNAL 3 20BK RD WT 5 VOLT SUPPLY ESP OFF SWITCH BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 20BK BL ESP OFF SWITCH...

Page 1849: ... EVAP PURGE SOLENOID CONTROL EVAPORATOR TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 22BR YL EVAPORATOR TEMPERATURE SENSOR GROUND 2 22GY RD EVAPORATOR TEMPERATURE SENSOR SIGNAL FUEL INJECTOR NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18GY BK FUSED ENGINE CONTROL RELAY OUTPUT 2 18GY BK FUEL INJECTOR NO 1 CONTROL FUEL INJECTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18GY RD FUSED ENGINE CONTRO...

Page 1850: ...INJECTOR NO 4 CONTROL FUEL INJECTOR NO 5 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18GY YL FUSED ENGINE CONTROL RELAY OUTPUT 2 18GY YL FUEL INJECTOR NO 5 CONTROL FUEL INJECTOR NO 6 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18GY VT FUSED ENGINE CONTROL RELAY OUTPUT 2 18GY VT FUEL INJECTOR NO 6 CONTROL FUEL LEVEL SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GY FUEL LEVEL SENSOR RETURN 2 20BL BK FUEL LEVEL SENSO...

Page 1851: ...ION 1 20BR GROUND 2 3 20PK YL BK FUSED IGNITION SWITCH OUTPUT GENERATOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18BL LOW BATTERY INDICATOR OUTPUT 2 18BL WT SRT GENERATOR CONTROL GLOVE BOX LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 1 20BR GROUND 2 16BK BL FUSED B 2 16BK BL FUSED B GLOVE BOX SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR GY GLOVE BOX SWITCH SENSE ZH 8W 80 CONNECTOR...

Page 1852: ...D IGNITION SWITCH OUTPUT 3 16BK GY LEFT HEATED SEAT OUTPUT 4 14RD YL FUSED B HEATED WASHER NOZZLES BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18PK RD WT FUSED IGNITION SWITCH OUTPUT 2 18BR GROUND HEATER CORE TEMPERATURE SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 22GY DG RIGHT HEATER CORE TEMPERATURE SENSOR SIG NAL 2 22BR YL SENSOR GROUND 3 22GY PK LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL HOOD AJAR SWITCH...

Page 1853: ...LLUMINATION CONTROL MODULE OUTPUT 7 18BK RD LHD BRAKE LAMP RELAY OUTPUT 8 14YL BK FOG LAMP SWITCH OUTPUT 9 20GY YL A T SHIFT LEVER ASSEMBLY REVERSE SUPPLY VOLTAGE 9 20GY YL M T BACKUP LAMP SWITCH OUTPUT 10 18DG WT LHD FUSED ILLUMINATION CONTROL MODULE OUTPUT 10 18BK RD RHD BRAKE LAMP RELAY OUTPUT 11 18GY RD LHD FUSED RIGHT STANDING PARK LAMPS OUTPUT 11 18BK RD RHD BRAKE LAMP RELAY OUTPUT 12 18GY V...

Page 1854: ...UT 20 18GY BK RHD FUSED ILLUMINATION CONTROL MODULE OUTPUT 21 18GY YL LHD FUSED FOG LAMP OUTPUT 21 16WT BK RHD FUSED HIGH BEAM OUTPUT ILLUMINATION CONTROL MODULE D BLACK 10 WAY CAV CIRCUIT FUNCTION 1 16BK WT BL FUSED IGNITION SWITCH OUTPUT 2 16WT YL HEADLAMP SUPPLY 3 18DG WT LHD FUSED IGNITION SWITCH OUTPUT 3 20BL WT RHD FUSED ILLUMINATION CONTROL MODULE OUTPUT 4 20BR BK LHD FUSED ILLUMINATION CON...

Page 1855: ... AMBIENT TEMPERATURE SENSOR SIGNAL 5A 18GY BL FUSED ILLUMINATION FEED 6A 20BR GY KEY IN IGNITION SWITCH SENSE 6B 20BR AMBIENT TEMPERATURE SENSOR GROUND 7B 20BR WT BRAKE FLUID LEVEL SWITCH SENSE 7A 20BR BK FUSED ILLUMINATION CONTROL MODULE OUTPUT 8A 22YL VT SERIAL COMMUNICATION K1 8B 9B 22WT CAN C BUS 9A 20PK RD BL FUSED IGNITION SWITCH OUTPUT 10A 20BK DG RIGHT TURN SIGNAL OUTPUT 10B 22DG CAN C BUS...

Page 1856: ...CH OUTPUT 2M 2D 2C 20PK AIRBAG WARNING INDICATOR DRIVER 2B 2A 2L 22BR GY LHD LEFT DOOR AJAR SWITCH SENSE 2L 22BR PK RHD RIGHT DOOR AJAR SWITCH SENSE 3D 3L 4L 20BL BK FUEL LEVEL SENSOR SIGNAL 5L 20BR GY FUEL LEVEL SENSOR RETURN 6L INTAKE AIR TEMPERATURE SENSOR SRT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR YL SENSOR GROUND 2 20YL DG IAT SENSOR SIGNAL INTRUSION SENSOR EXPORT 4 WAY CAV CIRCUIT FUNCTION ...

Page 1857: ...ETAINER SWITCH ZH27 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20DG WT LATCH RETAINER SWITCH SENSE LEFT DOOR AJAR SWITCH WHITE 3 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR GY LEFT DOOR AJAR SWITCH SENSE 2 20BR GY LEFT DOOR AJAR SWITCH SENSE 3 LEFT DOOR SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 16BR DG AMPLIFIED LEFT DOOR SPEAKER 2 16BK BL AMPLIFIED LEFT DOOR SPEAKER ZH 8W 80 CONNECTOR PI...

Page 1858: ...UT 2 16BR GROUND 3 16YL BK FUSED LOW BEAM OUTPUT 4 16WT BK FUSED HIGH BEAM OUTPUT 5 6 LEFT FRONT POWER WINDOW MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 14DG LEFT FRONT POWER WINDOW DRIVER UP 2 14BK LEFT FRONT POWER WINDOW DRIVER DOWN LEFT FRONT POWER WINDOW SWITCH BLACK 6 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20DG YL LEFT POWER WINDOW SWITCH SENSE 3 4 5 20DG WT ZH27 FUSED ILLUMINATION CONTROL MO...

Page 1859: ...OR DRIVER 3 20DG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP PLY 4 20BR LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT HEADLAMP LEVELING MOTOR EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 18BR GROUND 2 18YL VT HEADLAMP ADJUST SIGNAL 3 18DG WT FUSED ILLUMINATION CONTROL MODULE OUTPUT LEFT HEATED SEAT BACK HEATED SEAT CUSHION 2 WAY CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BK GY LEFT HEATED SEAT OUTPUT ZH 8W 80 ...

Page 1860: ...Y 2 18BR GROUND 3 4 18WT LEFT MIRROR HORIZONTAL DRIVER 5 18GY LEFT MIRROR COMMON DRIVER 6 18BK LEFT MIRROR VERTICAL DRIVER LEFT REAR LAMP ASSEMBLY BLACK 6 WAY CAV CIRCUIT FUNCTION 1 18BR GROUND 2 18GY BK LEFT TAIL LAMP OUTPUT 2 18GY BK LEFT STANDING PARK LAMPS OUTPUT 3 18BK WT LEFT TURN SIGNAL OUTPUT 4 18BK RD BRAKE LAMP RELAY OUTPUT 5 18GY YL BACKUP LAMP SWITCH OUTPUT 6 18GY DG LHD EXPORT REAR FO...

Page 1861: ...CUIT FUNCTION 1 20BR LEFT REAR WHEEL SPEED SENSOR SIGNAL 2 20BL LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY LEFT ROTATION RELAY ZH27 8 WAY CAV CIRCUIT FUNCTION 1 2 RD FUSED B 3 4 BK ROTATION RELAY GROUND 5 BK GROUND 6 DG LEFT ROTATION RELAY CONTROL 7 8 BK LEFT ROTATION RELAY OUTPUT 9 LEFT SIDE AIRBAG SQUIB YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 20BL GY LEFT SIDE SQUIB LINE 1 2 20BL RD LEFT SIDE SQUI...

Page 1862: ...P NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 18GY VT FUSED ILLUMINATION CONTROL MODULE OUTPUT LICENSE LAMP NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 18GY YL FUSED ILLUMINATION CONTROL MODULE OUTPUT LIFTGATE LOCK SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR BL ZH27 LIFTGATE LOCK SWITCH SENSE UNLOCK 2 20BR YL ZH29 LIFTGATE LOCK SWITCH SENSE UNLOCK 3 20BL GY ZH2...

Page 1863: ...2 20RD DG EXCEPT SRT MAP SENSOR SIGNAL 2 20RD BK SRT MAP SENSOR SIGNAL 3 20PK BK 5 VOLT SUPPLY MULTI FUNCTION SWITCH BLACK 12 WAY CAV CIRCUIT FUNCTION 1 16WT YL HEADLAMP SUPPLY 2 16WT HEADLAMP HIGH BEAM SUPPLY 3 4 18BK BL TURN SIGNAL MONITORED GROUND 5 6 7 18BL WIPER SWITCH MUX 8 16GY WASHER PUMP MOTOR CONTROL 8 18GY WASHER PUMP MOTOR CONTROL 9 18BK DG RIGHT TURN SIGNAL OUTPUT 10 18BK WT LEFT TURN...

Page 1864: ...E 2 11 20VT DRIVER SQUIB LINE 1 12 20GY DG DRIVER SEAT BELT SWITCH SENSE 13 20BL DG PASSENGER SQUIB LINE 2 14 20BR DG PASSENGER SQUIB LINE 1 15 20WT PASSENGER AIRBAG ON OFF SWITCH SIGNAL 16 20BL RD LEFT SIDE SQUIB LINE 2 17 20BL GY LEFT SIDE SQUIB LINE 1 18 20BL BK RIGHT SIDE SQUIB LINE 1 19 20BL WT RIGHT SIDE SQUIB LINE 2 20 20BL YL LEFT SIDE IMPACT SENSOR SIGNAL 21 20WT YL RIGHT SIDE IMPACT SENS...

Page 1865: ...SOR 1 1 SIGNAL OXYGEN SENSOR 1 2 DOWNSTREAM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 18RD DG FUSED ENGINE CONTROL RELAY OUTPUT 2 18BR WT OXYGEN SENSOR 1 2 HEATER CONTROL 3 20BR SENSOR GROUND 4 20YL BK OXYGEN SENSOR 1 2 SIGNAL OXYGEN SENSOR 2 1 UPSTREAM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 18RD DG FUSED ENGINE CONTROL RELAY OUTPUT 2 18BR BK EXCEPT SRT OXYGEN SENSOR 2 1 HEATER CONTROL 2 18BR GY SRT OXYGEN S...

Page 1866: ... ON OFF SWITCH SENSE ON 2 20GY 5 VOLT SUPPLY 3 20YL BL AIRBAG ON OFF SWITCH SENSE OFF 4 5 6 PASSENGER AIRBAG SQUIB YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 20BL DG PASSENGER SQUIB LINE 2 2 20BR DG PASSENGER SQUIB LINE 1 PASSENGER POWER SEAT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 14RD DG FUSED POWER SEAT RELAY OUTPUT 2 14BR GROUND PASSENGER SEAT BELT SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 20GY BL PASSENG...

Page 1867: ...AT OCCUPANT SIMULATOR C2 YELLOW 3 WAY CAV CIRCUIT FUNCTION 1 20BL WT AIRBAG ON OFF SWITCH SENSE ON 2 20GY 5 VOLT SUPPLY 3 20YL BL AIRBAG ON OFF SWITCH SENSE OFF POWER AMPLIFIER A BLACK 12 WAY CAV CIRCUIT FUNCTION 1 18BL RIGHT DOOR SPEAKER 2 18BL BR LEFT DOOR SPEAKER 3 18BL BR LEFT DOOR SPEAKER 4 16BR GROUND 5 18BL DG ENABLE SIGNAL TO AMPLIFIER 6 18YL VT LEFT REAR SPEAKER 7 18YL RIGHT REAR SPEAKER ...

Page 1868: ...R SPEAKER 17 16BR YL AMPLIFIED RIGHT DOOR SPEAKER 18 16BR DG AMPLIFIED LEFT DOOR SPEAKER POWER MIRROR SWITCH BLACK 8 WAY CAV CIRCUIT FUNCTION 1 18BR GROUND 2 3 18GY LEFT MIRROR COMMON DRIVER 4 18GY VT RIGHT MIRROR COMMON DRIVER 5 18WT RIGHT MIRROR VERTICAL DRIVER 5 18BK LEFT MIRROR VERTICAL DRIVER 6 18PK RD WT ZH27 FUSED B 6 18PK RD WT ZH29 FUSED IGNITION SWITCH OUTPUT 7 18WT LEFT MIRROR HORIZONTA...

Page 1869: ...R LOCK CONTROL 20 20BR YL POWER TOP SWITCH INDICATOR DRIVER 21 20BR VT TRUNK LATCH LOCKED SIGNAL 22 20BK VT TRUNK LATCH UNLOCKED SIGNAL 23 20YL RD MAIN CYLINDER TRAVEL SENSOR BASE 24 20DG YL MAIN CYLINDER TRAVEL SENSOR ROD 25 26 20GY VT REAR BOW CYLINDER TRAVEL SENSOR BASE 27 20WT YL REAR BOW CYLINDER TRAVEL SENSOR ROD 28 20BK YL SCI TRANSMIT POWER TOP CONTROL MODULE C2 ZH27 12 WAY CAV CIRCUIT FUN...

Page 1870: ...G MAIN CYLINDER TRAVEL SENSOR ROD 4 20DG YL MAIN CYLINDER TRAVEL SENSOR ROD 5 20GY REAR BOW CYLINDER TRAVEL SENSOR BASE 6 20GY VT REAR BOW CYLINDER TRAVEL SENSOR BASE 7 20WT REAR BOW CYLINDER TRAVEL SENSOR ROD 8 20WT YL REAR BOW CYLINDER TRAVEL SENSOR ROD POWERTRAIN CONTROL MODULE C1 BLACK 9 WAY CAV CIRCUIT FUNCTION 1 18BK PK SRT SUPERCHARGER CLUTCH CONTROL 2 18BK WT COIL ON PLUG DRIVER NO 1 3 18B...

Page 1871: ...ONTROL 24 18BR GY SRT OXYGEN SENSOR 2 1 HEATER CONTROL POWERTRAIN CONTROL MODULE C3 BLACK 52 WAY CAV CIRCUIT FUNCTION 1 2 20PK CAMSHAFT POSITION SENSOR SIGNAL 3 20BK SENSOR GROUND 4 20VT RIGHT KNOCK SENSOR SIGNAL 5 20DG RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 6 20DG SENSOR GROUND 7 20BK OXYGEN SENSOR 1 1 SIGNAL 8 20YL DG IAT SENSOR SIGNAL 9 20BR DG SENSOR GROUND 10 20RD DG EXCEPT SRT MAP SENSO...

Page 1872: ...SITION SENSOR SIGNAL 2 27 18GY BK FUEL INJECTOR NO 1 CONTROL 28 18GY BL FUEL INJECTOR NO 4 CONTROL 29 30 31 32 33 34 35 36 37 38 39 20RD YL 5 VOLT SUPPLY 40 41 42 43 44 18GY COIL ON PLUG DRIVER NO 6 45 18DG COIL ON PLUG DRIVER NO 3 46 18BL COIL ON PLUG DRIVER NO 4 47 18BK COIL ON PLUG DRIVER NO 1 48 49 18VT COIL ON PLUG DRIVER NO 5 50 18YL COIL ON PLUG DRIVER NO 2 51 52 8W 80 54 8W 80 CONNECTOR PI...

Page 1873: ...GEN SENSOR 2 2 SIGNAL 17 20DG FUEL TANK PRESSURE SENSOR SIGNAL 18 20OR SENSOR GROUND 19 20YL WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY 20 21 22 20GY OFF SIGNAL 23 20DG RD ACCEL SET SIGNAL 24 25 20VT A T FUSED IGNITION SWITCH OUTPUT 25 20VT M T CLUTCH INTERLOCK SWITCH OUTPUT 26 20DG BL ON SIGNAL 27 28 20YL DG DECEL SET SIGNAL 29 22BL SCI TRANSMIT 30 20BL RD RESUME SIGNAL 31 32 20DG YL SCI ...

Page 1874: ...LSE MODULE A BLACK 5 WAY CAV CIRCUIT FUNCTION 1 12BK FUSED B 2 20PK RD SENSOR GROUND 3 4 5 12BR GROUND PULSE MODULE B BLACK 2 WAY CAV CIRCUIT FUNCTION 1 16VT A T FUSED IGNITION SWITCH OUTPUT 1 20VT M T CLUTCH INTERLOCK SWITCH OUTPUT 2 14PK RD FUSED IGNITION SWITCH OUTPUT PULSE MODULE E SRT 7 WAY CAV CIRCUIT FUNCTION 1 2 18PK RD FUSED IGNITION SWITCH OUTPUT 3 4 5 18GY BL CHARGE AIR COOLER CIRCULATI...

Page 1875: ...CONTROL MODULE GROUND 2 8BK DG RADIATOR FAN CONTROL MODULE OUTPUT RADIO BLACK 16 WAY CAV CIRCUIT FUNCTION 1B 1A 20DG WT NAVIGATION WHEEL SPEED SENSOR OUTPUT 2B 2A 20GY YL NAVIGATION SHIFT LEVER ASSEMBLY REVERSE SUPPLY VOLTAGE 2A 20GY YL NAVIGATION SHIFT LEVER ASSEMBLY REVERSE SUPPLY VOLTAGE 3B 18YL RIGHT REAR SPEAKER 3A 4A 14RD DG FUSED B 4B 18YL VT LEFT REAR SPEAKER 5B 18BL RIGHT DOOR SPEAKER 5A ...

Page 1876: ...AV CIRCUIT FUNCTION 1 20BR GROUND 2 20GY OR REAR BOW SENSE REAR SPOILER LIMIT SWITCH EXCEPT SRT BLACK 4 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR YL SPOILER LIMIT SWITCH SIGNAL DOWN 3 20BR GY SPOILER LIMIT SWITCH SIGNAL UP 4 REAR SPOILER MOTOR EXCEPT SRT BLUE 2 WAY CAV CIRCUIT FUNCTION 1 16BR WT REAR SPOILER DRIVER UP 2 16RD WT REAR SPOILER DRIVER DOWN 8W 80 58 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1877: ...AV CIRCUIT FUNCTION 1 20BR VT EXCEPT SRT AIR PUMP RELAY CONTROL 1 20GY BL SRT AIR PUMP RELAY CONTROL 2 16RD BL FUSED ENGINE CONTROL RELAY OUTPUT 3 16RD DG FUSED ENGINE CONTROL RELAY OUTPUT 4 12RD WT AIR PUMP RELAY OUTPUT RELAY CONTROL MODULE B BLACK 5 WAY CAV CIRCUIT FUNCTION 1 12RD FUSED B 2 12RD FUSED B 3 14RD DG FUEL PUMP RELAY OUTPUT 4 14RD FUSED B 5 18BR GROUND RELAY CONTROL MODULE C BLACK 5 ...

Page 1878: ...ENGINE CONTROL RELAY OUTPUT 6 18RD DG FUSED ENGINE CONTROL RELAY OUTPUT 7 RIGHT DOOR AJAR SWITCH WHITE 3 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20BR PK RIGHT DOOR AJAR SWITCH SENSE 2 20BR PK RIGHT DOOR AJAR SWITCH SENSE 3 RIGHT DOOR SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 16BR DG AMPLIFIED RIGHT DOOR SPEAKER 2 16BK BL AMPLIFIED RIGHT DOOR SPEAKER RIGHT DOOR TWEETER BLACK 2 WAY CAV CIRCUIT FUN...

Page 1879: ...GH BEAM OUTPUT 5 6 RIGHT FRONT POWER WINDOW MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 14DG RIGHT FRONT POWER WINDOW DRIVER UP 2 14BK RIGHT FRONT POWER WINDOW DRIVER DOWN RIGHT FRONT POWER WINDOW SWITCH BLACK 6 WAY CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20WT BL RIGHT POWER WINDOW SWITCH SENSE 3 4 5 20DG WT ZH27 FUSED ILLUMINATION CONTROL MODULE OUTPUT 5 20GY BL ZH29 FUSED ILLUMINATION CONTROL MODULE O...

Page 1880: ...R DRIVER 3 20BR RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 4 20WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT HEADLAMP LEVELING MOTOR EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 18BR GROUND 2 18YL VT HEADLAMP ADJUST SIGNAL 3 18DG WT FUSED ILLUMINATION CONTROL MODULE OUTPUT RIGHT HEATED SEAT BACK HEATED SEAT CUSHION 2 WAY CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BK VT RIGHT HEATED SEAT OUTPUT 8W 80 ...

Page 1881: ...ATED MIRROR SUPPLY 2 18BR GROUND 3 4 18WT RIGHT MIRROR VERTICAL DRIVER 5 18GY RIGHT MIRROR COMMON DRIVER 6 18BK RIGHT MIRROR HORIZONTAL DRIVER RIGHT REAR LAMP ASSEMBLY BLACK 6 WAY CAV CIRCUIT FUNCTION 1 18BR GROUND 2 18GY RD RIGHT TAIL LAMP OUTPUT 2 18GY RD FUSED STANDING PARK LAMPS OUTPUT 3 18BK DG RIGHT TURN SIGNAL OUTPUT 4 18BK YL BRAKE LAMP RELAY OUTPUT 5 18GY YL BACKUP LAMP SWITCH OUTPUT 6 RI...

Page 1882: ...IRCUIT FUNCTION 1 20BR RIGHT REAR WHEEL SPEED SENSOR SIGNAL 2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY RIGHT ROTATION RELAY ZH27 8 WAY CAV CIRCUIT FUNCTION 1 2 RD FUSED B 3 4 BK ROTATION RELAY GROUND 5 BK GROUND 6 BR RIGHT ROTATION RELAY CONTROL 7 8 RD RIGHT ROTATION RELAY OUTPUT 9 RIGHT SIDE AIRBAG SQUIB YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 20BL GY RIGHT SIDE SQUIB LINE 2 2 20BL RD RIGHT...

Page 1883: ...IDER SENSE 2 20BK ROOF CARGO DIVIDER SENSE SENTRY KEY REMOTE ENTRY MODULE C1 BLACK 18 WAY CAV CIRCUIT FUNCTION 1 22GY BK DOOR UNLOCK SWITCH SENSE 2 20BK YL REMOTE KEYLESS ENTRY RELAY CONTROL 3 22GY RD RKE STATUS OUTPUT 4 5 6 22WT RKE ANTENNA 7 SHIELD SHIELD 8 20BK DRIVER CYLINDER LOCK SWITCH SENSE UNLOCK 9 20BL DRIVER CYLINDER LOCK SWITCH SENSE LOCK 10 22PK RD BL FUSED IGNITION SWITCH OUTPUT 11 22...

Page 1884: ... SCI TRANSMIT 4 20BR GROUND 5 20RD BL BTSI FEED 6 22WT CAN C BUS 7 22DG CAN C BUS 8 20RD DG TRACTION SYSTEM RELAY OUTPUT 9 20PK RD FUSED IGNITION SWITCH OUTPUT 10 20GY YL SHIFT LEVER ASSEMBLY REVERSE SUPPLY VOLTAGE SHORT RUNNER VALVE SOLENOID EXCEPT SRT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20DG VT SHORT RUNNER VALVE SOLENOID CONTROL 2 20RD DG FUSED ENGINE CONTROL RELAY OUTPUT SIREN BLACK 3 WAY CAV C...

Page 1885: ...SENSOR SIGNAL 2 20PK RD FUSED IGNITION SWITCH OUTPUT 3 20BR GROUND 4 18RD DG FUSED B SUPERCHARGER CLUTCH SRT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18BK PK SUPERCHARGER CLUTCH CONTROL 2 18RD DG FUSED ENGINE CONTROL RELAY OUTPUT THROTTLE BODY BLACK 6 WAY CAV CIRCUIT FUNCTION 1 18BL THROTTLE CONTROL MOTOR 1 2 20VT 5 VOLT SUPPLY 3 20GY SENSOR GROUND 4 18BK THROTTLE CONTROL MOTOR 2 5 20WT THROTTLE POSITIO...

Page 1886: ... AWAY ALARM SWITCH BLACK 3 WAY CAV CIRCUIT FUNCTION 2 22RD DG TOW AWAY ALARM SWITCH LED CONTROL 4 6 20WT DG TOW AWAY ALARM SWITCH SENSE TRANSMISSION CONTROL MODULE C1 BLACK 18 WAY CAV CIRCUIT FUNCTION 1 22DG SCI TRANSMIT 2 3 4 5 6 7 8 9 10 23 24 25 26 27 28 29 18RD DG TRACTION SYSTEM RELAY OUTPUT 30 18BR GROUND 8W 80 68 8W 80 CONNECTOR PIN OUTS ZH ...

Page 1887: ...OL 38 18RD SOLENOID SUPPLY VOLTAGE H L TRANSMISSION CONTROL MODULE C3 BLACK 2 WAY CAV CIRCUIT FUNCTION H 22WT CAN C BUS L 22DG CAN C BUS TRANSMISSION SOLENOID ASSEMBLY BLACK 13 WAY CAV CIRCUIT FUNCTION 1 20BK N3 INPUT SPEED SENSOR 2 20DG YL MODULATION PRESSURE SOLENOID CONTROL 3 20WT N2 INPUT SPEED SENSOR 4 20BL YL TEMP SENSOR P N SWITCH 5 6 18RD SOLENOID SUPPLY VOLTAGE 7 20BL DG SENSOR SUPPLY VOL...

Page 1888: ...SAL GARAGE DOOR OPENER TIRE PRESSURE MONITOR WHITE 6 WAY CAV CIRCUIT FUNCTION 1 20PK YL DG FUSED IGNITION SWITCH OUTPUT 2 20GY YL LOW TIRE PRESSURE WARNING INDICATOR CON TROL 3 20BR GROUND 4 20BK BL SCI TRANSMIT 5 20RD GY FUSED B 6 WASHER FLUID LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 20BR COOLANT WASHER LEVEL RETURN 2 20BR BL COOLANT WASHER LEVEL COMBINATION WASHER PUMP MOTOR BLACK 2 WAY C...

Page 1889: ...Pedal NS Air Pump Except SRT BK Center Top Engine N S Air Pump SRT Left Side Engine 18 Air Pump Fuse On the Relay Control Module 8 Air Pump Relay In the Relay Control Module 8 Air Pump Switchover Solenoid BK Front of Engine 12 Airbag Off Indicator Lamp BK Center of Instrument Panel N S Airbag ON OFF Switch Right Side of Dash N S Ambient Temperature Sensor BK Lower Left Grille N S Antenna C1 ZH27 B...

Page 1890: ...05 BK Left Rear of Engine Compartment Under the Underhood Accessory Fuse Block 4 C106 BK In the Control Module Box at Right Rear of Engine Compartment 8 C200 BK Left of Steering Column Behind the Instrument Panel N S C201 BK Behind the Passenger Footwell 2 C204 Except Export BL Behind the Passenger Footwell 2 C206 BK Behind the Passenger Footwell 2 C207 A T BK Behind the Passenger Footwell 2 C210 ...

Page 1891: ...nter of the Instrument Panel N S Clockspring BK Center of the Steering Wheel N S Clutch Interlock Switch BK Top of the Clutch Pedal N S Clutch Pedal Position Switch BK Top of the Clutch Pedal N S Coil On Plug No 1 BK On the Right Valve Cover 20 Coil On Plug No 2 BK On the Right Valve Cover 20 Coil On Plug No 3 BK On the Right Valve Cover 20 Coil On Plug No 4 BK On the Left Valve Cover 11 Coil On P...

Page 1892: ...Under the Center Console 7 ESP Yaw Rate Lateral Acceleration Sensor MK25 Under the Center Console 23 EVAP Purge Solenoid BK Left Side of Engine Compartment 1 Evaporator Temperature Sensor BK Right Side of Driver Footwell N S Fuel Injector No 1 BK Right Side of Intake Manifold 20 Fuel Injector No 2 BK Right Side of Intake Manifold 20 Fuel Injector No 3 BK Right Side of Intake Manifold 20 Fuel Injec...

Page 1893: ...ar Switch WT Rear of Left Door N S Left Door Speaker BK Left Door NS Left Door Tweeter BK Left Door NS Left Fog Lamp WT Left Front of Fascia Below Headlamp N S Left Front Lamp Assembly BK Left Front of Vehicle NS Left Front Power Window Motor BK Left Door NS Left Front Power Window Switch BK NS Left Front Side Marker Lamp Except Export Left Front Side NS Left Front WSS Brake Pad Wear Sensor BK Lef...

Page 1894: ... RD Passenger Seat Belt Tensioner N S Passenger Seat Belt Tensioner Squib YL Passenger Seat Belt Tensioner N S Passenger Seat Occupant Simulator C1 YL Behind the Passenger Footwell 2 Passenger Seat Occupant Simulator C2 YL Behind the Passenger Footwell 2 Power Amplifier A BK Behind the Passenger Footwell 2 Power Amplifier B BK Behind the Passenger Footwell 2 Power Mirror Switch BK Center Console N...

Page 1895: ...pt SRT BL Rear of Vehicle NS Rear Spoiler Switch Except SRT BK Rear of Vehicle NS Rear Window Defogger Left Rear Quarter Panel 22 Recirculated Air Switchover Valve GY Lower Passenger Instrument Panel N S Relay Control Module A BK In Control Module Box at Right Rear of Engine Compartment 8 Relay Control Module B BK In Control Module Box at Right Rear of Engine Compartment 8 Relay Control Module C B...

Page 1896: ...r YL Under Carpet Below Right Seat N S Right Turn Signal Lamp Export NS Roof Open Switch ZH27 BK NS Sentry Key Antenna Ring BK On Ignition Key Cylinder N S Sentry Key Remote Entry Module C1 BK Behind Instrument Cluster N S Sentry Key Remote Entry Module C2 WT Behind Instrument Cluster N S Sentry Key Remote Entry Module C3 BK Behind Instrument Cluster N S Shift Lever Assembly BK Center Console 7 Sh...

Page 1897: ...LOCATION FIG G100 Left Side of Engine Compartment 9 G101 Right Side of Engine Compartment 8 G104 Top Front of Engine N S G107 Right Side of Engine Compartment Battery Negative Ground 8 G200 Behind Left Side of Instrument Panel at Base of Windshield N S G201 Lower Left Footwell Behind Kickpanel 29 G202 Under the Center Console at the Occupant Restraint Controller 7 G203 Under the Center Console 7 G...

Page 1898: ...23 Engine Compartment Behind the Engine N S S124 A T Engine Compartment Behind the Engine N S S125 A T Engine Compartment Behind the Engine N S S211 Behind the Instrument Cluster N S S212 Behind the Instrument Cluster N S S213 Behind the Instrument Cluster N S S215 Behind the Upper Instrument Panel N S S216 Behind the Upper Instrument Panel N S S217 Behind the Upper Instrument Panel N S S218 At th...

Page 1899: ... Block 100 Left Rear of Engine Compartment Behind the Underhood Accessory Fuse Block 5 Splice Block 101 Left Rear of Engine Compartment Behind the Underhood Accessory Fuse Block 5 Splice Block 102 Left Rear of Engine Compartment Behind the Underhood Accessory Fuse Block 5 Splice Block 200 Under the Center Console 7 ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 11 ...

Page 1900: ...Fig 1 MODULE OVERVIEW 8W 91 12 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1901: ...Fig 2 LEFT SIDE ENGINE COMPARTMENT Fig 3 RIGHT SIDE FLOOR ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 ...

Page 1902: ...Fig 4 RIGHT SIDE TRUNK Fig 5 LEFT SIDE ENGINE COMPARTMENT PULSE MODULE 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1903: ...Fig 6 RIGHT SIDE DOOR Left hand similar ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 ...

Page 1904: ...Fig 7 CENTER CONSOLE Fig 8 RIGHT SIDE ENGINE COMPARTMENT 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1905: ...Fig 9 ENGINE COMPARTMENT Fig 10 RIGHT SIDE ENGINE COMPARTMENT SPLICES ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 ...

Page 1906: ...Fig 11 ENGINE SIDE VIEW Fig 12 ENGINE FRONT VIEW 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1907: ...Fig 13 ENGINE REAR Fig 14 MANUAL TRANSMISSION ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 ...

Page 1908: ...Fig 15 AUTOMATIC TRANSMISSION Fig 16 INTERIOR 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1909: ...Fig 17 POWER TOP CONTROL MODULE ROADSTER Fig 18 UNDERHOOD SRT ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 ...

Page 1910: ...Fig 19 CHARGE AIR COOLER CIRCULATION PUMP SRT 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1911: ...Fig 20 FRONT OF ENGINE SRT ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 ...

Page 1912: ...Fig 21 REAR OF ENGINE SRT Fig 22 REAR WINDOW TRUNK COUPE 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1913: ...Fig 23 TRUNK ROADSTER Fig 24 D HANDLE LOCK SWITCH ROADSTER ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 ...

Page 1914: ...Fig 25 HEADLAMP SWITCH Fig 26 TONNEAU COVER SWITCH ROADSTER 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1915: ...Fig 27 CONSOLE SWITCH GROUP Fig 28 TRUNK ROADSTER ZH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 ...

Page 1916: ...Fig 29 LEFT KICK PANEL Fig 30 TRUNK 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION ZH ...

Page 1917: ...distribution of the electrical current required to operate all of the many standard and optional factory installed electrical and electronic powertrain chassis safety comfort and convenience systems At the same time these sys tems were designed to provide centralized locations for conducting diagnosis of faulty circuits and for sourcing the additional current requirements of many aftermarket vehic...

Page 1918: ...gine Fuse Block through the cable and eyelet that are secured with a nut to the Engine Fuse Block B terminal stud located on one end of the Engine Fuse Block housing The Engine Fuse Block terminal stud cover is unlatched and opened or removed to access the Fuses REMOVAL 1 Disconnect and isolate the negative battery cable 2 Open the lid 1 of the engine fuse block 3 Remove the nuts and the electrica...

Page 1919: ...E DESCRIPTION The Relay Control Module controls many of the vehicle relays The Relay Control Module is located inside the con trol module box The Relay Control Module can not be serviced and it must be replaced as a unit OPERATION The Relay Control Module is a solid state device containing the following internal relays Air Pump Relay Engine Control Relay Traction System Relay Horn Relay Fuel Pump ...

Page 1920: ...side of the box to access the clip 1 that holds the relay control module in the control module box 4 Push the clip 1 back away from the relay control module and lift the relay control module out of the control module box 5 Remove all of the relay harness connectors from the relay control module 8W 97 4 8W 97 POWER DISTRIBUTION ZH ...

Page 1921: ...he vehicles electrical system The Underhood Accessory Fuse Block is located on the left side of the engine compartment just in front of the brake booster The Underhood Accessory Fuse Block can not be serviced it must be replaced as a unit OPERATION All of the circuits entering and leaving the Underhood Accessory Fuse Block do so through seperate wires There are NO seperate wiring harness connector...

Page 1922: ...accessory fuse block 3 Push the front of the underhood accessory fuse box forward releasing the tabs 1 on the underhood fuse block 4 Pull the underhood accessory fuse block out of the box and remove all of the underhood accessory fuse block harness connectors 8W 97 6 8W 97 POWER DISTRIBUTION ZH ...

Page 1923: ...t be adjusted or repaired If faulty or damaged the entire module assembly must be replaced as a unit Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEADLAMP SWITCH REMOVAL OPERATION The Fuse Block on the side of the Illumination Control Module houses the Fuses for the following Fuse 2 Brake Lamp Fuse 3 Right High Beam High Beam Indicator Lamp Fuse 4 Reverse Lamp Turn Signal Lamp Rear View Mirror Fu...

Page 1924: ......

Page 1925: ...RE SENSOR CIRCUIT LOW 71 P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH 73 P0120 ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE 75 P0120 THROTTLE POSITION SENSOR 1 2 CORRELATION 89 P0121 APPS 5 VOLT SUPPLY CIRCUIT 92 P0122 APPS SIGNAL 1 CIRCUIT LOW 99 P0123 APPS SIGNAL 1 CIRCUIT HIGH 105 P0128 FORCED LIMITED POWER EXCESSIVE HIGH COOLANT TEMP 111 P0128 THERMOSTAT RATIONALITY 115 P0131 O2 SENSO...

Page 1926: ... IDLE 270 P0175 FUEL SYSTEM 2 1 OVERCORRECTION OF FUEL MIXTURE OFF IDLE 273 P0175 FUEL SYSTEM 2 1 LEAN CONTROL BELOW LIMIT AT IDLE 276 P0200 FUEL INJECTOR CIRCUIT 279 P0201 FUEL INJECTOR 1 CIRCUIT 281 P0202 FUEL INJECTOR 2 CIRCUIT 286 P0203 FUEL INJECTOR 3 CIRCUIT 288 P0204 FUEL INJECTOR 4 CIRCUIT 290 P0205 FUEL INJECTOR 5 CIRCUIT 292 P0206 FUEL INJECTOR 6 CIRCUIT 294 P0211 THROTTLE ACTUATOR STUCK...

Page 1927: ...ULE SLA 579 P0600 NO CLUSTER BUS MESSAGE 586 P0602 PCM PROGRAMMED INCORRECT TRANS NO COMM FROM TCM 593 P0606 INTERNAL PCM PROCESSOR 595 P0700 TRANSMISSION CONTROL SYSTEM MIL REQUEST 597 P0702 TRANSMISSION CONTROL MODULE LOW VOLTAGE 599 P0702 TRANSMISSION CONTROL SYSTEM MIL REQUEST 601 P0702 LOSS OF TORQUE MANAGEMENT SIGNAL 603 P0702 TCM TORQUE MANAGEMENT REQUEST PERFORMANCE 605 P0705 SLA CONTROL S...

Page 1928: ... VERIFICATION TEST VER 1 696 POWERTRAIN VERIFICATION TEST VER 2 697 POWERTRAIN VERIFICATION TEST VER 3 698 POWERTRAIN VERIFICATION TEST VER 4 699 POWERTRAIN VERIFICATION TEST VER 5 700 SCHEMATICS AND DIAGRAMS 701 ENGINE ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING 9 4 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1929: ... P0040 1 1 AND 2 1 O2 SENSOR HARNESS CONNECTORS REVERSED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 5 ...

Page 1930: ...ROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB III...

Page 1931: ...as necessary If OK replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 3 3 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can se...

Page 1932: ... P0101 MAF SENSOR PERFORMANCE 9 8 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1933: ...LE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0102 MASS AIR FLOW CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at ...

Page 1934: ... P0102 MASS AIR FLOW CIRCUIT 9 10 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1935: ...RCUIT SHORT TO SENSOR GROUND CIRCUIT MASS AIR FLOW SENSOR SIGNAL CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT SENSOR GROUND CIRCUIT OPEN MASS AIR FLOW SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND D...

Page 1936: ...ED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN Turn the ignition off Disconnect the MAF Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Connect a 12 volt test light between ground and the Fused Engine Control Relay Output circuit Note The test light must illuminate brightly Compare the bright ness to when connected directly to B Does the test light illumi...

Page 1937: ... Sensor harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair the 5 Volt Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the 5 Volt Supply circuit Is the resistance above 100 kohms Yes Go To 7 No Repair the 5 Volt Supply circuit for a short to ground Perf...

Page 1938: ...O VOLTAGE Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the MAF Sensor harness connector Is the voltage below 1 0 volt Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform...

Page 1939: ...CUIT Turn the ignition off Measure the resistance between the MAF Sensor Signal circuit and the 5 Volt Supply circuit at the MAF Sensor harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the MAF Sensor Signal ...

Page 1940: ...E REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 14 MAF SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the MAF Sensor Signal circuit from the MAF Sensor harness connector to the PCM C3 harn...

Page 1941: ...ort to ground Perform POWERTRAIN VERIFICATION TEST VER 2 16 MAF SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the MAF Sensor Signal circuit and the Sensor Ground circuit at the MAF Sensor harness connector Is the resistance above 100 kohms Yes Go To 17 No Repair the MAF Sensor Signal circuit for a short to the Sensor Ground circuit Perfor...

Page 1942: ...IN VERIFICATION TEST VER 2 18 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Using the wiring diagrams as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorts and or open circuits Note Check for any Technical Service Bulletins that may apply Note Check for any of the following conditi...

Page 1943: ... P0103 MAF SENSOR CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 19 ...

Page 1944: ...ete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0102 MASS AIR FLOW CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note...

Page 1945: ... P0104 MAF SENSOR THROTTLE ANGLE AND SPEED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 21 ...

Page 1946: ...L MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0102 MASS AIR FLOW CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not prese...

Page 1947: ... P0106 MAP SENSOR PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 23 ...

Page 1948: ...UND 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN ENGINE OIL SENSOR MANIFOLD ABSOLUTE PRESSURE SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Modul...

Page 1949: ...ng to duplicate these conditions may assist when check ing for an active DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 20 3 CHECK FOR CMP SENSOR ENGINE COOLANT TEMP SENSOR AND OIL SENSOR DTCS With the ignition on With the DRB IIIT read PCM DTC...

Page 1950: ...he PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 5 CHECK FOR ENGINE OIL SENSOR DTC With the ignition on With the DRB ...

Page 1951: ...gnition on Measure the voltage of the 5 Volt Supply circuit at the MAP Sensor harness connector Is the voltage between 4 7 and 5 2 volts Yes Replace the Engine Oil Sensor Refer to 9 ENGINE LU BRICATION OIL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No If the voltage is above 5 2 volts Go To 8 If the voltage is below 4 7 volts Go To 9 8 5 VOLT SUPPLY SHORT TO VOLTAGE Turn the ignition off D...

Page 1952: ...PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 10 No Repair the 5 Volt Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 10 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the 5 Volt Supply circuit Is the resistance above 100 kohms Yes Go To 11 No Repair the 5 Volt Supply circuit for a short to ground Pe...

Page 1953: ...erform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to the Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 12 MEASURE THE MAP SENSOR SIGNAL CIRCUIT VOLTAGE Turn the ignition off Disconnect the MAP Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the MAP Sensor Signal circuit a...

Page 1954: ...ircuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 14 5 VOLT SUPPLY CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the 5 Volt Supply circuit from the MAP Sen sor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace the Manifold Absolute Pressure...

Page 1955: ...m POWERTRAIN VERIFICATION TEST VER 2 16 5 VOLT SUPPLY CIRCUIT SHORT TO MAP SENSOR SIGNAL CIRCUIT Turn the ignition off Measure the resistance between the MAP Sensor Signal circuit and the 5 Volt Supply circuit at the MAP Sensor harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTRO...

Page 1956: ...s Yes Go To 18 No Repair the MAP Sensor Signal circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 18 SENSOR GROUND CIRCUIT SHORT TO MAP SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the MAP Sensor Signal circuit and the Sensor Ground circuit at the MAP Sensor harness connector Is the resistance above 100 kohms Yes Go To 19 No Repair the MAP Sensor...

Page 1957: ...Repair the MAP Sensor Signal circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 20 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagrams as a guide...

Page 1958: ... P0107 MAP SENSOR CIRCUIT LOW 9 34 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1959: ...SOR SIGNAL CIRCUIT SHORT TO GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN ENGINE O...

Page 1960: ...matic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for...

Page 1961: ... P0108 MAP SENSOR CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 37 ...

Page 1962: ...SIGNAL CIRCUIT SHORT TO GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN ENGINE OIL S...

Page 1963: ...matic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for...

Page 1964: ... P0111 INTAKE AIR TEMPERATURE SENSOR CIRCUIT PERFORMANCE SRT 9 40 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1965: ... CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0113 IAT SENSOR CIRCUIT HIGH SRT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring dia...

Page 1966: ... P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW SRT 9 42 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1967: ...CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0113 IAT SENSOR CIRCUIT HIGH SRT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diag...

Page 1968: ... P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW EXCEPT SRT 9 44 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1969: ...o terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If the PCM detects and stores a DTC the PCM also stores the e...

Page 1970: ... Air Temperature Sen sor Refer to 14 FUEL SYSTEM FUEL INJECTION MANIFOLD AIR FLOW MAF SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 IAT SENSOR SIGNAL CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the IAT Sensor Signal circuit Is the resistance a...

Page 1971: ...cuit for a short to the Sen sor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 6 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking ...

Page 1972: ... P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH SRT 9 48 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1973: ...ND CIRCUIT OPEN INTAKE AIR TEMPERATURE SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs...

Page 1974: ...ition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 10 3 CHECK FOR IAT SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the Intake Air Temperature Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on W...

Page 1975: ...rform the POWERTRAIN VERIFICATION TEST VER 2 5 IAT SENSOR SHORT INTERNALLY Turn the ignition off Reconnect the PCM C3 harness connector Connect a jumper wire between IAT Sensor harness connector cavities 1 and 2 Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Is DTC P0112 INTAKE AIR TEMPERATU...

Page 1976: ...sor Signal circuit for an open Perform the POWERTRAIN VERIFICATION TEST VER 2 7 MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance of the Sensor Ground circuit from the IAT har ness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MO...

Page 1977: ...orm the POWERTRAIN VERIFICATION TEST VER 2 9 MEASURE THE RESISTANCE BETWEEN THE SENSOR GROUND CIRCUIT AND THE IAT SENSOR SIGNAL CIRCUIT With the ignition off Measure the resistance between the Sensor Ground circuit and the IAT Sensor Signal circuit at the IAT harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC C...

Page 1978: ...ns can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform the POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently n...

Page 1979: ... P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH EXCEPT SRT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 55 ...

Page 1980: ...ENSOR GROUND CIRCUIT OPEN INTAKE AIR TEMPERATURE SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any T...

Page 1981: ...ith the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 10 3 MEASURE THE VOLTAGE OF THE ENGINE CONTROL RELAY OUPUT CIRCUIT Turn the ignition off Disconnect the MAF IAT Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the volta...

Page 1982: ... voltage is below 4 7 volts Go To 9 5 CHECK FOR 5 VOLT SUPPLY CIRCUIT SHORT TO IAT SIGNAL CIRCUIT Turn the ignition off Disconnect PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance between the IAT Signal circuit and the 5 Volt Supply circuit at the MAF IAT Sensor harness connector Is the resistance above 100 kohms Yes Go To 6 No Repair the IAT Signal c...

Page 1983: ...t the PCM C3 harness connector Connect a jumper wire between the IAT Sensor Signal circuit and the Sensor Ground circuit at the MAF IAT Sensor harness connector Turn the ignition on With the DRB IIIT read PCM DTCs Is DTC P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW present Yes Replace the Mass Air Flow Intake Air Temperature Sen sor Refer to 14 FUEL SYSTEM FUEL INJECTION MANIFOLD AIR FLOW MAF S...

Page 1984: ...EST VER 2 No Repair the IAT Signal circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 IAT SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the IAT Sensor Signal circuit from the MAF IAT Sensor harness connector to the PCM C3 harness connector Is the resistance ...

Page 1985: ...heck connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER...

Page 1986: ... P0116 ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE 9 62 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 1987: ...NSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN IMPROPER COOLANT LEVEL ENGINE COOLANT THERMOSTAT ENGINE COOLANT TEMPERATURE SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low engine ...

Page 1988: ...s DTC set again Yes Go To 3 No Go To 11 3 MONITOR THE ECT SENSOR TEMPERATURE With the ignition on With the DRB IIIT monitor the ENG COOLANT TEMP value Choose a conclusion that best matches the ENG COOLANT TEMP value If the value is greater than 169 C 336 F Go To 4 If the value is less than 39 C 38 F Go To 7 If the temp value is within normal operating range Go To 11 4 ECT SENSOR Turn the ignition ...

Page 1989: ...e and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the ECT Sensor Signal circuit for a short to the Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 7 ENGINE COOLANT TEMPERATURE SENSOR Turn the ignition off Disconnect the ECT Sensor harness connector Note...

Page 1990: ...connector Is the voltage below 1 0 volt Yes Go To 9 No Repair the ECT Sensor Signal circuit for a short to volt age Perform POWERTRAIN VERIFICATION TEST VER 2 9 SENSOR GROUND CIRCUIT OPEN Turn the ignition off Measure the resistance of the Sensor Ground circuit from the ECT Sensor harness connector to the PCM C3 harness connector Is the resistance less than 5 0 ohms Yes Go To 10 No Repair the ECT ...

Page 1991: ...OWERTRAIN VERIFICATION TEST VER 2 No Repair the ECT Sensor Signal circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 11 CHECKING THE COOLANT LEVEL AND CONDITION WARNING NEVER OPEN THE COOLING SYSTEM WHEN THE ENGINE IS HOT THE SYSTEM IS UNDER PRESSURE EXTREME BURNS OR SCALDING MAY RESULT ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM Turn the ignition off Check the coolant l...

Page 1992: ... ENGINE COOLANT TEMP SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 13 CHECKING COOLANT THERMOSTAT OPERATION Turn the ignition off Remove the thermostat Using the appropriate service information perform thermostat diagnosis Did the thermostat open at the proper temperature and to the proper stroke Yes Go To 14 No Replace the thermostat Refer to 7 COOLING ENGINE ENGINE COOLANT THERMOSTAT...

Page 1993: ... P0116 ENGINE COOLANT TEMPERATURE SENSOR SHORT CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 69 ...

Page 1994: ...T read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0116 ENGINE COOLANT TEMPERATURE SENSOR PERFOR MANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspe...

Page 1995: ... P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 71 ...

Page 1996: ... PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0116 ENGINE COOLANT TEMPERATURE SENSOR PERFOR MANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the...

Page 1997: ... P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 73 ...

Page 1998: ...tion on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0116 ENGINE COOLANT TEMPERATURE SENSOR PERFOR MANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram sc...

Page 1999: ... P0120 ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 75 ...

Page 2000: ...TO GROUND SENSOR GROUND CIRCUIT OPEN THROTTLE CONTROL MOTOR CIRCUIT S SHORT TO VOLTAGE THROTTLE CONTROL MOTOR CIRCUIT S SHORT TO GROUND THROTTLE CONTROL MOTOR CIRCUIT S OPEN THROTTLE BODY POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a full...

Page 2001: ...o duplicate these conditions may assist when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 If DTC P0121 APPS 5 VOLT SUPPLY CIRCUIT is present with this DTC Go To 10 No Go To 25 3 CHECK FOR THROTTLE PLATE BINDING STICKING OR OBSTRUCTION ...

Page 2002: ...he TP Sensor Signal 2 circuit at the Throttle Body harness connector TP Sensor 2 voltage should change from approximately 0 volts to 5 0 volts Note Remove the jumper wire before continuing Are the TP 1 and TP 2 voltage readings within the listed specifications Yes Go To 5 No Go To 10 5 MEASURE THE VOLTAGE OF THE THROTTLE CONTROL MOTOR CIRCUITS With the ignition on Measure the voltage of the Thrott...

Page 2003: ...o Repair the Throttle Control Motor circuit s for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 7 CHECK THE THROTTLE CONTROL MOTOR CIRCUITS FOR A SHORT TO GROUND Turn the ignition off Disconnect the PCM C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Throttle Control Motor circuit s that measured below 3 1 volts in ...

Page 2004: ...circuit Perform POWERTRAIN VERIFICATION TEST VER 2 9 THROTTLE CONTROL MOTOR CIRCUIT S OPEN With the ignition off Measure the resistance of the Throttle Control Motor 1 circuit from the Throttle Body harness connector to the PCM C1 harness connector Measure the resistance of the Throttle Control Motor 2 circuit from the Throttle Body harness connector to the PCM C1 harness connector Is the resistan...

Page 2005: ...nector Is the voltage between 4 7 and 5 2 volts Yes Go To 11 No If the voltage is above 5 2 volts Go To 16 If the voltage is below 4 7 volts Go To 18 11 CHECK THE SENSOR GROUND CIRCUIT Turn the ignition off Measure the resistance between ground and the Sensor Ground cir cuit at the Throttle Body harness connector Is the resistance below 5 0 ohms Yes Go To 12 No Go To 23 ZH ENGINE ELECTRICAL DIAGNO...

Page 2006: ...circuit s for a short to volt age Perform POWERTRAIN VERIFICATION TEST VER 2 13 CHECK THE TP SENSOR SIGNAL CIRCUITS FOR A SHORT TO OTHER CIRCUITS Turn the ignition off Measure the resistance between the TP Sensor Signal 1 circuit and all other circuits in the Throttle Body harness connector Measure the resistance between the TP Sensor Signal 2 circuit and all other circuits in the Throttle Body ha...

Page 2007: ... Go To 15 No Repair the TP Sensor Signal circuit s for an open Perform POWERTRAIN VERIFICATION TEST VER 2 15 MEASURE THE RESISTANCE BETWEEN GROUND AND THE TP SENSOR SIGNAL CIRCUITS With the ignition off Measure the resistance between ground and the TP Sensor Signal 1 circuit at the Throttle Body harness connector Measure the resistance between ground and the TP Sensor Signal 2 circuit at the Throt...

Page 2008: ...o Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 17 CHECK THE APP SENSOR 5 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the APP Sensor 5 Volt Supply circuit at the PCM C4 harness connector Is the ...

Page 2009: ...he 5 Volt Supply circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 19 MEASURE RESISTANCE BETWEEN THE 5 VOLT SUPPLY CIRCUIT AND SENSOR GROUND CIRCUITS With the ignition off Measure the resistance between the 5 Volt Supply circuit and all Sen sor Ground circuits in the PCM C3 harness connector Is the resistance above 100 kohms for all measurements Yes Go To 20 No Repair the 5 ...

Page 2010: ...pair the APP Sensor 5 Volt Supply circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 21 MEASURE RESISTANCE BETWEEN THE APP SENSOR 5 VOLT SUPPLY CIRCUIT AND SENSOR GROUND CIRCUITS With the ignition off Measure the resistance between the APP Sensor 5 Volt Supply circuit and all Sensor Ground circuits in the PCM C4 harness connector Is the resistance above 100 kohms for all meas...

Page 2011: ...Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 23 SENSOR GROUND CIRCUIT OPEN With the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sensor Ground circuit from the Throttle Body harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 24 No Repair the Senso...

Page 2012: ...sor 2 should start at approximately 4 2 volts and decrease to approximately 3 6 volts Are the voltages within the range specified for the appropriate TP Sensor Yes Go To 26 No Replace the Throttle Body Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 26 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently n...

Page 2013: ... P0120 THROTTLE POSITION SENSOR 1 2 CORRELATION ZH ENGINE ELECTRICAL DIAGNOSTICS 9 89 ...

Page 2014: ...OUND 5 VOLT SUPPLY CIRCUIT OPEN APP SENSOR 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE APP SENSOR 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND SENSOR GROUND CIRCUIT OPEN THROTTLE CONTROL MOTOR CIRCUIT S SHORT TO VOLTAGE THROTTLE CONTROL MOTOR CIRCUIT S SHORT TO GROUND THROTTLE CONTROL MOTOR CIRCUIT S OPEN THROTTLE BODY POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to...

Page 2015: ...gram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring ha...

Page 2016: ... P0121 APPS 5 VOLT SUPPLY CIRCUIT 9 92 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2017: ...GROUND TP SENSOR 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT S ACCELERATOR PEDAL POSITION SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to term...

Page 2018: ...n With the DRB IIIT clear PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 11 3 CHECK THE APP SENSOR 5 VOLT SUPPLY CIRCUIT VOLTAGE Turn the ignition off Disconnect the APP Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the AP...

Page 2019: ...RATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 5 CHECK THE APP SENSOR 5 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the APP Sensor 5 Volt Supply circuit at the APP Sensor harness connector Is the voltage below 1 0 volt Yes Go To 6 ...

Page 2020: ...S POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 7 MEASURE THE RESISTANCE BETWEEN GROUND AND THE TP SENSOR 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the PCM C3 harness connector Disconnect the Throttle Body harness connector Note Check connectors Clean re...

Page 2021: ... the Sensor Ground circuit that measured below 100 kohms Perform POWERTRAIN VERIFICATION TEST VER 2 9 MEASURE THE RESISTANCE BETWEEN GROUND AND THE APP SENSOR 5 VOLT SUPPLY CIRCUIT With the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the APP Sensor 5 Volt Supply circuit at the PCM C4 harness connecto...

Page 2022: ...elow 100 kohms Perform POWERTRAIN VERIFICATION TEST VER 2 11 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using th...

Page 2023: ... P0122 APPS SIGNAL 1 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 99 ...

Page 2024: ...RATOR PEDAL POSITION SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the pr...

Page 2025: ...volts Yes Go To 4 No Go To 8 4 APP SENSOR With the ignition on Connect a jumper wire between the APP Sensor 5 Volt Supply circuit and the APP Sensor Signal 1 circuit in the APP Sensor harness con nector With the DRB IIIT read the APP 1 voltage Note Remove the jumper wire after this step has been com pleted Is the voltage above 4 7 volts Yes Replace the Accelerator Pedal Position Sensor Refer to 14...

Page 2026: ...es Go To 6 No Repair the APP Sensor Signal 1 circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 6 APP SENSOR SIGNAL 1 CIRCUIT SHORT TO SENSOR GROUND CIRCUIT S With the ignition off Measure the resistance between the Sensor Ground circuits and the APP Sensor Signal 1 circuit Is the resistance above 100 kohms Yes Go To 7 No Repair the APP Sensor Signal 1 circuit for a short to ...

Page 2027: ...o Repair the APP Sensor Signal circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8 APP SENSOR 5 VOLT SUPPLY CIRCUIT OPEN With the ignition on Measure the resistance of the APP Sensor 5 Volt Supply circuit from the APP Sensor harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Go To 9 No Repair the APP Sensor 5 Volt Supply circuit for an open Perform ...

Page 2028: ... 4 5 volts with a smooth transition Yes Go To 11 No Replace the Accelerator Pedal Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION ACCELERATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 11 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check conne...

Page 2029: ... P0123 APPS SIGNAL 1 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 105 ...

Page 2030: ...TROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB II...

Page 2031: ...he voltage of the APP Sensor Signal 1 circuit at the APP Sensor harness connector Is the voltage below 0 05 volt Yes Go To 4 No Go To 7 4 MEASURE THE RESISTANCE BETWEEN GROUND AND THE SENSOR GROUND CIRCUIT Turn the ignition off Measure the resistance between ground and the Sensor Ground cir cuit at APP Sensor harness connector cavity 6 Is the resistance below 5 0 ohms Yes Go To 5 No Go To 6 ZH ENG...

Page 2032: ...above 4 7 volts Yes Replace the Accelerator Pedal Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION ACCELERATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 9 6 SENSOR GROUND CIRCUIT OPEN With the ignition off Measure the resistance of the Sensor Ground circuit from APP Sensor harness connector cavity 6 to PCM C4 harness connector cavity 6 Is the resistance below 5 0 ohms...

Page 2033: ... circuit and the APP Sensor 5 Volt Supply circuit at the APP Sensor harness connec tor Is the resistance above 100 kohms Yes Go To 9 No Repair the APP Sensor Signal 1 circuit for a short to the APP Sensor 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 2 9 PCM Note Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessa...

Page 2034: ...ondition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle t...

Page 2035: ... P0128 FORCED LIMITED POWER EXCESSIVE HIGH COOLANT TEMP ZH ENGINE ELECTRICAL DIAGNOSTICS 9 111 ...

Page 2036: ...E For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PC...

Page 2037: ...ION TEST VER 2 3 THERMOSTAT OPERATION Note This test works best if performed on a cold engine cold soak Turn the ignition on With the DRBIIIT read the ENG COOLANT TEMP 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 tempera ture Note If engine coolant temperature is above 82 C 180 F allow the engine ...

Page 2038: ...REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring an...

Page 2039: ... P0128 THERMOSTAT RATIONALITY ZH ENGINE ELECTRICAL DIAGNOSTICS 9 115 ...

Page 2040: ...MPERATURE SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT SENSOR GROUND CIRCUIT OPEN ENGINE COOLANT TEMPERATURE ECT SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary P...

Page 2041: ...THE COOLANT LEVEL AND CONDITION WARNING NEVER OPEN THE COOLING SYSTEM WHEN THE ENGINE IS HOT THE SYSTEM IS UNDER PRESSURE EXTREME BURNS OR SCALDING MAY RESULT ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM Note If an Engine Coolant Temperature ECT 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...

Page 2042: ...lant temperature with a thermometer Note As the engine warms up to operating temperature the actual coolant temperature thermometer read ing and the ENG COOLANT TEMP value in the DRB IIIT should stay relatively close to each other Using the appropriate service information determine the proper opening temperature of the thermostat Did the thermostat open at the proper temperature Yes Go To 5 No Rep...

Page 2043: ...PROCEDURE Ensure the Temperature sensors are properly mounted Ensure the CMP and CKP sensors are mounted properly Check the connectors for any signs of damage 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 Refer to any Technical Service Bulletins TSBs that may apply With the engine runni...

Page 2044: ...ircuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 MEASURE THE ENGINE COOLANT TEMPERATURE SENSOR VOLTAGE WITH THE DRB IIIT With the ignition on With the DRB IIIT read the COOLANT TEMP ADC voltage Is the voltage above 4 6 volts Yes Go To 10 No Go To 13 10 ECT SENSOR VOLTAGE BELOW 1 0 VOLT Turn the ignition off Using a jumper wire jumper across the ECT Sensor harness connec t...

Page 2045: ...rcuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 12 SENSOR GROUND CIRCUIT OPEN With the ignition off Measure the resistance of the Sensor Ground circuit from the ECT Sensor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REM...

Page 2046: ... VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for a short to the ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 15 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections...

Page 2047: ... P0131 O2 SENSOR 1 1 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 123 ...

Page 2048: ... P0131 O2 SENSOR 1 1 CIRCUIT LOW CONTINUED 9 124 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2049: ...he O2 Sensor heater has been ON for at least 220 seconds POSSIBLE CAUSES O2 SENSOR SIGNAL CIRCUIT OPEN O2 SENSOR SIGNAL CIRCUIT SHORT TO GROUND O2 SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE SENSOR GROUND CIRCUIT OPEN ENGINE EXHAUST LEAK O2 SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTI...

Page 2050: ...nutes and 40 seconds With the DRB IIIT monitor the O2 Sensor Signal voltage Does the O2 Sensor voltage stay between 0 4 and 0 6 volt Yes Go To 12 No Go To 8 4 DISCONNECT THE O2 SENSOR Turn the ignition off Disconnect the O2 Sensor harness connector of the affected sensor Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT monitor the O2 Sensor Signal voltage Is t...

Page 2051: ...T THE O2 SENSOR Turn the ignition off Disconnect the O2 Sensor harness connector of the affected sensor Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT monitor the O2 Sensor Signal voltage Is the O2 Sensor voltage above 0 15 volt Yes Note Determine the cause of any contamination before replacing the sensor Inspect for the following before replacing the O2 Sen...

Page 2052: ...e Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the O2 Sensor Signal circuit for a short to ground or any ground circuit in the PCM harness connector Perform POWERTRAIN VERIFICATION TEST VER 2 8 O2 SENSOR SYSTEM INSPECTION Turn the ignition off Inspect for the following conditions Exhaust leak Refer to 11 EXH...

Page 2053: ...10 No Go To 11 10 O2 SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM harness connectors Note Check connectors Clean repair as necessary Measure the resistance of the O2 Sensor Signal circuit from the O2 Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CON...

Page 2054: ...RAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using th...

Page 2055: ... P0132 O2 SENSOR 1 1 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 131 ...

Page 2056: ...1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the w...

Page 2057: ... P0133 O2 SENSOR 1 1 SHORT DELAY TIME ZH ENGINE ELECTRICAL DIAGNOSTICS 9 133 ...

Page 2058: ...OR SIGNAL CIRCUIT SHORT TO GROUND SENSOR GROUND CIRCUIT OPEN SENSOR GROUND CIRCUIT SHORT TO VOLTAGE SENSOR GROUND CIRCUIT SHORT TO GROUND O2 SENSOR For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary ...

Page 2059: ... PCM DTCs Did this DTC set again Yes Go To 3 No Go To 6 3 EXHAUST LEAK Start the engine Inspect the exhaust system for leaks between the engine and the O2 Sensors Are there any exhaust leaks Yes Repair or replace the leaking exhaust parts as necessary Refer to 11 EXHAUST SYSTEM CATA LYTIC CONVERTER REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 O2 SENSOR SIGNAL CIRCUIT Turn the ig...

Page 2060: ...OR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts a...

Page 2061: ... P0133 O2 SENSOR 1 1 LONG PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 137 ...

Page 2062: ... Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repa...

Page 2063: ... P0133 O2 SENSOR 1 1 LONG DELAY TIME ZH ENGINE ELECTRICAL DIAGNOSTICS 9 139 ...

Page 2064: ...Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repai...

Page 2065: ... P0133 O2 SENSOR 1 1 SHORT PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 141 ...

Page 2066: ... Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repa...

Page 2067: ... P0134 O2 SENSOR 1 1 CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 143 ...

Page 2068: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2069: ... P0135 O2 SENSOR 1 1 HEATER CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 145 ...

Page 2070: ...T read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 O2 HEATER ELEMENT Note Check the Engine Control Fuse 2 in the Relay Control Mod ule If it is open multiple DTCs will be set in the PCM Determine the cause of the open fuse before continuing using the wiring diagrams...

Page 2071: ...the resistance above 100 kohms Yes Before continuing check the PCM harness connector ter minals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Con trol Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MOD ULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the O2 Heater Control circuit for a short to ground Pe...

Page 2072: ... P0135 O2 SENSOR 1 1 HEATER PERFORMANCE 9 148 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2073: ...necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If the PCM detects and stores a DTC the P...

Page 2074: ...M harness connector Is the voltage above 10 volts Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 O2 SENSOR HEATER CONTROL CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the O2 Sensor harness connector Note Check connectors Clean repair as neces...

Page 2075: ...O2 Sensor Heater Control circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 6 O2 SENSOR HEATER CONTROL CIRCUIT OPEN Turn the ignition off Measure the resistance of the O2 Sensor Heater Control circuit from the O2 Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the O2 Sensor Heater Control circuit for an open Perfor...

Page 2076: ... condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle...

Page 2077: ... P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 153 ...

Page 2078: ...t DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If the PCM detects and stores a DTC the PCM also stores the engine vehicle operating condi...

Page 2079: ...O2 HEATER ELEMENT Note Check the Engine Control Fuse 2 in the Relay Control Mod ule If it is open multiple DTCs will be set in the PCM Determine the cause of the open fuse before continuing using the wiring diagrams schematics as a guide Turn the ignition off Note Allow the O2 Sensor to cool down to room temperature Raising the hood may help in reducing under hood temperatures Disconnect the O2 Se...

Page 2080: ...HEATER CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the PCM harness connectors Note Check connectors Clean repair as necessary Measure the resistance of the O2 Heater Control circuit from the O2 Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERT...

Page 2081: ... schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harnes...

Page 2082: ... P0135 O2 SENSOR 1 1 HEATER CIRCUIT OPEN 9 158 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2083: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2084: ... P0137 O2 SENSOR 1 2 BELOW THRESHOLD 9 160 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2085: ... DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0137 O2 SENSOR 2 2 ABOVE THRESHOLD No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram s...

Page 2086: ... P0137 O2 SENSOR 1 2 ABOVE THRESHOLD 9 162 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2087: ... DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0137 O2 SENSOR 2 2 ABOVE THRESHOLD No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram s...

Page 2088: ... P0137 O2 SENSOR 2 2 ABOVE THRESHOLD 9 164 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2089: ... O2 SENSOR SIGNAL CIRCUIT OPEN O2 SENSOR GROUND CIRCUIT SHORT TO VOLTAGE O2 SENSOR GROUND CIRCUIT SHORT TO GROUND O2 SENSOR GROUND CIRCUIT OPEN O2 SENSOR For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as nece...

Page 2090: ...sing stored DTCs record these conditions Attempting to duplicate these conditions may assist when check ing for an active DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 6 3 EXHAUST LEAK Start the engine Inspect the exhaust system for leaks betw...

Page 2091: ...m POWERTRAIN VERIFICATION TEST VER 2 5 SENSOR GROUND CIRCUIT Turn the ignition off Disconnect the PCM harness connectors Note Check connectors Clean repair as necessary Measure the resistance of the Sensor Ground circuit from the O2 Sen sor harness connector to the PCM harness connector Is the resistance below 5 0 ohms Yes Replace the Oxygen Sensor Refer to 14 FUEL SYS TEM FUEL INJECTION O2 SENSOR...

Page 2092: ...chematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness ...

Page 2093: ... P0137 O2 SENSOR 2 2 BELOW THRESHOLD ZH ENGINE ELECTRICAL DIAGNOSTICS 9 169 ...

Page 2094: ... DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0137 O2 SENSOR 2 2 ABOVE THRESHOLD No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram s...

Page 2095: ... P0138 O2 SENSOR 1 2 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 171 ...

Page 2096: ...1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the w...

Page 2097: ... P0138 O2 SENSOR 1 2 CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 173 ...

Page 2098: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2099: ... P0138 O2 SENSOR 2 2 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 175 ...

Page 2100: ... DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connectio...

Page 2101: ... P0138 O2 SENSOR 2 2 CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 177 ...

Page 2102: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2103: ... P0140 O2 SENSOR 1 2 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 179 ...

Page 2104: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2105: ... P0140 O2 SENSOR 2 2 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 181 ...

Page 2106: ...c Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Usin...

Page 2107: ... P0141 O2 SENSOR 1 2 HEATER CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 183 ...

Page 2108: ...sis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while ...

Page 2109: ... P0141 O2 SENSOR 1 2 HEATER CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 185 ...

Page 2110: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2111: ... P0141 O2 SENSOR 1 2 HEATER CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 187 ...

Page 2112: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2113: ... P0141 O2 SENSOR 1 2 HEATER PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 189 ...

Page 2114: ...gnition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as ...

Page 2115: ... P0151 O2 SENSOR 2 1 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 191 ...

Page 2116: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2117: ... P0152 O2 SENSOR 2 1 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 193 ...

Page 2118: ...1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the w...

Page 2119: ... P0153 O2 SENSOR 2 1 LONG PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 195 ...

Page 2120: ... Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repa...

Page 2121: ... P0153 O2 SENSOR 2 1 LONG DELAY TIME ZH ENGINE ELECTRICAL DIAGNOSTICS 9 197 ...

Page 2122: ...Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repai...

Page 2123: ... P0153 O2 SENSOR 2 1 SHORT DELAY TIME ZH ENGINE ELECTRICAL DIAGNOSTICS 9 199 ...

Page 2124: ... Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repa...

Page 2125: ... P0153 O2 SENSOR 2 1 SHORT PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 201 ...

Page 2126: ... Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0133 O2 SENSOR 1 1 SHORT DELAY TIME No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repa...

Page 2127: ... P0154 O2 SENSOR 2 1 CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 203 ...

Page 2128: ... For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0131 O2 SENSOR 1 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present a...

Page 2129: ... P0155 O2 SENSOR 2 1 HEATER CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 205 ...

Page 2130: ...sis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while ...

Page 2131: ... P0155 O2 SENSOR 2 1 HEATER CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 207 ...

Page 2132: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2133: ... P0155 O2 SENSOR 2 1 HEATER CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 209 ...

Page 2134: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2135: ... P0155 O2 SENSOR 2 1 HEATER PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 211 ...

Page 2136: ...gnition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as ...

Page 2137: ... P0161 O2 SENSOR 2 2 HEATER PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 213 ...

Page 2138: ...gnition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as ...

Page 2139: ... P0161 O2 SENSOR 2 2 HEATER CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 215 ...

Page 2140: ...sis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while ...

Page 2141: ... P0161 O2 SENSOR 2 2 HEATER CIRCUIT OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 217 ...

Page 2142: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2143: ... P0161 O2 SENSOR 2 2 HEATER CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 219 ...

Page 2144: ... DTC present Yes For complete diagnosis of this DTC refer to P0135 O2 SENSOR 1 1 HEATER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2145: ... P0171 FUEL SYSTEM 1 1 UNDERCORRECTION OF FUEL MIXTURE OFF IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 221 ...

Page 2146: ... P0171 FUEL SYSTEM 1 1 UNDERCORRECTION OF FUEL MIXTURE OFF IDLE CONTINUED 9 222 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2147: ...S RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR SIGNAL CIRCUIT O2 SENSOR GROUND CIRCUIT O2 SENSOR HEATER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA ...

Page 2148: ...ing diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wi...

Page 2149: ... P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 225 ...

Page 2150: ... P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT IDLE CONTINUED 9 226 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2151: ...GE SOLENOID OPERATION O2 SIGNAL CIRCUIT RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA...

Page 2152: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2153: ... P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT LOAD ZH ENGINE ELECTRICAL DIAGNOSTICS 9 229 ...

Page 2154: ... P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT LOAD CONTINUED 9 230 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2155: ...IT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check c...

Page 2156: ...r this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 12 3 CHECKING FUEL PRESSURE WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRES SURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SERVICING ANY FUEL SYSTEM HOSE FITTING OR LINE THE FUEL SYSTEM PRESSURE MUST BE RELEASED Turn the ignition off Install a fuel pressure gauge Turn the ignition on With the DRB IIIT a...

Page 2157: ...e Did the Evap Purge Solenoid hold vacuum Yes Go To 6 No Replace the Evap Purge Solenoid Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS EVAP PURGE SOLENOID REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 MAP SENSOR OPERATION With the ignition off Connect a Vacuum Gauge to a Manifold Vacuum source Start the engine Allow the engine to idle Note If engine will not idle maintain a constant R...

Page 2158: ...ngine Coolant Temperature value increase with a smooth transition and did it reach at least 82 C 180 F Yes Go To 8 No Replace the Engine Coolant Temperature Sensor Refer to 7 COOLING ENGINE ENGINE COOLANT TEMP SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 8 ENGINE MECHANICAL PROBLEM Turn the ignition off Check for any of the following conditions mechanical problems AIR INDUCTION SYSTEM...

Page 2159: ... wire connected Did the O2 Sensor voltage drop from 0 47 volt to 0 0 volt Yes Replace the Oxygen Sensor Refer to 14 FUEL SYS TEM FUEL INJECTION O2 SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 10 10 O2 SIGNAL CIRCUIT With the ignition on Measure the voltage of the O2 Sensor Signal circuit at the O2 Sensor harness connector Is the voltage above 0 47 volt Yes Check the O2 Signal...

Page 2160: ... Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal ...

Page 2161: ... P0172 FUEL SYSTEM 1 1 OVERCORRECTION OF FUEL MIXTURE AT IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 237 ...

Page 2162: ... P0172 FUEL SYSTEM 1 1 OVERCORRECTION OF FUEL MIXTURE AT IDLE CONTINUED 9 238 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2163: ... PURGE SOLENOID OPERATION O2 SIGNAL CIRCUIT RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND...

Page 2164: ...ng diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wir...

Page 2165: ... P0172 FUEL SYSTEM 1 1 LEAN CONTROL BELOW LIMIT AT LOAD ZH ENGINE ELECTRICAL DIAGNOSTICS 9 241 ...

Page 2166: ... P0172 FUEL SYSTEM 1 1 LEAN CONTROL BELOW LIMIT AT LOAD CONTINUED 9 242 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2167: ...ER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connec...

Page 2168: ...t when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 13 3 CHECKING FUEL PRESSURE WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRES SURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SERVICING ANY FUEL SYSTEM HOSE FITTING OR LINE TH...

Page 2169: ...tion on With the DRB IIIT monitor O2 Sensor voltage for at least 2 minutes CAUTION Remove the jumper wire after this Step is complete Does the voltage stay above 0 47 volt Yes Replace the Oxygen Sensor Refer to 14 FUEL SYS TEM FUEL INJECTION O2 SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 6 6 MAP SENSOR OPERATION Connect a Vacuum Gauge to a Manifold Vacuum source Start the en...

Page 2170: ...ase with a smooth transition and did it reach at least 82 C 180 F Yes Go To 8 No Replace the Engine Coolant Temperature Sensor Refer to 7 COOLING ENGINE ENGINE COOLANT TEMP SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 8 ENGINE MECHANICAL PROBLEM Check for any of the following conditions mechanical problems AIR INDUCTION SYSTEM must be free from leaks ENGINE VACUUM must be at least 440...

Page 2171: ... connected Did the O2 Sensor voltage drop from 0 47 volt to 0 0 volt Yes Replace the Oxygen Sensor Refer to 14 FUEL SYS TEM FUEL INJECTION O2 SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 10 10 O2 SENSOR SIGNAL CIRCUIT With the ignition on With the DRB IIIT monitor the O2 Sensor voltage Is the voltage below 0 45 volt Yes Go To 11 No Check the O2 Sensor Signal circuit for a sho...

Page 2172: ...G OR LINE THE FUEL SYSTEM PRES SURE MUST BE RELEASED With the ignition off Remove and inspect the Fuel Pump Inlet Strainer Is the Fuel Pump Inlet Strainer plugged Yes Replace the Fuel Pump Inlet Strainer Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL FILTER REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the Fuel Pump Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP REMOVAL Perform POWERT...

Page 2173: ... P0172 FUEL SYSTEM 1 1 LEAN CONTROL BELOW LIMIT AT IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 249 ...

Page 2174: ... P0172 FUEL SYSTEM 1 1 LEAN CONTROL BELOW LIMIT AT IDLE CONTINUED 9 250 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2175: ...STRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR SIGNAL CIRCUIT O2 SENSOR GROUND CIRCUIT O2 SENSOR HEATER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAM...

Page 2176: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2177: ... P0173 FUEL SYSTEM 2 1 RICH CONTROL OVER LIMIT AT LOAD ZH ENGINE ELECTRICAL DIAGNOSTICS 9 253 ...

Page 2178: ...ER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM FUEL PUMP O2 SENSOR FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connec...

Page 2179: ... when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 13 3 CHECKING FUEL PRESSURE WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRES SURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SERVICING ANY FUEL SYSTEM HOSE FITTING OR LINE THE...

Page 2180: ... switching between 0 4 and 0 6 volt Yes Go To 5 No Go To 9 5 O2 SENSOR HEATER OPERATION Turn the ignition off Note Allow the O2 Sensor to cool down before continuing the test Raising the hood may help in reducing under hood temper atures Connect a jumper wire between ground and the Oxygen Sensor Heater Control circuit at the PCM harness connector leaving the har ness connector connected to the PCM...

Page 2181: ...ine cold soak Turn the engine off Turn the ignition on With the DRB IIIT read the Engine Coolant Temperature ECT Sen sor 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 F allow the engine to cool until 65 C 150 F is reached Start the en...

Page 2182: ...wire not connected to correct injector Are there any engine mechanical problems Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 13 9 O2 SENSOR Turn the ignition off Disconnect the O2 Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT monitor the O2 Sensor voltage The O2 Sensor voltage should read 0 47 volt on ...

Page 2183: ...PECTION Perform POWERTRAIN VERIFICATION TEST VER 2 No Check the Sensor Ground 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 pro gram the Powertrain Control Module Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 12 FUEL PUMP INLET ST...

Page 2184: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2185: ... P0174 FUEL SYSTEM 2 1 RICH CONTROL OVER LIMIT AT IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 261 ...

Page 2186: ...GE SOLENOID OPERATION O2 SIGNAL CIRCUIT RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA...

Page 2187: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2188: ... P0174 FUEL SYSTEM 2 1 RICH CONTROL OVER LIMIT AT LOAD 9 264 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2189: ...GE SOLENOID OPERATION O2 SIGNAL CIRCUIT RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA...

Page 2190: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2191: ... P0174 FUEL SYSTEM 2 1 LEAN CONTROL BELOW LIMIT AT LOAD ZH ENGINE ELECTRICAL DIAGNOSTICS 9 267 ...

Page 2192: ...STRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR SIGNAL CIRCUIT O2 SENSOR GROUND CIRCUIT O2 SENSOR HEATER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAM...

Page 2193: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2194: ... P0174 FUEL SYSTEM 2 1 UNDERCORRECTION OF FUEL MIXTURE OFF IDLE 9 270 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2195: ...S RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR SIGNAL CIRCUIT O2 SENSOR GROUND CIRCUIT O2 SENSOR HEATER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA ...

Page 2196: ...ing diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wi...

Page 2197: ... P0175 FUEL SYSTEM 2 1 OVERCORRECTION OF FUEL MIXTURE OFF IDLE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 273 ...

Page 2198: ... PURGE SOLENOID OPERATION O2 SIGNAL CIRCUIT RESTRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR GROUND CIRCUIT MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION O2 SENSOR ENGINE MECHANICAL PROBLEM FUEL FILTER PRESSURE REGULATOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND...

Page 2199: ...ing diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wi...

Page 2200: ... P0175 FUEL SYSTEM 2 1 LEAN CONTROL BELOW LIMIT AT IDLE 9 276 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2201: ...STRICTED FUEL SUPPLY LINE FUEL PUMP INLET STRAINER PLUGGED O2 SENSOR SIGNAL CIRCUIT O2 SENSOR GROUND CIRCUIT O2 SENSOR HEATER OPERATION MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION ENGINE COOLANT TEMPERATURE SENSOR OPERATION ENGINE MECHANICAL PROBLEM O2 SENSOR FUEL PUMP FUEL CONTAMINATION EXHAUST LEAK For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAM...

Page 2202: ...diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring...

Page 2203: ... P0200 FUEL INJECTOR CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 279 ...

Page 2204: ...C Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic ...

Page 2205: ... P0201 FUEL INJECTOR 1 CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 281 ...

Page 2206: ...TOR CONTROL CIRCUIT FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to ...

Page 2207: ... IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 8 3 FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN Turn the ignition off Disconnect the Fuel Injector harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Engine Contr...

Page 2208: ...PCM harness connector Is the resistance below 5 0 ohms Yes Go To 5 No Repair the Injector Control circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 5 INJECTOR CONTROL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Injector Control cir cuit Is the resistance above 100 kohms Yes Go To 6 No Repair the Injector Control circuit for a short to gr...

Page 2209: ... to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the Fuel Injector Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL INJECTOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 8 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a p...

Page 2210: ... P0202 FUEL INJECTOR 2 CIRCUIT 9 286 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2211: ...TC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic...

Page 2212: ... P0203 FUEL INJECTOR 3 CIRCUIT 9 288 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2213: ...TC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic...

Page 2214: ... P0204 FUEL INJECTOR 4 CIRCUIT 9 290 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2215: ...TC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic...

Page 2216: ... P0205 FUEL INJECTOR 5 CIRCUIT 9 292 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2217: ...TC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic...

Page 2218: ... P0206 FUEL INJECTOR 6 CIRCUIT 9 294 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2219: ...TC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0201 FUEL INJECTOR 1 CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic...

Page 2220: ... P0211 THROTTLE ACTUATOR STUCK 9 296 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2221: ...ND THROTTLE CONTROL MOTOR 1 CIRCUIT SHORT TO GROUND THROTTLE PLATE STUCK ABOVE LIMP HOME POSITION POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal con...

Page 2222: ...DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 11 3 THROTTLE PLATE STUCK OPEN Note The PCM tests the Throttle Body Motor by opening and closing the Throttle Plate before starting the engine If the Throttle plate does not return to the closed position during this test this DTC will set Remove the Air Cleaner Housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLE...

Page 2223: ...nnector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Throttle Control Motor 1 circuit at the Throttle Body harness connector Is the voltage below 1 0 volt Yes Go To 6 No Repair the Throttle Control Motor 1 circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 6 THROTTLE CONTROL MOTOR 1 CIRCUIT OPEN Turn the ignition off Measure...

Page 2224: ...ion off Measure the resistance between ground and the Throttle Control Motor 1 circuit at the PCM C1 harness connector Is the resistance above 100 kohms Yes Go To 9 No Repair the Throttle Control Motor 1 circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 9 THROTTLE CONTROL MOTOR 2 CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Thro...

Page 2225: ...RIFICATION TEST VER 2 11 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for...

Page 2226: ... P0211 THROTTLE ACTUATOR STUCK 9 302 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2227: ...OR 1 CIRCUIT SHORT TO GROUND THROTTLE CONTROL MOTOR 2 CIRCUIT SHORT TO GROUND POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTC...

Page 2228: ... DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 10 3 THROTTLE PLATE STUCK OPEN Note The PCM tests the ETC Motor by opening and closing the Throttle Plate before starting the engine If the Throttle Plate does not open and return to the closed position during this test this DTC will set Turn the ignition off Remove the Air Cleaner Housing Refer to 9 ENGINE AIR...

Page 2229: ... THROTTLE CONTROL MOTOR 1 CIRCUIT OPEN Turn the ignition off Measure the resistance of the Throttle Control Motor 1 circuit from the Throttle Body harness connector to the PCM C1 harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair the Throttle Control Motor 1 circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 THROTTLE CONTROL MOTOR 2 CIRCUIT OPEN With the ignitio...

Page 2230: ...t Is the resistance above 100 kohms Yes Go To 9 No Repair the Throttle Control Motor 2 circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 9 PCM Note Before continuing check the PCM C1 harness connector 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 ...

Page 2231: ... DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Ins...

Page 2232: ... P0221 APPS SENSOR 1 AND 2 VOLTAGE CORRELATION 9 308 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2233: ...ssary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If the PCM detects and stores a DTC the PCM a...

Page 2234: ...te Check connectors Clean repair as necessary Measure the resistance between the APP Sensor Signal 1 circuit and the APP Sensor Signal 2 circuit at the PCM C4 harness connector Is the resistance above 100 kohms Yes Go To 5 No Repair the APP Sensor Signal circuits for a short together Perform POWERTRAIN VERIFICATION TEST VER 2 5 PCM Note Before continuing check the PCM harness connector terminals f...

Page 2235: ...chnical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring har...

Page 2236: ... P0221 IDLE SPEED PERFORMANCE 9 312 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2237: ...s POSSIBLE CAUSES AIR INTAKE SYSTEM VACUUM LEAKS THROTTLE BODY OPERATION POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Not...

Page 2238: ...DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 AIR INTAKE SYSTEM Turn the ignition off Inspect the Air Intake 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 Remove the Air Cleaner Housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR C...

Page 2239: ...Power and Ground circuits If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CON TROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 7 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harne...

Page 2240: ... P0221 ELECTRONIC THROTTLE CONTROL MODULE PERFORMANCE 9 316 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2241: ...c Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0120 ELECTRONIC THROTTLE CONTROL MOTOR PERFOR MANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connecti...

Page 2242: ... P0221 ELECTRONIC THROTTLE CONTROL MODULE PROCESSOR 9 318 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2243: ... Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0120 ELECTRONIC THROTTLE CONTROL MOTOR PERFOR MANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connectio...

Page 2244: ... P0222 APPS SIGNAL 2 CIRCUIT LOW 9 320 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2245: ...SITION SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the...

Page 2246: ...celerator Pedal Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION ACCELERATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 APP SENSOR SIGNAL 2 CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the APP Sensor Signal 2 circuit Is the resistance a...

Page 2247: ...e APP Sensor Signal 2 circuit for a short to the Sensor Ground circuit s Perform POWERTRAIN VERIFICATION TEST VER 2 6 APP SENSOR SIGNAL 2 CIRCUIT OPEN With the ignition off Measure the resistance of the APP Sensor Signal 2 circuit from the APP Sensor harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the APP Sensor Signal 2 circuit for an open ...

Page 2248: ...e 2 3 volts with a smooth transition Yes Go To 9 No Replace the Accelerator Pedal Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION ACCELERATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 9 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connec...

Page 2249: ... P0223 APPS SIGNAL 2 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 325 ...

Page 2250: ...TROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB II...

Page 2251: ...he voltage of the APP Sensor Signal 2 circuit at the APP Sensor harness connector Is the voltage below 0 05 volt Yes Go To 4 No Go To 7 4 MEASURE THE RESISTANCE BETWEEN GROUND AND THE SENSOR GROUND CIRCUIT Turn the ignition off Measure the resistance between ground and the Sensor Ground cir cuit at APP Sensor harness connector cavity 6 Is the resistance below 5 0 ohms Yes Go To 5 No Go To 6 ZH ENG...

Page 2252: ...above 4 7 volts Yes Replace the Accelerator Pedal Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION ACCELERATOR PEDAL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 9 6 SENSOR GROUND CIRCUIT OPEN With the ignition off Measure the resistance of the Sensor Ground circuit from APP Sensor harness connector cavity 3 to PCM C4 harness connector cavity 18 Is the resistance below 5 0 ohm...

Page 2253: ... circuit and the APP Sensor 5 Volt Supply circuit at the APP Sensor harness connec tor Is the resistance above 100 kohms Yes Go To 9 No Repair the APP Sensor Signal 2 circuit for a short to the APP Sensor 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 2 9 PCM Note Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessa...

Page 2254: ...condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle ...

Page 2255: ... P023A CHARGE AIR COOLER CIRCULATION PUMP CONTROL CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 331 ...

Page 2256: ... COOLER CIRCULATION PUMP CONTROL CIRCUIT OPEN PULSE MODULE POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for ap...

Page 2257: ...en check ing for a DTC With the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 9 3 MEASURE VOLTAGE OF CHARGE AIR COOLER CIRCULATION PUMP CONTROL CIRCUIT WITH IGNITION OFF Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Cl...

Page 2258: ...ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform the POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN Turn the ignition off Disconnect the Pulse Module E harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the Pulse Module E harness conn...

Page 2259: ...rol cir cuit for a short to ground Perform the POWERTRAIN VERIFICATION TEST VER 2 7 CHARGE AIR COOLER CIRCULATION PUMP CONTROL CIRCUIT OPEN With the ignition off Measure the resistance of the Charge Air Cooler Circulation Pump Control circuit from the Pulse Module E harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Replace the Pulse Module Perform the POWERTRAI...

Page 2260: ...IN VERIFICATION TEST VER 2 9 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a ...

Page 2261: ... P023B CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 337 ...

Page 2262: ...M DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P023A CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring...

Page 2263: ... P023C CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 339 ...

Page 2264: ...Yes For complete diagnosis of this DTC refer to P023A CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to...

Page 2265: ... P0300 MULTIPLE CYLINDER MISFIRE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 341 ...

Page 2266: ... P0300 MULTIPLE CYLINDER MISFIRE CONTINUED 9 342 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2267: ...ICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSB...

Page 2268: ... Did this DTC set again Yes Go To 3 No Go To 19 3 VISUAL AND PHYSICAL INSPECTION Note Reviewing the vehicle repair history may aid in the repair of the misfire condition Turn the ignition off Visually and physically inspect the engine for any of the following conditions Worn serpentine belt Binding Engine Driven accessories Misaligned water pump P S pump and A C compressor pulleys Improper CKP Sen...

Page 2269: ...observe the spark coming from the spark testers Note A crisp blue spark should be generated that is able to jump the gap of the spark testers Note Before continuing with next Step reinstall Fuel Pump Fuse in the Relay Control Module Is good spark present Yes Go To 5 No Go To 16 5 SPARK PLUG With the ignition off Remove the Spark Plug Inspect the Spark Plug for the following conditions Cracks Carbo...

Page 2270: ...cal problems Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 7 7 CHECKING FUEL PRESSURE 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 PRES SURE MUST BE RELEASED With the ignition off Install a fuel pressure test gauge to the fuel rail Start the engine and obs...

Page 2271: ... filter Monitor the fuel pressure gauge for a minimum of 5 minutes Note The pressure should not fall below 3 0 bar 44 psi within 5 minutes and should not fall below 2 5 bar 36 psi within 30 minutes Does the fuel pressure gauge fall below the above specification Yes Repair or replace the leaking component between the Fuel Pump and Injector s Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 9 Not...

Page 2272: ...CM harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fuel Injector Control circuit at the Fuel Injector harness connector Is the voltage below 1 0 volt Yes Go To 12 No Repair the Fuel Injector Control circuit for a short to volt age Perform POWERTRAIN VERIFICATION TEST VER 2 12 FUEL INJECTOR CONTROL CIRCUIT SHORT TO GROUND Turn the ig...

Page 2273: ...ROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 14 RESTRICTED FUEL SUPPLY LINE WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRES SURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SERVICING ANY FUEL SYSTEM HOSE FITTING OR LINE THE FUEL SYSTEM PRESSURE MUST BE RELEASED Turn the ignition off Raise vehicle on hoist and disconnect the fuel pressure line at the fuel pump Install a fuel pressu...

Page 2274: ...ng check the Fuel Pump harness connector terminals for corrosion damage or terminal push out Ensure the ground circuit is operating properly Repair as necessary Replace the Fuel Pump Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 16 FUSED IGNITION SWITCH OUTPUT CIRCUIT Turn the ignition off Disconnect the Coil On Plug harness connector Turn the i...

Page 2275: ...the ignition off Disconnect the PCM harness connector Note Check connectors Clean repair as necessary Check the Coil On Plug Driver circuits for a short to voltage short to ground or open Was a problem found with the Coil On Plug Driver circuits Yes Repair the Coil On Plug Driver circuits for the problem found Perform POWERTRAIN VERIFICATION TEST VER 2 No NOTE Before continuing check the PCM harne...

Page 2276: ...afed pierced pinched partially broken wires and broken bent pushed out or corroded terminals 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 physically inspect the engine for any of the following conditions Worn serpentine belt Binding Engine Driven accessories Misaligned water pump P S pump ...

Page 2277: ... P0301 CYLINDER 1 MISFIRE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 353 ...

Page 2278: ... P0301 CYLINDER 1 MISFIRE CONTINUED 9 354 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2279: ...ICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSB...

Page 2280: ...ehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 17 3 VISUAL AND PHYSICAL INSPECTION Note Reviewing the vehicle repair history may aid in the repair of the misfire condition Visually and physically inspect the engine for any of the following con ditions Worn serpentine belt Binding Engine Driven accessories Misaligned water pump P S pump and A ...

Page 2281: ...ine observe the spark coming from the spark testers Note A crisp blue spark should be generated that is able to jump the gap of the spark testers Note Before continuing with next Step reinstall Fuel Pump Fuse in the Relay Control Module Is good spark present Yes Go To 5 No Go To 14 5 SPARK PLUG Turn the ignition off Remove the Spark Plug Inspect the Spark Plug for the following conditions Cracks C...

Page 2282: ...blems Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 7 7 CHECKING FUEL PRESSURE 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 PRES SURE MUST BE RELEASED With the ignition off Install a fuel pressure gauge to the fuel rail Start the engine and observe the fue...

Page 2283: ... pressure gauge for a minimum of 5 minutes Note The pressure should not fall below 3 0 bar 44 psi within 5 minutes and should not fall below 2 5 bar 36 psi within 30 minutes Does the fuel pressure gauge fall below the above specification Yes Replace the leaking component between the Fuel Pump and Injector s Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 9 Note Remove the hose clamp pliers bef...

Page 2284: ...onnector s Note Check connectors Clean repair as necessary Measure the resistance of the Fuel Injector Control circuit from the Fuel Injector harness connector to the PCM harness connector Is the resistance below 5 0 ohms Yes NOTE Before continuing check the PCM harness con nector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Pow ertrain Control Mo...

Page 2285: ...STEM PRES SURE MUST BE RELEASED Turn the ignition off Remove the and inspect the Fuel Strainer Is the Fuel Strainer plugged Yes Replace the Fuel Strainer Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL FILTER REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No NOTE Before continuing check the Fuel Pump Module harness connector terminals for corrosion dam age or terminal push out Ensure the ground cir...

Page 2286: ... ignition off Disconnect the PCM harness connector Note Check connectors Clean repair as necessary Check the Coil On Plug Driver circuits for a short to voltage short to ground or open Was a problem found with the Coil On Plug Driver circuits Yes Repair the Coil On Plug Driver circuits for the problem found Perform POWERTRAIN VERIFICATION TEST VER 2 No NOTE Before continuing check the PCM harness ...

Page 2287: ...chafed pierced pinched partially broken wires and broken bent pushed out or corroded terminals 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 physically inspect the engine for any of the following conditions Worn serpentine belt Binding Engine Driven accessories Misaligned water pump P S pum...

Page 2288: ... P0302 CYLINDER 2 MISFIRE 9 364 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2289: ... P0302 CYLINDER 2 MISFIRE CONTINUED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 365 ...

Page 2290: ... IGNITION SWITCH OUTPUT CIRCUIT COIL ON PLUG DRIVER CIRCUIT ENGINE MECHANICAL PROBLEM COIL ON PLUG SPARK PLUG FUEL STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DT...

Page 2291: ...ic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a ...

Page 2292: ... P0303 CYLINDER 3 MISFIRE 9 368 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2293: ... P0303 CYLINDER 3 MISFIRE CONTINUED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 369 ...

Page 2294: ... IGNITION SWITCH OUTPUT CIRCUIT COIL ON PLUG DRIVER CIRCUIT ENGINE MECHANICAL PROBLEM COIL ON PLUG SPARK PLUG FUEL STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DT...

Page 2295: ...ic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a ...

Page 2296: ... P0304 CYLINDER 4 MISFIRE 9 372 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2297: ... P0304 CYLINDER 4 MISFIRE CONTINUED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 373 ...

Page 2298: ... IGNITION SWITCH OUTPUT CIRCUIT COIL ON PLUG DRIVER CIRCUIT ENGINE MECHANICAL PROBLEM COIL ON PLUG SPARK PLUG FUEL STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DT...

Page 2299: ...ic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a ...

Page 2300: ... P0305 CYLINDER 5 MISFIRE 9 376 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2301: ... P0305 CYLINDER 5 MISFIRE CONTINUED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 377 ...

Page 2302: ... IGNITION SWITCH OUTPUT CIRCUIT COIL ON PLUG DRIVER CIRCUIT ENGINE MECHANICAL PROBLEM COIL ON PLUG SPARK PLUG FUEL STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DT...

Page 2303: ...ic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a ...

Page 2304: ... P0306 CYLINDER 6 MISFIRE 9 380 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2305: ... P0306 CYLINDER 6 MISFIRE CONTINUED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 381 ...

Page 2306: ... IGNITION SWITCH OUTPUT CIRCUIT COIL ON PLUG DRIVER CIRCUIT ENGINE MECHANICAL PROBLEM COIL ON PLUG SPARK PLUG FUEL STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP FUEL INJECTOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DT...

Page 2307: ...ic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a ...

Page 2308: ... P0325 KNOCK SENSOR 1 CIRCUIT LOW 9 384 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2309: ...NAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT KNOCK SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for appli...

Page 2310: ...gram the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 KNOCK SENSOR SIGNAL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Knock Sensor Signal circuit Is resistance above 100 kohms Yes Go To 5 No Repair the Knock Sensor Signal circuit fo...

Page 2311: ...epair the Sensor Ground circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 6 SENSOR GROUND CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the Sensor Ground circuit at the PCM C3 har ness connector Is the voltage below 1 0 volt Yes Go To 7 No Repair the Sensor Ground circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ENGINE ELECT...

Page 2312: ...e Perform POWERTRAIN VERIFICATION TEST VER 2 8 KNOCK SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the Knock Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Knock Sensor Signal circuit from the Knock Sensor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 9 No Repair the Knock Sensor Si...

Page 2313: ...T VER 2 10 KNOCK SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the Knock Sensor Signal circuit and the Sensor Ground circuit at the Knock Sensor harness connector Is resistance above 100 kohms Yes Replace the Knock Sensor Refer to 8 ELECTRICAL IG NITION CONTROL KNOCK SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the ...

Page 2314: ...hematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness f...

Page 2315: ... P0325 KNOCK SENSOR 1 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 391 ...

Page 2316: ...Cs Is this DTC present Yes For complete diagnosis of this DTC refer to P0325 KNOCK SENSOR 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors spec...

Page 2317: ... P0330 KNOCK SENSOR 2 CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 393 ...

Page 2318: ...Cs Is this DTC present Yes For complete diagnosis of this DTC refer to P0325 KNOCK SENSOR 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors spec...

Page 2319: ... P0330 KNOCK SENSOR 2 CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 395 ...

Page 2320: ...th the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0325 KNOCK SENSOR 1 CIRCUIT LOW No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the...

Page 2321: ... P0335 CRANKSHAFT POSITION SENSOR CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 397 ...

Page 2322: ...OR SIGNAL 2 CIRCUIT SHORT TO GROUND CRANKSHAFT POSITION SENSOR SIGNAL 1 CIRCUIT SHORT TO CRANKSHAFT POSITION SENSOR SIGNAL 2 CIRCUIT CRANKSHAFT POSITION SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check...

Page 2323: ... Go To 3 No Go To 14 3 CKP WIRE HARNESS INSPECTION Turn the ignition off Visually inspect the related wire 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 Ensure the Crankshaft Position CKP Sensor and the Camshaft Position Sensor are properly installed and the mounting b...

Page 2324: ...ir as necessary Turn the ignition on Measure the voltage of the CKP Sensor Signal 2 circuit at the CKP Sensor harness Is the voltage below 1 0 volt Yes Go To 7 No Repair the CKP Sensor Signal 2 circuit for a short to volt age Perform POWERTRAIN VERIFICATION TEST VER 2 7 CKP SENSOR SIGNAL 2 CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the CKP Sensor Signal...

Page 2325: ... Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CKP Sensor Signal 2 circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 9 CKP SENSOR SIGNAL 1 CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the CKP Sensor Signal 1 circuit at the CKP Sensor harness ...

Page 2326: ...e CKP Sensor Signal 1 circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 11 CKP SENSOR SIGNAL 1 CIRCUIT OPEN With the ignition off Measure the resistance of the CKP Sensor Signal 1 circuit from the CKP harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 12 No Repair the CKP Sensor Signal 1 circuit for an open Perform POWERTRAIN VERIFIC...

Page 2327: ...Wheel Pulse Ring as necessary Refer to 9 ENGINE ENGINE BLOCK FLEX PLATE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the Crankshaft Position Sensor Refer to 14 FUEL SYSTEM FUEL INJECTION CRANK SHAFT POSITION SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 14 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the ...

Page 2328: ... P0341 CAMSHAFT POSITION TIMING OVER RETARDED 9 404 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2329: ...e Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using th...

Page 2330: ...icate these conditions may assist when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 CHECKING CMP SIGNAL Turn the ignition off With the DRB IIIT lab scope probe and the Special Tool 6801 back probe the CMP Signal circuit at...

Page 2331: ...s present Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 TONE WHEEL PULSE RING INSPECTION With the ignition off Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found Yes Repair or replace the Tone Wheel Pulse Ring as necessary Refer to 9 ENGINE ENGINE BLOCK FLEX PLATE REMOVAL ...

Page 2332: ...aft Position Sensor Refer to 8 ELECTRICAL IGNITION CONTROL CAMSHAFT POSITION SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 8 8 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connecti...

Page 2333: ... P0341 CAMSHAFT POSITION TIMING OVER ADVANCED ZH ENGINE ELECTRICAL DIAGNOSTICS 9 409 ...

Page 2334: ...or complete diagnosis of this DTC refer to P0341 CAMSHAFT POSITION TIMING OVER RETARDED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC...

Page 2335: ... P0341 CAMSHAFT POSITION SENSOR PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 411 ...

Page 2336: ...IGNAL CIRCUIT SHORT TO VOLTAGE CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT SENSOR GROUND CIRCUIT OPEN CAMSHAFT POSITION SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check conne...

Page 2337: ...te these conditions may assist when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 10 3 FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN Turn the ignition off Disconnect the CMP Sensor harness connector Note Check connectors Clean...

Page 2338: ... the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 5 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 5 CMP SIGNAL CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the CMP Signal circuit at the CMP Sensor har ness connector Is the voltage below 1 0 volt Yes Go To 6 No Repair the CMP Signal circuit for a short to vo...

Page 2339: ...rcuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 7 CMP SIGNAL CIRCUIT OPEN With the ignition off Measure the resistance of the CMP Signal circuit from the CMP Sen sor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Go To 8 Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CMP Signal circuit for an open Perform POWERTRAIN VERIFICAT...

Page 2340: ...t to the Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 9 CAMSHAFT POSITION SENSOR With the ignition off Replace the Camshaft Position Sensor Refer to 8 ELECTRICAL IG NITION CONTROL CAMSHAFT POSITION SENSOR REMOVAL Attempt to start the engine With the DRB IIIT read engine DTCs Did this DTC set again Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECT...

Page 2341: ...amshaft Position Sensor Refer to 8 ELECTRICAL IGNITION CONTROL CAMSHAFT POSITION SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 11 11 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal co...

Page 2342: ... P0400 EGR SYSTEM PERFORMANCE 9 418 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2343: ...CONTROL RELAY OUTPUT CIRCUIT OPEN EGR SOLENOID EGR VALVE POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for appl...

Page 2344: ...B IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 10 3 EGR OPERATION Turn the ignition on Turn all accessories off Start the engine Allow the engine to reach normal operating temperature Does the engine run rough or stall Yes Go To 4 No Go To 5 4 EGR VALVE OPEN AT IDLE Turn the igni...

Page 2345: ...5 EMISSIONS CONTROL EXHAUST GAS RECIRCULATION SOLENOID REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 6 6 FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN With the ignition on Measure the voltage of the Fused Engine Control Relay Output circuit at the EGR Solenoid harness connector Is the voltage above 10 volts Yes Go To 7 No Repair the Engine Control Relay Output circuit for an open Pe...

Page 2346: ...OWERTRAIN VERIFICATION TEST VER 2 9 EGR SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the EGR Solenoid Control circuit at the EGR Solenoid connector Is the voltage below 1 0 volt Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 N...

Page 2347: ... DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Ins...

Page 2348: ... P0403 EGR CONTROL CIRCUIT 9 424 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2349: ...ontrol Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0400 EGR SYSTEM PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connecto...

Page 2350: ... P0410 SECONDARY AIR INJECTION SYSTEM 9 426 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2351: ...NG MISROUTED OR PLUGGED VACUUM LINES AIR PUMP SWITCHOVER VALVES AIR PUMP RELAY AIR PUMP POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections c...

Page 2352: ...M DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 13 3 INSPECT THE SECONDARY AIR INJECTION SYSTEM Turn the ignition off Inspect the Air Pump system for the following Damage to any component Cracked missing misrouted or plugged vacuum lines Damaged or misrouted electrical wires Did you find any of ...

Page 2353: ... sensor voltage for both sensors drop to less than 0 1 volt Yes Go To 13 No Remove the Air Pump Switchover Valve for the affected bank and inspect for damage or restriction If no restriction or damage is found replace the Air Pump Switchover Valve Refer to 25 EMISSIONS CONTROL AIR INJECTION SWITCHOVER VALVE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 7 AIR PUMP SOLENOID VACUUM CHECK Turn th...

Page 2354: ...n off Measure the resistance between ground and the Air Pump Ground cir cuit Is the resistance less than 5 0 ohms Yes Replace the Air Pump Refer to 25 EMISSIONS CON TROL AIR INJECTION PUMP REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Air Pump Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 10 INSPECT THE AIR PUMP FUSE With the ignition on With a test light...

Page 2355: ...m POWERTRAIN VERIFICATION TEST VER 2 12 CHECK THE AIR PUMP RELAY With the ignition off Reconnect the Air Pump harness connector Disconnect the Relay Control Module A and B harness connectors Note Check connectors Clean repair as necessary Connect a fused jumper wire between pin 2 of the Relay Control Mod ule B harness connector and pin 4 of the Relay control Module A har ness connector Turn the ig...

Page 2356: ... set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present...

Page 2357: ... P0412 SECONDARY AIR INJECTION SWITCHOVER SOLENOID CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 433 ...

Page 2358: ...NGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring...

Page 2359: ... Engine Control Relay Output circuit and the Air Pump Switchover Solenoid Control circuit at the Air Pump Switchover Solenoid harness connector Does the voltage toggle between B and 0 volts Yes Replace the Air Pump Switchover Solenoid Refer to 25 EMISSIONS CONTROL AIR INJECTION SWITCHOVER SOLENOID REMOVAL Perform the POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 FUSED ENGINE CONTROL RELAY OUTPUT...

Page 2360: ...trol circuit for an open Perform the POWERTRAIN VERIFICATION TEST VER 2 6 AIR PUMP SWITCHOVER SOLENOID CONTROL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Air Pump Switchover Solenoid Control circuit at the Air Pump Switchover Solenoid harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8...

Page 2361: ...ions can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform the POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently...

Page 2362: ... P0418 SECONDARY AIR INJECTION SYSTEM CONTROL CIRCUIT 9 438 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2363: ... DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this pro...

Page 2364: ...ignition on Measure the voltage of the Air Pump Relay Control circuit at the PCM C4 harness connector Is the voltage above 10 volts Yes Go To 4 No Go To 6 4 AIR PUMP RELAY CONTROL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the Relay Control Module A harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Air Pump Relay Contro...

Page 2365: ...RTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Air Pump Relay Control circuit for a short to the Air Pump Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 2 6 AIR PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the Relay Control Module A harness connector Note Check connectors Clean repair as necessary Measure the res...

Page 2366: ...ion that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wi...

Page 2367: ... P0422 CATALYTIC 1 1 EFFICIENCY ZH ENGINE ELECTRICAL DIAGNOSTICS 9 443 ...

Page 2368: ...or DTC s before continuing with this diagnosis Note Check for contaminants that may have damaged the O2 Sensor and three way catalytic converter contaminated fuel unapproved silicone products oil or coolant and repair as necessary Note Engine exhaust leaks can be the cause of this DTC Inspect the exhaust system for leaks before diag nosing this DTC Note Always perform diagnostics with a fully char...

Page 2369: ...the O2 Sensors Are there any exhaust leaks Yes Repair or replace the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the three way catalytic converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ENGINE ELECTRICAL DIAGNOSTICS 9 445 ...

Page 2370: ... P0432 CATALYTIC 2 1 EFFICIENCY 9 446 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2371: ...s that may have damaged the O2 Sensor and TWC converter contaminated fuel unapproved silicone products oil or coolant and repair as necessary Note Engine exhaust leaks can be the cause of this DTC Inspect the exhaust system for leaks before diag nosing this DTC Note Always perform diagnostics with a fully charged battery Turn the ignition off Inspect the TWC for the following damage Dents or holes...

Page 2372: ... P0440 GENERAL EVAP SYSTEM FAILURE 9 448 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2373: ...9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0455 EVAP SYSTEM LARGE LEAK No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin t...

Page 2374: ... P0441 EVAP PURGE VALVE 9 450 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2375: ...e DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0445 EVAP PURGE SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wir...

Page 2376: ... P0442 EVAP SYSTEM SMALL LEAK 9 452 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2377: ...efer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0455 EVAP SYSTEM LARGE LEAK No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Po...

Page 2378: ... P0445 EVAP PURGE SOLENOID CIRCUIT 9 454 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2379: ...E SOLENOID POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ig...

Page 2380: ...t maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN Note Check the Engine Control Fuse 2 in the Relay Control Mod ule If it is open multiple DTCs will be set in the PCM Determine the cause of the open fuse before continuing using the wiring diagrams schematics a...

Page 2381: ... the ignition off Replace the EVAP Purge Solenoid Refer to 25 EMISSIONS CON TROL EVAPORATIVE EMISSIONS EVAP PURGE SOLENOID REMOVAL Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set Note The engine controls must go into closed loop and purge control must be active for at least 2 minutes With the DRB IIIT read the PCM DTCs Did ...

Page 2382: ...NTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking...

Page 2383: ... P0446 CHARCOAL CANISTER SHUTOFF VALVE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 459 ...

Page 2384: ...TROL CIRCUIT SHORT TO VOLTAGE CHARCOAL CANISTER SHUTOFF VALVE POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for...

Page 2385: ...t again Yes Go To 3 No Go To 8 3 CHARCOAL CANISTER SHUTOFF VALVE Note Check the Engine Control Fuse 2 in the Relay Control Mod ule If it is open multiple DTCs will be set in the PCM Determine the cause of the open fuse before continuing using the wiring diagrams schematics as a guide Turn the ignition off Disconnect the Charcoal Canister Shutoff Valve harness connector Note Check connectors Clean ...

Page 2386: ...open Perform POWERTRAIN VERIFICATION TEST VER 2 5 CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Charcoal Canister Shutoff Valve Control circuit at the Charcoal Canister Shutoff Valve harness connector Is the voltage below 1...

Page 2387: ...FICATION TEST VER 2 7 CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Charcoal Canister Shutoff Valve Control circuit at the Charcoal Canister Shutoff Valve harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWE...

Page 2388: ...et DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform the POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not prese...

Page 2389: ... P0446 EVAP PURGE SOLENOID STUCK OPEN ZH ENGINE ELECTRICAL DIAGNOSTICS 9 465 ...

Page 2390: ...related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior to symptom diagnosis Continue Go To 2 2 CHECK FOR CURRENT DTC Note If any EVAP Charcoal Canister DTCs are set diagnose them first before continuing with P0446 Note If the PCM detects and stores a...

Page 2391: ...ct the vacuum port for any damage or restriction Were any problems found Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No Replace the EVAP Purge Solenoid Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS EVAP PURGE SOLENOID REMOVAL 5 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the r...

Page 2392: ... P0451 FUEL TANK PRESSURE SENSOR PERFORMANCE 9 468 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2393: ...E SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT SENSOR GROUND CIRCUIT OPEN FUEL TANK PRESSURE SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnosti...

Page 2394: ...yed Note Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist when check ing for a DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 18 3 READ FUEL TANK PRESSURE Note If an Evap System DTC has been...

Page 2395: ...re the voltage of the 5 Volt Supply circuit at the Fuel Tank Pres sure Sensor harness connector Is the voltage between 4 7 and 5 2 volts Yes Go To 6 No If the voltage is above 5 2 volts Go To 9 If the voltage is below 4 7 volts Go To 10 6 FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean...

Page 2396: ...connector Connect a jumper wire between the Fuel Tank Pressure Sensor Signal circuit and the Sensor Ground circuit at the Fuel Tank Pressure Sen sor harness connector Turn the ignition on With the DRB IIIT read the GAS TANK PRES DIFF Is the Fuel Tank Pressure below 1 hPa 0 02 psi Yes Replace the Fuel Tank Pressure Sensor Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL LEVEL SENDING UNIT SENSOR REMOVAL ...

Page 2397: ...ST VER 2 No Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 5 VOLT SUPPLY CIRCUIT OPEN Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the 5 Volt Supply circuit from the PCM C4 harness connector to the Fuel Tank Pressure Sensor harness connec tor Is the resi...

Page 2398: ...ION TEST VER 2 No Repair the Fuel Tank Pressure Sensor Signal circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 12 FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Fuel Tank Pressure Sensor Signal cir cuit from the PCM C4 harness connector...

Page 2399: ...the Fuel Tank Pressure above 30 hPa 0 435 psi Yes Replace the Fuel Tank Pressure Sensor Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL LEVEL SENDING UNIT SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 14 14 FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure th...

Page 2400: ...tor Is the resistance above 100 kohms Yes Go To 16 No Repair the Fuel Tank Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 2 16 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the 5 Volt Supply circuit Is the resistance above 100 kohms Yes Go To 17 No Repair the 5 Volt Supply circ...

Page 2401: ...ION TEST VER 2 18 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the w...

Page 2402: ... P0452 FUEL TANK PRESSURE SENSOR CIRCUIT LOW 9 478 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2403: ... Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0451 FUEL TANK PRESSURE SENSOR PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repai...

Page 2404: ... P0453 FUEL TANK PRESSURE SENSOR CIRCUIT HIGH 9 480 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2405: ...in Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0451 FUEL TANK PRESSURE SENSOR PERFORMANCE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time ...

Page 2406: ... P0455 EVAP SYSTEM LARGE LEAK 9 482 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2407: ...d a Large Leak error is detected POSSIBLE CAUSES EVAPORATIVE EMISSION SYSTEM LEAK FUEL TANK PRESSURE SENSOR For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set...

Page 2408: ...tored DTCs record these conditions Attempting to duplicate these conditions may assist when check ing for an active DTC Turn the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 8 3 VISUAL AND PHYSICAL INSPECTION Turn the ignition off Perform a visual and phy...

Page 2409: ...ice on the tester s control panel 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 Special To...

Page 2410: ...l tank release the remote smoke air start button and use the ultra violet 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 filteri...

Page 2411: ...UEL DELIVERY FUEL LEVEL SENDING UNIT SENSOR REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 8 INTERMITTENT CONDITION 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 Review the DRB IIIT Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refe...

Page 2412: ... P0456 EVAP SYSTEM SMALL LEAK 9 488 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2413: ...MATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0455 EVAP SYSTEM LARGE LEAK No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal co...

Page 2414: ... P0457 EVAP PURGE VALVE LEAKING 9 490 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2415: ...Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 CHECK FOR CURRENT DTC Turn the ignition on With the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0455 EVAP SYSTEM LARGE LEAK No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary P...

Page 2416: ... P0460 FUEL LEVEL SENSOR CIRCUIT 9 492 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2417: ...ION Turn the ignition off Perform the FUEL GAUGE INOPERATIVE diagnostic test Refer to 8 ELECTRICAL INSTRUMENT CLUSTER DIAGNOSIS AND TEST ING After performing the FUEL GAUGE INOPERATIVE test use the DRB IIIT to erase PCM DTCs Turn the ignition off then back on With the DRB IIIT read PCM DTCs Monitor the DRB IIIT for this DTC Note It may be necessary to take the vehicle on a test drive It may be nec...

Page 2418: ... P0480 COOLING FAN CONTROL CIRCUIT 9 494 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2419: ...TROL CIRCUIT SHORT TO VOLTAGE RADIATOR FAN CONTROL MODULE POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for app...

Page 2420: ...DTC With the ignition on With the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 8 3 FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN Note If an Engine Coolant Temperature ECT Sensor DTC has been set diagnose the Engine Coolant Temperature Sensor DTC before continuing Turn the ignitio...

Page 2421: ...tor Fan Control Module Refer to 7 COOLING ENGINE PWM FAN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 5 RADIATOR FAN CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Radiator Fan Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Radiator Fan Control circuit from the PCM C4 harness connector to the Radiator F...

Page 2422: ...ON TEST VER 2 No Repair the Radiator Fan Control circuit for a short to volt age Perform POWERTRAIN VERIFICATION TEST VER 2 8 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note ...

Page 2423: ... P0480 COOLING FAN CONTROL CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 499 ...

Page 2424: ...s this DTC present Yes For complete diagnosis of this DTC refer to P0480 COOLING FAN CONTROL CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specifi...

Page 2425: ... P0480 COOLING FAN CONTROL CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 501 ...

Page 2426: ...e DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0480 COOLING FAN CONTROL CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wir...

Page 2427: ... P0500 NO VEHICLE SPEED SIGNAL CAB CAN MESSAGE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 503 ...

Page 2428: ... PRESENT IN CONTROLLER ANTILOCK BRAKE CAB This is an informational DTC letting you know that a DTC s is stored in the CAB Using the DRB IIIT read the ABS DTC s and refer to the ABS Cate gory to perform the appropriate symptom Erase this DTC from the PCM after all ABS DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 504 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2429: ... P0500 VEHICLE SPEED PERFORMANCE ESP MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 505 ...

Page 2430: ...RESENT IN CAB This is an informational DTC letting you know that a DTC s is stored in the CAB Using the DRB IIIT read the ABS DTC s and refer to the Brake BAS Electrical Diagnostics Category to perform the appropriate symptom Erase this DTC from the PCM after all the ABS DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 506 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2431: ... P0521 ENGINE OIL SENSOR LEVEL PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 507 ...

Page 2432: ...LY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE OIL SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK ...

Page 2433: ... until operating temperature is reached Closed Loop Note It may be necessary to road test the vehicle With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 21 3 CHECKING FOR OTHER OIL SENSOR DTCS With the ignition on With the DRB IIIT read PCM DTCs Is this DTC the only Engine Oil Sensor DTC present Yes Replace the Engine Oil Sensor Refer to 9 ENGINE LU BRICATION OIL REMOVAL P...

Page 2434: ...sor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 CHECK FOR MAP SENSOR DTC With the igniti...

Page 2435: ...ONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 8 8 MEASURE THE 5 VOLT SUPPLY CIRCUIT VOLTAGE WITH MAP SENSOR DISCONNECTED Turn the ignition off Disconnect the MAP Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the Oil Sensor har ness connector Is the voltage 4 7 5 2 volts Y...

Page 2436: ...OL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 5 VOLT SUPPLY CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the 5 Volt Supply circuit from the Oil Senso...

Page 2437: ...CUIT SHORT TO SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the Sensor Ground circuit and the 5 Volt Supply circuit at the Oil Sensor harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Re...

Page 2438: ...2 volts Yes Go To 14 No If the voltage is above 5 2 volts Go To 16 If the voltage is below 4 7 volts Go To 18 14 SENSOR GROUND CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sensor Ground circuit from the Oil Sen sor harness connector to the PCM C3 harness connector Is the resistance below 5 0...

Page 2439: ...rform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 16 OIL SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Oil Sensor Signal circuit at the Oil Sensor harness connector Is...

Page 2440: ...rm POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to the Oil Sen sor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 18 MEASURE RESISTANCE BETWEEN GROUND AND OIL SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Oil Sensor Sig...

Page 2441: ...EST VER 2 20 OIL SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Oil Sensor Signal circuit from the PCM C3 harness connector to the Oil Sensor harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC ...

Page 2442: ...can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not pres...

Page 2443: ... P0521 ENGINE OIL SENSOR OVER TEMPERATURE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 519 ...

Page 2444: ...ROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE OIL SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diag...

Page 2445: ...ngine and run until operating temperature is reached Closed Loop Note It may be necessary to road test the vehicle Did this DTC set again Yes Go To 3 No Go To 21 3 CHECKING FOR OTHER OIL SENSOR DTCS With the ignition on With the DRB IIIT read PCM DTCs Is this DTC the only Engine Oil Sensor DTC present Yes Replace the Engine Oil Sensor Refer to 9 ENGINE LU BRICATION OIL REMOVAL Perform POWERTRAIN V...

Page 2446: ...or harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 CHECK FOR MAP SENSOR DTC With the ignitio...

Page 2447: ...MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 8 8 MEASURE THE 5 VOLT SUPPLY CIRCUIT VOLTAGE WITH MAP SENSOR DISCONNECTED Turn the ignition off Disconnect the MAP Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the Oil Sensor har ness connector Is the voltage 4 7 5 2 volts Yes Repl...

Page 2448: ...L MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 5 VOLT SUPPLY CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the 5 Volt Supply circuit from the Oil Sensor...

Page 2449: ...CUIT SHORT TO SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the Sensor Ground circuit and the 5 Volt Supply circuit at the Oil Sensor harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Re...

Page 2450: ...2 volts Yes Go To 14 No If the voltage is above 5 2 volts Go To 16 If the voltage is below 4 7 volts Go To 18 14 SENSOR GROUND CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sensor Ground circuit from the Oil Sen sor harness connector to the PCM C3 harness connector Is the resistance below 5 0...

Page 2451: ...rform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 16 OIL SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Oil Sensor Signal circuit at the Oil Sensor harness connector Is...

Page 2452: ...rm POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to the Oil Sen sor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 18 MEASURE RESISTANCE BETWEEN GROUND AND OIL SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Oil Sensor Sig...

Page 2453: ...ST VER 2 20 OIL SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Oil Sensor Signal circuit from the PCM C3 harness connector to the Oil Sensor harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC C...

Page 2454: ...an set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not prese...

Page 2455: ... P0521 ENGINE OIL SENSOR PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 531 ...

Page 2456: ...T SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE OIL SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram...

Page 2457: ...chematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness ...

Page 2458: ... P0521 ENGINE OIL SENSOR QUALITY PERFORMANCE 9 534 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2459: ... OIL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE OIL SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with ...

Page 2460: ...ture is reached Closed Loop Note It may be necessary to road test the vehicle Did this DTC set again Yes Go To 3 No Go To 21 3 CHECKING FOR OTHER OIL SENSOR DTCS With the ignition on With the DRB IIIT read PCM DTCs Is this DTC the only Engine Oil Sensor DTC present Yes Replace the Engine Oil Sensor Refer to 9 ENGINE LU BRICATION OIL REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 4 4 C...

Page 2461: ... sor harness connector to the PCM C3 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the Sensor Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 6 CHECK FOR MAP SENSOR DTC With the ignit...

Page 2462: ...L MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 8 8 MEASURE THE 5 VOLT SUPPLY CIRCUIT VOLTAGE WITH MAP SENSOR DISCONNECTED Turn the ignition off Disconnect the MAP Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the Oil Sensor har ness connector Is the voltage 4 7 5 2 volts Yes Re...

Page 2463: ...ROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 5 VOLT SUPPLY CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the 5 Volt Supply circuit from the Oil Sens...

Page 2464: ...RCUIT SHORT TO SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between the Sensor Ground circuit and the 5 Volt Supply circuit at the Oil Sensor harness connector Is the resistance above 100 kohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No R...

Page 2465: ... 2 volts Yes Go To 14 No If the voltage is above 5 2 volts Go To 16 If the voltage is below 4 7 volts Go To 18 14 SENSOR GROUND CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sensor Ground circuit from the Oil Sen sor harness connector to the PCM C3 harness connector Is the resistance below 5 ...

Page 2466: ...erform POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 16 OIL SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Oil Sensor Signal circuit at the Oil Sensor harness connector I...

Page 2467: ...orm POWERTRAIN VERIFICATION TEST VER 2 No Repair the 5 Volt Supply circuit for a short to the Oil Sen sor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 18 MEASURE RESISTANCE BETWEEN GROUND AND OIL SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Oil Sensor Si...

Page 2468: ...TEST VER 2 20 OIL SENSOR SIGNAL CIRCUIT OPEN Turn the ignition off Disconnect the PCM C3 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Oil Sensor Signal circuit from the PCM C3 harness connector to the Oil Sensor harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC...

Page 2469: ... can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not pre...

Page 2470: ... P0521 ENGINE OIL SENSOR WATER CONTAMINATION 9 546 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2471: ... VOLT SUPPLY CIRCUIT SHORT TO GROUND 5 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE 5 VOLT SUPPLY CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT OIL SENSOR SIGNAL CIRCUIT SHORT TO 5 VOLT SUPPLY CIRCUIT SENSOR GROUND CIRCUIT OPEN MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE OIL SENSOR POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Dia...

Page 2472: ...am schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harn...

Page 2473: ... P0561 BATTERY SYSTEM VOLTAGE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 549 ...

Page 2474: ...or any Technical Service Bulletins that may apply Turn the ignition on With the DRB IIIT erase PCM DTCs Turn the ignition off then back on Monitor the DRB IIIT for this DTC With the DRB IIIT read PCM DTCs If possible operate the vehicle within the conditions that set the DTC Is the Battery System Voltage DTC present Yes Go To 2 a No Go To 4 2 ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN Turn the ignit...

Page 2475: ...RMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking fo...

Page 2476: ... P0562 BATTERY SYSTEM LOW 9 552 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2477: ...mplete diagnosis of this DTC refer to P0561 BAT TERY SYSTEM VOLTAGE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires wh...

Page 2478: ... P0563 BATTERY SYSTEM HIGH 9 554 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2479: ...C refer to P0561 BAT TERY SYSTEM VOLTAGE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and...

Page 2480: ... P0571 STOP LAMP SWITCH CAN SIGNAL LOST TO TRANS PERFORMANCE 9 556 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2481: ...t 1 DTC PRESENT IN CONTROLLER ANTILOCK BRAKE CAB This is an informational DTC letting you know that a DTC s is stored in the CAB Using the DRB IIIT read the ABS DTC s and refer to the ABS Cate gory to perform the appropriate symptom Erase this DTC from the PCM after all ABS DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH ENGINE ELECTRICAL DIAGNOSTICS 9 557 ...

Page 2482: ... P0571 STOP LAMP SWITCH SIGNAL PERFORMANCE 9 558 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2483: ...RESENT IN CONTROLLER ANTILOCK BRAKE CAB This is an informational DTC letting you know that a DTC s is stored in the CAB Using the DRB IIIT read the ABS DTC s and refer to the ABS Cate gory to perform the appropriate symptom Erase this DTC from the PCM after all CAB DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH ENGINE ELECTRICAL DIAGNOSTICS 9 559 ...

Page 2484: ... P0575 SPEED CONTROL SWITCH INPUT CIRCUIT 9 560 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2485: ...WITCH POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignitio...

Page 2486: ...h the DRB IIIT erase PCM DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 PCM Turn the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Speed Control Off Signal circuit at the PCM C4 harness conn...

Page 2487: ... above 100 kohms Yes Go To 5 No Repair the Speed Control Off Signal circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 5 5 SPEED CONTROL OFF SIGNAL CIRCUIT OPEN With the ignition off Measure the resistance of the Speed Control Off Signal circuit from the PCM C4 harness connector to the Speed Control Switch harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair...

Page 2488: ...RTRAIN VERIFICATION TEST VER 5 7 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagrams as a guide inspect the wiring and connectors specific to this DTC Wiggle...

Page 2489: ... P0600 NO CAN MESSAGE FROM CAB MODULE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 565 ...

Page 2490: ...or a complete Electronic Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF CAB DTCS ARE PRESENT Turn ignition on With the DRB IIIT read CAB DTCs Are any performance or BUS related DTCs present Yes Repair all CAB DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS With the ...

Page 2491: ...the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the SKREEM CAN C BUS termination by backprobing between the CAN C BUS circuit and the CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer t...

Page 2492: ...ry Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES EN TRY MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 CAN C BUS CIRCUIT OPEN With the ignition off Disconnect the SKREEM C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the SKREEM C2 harness connector to the PCM C4 harness connector Is the resistance bel...

Page 2493: ...e below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8 CAN C BUS CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ENGIN...

Page 2494: ...t for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 CAN C BUS CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the CAN C BUS cir cuit Is the resistance above 100 kohms Yes Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VER...

Page 2495: ...AIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as ...

Page 2496: ... P0600 NO TRANSMISSION BUS MESSAGE 9 572 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2497: ...or a complete Electronic Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF TCM DTCS ARE PRESENT Turn ignition on With the DRB IIIT read TCM DTCs Are any performance or BUS related DTCs present Yes Repair all TCM DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS With the ...

Page 2498: ...he ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the SKREEM CAN C BUS termination by backprobing between the CAN C BUS circuit and the CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to...

Page 2499: ... Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES EN TRY MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 CAN C BUS CIRCUIT OPEN With the ignition off Disconnect the SKREEM C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the SKREEM C2 harness connector to the PCM C4 harness connector Is the resistance below...

Page 2500: ...below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8 CAN C BUS CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 576 ENGI...

Page 2501: ...for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 CAN C BUS CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the CAN C BUS cir cuit Is the resistance above 100 kohms Yes Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VERIF...

Page 2502: ...TCM C3 harness connector Perform POWERTRAIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and...

Page 2503: ... P0600 LOST COMM WITH ELECTRIC GEAR SHIFT MODULE SLA ZH ENGINE ELECTRICAL DIAGNOSTICS 9 579 ...

Page 2504: ...or a complete Electrical Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF SLA DTCS ARE PRESENT Turn ignition on With the DRB IIIT read SLA DTCs Are any performance or BUS related DTCs present Yes Repair all SLA DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS With the ...

Page 2505: ...cuit and the CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the S...

Page 2506: ...e PCM C4 harness connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C BUS circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit ...

Page 2507: ...lt Yes Go To 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 CAN C BUS CIRCUIT SHORT TO VOLTAGE With the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 10 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ENGINE ...

Page 2508: ... CAN C BUS CIRCUIT OPEN FROM SLA TO PCM With the ignition off Disconnect the SLA harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the SLA har ness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C BUS circuit for an open between the PCM C4 harness and the SLA harness connector Perfor...

Page 2509: ...ns can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently no...

Page 2510: ... P0600 NO CLUSTER BUS MESSAGE 9 586 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2511: ... Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF INSTRUMENT CLUSTER DTCS ARE PRESENT Turn ignition on With the DRB IIIT read Instrument Cluster DTCs Are any performance or BUS related DTCs present Yes Repair all Instrument Cluster DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY D...

Page 2512: ...e CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the SKREEM CAN C...

Page 2513: ...ness connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C BUS circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open ...

Page 2514: ... 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 CAN C BUS CIRCUIT SHORT TO VOLTAGE With the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 10 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 590 ENGINE ELECTRICA...

Page 2515: ...With the ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the Instru ment Cluster C1 harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C BUS circuit for an open between the PCM C4 harness and the Instrument Cluster C1 harness co...

Page 2516: ...DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER No The condition that caused this DTC to set is currently not present Ins...

Page 2517: ... P0602 PCM PROGRAMMED INCORRECT TRANS NO COMM FROM TCM ZH ENGINE ELECTRICAL DIAGNOSTICS 9 593 ...

Page 2518: ...h the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0600 NO TRANSMISSION BUS MESSAGE No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the...

Page 2519: ... P0606 INTERNAL PCM PROCESSOR ZH ENGINE ELECTRICAL DIAGNOSTICS 9 595 ...

Page 2520: ... Turn the ignition on With the DRB IIIT erase PCM DTCs Turn the ignition off Turn the ignition on Start the engine if it will start Note It may be necessary to drive the vehicle With the DRB IIIT read PCM DTCs Is DTC P0606 INTERNAL PCM PROCESSOR present Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform P...

Page 2521: ... P0700 TRANSMISSION CONTROL SYSTEM MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 597 ...

Page 2522: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 598...

Page 2523: ... P0702 TRANSMISSION CONTROL MODULE LOW VOLTAGE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 599 ...

Page 2524: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 600...

Page 2525: ... P0702 TRANSMISSION CONTROL SYSTEM MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 601 ...

Page 2526: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 602...

Page 2527: ... P0702 LOSS OF TORQUE MANAGEMENT SIGNAL ZH ENGINE ELECTRICAL DIAGNOSTICS 9 603 ...

Page 2528: ...N CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 604 ENG...

Page 2529: ... P0702 TCM TORQUE MANAGEMENT REQUEST PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 605 ...

Page 2530: ...ISSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 60...

Page 2531: ... P0705 SLA CONTROL SYSTEM MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 607 ...

Page 2532: ...TC PRESENT IN SHIFT LEVER ASSEMBLY SLA This is an informational DTC letting you know that a DTC s is stored in the SLA Using the DRB IIIT read the SLA DTC s and refer to the Shift Lever Assembly Category to perform the appropriate symptom Erase this DTC from the PCM after all SLA DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 608 ENGINE ELECTRICAL DIAGNOSTICS...

Page 2533: ... P0705 TRANSMISSION CONTROL SYSTEM MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 609 ...

Page 2534: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 610...

Page 2535: ... P0715 TRANSMISSION CONTROL SYSTEM MIL REQUEST ZH ENGINE ELECTRICAL DIAGNOSTICS 9 611 ...

Page 2536: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete 9 612...

Page 2537: ... P0720 TRANSMISSION INCORRECT TORQUE REQUEST FROM ESP ZH ENGINE ELECTRICAL DIAGNOSTICS 9 613 ...

Page 2538: ...or a complete Electronic Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF TCM DTCS ARE PRESENT Turn ignition on With the DRB IIIT read TCM DTCs Are any performance or BUS related DTCs present Yes Repair all TCM DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS With the ...

Page 2539: ...ON With the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the SKREEM CAN C BUS termination by backprobing the CAN C BUS circuit to the CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to...

Page 2540: ...Entry Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES EN TRY MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 CAN C BUS CIRCUIT OPEN With the ignition off Disconnect the SKREEM C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the SKREEM C2 harness connector to the PCM C4 harness connector Is the resistance ...

Page 2541: ...esistance below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8 CAN C BUS CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ...

Page 2542: ...S circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 CAN C BUS CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the CAN C BUS cir cuit Is the resistance above 100 kohms Yes Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CAN C BUS circuit for a short to ground Perform POWERT...

Page 2543: ...erform POWERTRAIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram...

Page 2544: ... P0720 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 620 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2545: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2546: ... P0730 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 622 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2547: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2548: ... P0740 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 624 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2549: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2550: ... P0743 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 626 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2551: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2552: ... P0748 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 628 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2553: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2554: ... P0753 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 630 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2555: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2556: ... P0758 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 632 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2557: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2558: ... P0763 TRANSMISSION CONTROL SYSTEM MIL REQUEST 9 634 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2559: ...SSION CONTROL MODULE TCM This is an informational DTC letting you know that a DTC s is stored in the Transmission Control Module Using the DRB IIIT read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom Erase this DTC from the PCM after all Transmission DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete ZH EN...

Page 2560: ... P1386 KNOCK SENSOR SYSTEM FAILURE 9 636 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2561: ...m the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor p...

Page 2562: ... P1600 ROUGH ROAD DETECTED 9 638 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2563: ...For a complete Electronic Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF CAB DTCS ARE PRESENT Turn ignition on With the DRB IIIT read CAB DTCs Are any performance or BUS related DTCs present Yes Repair all CAB DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS With the...

Page 2564: ...N C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 SKREEM TERMINATION With the ignition off Measure the resistance of the SKREEM CAN C BUS...

Page 2565: ...ss connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 7 CAN C BUS CIRCUIT OPEN With the ignition off Measure the resistance of the CAN C BUS circuit from the PCM C4 harness connector to the SKREEM C2 harness connector Is the resistance below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open Pe...

Page 2566: ...9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 CAN C BUS CIRCUIT SHORT TO VOLTAGE With the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 10 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 9 642 ENGINE ELECTRICAL...

Page 2567: ...IRCUIT OPEN FROM CAB TO PCM With the ignition off Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the CAB harness connector to the PCM C4 harness connector Is the resistance below 5 0 ohms Yes Repair the CAN C BUS circuit for an open between the PCM C4 harness and the CAB harness connector Perform POWERTRAIN ...

Page 2568: ...Cs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Ins...

Page 2569: ... P1612 MAXIMUM GOVERNOR SPEED DEVIATION FUEL LIMITING ZH ENGINE ELECTRICAL DIAGNOSTICS 9 645 ...

Page 2570: ... MOTOR 1 CIRCUIT SHORT TO GROUND THROTTLE CONTROL MOTOR 2 CIRCUIT SHORT TO GROUND THROTTLE BODY POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal conne...

Page 2571: ...fer to 14 FUEL SYSTEM FUEL INJECTION MANIFOLD AIR FLOW MAF SENSOR REMOVAL from the Throttle Body Check for any signs of a foreign material causing the throttle plate to remain open Manually open and close the throttle plate using your hands Does the Throttle Plate move Yes Go To 4 No Remove the debris if possible or replace the Throttle Body Refer to 14 FUEL SYSTEM FUEL INJEC TION THROTTLE BODY RE...

Page 2572: ...off Measure the resistance of the Throttle Control Motor 2 circuit from the Throttle Body harness connector to the PCM C1 harness connector Is the resistance below 5 0 ohms Yes Go To 7 No Repair the Throttle Control Motor 2 circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 7 THROTTLE CONTROL MOTOR 1 CIRCUIT SHORTED TO GROUND With the ignition off Measure the resistance between ground ...

Page 2573: ...remaining view repair Repair Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 10 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can se...

Page 2574: ... P2008 SHORT RUNNER SOLENOID CIRCUIT 9 650 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2575: ...fer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect ...

Page 2576: ...HECK THE SHORT RUNNER VALVE SOLENOID With the ignition on With the DRB IIIT actuate the Short Runner Valve Solenoid Using a 12 volt test light connected across the Short Runner Valve Solenoid harness connector Does the 12 volt test light flash on and off Yes Replace the Short Runner Valve Solenoid Refer to 14 FUEL SYSTEM FUEL INJECTION MANIFOLD TUNE VALVE REMOVAL Perform POWERTRAIN VERIFICATION TE...

Page 2577: ...HORT RUNNER VALVE SOLENOID CONTROL CIRCUIT OPEN With the ignition off Measure the resistance of the Short Runner Valve Solenoid Control circuit from the Short Runner Valve Solenoid harness connector to the PCM C2 harness connector Is the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL...

Page 2578: ...ematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and or open circuits Note Check for any Technical Service Bulletins that may apply Were there any problems found Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 2 No The condition that caused this DTC to set is currently not present Inspect the related wiring harness...

Page 2579: ... P2009 SHORT RUNNER SOLENOID CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 655 ...

Page 2580: ...IIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P2008 SHORT RUNNER SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring a...

Page 2581: ... P2010 SHORT RUNNER SOLENOID CIRCUIT HIGH ZH ENGINE ELECTRICAL DIAGNOSTICS 9 657 ...

Page 2582: ...r complete diagnosis of this DTC refer to P2008 SHORT RUNNER SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle th...

Page 2583: ... P2263 SUPERCHARGER CLUTCH CONTROL CIRCUIT ZH ENGINE ELECTRICAL DIAGNOSTICS 9 659 ...

Page 2584: ...OPEN SUPERCHARGER CLUTCH POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the probl...

Page 2585: ... It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 MEASURE THE FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT VOLTAGE Turn the ignition off Disconnect the supercharger clutch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Connect a 12 volt test light between ground and t...

Page 2586: ...arness connector Is the voltage below 1 0 volt Yes Go To 5 No Repair the Supercharger Clutch Control circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 5 SUPERCHARGER CLUTCH CONTROL CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the Supercharger Clutch Control circuit Is the resistance above 100 kohms Yes Go To 6 No Repair the Superch...

Page 2587: ...T WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors ...

Page 2588: ... P2513 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT HIGH 9 664 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2589: ...ER CIRCUIT OPEN OCCUPANT RESTRAINT CONTROLLER POWERTRAIN CONTROL MODULE For a complete Powertrain Control Module Circuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs...

Page 2590: ...ds at each key off and key on Turn the ignition on With the DRB IIIT read PCM DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT SHORT TO VOLTAGE WARNING TURN THE IGNITION OFF DISCONNECT THE BAT TERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING WHEN RECONNECTING AIRBAG SYSTEM COMPO NENTS THE IGNITION MUST BE TURNED OFF AND THE BAT TERY MUST BE DISCONNECT...

Page 2591: ...ced Accident Report Driver circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 5 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT OPEN With the ignition off Measure the resistance of the Enhanced Accident Report Driver circuit from the PCM C4 harness connector to the ORC harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair the Enhanced Accident Report Driver circuit...

Page 2592: ...LECTRICAL ELECTRONIC CON TROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 No Test Complete 7 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DT...

Page 2593: ... P2513 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT LOW ZH ENGINE ELECTRICAL DIAGNOSTICS 9 669 ...

Page 2594: ... the DRB IIIT read PCM DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P2513 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT HIGH No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a g...

Page 2595: ... P2545 ESP TORQUE MANAGEMENT REQUEST PERFORMANCE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 671 ...

Page 2596: ... For a complete Electronic Control Module Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK TO SEE IF CAB DTCS ARE PRESENT Turn ignition on With the DRB IIIT read CAB DTCs Are there any performance or BUS related DTCs present Yes Repair all CAB DTCs before proceeding Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 VERIFY DTCS W...

Page 2597: ... With the ignition off Disconnect the PCM C4 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the SKREEM CAN C BUS termination by backprobing between the CAN C BUS circuit and the CAN C BUS circuit at the PCM C4 harness connector Is the SKREEM CAN C BUS termination resistance between 110 and 130 ohms Yes Replace and program the Powertrain Control Module R...

Page 2598: ...e Entry Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES EN TRY MODULE REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 2 6 CAN C BUS CIRCUIT OPEN With the ignition off Disconnect the SKREEM C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN C BUS circuit from the SKREEM C2 harness connector to the PCM C4 harness connector Is the resistanc...

Page 2599: ...stance below 5 0 ohms Yes Go To 8 No Repair the CAN C BUS circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 8 CAN C BUS CIRCUIT SHORT TO VOLTAGE Turn the ignition on Measure the voltage of the CAN C BUS circuit at the PCM C4 har ness connector Is the voltage below 1 0 volt Yes Go To 9 No Repair the CAN C BUS circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 ZH ...

Page 2600: ...ircuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 2 10 CAN C BUS CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the CAN C BUS cir cuit Is the resistance above 100 kohms Yes Repair the CAN C BUS circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 2 No Repair the CAN C BUS circuit for a short to ground Perform POWERTRAI...

Page 2601: ...OWERTRAIN VERIFICATION TEST VER 2 12 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schemat...

Page 2602: ... P2561 HVAC CONTROL MODULE REQUESTED MIL ILLUMINATION 9 678 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2603: ...LE This is an informational DTC letting you know that a DTC s is stored in the A C Heater Control Module Using the DRB IIIT read the A C Heater Control Module DTC s and refer to the A C Heater Control Module Category to perform the appro priate symptom Erase this DTC from the PCM after all A C Heater Control Module DTC s have been repaired PCM Diagnostic Information complete Continue Test Complete...

Page 2604: ... CHECKING FUEL DELIVERY 9 680 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2605: ...cuit Diagram Refer to 9 ENGINE SCHEMATICS AND DIA GRAMS Diagnostic Test 1 FUEL PUMP OPERATION WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRES SURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SER VICING ANY FUEL SYSTEM HOSE FITTING OR LINE THE FUEL SYSTEM PRESSURE MUST BE RELEASED Verify that the fuel tank is not empty before continuing Turn the ignition on With the DRB IIIT actuate the Fuel Pump L...

Page 2606: ...ce the Fuel Filter Fuel Pressure Regulator Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL FILTER REMOVAL Perform POWERTRAIN VERIFICATION TEST VER 3 3 CHECKING FUEL PUMP INLET STRAINER 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 Turn the ignition off Remove and in...

Page 2607: ...se 5 from the Relay Control Module Is the Fuel Pump Fuse 5 good Yes Go To 6 No Go To 7 6 FUEL PUMP RELAY OUTPUT CIRCUIT OPEN With the ignition off Disconnect the Relay Control Module B harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Fuel Pump Relay Output circuit from the Fuel Pump harness connector to the Relay Control Module B harness connector Is ...

Page 2608: ...lay Output circuit for a short to ground and replace the Fuel Pump fuse Perform POWERTRAIN VERIFICATION TEST VER 3 8 FUEL PUMP Note Check connectors It is critical that the connector is free from any signs of corrosion or deformities Clean repair as nec essary With the ignition on Using a 12 volt test light connected across the Fuel Pump harness connector With the DRB IIIT actuate the Fuel Pump Do...

Page 2609: ... CHECKING HARD START FUEL SYSTEM ZH ENGINE ELECTRICAL DIAGNOSTICS 9 685 ...

Page 2610: ...serve the fuel pres sure gauge Note Fuel pressure specification is 3 7 to 4 2 bar 54 to 61 psi Choose a conclusion that best matches your fuel pressure reading Below Specification Go To 2 Within Specification Go To 4 2 RESTRICTED FUEL FILTER FUEL PRESSURE REGULATOR WARNING THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE TESTING OR SERVICING ANY FUEL SYSTEM HOSE FITTING...

Page 2611: ...RAIN VERIFICATION TEST VER 1 4 FUEL INJECTOR S 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 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off Note Fuel pressure specification is 3 7 to 4 2 bar 54 to 61 psi Apply special...

Page 2612: ... ENGINE CRANKS BUT DOES NOT START 9 688 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2613: ...e PCM memory If the PCM reports a No Response condition refer to the Section 8E Electronic Control Module category for the proper tests Read the PCM DTCs with the DRB IIIT If any DTCs are present they must be repaired before continuing with any other No Start diagnostic tests Refer to the Section 9 Engine Diagnostics for a list of the related P codes that are reported by the PCM Ensure that the Bu...

Page 2614: ...he Fuel Pump harness connectors Note Check connectors Clean repair as necessary Verify the Fuel Pump Relay is getting voltage on the Fused Engine Control Relay Output circuit and Fused B circuit before continuing Measure the resistance of the Fuel Pump Relay Output circuit from the Relay Control Module B harness connector to the Fuel Pump harness connector Is the resistance below 5 0 ohms Yes Go T...

Page 2615: ... CHARGE AIR COOLER CIRCULATION PUMP INOPERATIVE ZH ENGINE ELECTRICAL DIAGNOSTICS 9 691 ...

Page 2616: ...HECK OUT Note Always perform diagnostics with a fully charged battery Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for applicable TSBs related to the problem Turn the ignition on With the DRB IIIT read PCM DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform this procedure prior ...

Page 2617: ...f Fuse 13 Is the voltage above 10 volts Yes Go To 4 No Go To 6 4 FUSED CHARGE AIR COOLER CIRCULATION PUMP DRIVER CIRCUIT OPEN Turn the ignition off Disconnect the Charge Air Cooler Circulation Pump harness connec tor Note Check connectors Clean repair as necessary Measure the resistance of the Fused Charge Air Cooler Circulation Pump Driver circuit from the Charge Air Cooler Circulation Pump har n...

Page 2618: ...ON TEST VER 2 No Repair the Ground circuit for an open Perform the POWERTRAIN VERIFICATION TEST VER 2 6 CHARGE AIR COOLER CIRCULATION PUMP DRIVER CIRCUIT OPEN Turn the ignition off Disconnect the Pulse Module E harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Charge Air Cooler Circulation Pump Driver circuit from the Pulse Module E harness connector t...

Page 2619: ...IRCULATION PUMP DRIVER CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the Charge Air Cooler Circulation Pump harness connec tor Note Check connectors Clean repair as necessary Measure the resistance between ground and the Fused Charge Air Cooler Circulation Pump Driver circuit at the Charge Air Cooler Circu lation Pump harness connector Is the resistance above 100 kohms Yes Replace the C...

Page 2620: ... engine If the No Start condition is still present refer to the symptom list and perform the diagnostic testing as necessary Refer to any technical service bulletins that may apply Run the engine for one warm up cycle to verify operation With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If a DTC is present refer to the appropriate category and sele...

Page 2621: ... DTC has set return to the symptom list and follow the path specified for that DTC With the DRB IIIT monitor the appropriate pre test enabling conditions until all conditions have been met Once the conditions have been met switch screen to the appropriate OBD II monitor IF the monitor ran and the Good Trip counter changed to one or more the repair was successful and is now com plete Note It may be...

Page 2622: ...o this repair With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If this test is being performed after a No Trouble Code test verify the symptom is no longer present If the symptom is still present or any other symptom or DTC is present refer to the appropriate category and per form the corresponding symptom Refer to any Technical Service Bulletins ...

Page 2623: ...r output test Refer to the appropriate service information as necessary Start the engine and set engine speed to 2000 RPM for at least thirty seconds Cycle the key off and on With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If there are no DTCs present and all components are functioning properly the repair is complete Are any DTCs present YES Repa...

Page 2624: ...ntrol problems and then return to the symptom list Using caution press and release the brake pedal If the speed control did not disengage the repair is not complete Check for TSBs that pertain to speed control problems and then return to the symptom list Bring the vehicle speed back up to 35 mph Press the RESUME switch If the speed control did not resume the previously set speed the repair is not ...

Page 2625: ...SCHEMATICS AND DIAGRAMS ZH ENGINE ELECTRICAL DIAGNOSTICS 9 701 ...

Page 2626: ...9 702 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2627: ...ZH ENGINE ELECTRICAL DIAGNOSTICS 9 703 ...

Page 2628: ...9 704 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2629: ...ZH ENGINE ELECTRICAL DIAGNOSTICS 9 705 ...

Page 2630: ...9 706 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2631: ...ZH ENGINE ELECTRICAL DIAGNOSTICS 9 707 ...

Page 2632: ...POWERTRAIN CONTROL MODULE CIRCUIT DIAGRAM SRT 8 OF 9 9 708 ENGINE ELECTRICAL DIAGNOSTICS ZH ...

Page 2633: ...POWERTRAIN CONTROL MODULE CIRCUIT DIAGRAM SRT 9 OF 9 ZH ENGINE ELECTRICAL DIAGNOSTICS 9 709 ...

Page 2634: ...L 735 INSTALLATION 735 CYLINDER HEAD DESCRIPTION 735 OPERATION 736 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 736 REMOVAL 737 CLEANING 740 INSPECTION 740 INSTALLATION 741 CYLINDER HEAD COVER DESCRIPTION 744 REMOVAL 744 INSTALLATION 745 CAMSHAFT BEARING BRIDGE REMOVAL 746 INSTALLATION 749 ROCKER ARM ADJUSTER ASSY DISASSEMBLY REMOVAL 752 ASSEMBLY INSTALLATION 753 CAMSHAFT DESCRIPTION 753 OPERATION 7...

Page 2635: ...PAN REMOVAL LOWER OIL PAN 797 REMOVAL UPPER OIL PAN 799 INSTALLATION LOWER OIL PAN 801 INSTALLATION UPPER OIL PAN 803 OIL LEVEL TEMPERATURE SENSOR REMOVAL 805 INSTALLATION 806 OIL SPRAY NOZZLES REMOVAL 807 INSTALLATION 807 OIL PUMP DESCRIPTION 807 REMOVAL 807 CLEANING 808 INSTALLATION 809 OIL PUMP DRIVE CHAIN REMOVAL 810 INSTALLATION 810 OIL PRESSURE RELIEF VALVE DESCRIPTION 810 INTAKE MANIFOLD DE...

Page 2636: ...UCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine main tenance These malfunctions may be classified as either mechanical e g a strange noise or performance e g engine idles rough and stalls Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be iso lated with the Service Diagnosis c...

Page 2637: ...bly 8 Worn valve guides 8 Ream guides and install new valves with oversize stems 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves 10 Missing adjuster pivot 10 Replace rocker arm 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 3 Thin or diluted oil 3 Change oil to co...

Page 2638: ...n oil pump 5 Replace oil pump 6 Thin or diluted oil 6 Change oil to correct viscosity 7 Oil pump relief valve stuck 7 Replace the oil pump 8 Oil pump suction tube loose 8 Remove oil pan and install new tube or clean if necessary 9 Oil pump warped or cracked 9 Install new oil pump 10 Excessive bearing clearance 10 Measure bearings for correct clearance OIL LEAKS 1 Misaligned or deteriorated gaskets...

Page 2639: ... Replace cylinder head gasket s 6 Low compression 6 Test cylinder compression 7 Burned warped or pitted valves 7 Install new or reface valves as necessary 8 Plugged or restricted exhaust 8 Replace parts as necessary 9 Faulty ignition cables 9 Replace ignition cables as necessary 10 Faulty coil s 10 Test and replace as necessary ENGINE STALLS OR ROUGH IDLE 1 Carbon build up on throttle plate s 1 Re...

Page 2640: ...be disassembled to determine the cause of low compression unless some form of malfunction is present 11 If the same cylinder or cylinders repeat an abnormally low reading on the second compression test it could indicate the existence of a problem in the cylinder in question DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESSURE LEAKAGE TEST The combustion pressure leakage test provides an accurate mea...

Page 2641: ...out worn or damaged threads tapping the hole with a special Heli CoilT Tap or equivalent and installing an insert into the tapped hole This brings the hole back to its original thread size Heli CoilT tools and inserts are readily available from automotive parts jobbers STANDARD PROCEDURE FORM IN PLACE GASKETS AND SEALERS There are numerous places where form in place gaskets are used on the engine ...

Page 2642: ...bly to prevent smearing material off the location MoparT Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 0 120 in 3 mm in diameter All mounting holes must be circled For corner sealing a 1 8 or 1 4 in 3 17 or 6 35 mm drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel Components should be torqued...

Page 2643: ...result and cause serious engine problems Thoroughly clean the inside of the cup plug hole in the cylinder block or head Be sure to remove any old sealer Lightly coat the inside of the cup plug hole with MoparT Stud and Bearing Mount Make certain the new plug is cleaned of all oil or grease Using the proper drive plug drive the plug into the hole so that the sharp edge of the plug is at least 0 020...

Page 2644: ...found in the engine specifications Refer to 9 ENGINE SPECIFICATIONS PlastigageT generally is accompanied by two scales One scale is in inches the other is a metric scale Note Plastigage is available in a variety of clearance ranges Use the most appropriate range for the spec ifications you are checking 4 Install the proper crankshaft bearings to achieve the specified bearing clearances REMOVAL 1 D...

Page 2645: ...xygen sensor harness connectors 1 MAF sensor harness connector 2 heater hose 3 at rear of engine and the fuel supply line 4 at the fuel rail 12 Disconnect the ignition coil s fuel injector s camshaft position sensor crankshaft position sensor throttle posi tion sensor map sensor engine coolant temperature sensor EGR solenoid air pump air pump switchover solenoid A C compressor and generator harnes...

Page 2646: ...13 Remove the lower radiator hose 1 and the cool ant bypass hose 2 from the water pump 14 Remove the upper radiator hose 1 from the ther mostat housing 9 722 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2647: ...o 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 20 Remove the starter motor Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 21 Remove the transmission Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 REMOVAL or Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL 22 Remove the A C compressor mounting bolts and position the A C compressor out of the way with lines attached Refer to 24 HEATIN...

Page 2648: ...fting eyes 2 Remove the engine from the engine stand 3 Lower the engine into the engine compartment and install the lower engine mount bolts 1 Tighten bolts to 55 N m 41 ft lbs 4 Install the transmission Refer to 21 TRANSMIS SION TRANSAXLE AUTOMATIC NAG1 INSTALLATION or Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION 5 Install the A C compressor Refer to 24 HEATING AIR CONDITIONING PLUMBING...

Page 2649: ...TOR INSTALLATION 8 Install the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 9 Install the front exhaust pipes Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 10 Install the lower splash shield 2 Tighten the screws 1 to 5 N m 44 in lbs 11 Lower the vehicle ZH ENGINE 3 2L SERVICE INFORMATION 9 725 ...

Page 2650: ...l ant bypass hose 2 at the water pump 13 Connect the heater hoses at the engine block and the intake manifold 14 Connect the upper radiator hose 1 at the ther mostat housing 15 Connect the engine wire harness 9 726 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2651: ...e ground lead at the power steering pump Tighten the bolt to 25 N m 18 ft lbs 21 Refill the power steering pump fluid reservoir 22 Connect the vacuum hoses at the brake booster intake manifold and the purge valve 23 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 24 Install and connect the radiator with the radiator fan Refer to 7 COOLING ENGINE RADIATO...

Page 2652: ...nkshaft Forged Steel Connecting Rods Forged Steel Pistons Aluminum Alloy Flat Topped Compression Pressure 689 kPa 100 psi Max Variation Between Cylinders 172 kPa 25 psi CYLINDER BLOCK Cylinder Bore Diameter Standard 89 900 89 915 mm 3 539 3 540 in Repair Max 90 150 90 165 mm 3 549 3 550 in Out of Round 0 014 mm 0005 in Taper 0 03 mm 0011 in PISTONS Piston Diameter 89 87 89 90 mm 3 538 3 539 in Pis...

Page 2653: ...aust 41 0 1 mm 1 614 in Length Intake 119 4 0 2 mm 4 700 in Exhaust 122 2 0 2 mm 4 811 in Valve Margin Intake 1 2 mm 0 047 in Exhaust 1 6 mm 0 062 in SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs A C Compressor Bolts 20 15 177 Balance Shaft Bolts 20 15 177 Body Bolts 40 30 354 Camshaft Bearing Bridge Stage One 15 11 133 Stage Two 90 Clockwise Camshaft Sprocket Bolts Sta...

Page 2654: ...o Cylinder Head Bolts 35 26 310 Flywheel Bolts Stage One 45 33 398 Stage Two 90 Clockwise Fuel Supply Line to Rail 38 28 336 Cylinder Head Bolts Stage One 20 15 177 Stage Two 50 37 443 Stage Three 60 70 Clockwise Stage Four 60 70 Clockwise Intake Manifold Bolts 20 15 177 Lower Splash Shield Screws 5 44 Main Bearing Journal Cap Bolts Stage One M8 20 15 177 Stage Two M8 90 Clockwise Stage One M10 30...

Page 2655: ...Sensor Screws 10 7 89 Oil Spray Nozzle Bolts 15 11 133 Power Steering Pump Ground Bolt 25 18 97 Power Steering Pump High Pressure Line 45 33 398 Timing Chain Cover Bolts 20 15 177 Timing Chain Tensioner Bolt 80 59 708 Transmission Mount Bolts 40 30 354 ZH ENGINE 3 2L SERVICE INFORMATION 9 731 ...

Page 2656: ...SPECIAL TOOLS VALVE SPRING COMPRESSOR C 3422 CF RIGHT CAMSHAFT LOCATING PLATE 9104 LEFT CAMSHAFT LOCATING PLATE 9105 INSERTION TOOL 9103 SLEEVE 9101 9 732 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2657: ...FLYWHEEL LOCKING TOOL 9102 REAR SEAL INSTALLER 9100 VALVE ASSEMBLY TOOL CASE 9106 PRESSURE TESTER ADAPTOR 9107 ZH ENGINE 3 2L SERVICE INFORMATION 9 733 ...

Page 2658: ... the engine cover 1 from the rear first then from the front INSTALLATION 1 Install the engine cover 1 Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 2 Install the air inlet tubes 2 9 734 ENGINE 3 2L SERVICE ...

Page 2659: ...leaner elements 2 from the air cleaner housing 1 INSTALLATION 1 Position the new air cleaner elements 2 in the air cleaner housing 1 2 Install the screws in the air cleaner element covers 3 3 Install the engine cover air cleaner housing and air inlet tubes CYLINDER HEAD DESCRIPTION Extremely compact single overhead camshaft aluminum alloy cylinder heads have two intake and one exhaust valve per cy...

Page 2660: ...ine overheating Loss of coolant Excessive steam white smoke emitting from exhaust Coolant foaming CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the Cylinder Compres sion Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a...

Page 2661: ...e oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE 7 Remove the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 8 Remove the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S 9 Disconnect the exhaust system at the exhaust manifolds Refer to 11 EXHAUST SYSTEM CATALYTIC CON VERTER REMOVAL 10 Position the crankshaft 40 ATDC Refer to 9 ENGINE VALVE T...

Page 2662: ...12 Remove the timing chain tensioner 1 13 Use a cable tie 1 to secure the timing chain to the right hand camshaft sprocket 9 738 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2663: ...sprockets 15 Remove Special Tools 9104 and 9105 Camshaft Locating Plates 16 Remove the camshafts Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S REMOVAL 17 Loosen the cylinder head bolts using the sequence diagram ZH ENGINE 3 2L SERVICE INFORMATION 9 739 ...

Page 2664: ...RD PROCEDURE Be careful not to gouge or scratch the aluminum head sealing surface Clean all engine oil passages INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean the cylinder head coolant and oil passages 3 Check the cylinder head for flatness CAUTION 0 20 mm 0 008 in MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface Deck tog...

Page 2665: ...ock dowels Note Measure and inspect cylinder head bolts before reuse Do not reuse bolts that exceed 144 mm 1 in length Note Apply a thin coat of lubricant to head bolt threads before installing 2 Install but do not tighten the cylinder head bolts 1 ZH ENGINE 3 2L SERVICE INFORMATION 9 741 ...

Page 2666: ...age one 10 N m 7 ft lbs Stage two 30 N m 22 ft lbs Stage three Rotate bolts 90 clockwise Stage four Rotate bolts 90 clockwise Tighten bolts 9 and 10 to 20 N m 7 15 ft lbs 5 Using Special Tools 9104 and 9105 Camshaft Locating Plates lock the camshafts 6 Install the camshaft sprockets and bolts 1 7 Tighten the camshaft sprocket bolts in two stages Stage one 50 N m 37 ft lbs Stage two Rotate bolts 90...

Page 2667: ...bolts to 20 N m 15 ft lbs 13 Install the cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 14 Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLA TION 15 Install and connect the ignition coils Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL INSTALLATION 16 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRI...

Page 2668: ...ealing are lighter than aluminum and dampen valve noise They are cast in two pieces to create internal ventilation passages with oil separators for crankcase vapor ventila tion This ventilation system virtually prevents the possibility of oil sludge formation due to the retention of water vapor in the engine REMOVAL 1 Remove the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER H...

Page 2669: ... 2 INSTALLATION 1 Check the gasket for tearing and breakage If damage is evident replace the gasket 2 Position the cylinder head covers 2 on the cylin der head Install the cylinder head cover bolts 1 and tighten to 10 N m 7 ft lbs ZH ENGINE 3 2L SERVICE INFORMATION 9 745 ...

Page 2670: ...E CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL Note Rotate engine at the crankshaft in running direction until scribe mark 40 on pulley vibration damper corresponds with scribe mark on timing chain cover Grooves in the camshafts must be toward the inside of the wedge 2 Positon the engine timing at 40 ATDC Refer to 9 ENGINE VALVE TIMING TIMING GEARS OPERATION 3 Using Special Tools 9104 1 and 9105 Ca...

Page 2671: ...4 Remove the timing chain tensioner 1 5 Use a cable tie 1 to secure the timing chains to the camshaft sprockets ZH ENGINE 3 2L SERVICE INFORMATION 9 747 ...

Page 2672: ...6 Remove the camshaft sprocket bolt 1 and sprocket 7 Partially loosen the bolts in the sequence shown See diagram 9 748 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2673: ...ON 1 Make sure the engine is at 40 ATDC 2 Position the camshaft bearing bridge on the cam shaft 3 Using Special Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshafts by placing the tool flush on the cylinder head and inserting it into the groove in the camshaft ZH ENGINE 3 2L SERVICE INFORMATION 9 749 ...

Page 2674: ...t do not tighten the bearing bridge bolts 5 Tighten the bolts in the sequence shown to 15 N m 11 ft lbs 6 Tighten the bolts in the sequence shown an addi tional 90 clockwise 9 750 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2675: ...nd bolts 1 Tighten the bolts to 50 N m 37 ft lbs 8 Tighten the camshaft sprocket bolts and additional 90 clockwise 9 Install the timing chain tensioner 1 Tighten the tensioner to 80 N m 59 ft lbs ZH ENGINE 3 2L SERVICE INFORMATION 9 751 ...

Page 2676: ...ARMS REMOVAL Note Wear protective gloves protective clothing and eye protection Note If shaft is tapped too hard there is a risk of distorting the camshaft bearing bridge and damaging the hollow rocker arm shaft 2 Use a 16 mm drift 1 to drive out the rocker shaft 2 Note If resistance is encountered while driving rocker shaft out of the camshaft bearing bridge the bearing must be heated Do not exce...

Page 2677: ...ft bearing bridge bolts through the attachment holes in the camshaft bearing bridge to align and secure the rocker arm shaft The oil supply holes in the rocker arm shaft points downward toward the cylinder head 4 Install the camshaft bearing bridge Refer to 9 ENGINE CYLINDER HEAD ROCKER ARMS INSTALLATION CAMSHAFT DESCRIPTION The induction hardened forged steel camshafts are hollow to minimize weig...

Page 2678: ...o check the cylinder head oil holes for clogging 2 Check the camshaft lobe and the bearing surfaces for abnormal wear and damage Replace the camshaft if it is defective 3 Measure the lobe actual wear and replace the camshaft if it is out of limit The standard value is 0 001 in 0 0254 mm The wear limit is 0 010 in 0 254 mm INSTALLATION 1 Position the camshaft 1 on the cylinder head 2 Install the ca...

Page 2679: ...er to 9 ENGINE CYLINDER HEAD CAMSHAFT S REMOVAL 3 Remove one spark plug from the cylinder to be repaired 4 Position the cylinder to be repaired to TDC 5 Using Special Tool 9102 Flywheel Locking Tool lock the flywheel by inserting the tool into the starter opening 6 Pressurize the combustion chamber Refer to 9 ENGINE DIAGNOSIS AND TESTING 7 Install the assembly tool 1 Compress the valve spring ZH E...

Page 2680: ...Assemble the valves completely before removing the air pressure from the cylinder 11 Repeat these steps for each cylinder required 12 Inspect all of the valve stems Damaged valves must be replaced INSTALLATION Note Valves with nicked or burred stems must be replaced Note The tools used in these valve stem seal procedures are part of Special Tool 9106 Valve Assembly Tool Case 9 756 ENGINE 3 2L SERV...

Page 2681: ...tive sleeve 2 over the valve stem 3 Press the new seal over the sleeve on to the valve stem using the seal pliers 1 4 Remove the protective sleeve 2 5 Install the valve spring seat 4 valve spring 3 and the valve spring retainer 2 ZH ENGINE 3 2L SERVICE INFORMATION 9 757 ...

Page 2682: ...ust valve per cylinder are operated by a double width roller chain driven camshaft per bank using roller rocker arms Lightweight hydraulic adjusters in the rocker arms at the valves take up valve clearance for quiet operation For minimum weight and maximum rigidity the compact rocker arms are pressure cast aluminum They pivot through roller bearings on rocker shafts bolted to the heads Using compu...

Page 2683: ... 9 ENGINE CYLINDER HEAD REMOVAL 2 Using Special Tool C 3422 CF Valve Spring Com pressor compress the valve spring 3 Remove the collets 1 Release the valve spring compressor and remove the valve retainer 2 and the valve spring 3 with spacer ZH ENGINE 3 2L SERVICE INFORMATION 9 759 ...

Page 2684: ...uired CLEANING 1 Clean all valves thoroughly and discard burned warped and cracked valves INSTALLATION 1 Install the valve into the cylinder head 2 Install the protective sleeve 2 over valve stem 3 Lubricate the valve stem seal before installing 4 Using Special Tool 9106 1 Valve Assembly Tool Case press the valve stem seal 3 onto valve stem 5 Remove the protective sleeve 2 9 760 ENGINE 3 2L SERVIC...

Page 2685: ...ve springs are conical to reduce spring and retainer weight and the exhaust valve heads are sodium filled to keep them cool for long life OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber ENGINE BLOCK DESCRIPTION A high pressure die cast aluminum alloy block uses cast in place cylinder bore liners made of a proprietary 9Silitec9 material fo...

Page 2686: ...ock and cylinder bores for cracks or fractures 4 Check block deck surfaces for flatness Deck surface must be within service limit of 0 004 in 0 1 mm CYLINDER BORE Note The cylinder bores should be measured at normal room temperature 21 C 70 F The cylinder walls should be checked for out of round and taper Refer to 9 ENGINE SPECIFICATIONS CRANKSHAFT OIL SEAL REAR REMOVAL Note The rear crankshaft oi...

Page 2687: ...ference for the rear crank shaft oil seal is clean and free of burrs Note Ensure that the sealing lip of the rear crank shaft oil seal is not damaged or compressed Note The circumference and the sealing lip of the rear crankshaft oil seal as well as the mating con tact surface MUST be free of oil and grease Note The rear crankshaft oil seal must be posi tioned at right angles to the crankshaft to ...

Page 2688: ...mating contact surface MUST be free of oil and grease 2 Fit the front crankshaft oil seal onto the Special Tool 9103 Insertion Tool 2 as shown 3 Align the slot of the tool with the crankshaft key 4 Using a suitable tool tap the insertion tool until the vibration damper bolt can be installed through the insertion tool 5 Use the vibration damper bolt to push the seal into the timing chain cover unti...

Page 2689: ...aring caps are not interchangeable and should be marked at removal to insure correct assembly The bearing shells must be installed with the tangs 1 inserted into the machined grooves in the rods and caps Install cap with the tangs on the same side as the rod Fit all rods on one bank until complete Limits of taper or out of round on any crankshaft jour nals should be held to 0 0006 in 0 015 mm Bear...

Page 2690: ...n In addition the upper portions are hard anodized to pro tect the top ring For optimal wear protection the pis ton skirts receive an iron coating Three low tension piston rings provide compression control with low oil consumption Forged steel connecting rods 8 and crankshaft provide requisite strength with light weight Connecting rods are forged in one piece from steel and cracked rather than mac...

Page 2691: ...e 70 F 21 C The piston and cylinder walls must be clean and dry Piston diameter should be measured 90 degrees to piston pin axis Cylinder bores should be measured halfway down the cylinder bore 2 and transverse to the engine crankshaft center line REMOVAL 1 Remove the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL ZH ENGINE 3 2L SERVICE INFORMATION 9 767 ...

Page 2692: ...connecting rods and rod caps 1 for reassembly 3 Mark the pistons facing direction if arrows are not visible 4 Remove the connecting rod bolts 1 and the con necting rod caps 9 768 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2693: ...nnecting rod 3 11 Inspect all parts to be reused for damage Replace as required INSPECTION CONNECTING ROD 1 Check the connecting rods for any twisting or bending 2 Check the condition of the large end Use an oil stone to remove any nicks and burrs 3 Check the condition of the pin bore in the small end of the connecting rod Use an oil stone to remove all nicks and burrs PISTON PIN 1 Inspect for fre...

Page 2694: ...ton and ring grooves for wear INSTALLATION 1 Fit the piston onto the connecting rod 3 2 Press in the piston pin 1 3 Install the snap rings 2 4 Replace the piston rings as required Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS REMOVAL 9 770 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2695: ...oad the piston connecting rod assembly 1 into a ring compressor 2 with light oil lubrication 6 Drive the piston into the cylinder using a wooden drift and a mallot ZH ENGINE 3 2L SERVICE INFORMATION 9 771 ...

Page 2696: ...e connecting rod caps with the marks 1 8 Install the connecting rod bolts 9 Tighten the connecting rod bolts in three stages Stage one 5 N m 44 in lbs Stage two 25 N m 18 ft lbs Stage three rotate bolts 90 clockwise 10 Test the engine for ease of rotation 11 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION PISTON RINGS REMOVAL 1 Remove the piston...

Page 2697: ...ng 3 Use a ring grove cleaner or a broken ring to remove deposits in the ring grooves 4 Inspect the pistons for heat scoring and distortion at the piston pin openings and piston skirts Replace as required INSTALLATION 1 Measure the end gap 1 with rings at the bottom of the cylinder Ring 1 clearance is 20 mm 007 in to 35 mm 013 in Ring 2 clearance is 20 mm 007 in to 40 mm 015 in ZH ENGINE 3 2L SERV...

Page 2698: ...Ring 1 clearance is 012 mm 0004 in to 060 mm 002 in 4 Ring 2 clearance is 010 mm 0003 in to 030 mm 001 in 5 Install the rings on the pistons as shown Compression ring 1 Sealing ring 2 Oil Ring Rail 3 Oil Ring Expander 4 9 774 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2699: ...dding material between the pins keeping the engine compact and reducing weight OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate REMOVAL 1 Remove the upper oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 2 Remove the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 3 Remove the rear crankshaft radial seal Refer to 9 ENGIN...

Page 2700: ...nd the connecting rod bearing cap 1 on one side next to each other for this step 5 Remove the connecting rod bolts 1 Note Do not dislodge the connecting rod bearings from the connecting rods 9 776 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2701: ...k the crankshaft bearing caps before removing CAUTION Carefully pry out the crankshaft bearing caps 8 Remove the crankshaft main bearing journal cap side bolts 2 9 Remove and discard the crankshaft main bearing journal cap bolts 1 10 Remove the crankshaft main bearing journal cap bolts 3 ZH ENGINE 3 2L SERVICE INFORMATION 9 777 ...

Page 2702: ...he engine block 12 Remove the crankshaft main bearing shells 1 and thrust washers 2 from the crankcase 13 Remove the crankshaft main bearing shells from the crankshaft main bearing journal caps 9 778 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2703: ...he engine block 3 Coat the surface of bearings lightly with engine oil 4 Position the crankshaft in the engine block 5 Fit the lower main bearing shells 5 into the main bearing journal caps 4 CAUTION The crankshaft main bearing journal cap bolts M8X75 and M10X90 must always be replaced oth erwise there is a risk of fracture 6 Install the main bearing journal caps 4 ZH ENGINE 3 2L SERVICE INFORMATI...

Page 2704: ...ON 10 Install the oil pump Refer to 9 ENGINE LUBRI CATION OIL PUMP INSTALLATION 11 Install the upper oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 12 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 13 Install a new crankshaft rear radial seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION VIBRATION DAMPER REMO...

Page 2705: ... if signs of leakage are present 3 Inspect the sealing surface of the vibration damper Smooth any roughness with emery paper or an oil stone 4 Measure the vibration damper bolt Replace the bolt if length exceeds 78 mm 5 Position the vibration damper on the front of the crankshaft 6 Lubricate the bolt threads with engine oil before installing 7 Install the vibration damper bolt and tighten 1st to 2...

Page 2706: ...he engine and check for leaks FLEX PLATE FLYWHEEL REMOVAL 1 Remove the transmission For manual Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL for automatic Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 REMOVAL 2 Remove the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 3 Using Special Tool 9102 Flywheel Locking Tool 1 lock the flywheel by inserting the tool in the starter open...

Page 2707: ...e New flywheel flexplate bolts must be used 1 Position the flywheel flexplate 3 and align on the cranshaft pin 2 Install the spacer and new flywheel flexplate bolts 1 Tighten bolts to 45 N m 33 ft lbs 3 Rotate the flywheel flexplate bolts an additional 90 clockwise 4 Install the clutch if equipped Refer to 6 CLUTCH CLUTCH DISC INSTALLATION ZH ENGINE 3 2L SERVICE INFORMATION 9 783 ...

Page 2708: ...ALLATION or Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION ENGINE MOUNT BRACKETS REMOVAL REMOVAL LEFT 1 Remove the engine mount Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT REMOVAL 2 Remove and discard the engine mount bracket bolts 2 3 Remove the engine mount bracket 1 REMOVAL RIGHT 1 Remove the engine mount Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT REMOVAL 9 784 ENGINE 3 2L SERVICE ...

Page 2709: ... INSTALLATION INSTALLATION LEFT 1 Position the engine mount brackets 1 on the engine block 2 Install the new bolts 2 Tighten to 20 N m 15 ft lbs plus 90 clockwise 3 Install the engine mounts Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION ZH ENGINE 3 2L SERVICE INFORMATION 9 785 ...

Page 2710: ...ine block 2 Install the new bolts 1 Tighten to 20 N m 15 ft lbs plus 90 clockwise 3 Install the engine mounts Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION FRONT MOUNT REMOVAL 1 Disconnect the negative battery cable 9 786 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2711: ... the engine mount upper bolt 1 and the heat shield 2 CAUTION Do not stretch lines and hoses while lifting engine 5 Raise the engine slightly 6 Raise and support the vehicle 7 Remove the lower splash shield screws 1 and the splash shield 8 Remove the engine mount lower bolt 9 Remove the engine mount ZH ENGINE 3 2L SERVICE INFORMATION 9 787 ...

Page 2712: ...l the engine mount lower bolt 4 Tighten the bolt to 35 N m 26 ft lbs Note The recesses of the heat shield must be located in the anti twist slots of the engine bracket 3 Lower the engine onto the engine mount Install the heat shield 2 and the engine mount upper bolt 1 4 Tighten the engine mount upper bolt 1 to 55 N m 41 ft lbs 9 788 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2713: ... AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 9 Connect the negative battery cable REAR MOUNT REMOVAL 1 Raise and support the vehicle 2 Support the transmission with a transmission jack 3 Remove the rear mount lower bolts 3 4 Raise the transmission slightly off of the rear cross member 5 Remove the rear mount upper bolts 1 6 Remove the rear mount ZH ENGINE 3 2L SERVICE INFORMATION 9 789 ...

Page 2714: ...d with a bright yellow color under a black light 3 Using a black light inspect the entire engine for fluorescent dye particularly at the suspected area of oil leak If the oil leak is found and identified repair as necessary 4 If dye is not observed drive the vehicle at various speeds for approximately 24 km 15 miles and repeat inspec tion 5 If the oil leak source is not positively identified at th...

Page 2715: ...icates seal leakage or crankshaft damage b Where leakage tends to run straight down possible causes are a porous block oil gallery cup plug bedplate to cylinder block mating surfaces and seal bore See proper repair procedures for these items 4 If no leaks are detected pressurize the crankcase as previously described CAUTION Do not exceed 20 6 kPa 3 psi 5 If the leak is not detected very slowly tur...

Page 2716: ... Do Not Run engine at 3000 RPM 4 Oil pressure engine at operating temperature Curb Idle 34 5 kPa 5 psi minimum 3000 RPM 300 724 kPa 45 105 psi 5 If the oil pressure is 0 psi at idle shut the off engine and check the pressure relief valve it may be stuck open or have a clogged oil pickup screen 6 Remove the oil pressure gauge 7 Install the oil pressure test plug 1 Tighten to 10 N m 89 in lbs after ...

Page 2717: ...indicator tube 2 and install it in the crankcase 3 Install the bolt 1 in the cylinder head cover Tighten to 10 N m 89 in lbs 4 Position the wire harness loom at the oil level indicator tube and fasten with new cable tie 3 5 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTAL LATION 6 Start the engine and check for leaks OIL DESCRIPTION Use synthetic engin...

Page 2718: ... ual 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 INTER NAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL P...

Page 2719: ...m 5 ft lbs 11 Lower the vehicle and fill the crankcase with spec ified type and amount of engine oil 12 Install a new oil filter Refer to 9 ENGINE LU BRICATION OIL FILTER INSTALLATION 13 Install the oil filler cap 14 Start the engine and inspect for leaks 15 Turn off the engine and inspect the oil level USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has b...

Page 2720: ...an oil filter wrench if necessary to remove the oil filter cap 1 2 Remove oil filter cap with the filter 3 Remove the oil filter INSTALLATION 1 Replace the oil filter cap seal 9 796 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2721: ...er 1 in the cap 3 Install the filter and cap 1 Tighten to 25 N m 18 ft lbs OIL PAN REMOVAL LOWER OIL PAN 1 Drain the engine oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE ZH ENGINE 3 2L SERVICE INFORMATION 9 797 ...

Page 2722: ...Remove the lower splash shield screws 1 and the splash shield 3 Remove the transmission oil cooler line retainer bolts 1 Reposition the cooler lines out of the way 9 798 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2723: ...ort the vehicle 3 Remove the lower splash shield screws 1 and the splash shield 2 4 Remove the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 5 Remove the front exhaust pipes Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 6 Disconnect the oil level temperature sensor harness connector ZH ENGINE 3 2L SERVICE INFORMATION 9 799 ...

Page 2724: ...e dipstick tube Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 11 Install and engine support bracket Note Be sure not to lift the engine to far Damage to the coolant hoses power steering lines and A C lines could occur 12 Raise the engine using the support bracket 13 Raise the vehicle 14 Remove the 24 upper oil pan bolts 1 9 800 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2725: ...pplica tion 1 Clean the lower oil pan and the lower portion of the upper oil pan gasket surfaces thoroughly 2 Apply a 1 5 mm to 2 5 mm bead of Loctite 5900 sealant or equivalent to the lower oil pan sealing surface 1 as shown 3 Install the lower oil pan and oil pan bolts Tighten the lower oil pan bolts to 14 N m 10 ft lbs ZH ENGINE 3 2L SERVICE INFORMATION 9 801 ...

Page 2726: ... lbs 5 Install and tighten the oil pan drain plug to 30 N m 22 ft lbs 6 Install the lower splash shield and screws 1 Tighten the screws to 5 N m 44 in lbs 7 Lower the vehicle 8 Fill the crankcase to the specified oil level 9 Start the engine and check for leaks 9 802 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2727: ...lt in the correct bolt hole 1 M6 X 20 2 M6 X 40 3 M6 X 90 4 M8 X 30 5 Tighten the M6 size bolts to 10 N m 89 in lbs Follow the tightening sequence diagram 6 Tighten the M8 size bolts to 20 N m 15 ft lbs Follow the tightening sequence diagram 7 Install the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION 8 Lower the vehicle 9 Lower the engine back into position using the support bra...

Page 2728: ...1 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 16 Install the lower splash shield 2 and retaining screws 1 Tighten screws to 5 N m 44 in lbs 17 Lower the vehicle 18 Install the engine cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLA TION 19 Refill engine oil to proper specification 20 Connect the negative battery cable 9 804 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2729: ...ENGINE LUBRICATION OIL PAN REMOVAL 2 Disconnect the oil level temperature sensor har ness connector 1 3 Remove the two oil level temperature sensor screws 1 4 Remove the two harness retainer screws 2 and the oil level temperature sensor ZH ENGINE 3 2L SERVICE INFORMATION 9 805 ...

Page 2730: ...ness retainer in the upper oil pan with the screws 2 3 Tighten all screws for the oil level temperature sen sor to 10 N m 89 in lbs 4 Connect the oil level temperature sensor harness connector 1 5 Install the lower oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 9 806 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2731: ...direction to clean the oil spray nozzles INSTALLATION Note Ensure the jet pipes of the oil spray nozzles are not damaged or bent during installation 1 Position the oil spray nozzles and bolts in the engine block Tighten the bolts to 15 N m 11 ft lbs 2 Install the upper oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION OIL PUMP DESCRIPTION The gear type oil pump is located below the cranks...

Page 2732: ... pump bolts 1 3 Release the oil pump chain tensioner 1 and remove the oil pump from the oil pump drive chain 2 CLEANING 1 Clean all of the parts thoroughly in a suitable solvent 9 808 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2733: ...mp drive chain for wear Replace any worn or damaged parts 4 Position the oil pump driven sprocket in the drive chain Position and install the oil pump and bolts Tighten the bolts to 20 N m 15 ft lbs 5 Install the lower oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 6 Refill the engine with motor oil to specified level 7 Start the engine and check for leaks ZH ENGINE 3 2L SERVICE INFOR...

Page 2734: ...necessary INSTALLATION 1 Check the oil pump drive chain guide for wear and replace as necessary 2 Install the new oil pump drive chain and the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLATION 3 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER INSTALLATION OIL PRESSURE RELIEF VALVE DESCRIPTION The oil pressure relief valve cannot be adjusted or repaired I...

Page 2735: ...switch the flow between long and short flow paths at approximately 3700 rpm The engine speed for switcho ver to the short tubes provides an imperceptible change in engine torque because the maximum supercharging effect is consistent throughout the 2000 to 5000 rpm speed range DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacu...

Page 2736: ...se ventilator and purge valve from the intake manifold 6 Disconnect the engine harness connectors 7 Disconnect the EGR pipe 1 at the EGR valve 2 8 Remove the air pump switchover valves 4 9 Remove the bolts the intake manifold 1 and the gaskets 2 INSTALLATION 1 Clean the gasket surfaces of the cylinder heads and the intake manifold 9 812 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2737: ...e air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 11 Connect the negative battery cable 12 Start the engine and check for leaks EXHAUST MANIFOLD DESCRIPTION Thin wall air gap construction for the exhaust manifolds reduces underhood temperature by keeping heat in the exhaust stream This also allows the catalytic converter to be mounted in a more advantageous posi...

Page 2738: ...support the vehicle 4 Remove the lower splash shield screws 1 and the splash shield 5 Remove the left side catalytic converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 6 Remove the exhaust manifold nuts 3 7 Lower the vehicle 8 Remove the left side exhaust manifold 1 and gas kets 2 from the engine compartment 9 814 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2739: ...SING REMOVAL 3 Raise and support the vehicle 4 Remove the lower splash shield screws 1 and the splash shield 5 Remove the right side catalytic converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 6 Remove exhaust manifold nuts 3 the exhaust manifold 2 and the gaskets 1 from below the vehicle ZH ENGINE 3 2L SERVICE INFORMATION 9 815 ...

Page 2740: ... converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 3 Install the lower splash shield and screws 1 Tighten to 5 N m 44 in lbs 4 Lower the vehicle 5 Install the air cleaner Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 6 Connect the negative battery cable 7 Start the engine and check for exhaust leaks 9 816 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2741: ... converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 4 Install the lower splash shield and screws 1 Tighten to 5 N m 44 in lbs 5 Lower the vehicle 6 Install the air cleaner Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 7 Connect the negative battery cable 8 Start the engine and check for exhaust leaks ZH ENGINE 3 2L SERVICE INFORMATION 9 817 ...

Page 2742: ... Disconnect the negative battery cable 2 Drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove the engine cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Remove the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Remove the idler pulley 7 R...

Page 2743: ...EAD CYLINDER HEAD COVER S REMOVAL 13 Remove the front cylinder head to timing chain cover retaining bolts 14 Remove the generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 15 Raise and support vehicle 16 Remove the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 17 Remove the upper oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 18 Remove the starter Refer to 8 ELECTRICAL ...

Page 2744: ...the timing chain tensioner Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER PULLEY REMOVAL 22 Remove the timing chain cover bolts and cover INSTALLATION 1 Be sure valve timing is still locked at 40 ATDC Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 9 820 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2745: ... 2 0 mm 0 5 mm bead assembled within 10 minutes and not be flattened or spread Note 2 Apply a 1 5 to 2 0 mm bead of Loctite 5900 or equivalent sealer to the area marked 1 as shown 3 Position the timing chain cover on the front of the engine Note Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly 4 Install the timing chain cover bolts and tighten to 20 ...

Page 2746: ...INE LUBRICATION OIL PAN INSTALLATION 9 Install the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION 10 Install the generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION Note Apply a thin coat of lubricant to head bolt threads before installing 11 Install the front cylinder head to timing chain cover bolts Tighten bolts to 20 N m 7 15 ft lbs 12 Install the cylinder head co...

Page 2747: ...belt tensioner Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS INSTALLATION 19 Install the accesory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 20 Install the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 21 Install the engine cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLA TION 22 Refill all engine fluids to specifications 23...

Page 2748: ...p drive chain 2 and tensioner 1 Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 3 Remove the left and right camshaft sprocket bolts 1 4 Remove the timing chain and camshaft sprockets 9 824 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2749: ...2 6 Clean and inspect all gasket surfaces chain guides and sprockets for wear or damage Repair or replace as necessary INSTALLATION 1 Invert the engine on the engine stand 2 Install the crankshaft sprocket 2 ZH ENGINE 3 2L SERVICE INFORMATION 9 825 ...

Page 2750: ...arking 4 Align the balance shaft sprocket with the timing mark 3 and the copper teeth 1 of the timing chain 5 Insert the camshaft sprockets 6 into the timing chain and align the camshaft sprocket timing marks 4 and 5 with the copper teeth 1 of the timing chain 9 826 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2751: ...he timing chain with the sprockets and route within in the timing chain guides 1 7 Using Special Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshaft sprockets ZH ENGINE 3 2L SERVICE INFORMATION 9 827 ...

Page 2752: ...UMP INSTALLATION 9 Rotate the engine to the upright position 10 Install the timing chain cover Tighten the bolts to 20 N m 15 ft lbs Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER INSTALLA TION 11 Remove Special Tools 9104 and 9105 Camshaft Locating Plates from the camshaft sprockets 9 828 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2753: ... a 90 degree V 6 engine It rotates at engine speed in the opposite direction Mounted above the crankshaft in the cylinder block it is driven by the timing chain REMOVAL 1 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER REMOVAL ZH ENGINE 3 2L SERVICE INFORMATION 9 829 ...

Page 2754: ... STARTER MOTOR REMOVAL 4 Using Special Tool 9102 Flywheel Locking Tool 1 lock the flywheel 5 Remove the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove the rear crankshaft oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL 9 830 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2755: ...ning bolt 2 8 Remove the balance shaft rear counter weight 1 from the balance shaft 9 Remove the balance shaft locking plate bolt 6 and locking plate at the front of the engine block 10 Remove the balance shaft 5 from the front of the engine ZH ENGINE 3 2L SERVICE INFORMATION 9 831 ...

Page 2756: ...retaining bolt 4 Tighten the bolt to 20 N m 15 ft lbs Rotate the bolt 4 an additional 90 3 Install the balance shaft locking plate and locking plate bolt 6 Tighten the balance shaft locking plate bolt to 20 N m 15 ft lbs 4 Install the crankshaft rear radial oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL 5 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT...

Page 2757: ...ENGINE VALVE TIMING GEAR HOUSING COVER INSTALLATION 7 Remove the Special Tool 9102 Flywheel Locking Tool 1 from the engine and install the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION ZH ENGINE 3 2L SERVICE INFORMATION 9 833 ...

Page 2758: ...ing chain guides 1 off of the mounting pins Inspect and replace worn or dam aged guides as required INSTALLATION 1 Install the timing chain guides on the mounting pins Lubricate surface with engine oil 2 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 9 834 ENGINE 3 2L SERVICE INFORMATION ZH ...

Page 2759: ...tains camshaft 6 and balance shaft 3 operation and timing Timing marks on the crankshaft 2 balance shaft 3 and camshafts 5 are aligned with copper links 1 in the timing chain to keep symetrical valve and ignition performance ZH ENGINE 3 2L SERVICE INFORMATION 9 835 ...

Page 2760: ...L REMOVAL UPPER 858 REMOVAL LOWER 859 INSTALLATION INSTALLATION UPPER 860 INSTALLATION LOWER 861 AIR CLEANER ELEMENT REMOVAL 863 INSTALLATION 864 CYLINDER HEAD DESCRIPTION 865 OPERATION 865 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 865 REMOVAL 866 CLEANING 870 INSPECTION 870 INSTALLATION 871 CYLINDER HEAD COVER DESCRIPTION 875 REMOVAL 875 INSTALLATION 876 CAMSHAFT BEARING BRIDGE REMOVAL 877 INSTA...

Page 2761: ...PAN 933 OIL LEVEL TEMPERATURE SENSOR REMOVAL 934 INSTALLATION 935 OIL SPRAY NOZZLES REMOVAL 936 INSTALLATION 936 OIL PUMP DESCRIPTION 937 REMOVAL 937 CLEANING 937 INSTALLATION 938 OIL PUMP DRIVE CHAIN REMOVAL 939 INSTALLATION 939 OIL PRESSURE RELIEF VALVE DESCRIPTION 939 OIL COOLER LINES DESCRIPTION 940 OPERATION 940 REMOVAL 941 INSTALLATION 944 INTAKE MANIFOLD DESCRIPTION 946 OPERATION 946 DIAGNO...

Page 2762: ...Gasket Failure Diagnosis Engine Oil Leak Inspection Intake Manifold Leakage Diagnosis DIAGNOSIS AND TESTING ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1 High or low oil level in crankcase 1 Check and correct engine oil level 2 Thin or diluted oil 2 Change oil to correct viscosity 3 Thick oil 3 a Change oil and filter b Run engine to operating temperature c Change...

Page 2763: ... engine to operating temperature c Change oil and filter again 5 Excessive bearing clearance 5 Measure bearings for correct clearance Repair as necessary 6 Excessive end play 6 Check thrust bearing for wear on flanges 7 Crankshaft journal out of round or worn 7 Replace crankshaft or grind journals 8 Loose flywheel or torque converter 8 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 1 ...

Page 2764: ... 5 Replace cylinder head s 6 Valve stem seal s worn or damaged 6 Replace seal s ENGINE DIAGNOSIS PERFORMANCE CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK 1 Weak or discharged battery 1 Charge or replace battery as necessary Check charging system 2 Corroded or loose battery connections 2 Clean tighten battery starter connections 3 Faulty starter or related circuits 3 Check starting sy...

Page 2765: ...nition cables as necessary 3 Dirt or water in fuel system 3 Clean system and replace fuel filter 4 Burned warped or pitted valves 4 Install new or reface valves as necessary 5 Faulty coil s 5 Test and replace as necessary DIAGNOSIS AND TESTING CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions Ensure the ba...

Page 2766: ...r 7 Calibrate the tester according to the manufacturer s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum with 552 kPa 80 psi recommended Perform the test procedures on each cylinder according to the tester manufacturer s instructions While testing lis ten for pressurized air escaping through the throttle body tailpipe and oil filler cap...

Page 2767: ...o engine oil Mois ture in the air causes the material to cure This material is available in three ounce tubes and has a shelf life of one year After one year this material will not properly cure Always inspect the package for the expiration date before use MOPART ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to ...

Page 2768: ...ration must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Never use the following to clean gasket surfaces Metal scraper 1 Abrasive pad or paper to clean cylinder block and head 2 High speed power tool with an abrasive pad or a wire brush Note Multi Layer Steel MLS head gaskets require a scratch free sealing surface CAUTION Excessive...

Page 2769: ... of the PlastigageT 1 Remove any oil film from the surface to be checked The plastigage will dissolve in oil 2 Place a piece of the PlastigageT 1 across the entire width of the bearing shell in the cap approx imately 1 4 in 6 35 mm off center and away from the oil holes In addition suspected areas can be checked by placing the Plastigage in the suspected area Torque the bearing cap bolts of the be...

Page 2770: ...TEM FUEL DELIVERY STANDARD PROCEDURE 6 Remove the radiator with the radiator fan Refer to 7 COOLING ENGINE RADIATOR REMOVAL 7 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 8 Disconnect the vacuum hoses at the vacuum booster the intake manifold and the purge valve 9 Remove the oil from the power steering pump res ervoir 10 Disconnect the ground lead at the p...

Page 2771: ... the lower splash shield screws 1 and the splash shield 2 19 Remove the A C compressor mounting bolts and position the A C compressor out of the way with the lines attached Refer to 24 HEATING AIR CONDITIONING PLUMBING A C COMPRESSOR REMOVAL 20 Remove the front exhaust pipes Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 21 Disconnect the ground cable 1 at the transmission 22 Remove the pr...

Page 2772: ...ehicle 27 Attach Special Tool 9109 Lifting Bracket to the engine and lift the engine from the vehicle 28 Mount the engine to an engine stand REMOVAL ENGINE COVER SRT 1 Firmly grasp both of the front corners of the front engine cover 1 and pull up firmly 2 Remove front engine cover 1 from vehicle 9 848 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2773: ...N TRANSAXLE AUTOMATIC NAG1 INSTALLATION 6 Install the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 7 Install the A C compressor Refer to 24 HEATING AIR CONDITIONING PLUMBING A C COMPRESSOR INSTALLATION 8 Install the ground cable at the transmission 1 Tighten to 40 N m 30 ft lbs 9 Install the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 10 Inst...

Page 2774: ...take manifold 14 Connect the lower radiator hose and coolant bypass hose to the waterpump 15 Connect the upper radiator hose to the thermostat housing 16 Connect the PCM wire harness connectors and the oxygen sensor harness connectors 17 Connect the fuel supply line 1 at the fuel rail Tighten the fitting to 38 N m 28 ft lbs 9 850 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2775: ...fan Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 24 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTAL LATION 25 Install the engine cover Refer to 9 ENGINE INSTALLATION 26 Fill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 27 Fill the engine with engine oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE 28 Connect the n...

Page 2776: ...ed Steel Pistons Aluminum Alloy Flat Topped Compression Pressure 689 kPa 100 psi Max Variation Between Cylinders 172 kPa 25 psi Supercharger Helical Two Rotor Design CYLINDER BLOCK Cylinder Bore Diameter Standard 89 900 89 915 mm 3 539 3 540 in Repair Max 90 150 90 165 mm 3 549 3 550 in Out of Round 0 014 mm 0005 in Taper 0 03 mm 0011 in PISTONS Piston Diameter 89 87 89 90 mm 3 538 3 539 in Piston...

Page 2777: ...ength Intake 119 4 0 2 mm 4 700 in Exhaust 122 2 0 2 mm 4 811 in Valve Margin Intake 1 2 mm 0 047 in Exhaust 1 6 mm 0 062 in SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs A C Compressor Bolts 20 15 177 Balance Shaft Bolts 20 15 177 Body Bolts 40 30 354 Camshaft Bearing Bridge Stage One 15 11 133 Stage Two 90 Clockwise Camshaft Sprocket Bolts Stage One 50 37 443 Stage Tw...

Page 2778: ...r Head Bolts 35 26 310 Flywheel Bolts Stage One 45 33 398 Stage Two 90 Clockwise Fuel Supply Line to Rail 38 28 336 Cylinder Head Bolts Stage One 20 15 177 Stage Two 50 37 443 Stage Three 60 70 Clockwise Stage Four 60 70 Clockwise Intake Manifold Bolts 20 15 177 Intake Plenum to Supercharger Bolts 10 7 88 Lower Splash Shield Screws 5 44 Main Bearing Journal Cap Bolts Stage One M8 20 15 177 Stage T...

Page 2779: ...ews 10 7 89 Oil Spray Nozzle Bolts 15 11 133 Power Steering Pump Ground Bolt 25 18 97 Power Steering Pump High Pressure Line 45 33 398 Supercharger to Cylinder Head Bolts 23 17 203 Timing Chain Cover Bolts 20 15 177 Timing Chain Tensioner Bolt 80 59 708 Transmission Mount Bolts 40 30 354 ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 855 ...

Page 2780: ...SPECIAL TOOLS C 3422 CF VALVE SPRING CLAMP 9104 CAMSHAFT LOCATING PLATE 9105 CAMSHAFT LOCATING PLATE 9103 INSERTION TOOL 9101 SLEEVE 9 856 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2781: ...9102 FLYWHEEL LOCKING TOOL 9100 RR SEAL INSTALLER 9106 VALVE ASSEMBLY TOOL CASE 9107 PRESSURE TESTER ADAPTER 9109 LIFTING BRACKET ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 857 ...

Page 2782: ...INE REMOVAL 2 Remove the upper air cleaner housing retaining screws 1 3 Disconnect the breather hose 2 from the throttle body inlet tube 4 Disconnect the air inlet tube from the throttle body 5 Remove the upper air cleaner housings from the engine 9 858 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2783: ...Remove the upper air cleaner housing retaining screws 1 3 Disconnect the breather hose 2 from the throttle body inlet tube 4 Disconnect the air inlet tube from the throttle body 5 Remove the upper air cleaner housings from the engine ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 859 ...

Page 2784: ...stall the upper air cleaner housings to the engine 2 Connect the air inlet to the throttle body 3 Connect the breather hose 2 to the throttle body inlet tube 4 Install the upper air cleaner housing retaining screws 1 and tighten them to N m 9 860 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2785: ...5 Install the front engine cover 1 Refer to 9 ENGINE INSTALLATION INSTALLATION LOWER 1 Install the lower air cleaner housing ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 861 ...

Page 2786: ...t to the throttle body 4 Connect the breather hose 2 to the throttle body inlet tube 5 Install the upper air cleaner housing retaining screws 1 and tighten them to N m 6 Install the front engine cover 1 Refer to 9 ENGINE INSTALLATION 9 862 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2787: ...ve the upper air cleaner housing retaining screws 1 Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 3 Raise the upper air cleaner housing and remove the air cleaner element 4 Remove the air cleaner elements from the air cleaner housing ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 863 ...

Page 2788: ...ll the screws 1 in the upper air cleaner ele ment cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 3 Realign engine cover retaining clips to mounting brackets and push down firmly to connect engine cover to mounting brackets 9 864 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2789: ...of engine power Engine misfiring Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are Engine overheating Loss of coolant Excessive steam white smoke emitting from exhaust Coolant foaming CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the Cylinder ...

Page 2790: ...connect the front exhaust pipes from the exhaust manifolds Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 5 Lower the vehicle 6 Remove the engine cover Refer to 9 ENGINE COVER REMOVAL 7 Remove the engine air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 8 Drain the engine coolant Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 9 Remove the radiator wi...

Page 2791: ...S SUPERCHARGER REMOVAL 14 Remove the cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S 15 Disconnect the exhaust system at the exhaust manifolds Refer to 11 EXHAUST SYSTEM CATALYTIC CON VERTER REMOVAL 16 Position the crankshaft 40 ATDC Refer to 9 ENGINE VALVE TIMING TIMING GEARS OPERATION 17 Using Special Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshafts by...

Page 2792: ...18 Remove the timing chain tensioner 1 19 Use a cable tie 1 to secure the timing chain to the right hand camshaft sprocket 9 868 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2793: ...rockets 21 Remove Special Tools 9104 and 9105 Camshaft Locating Plates 22 Remove the camshafts Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S REMOVAL 23 Loosen the cylinder head bolts using the sequence diagram ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 869 ...

Page 2794: ...OCEDURE Be careful not to gouge or scratch the aluminum head sealing surface Clean all engine oil passages INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean the cylinder head coolant and oil passages 3 Check the cylinder head for flatness CAUTION 0 20 mm 0 008 in MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface Deck together...

Page 2795: ...k dowels Note Measure and inspect cylinder head bolts before reuse Do not reuse bolts that exceed 144 mm 1 in length Note Apply a thin coat of lubricant to head bolt threads before installing 2 Install but do not tighten the cylinder head bolts 1 ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 871 ...

Page 2796: ...ne 20 N m 15 ft lbs Stage two 50 N m 37 ft lbs Stage three Rotate bolts 60 70 clockwise Stage four Rotate bolts 60 70 clockwise Tighten bolts 9 and 10 to 25 N m 18 ft lbs 5 Using Special Tools 9104 and 9105 Camshaft Locating Plates lock the camshafts 6 Install the camshaft sprockets and bolts 1 7 Tighten the camshaft sprocket bolts in two stages Stage one 50 N m 37 ft lbs Stage two Rotate bolts 90...

Page 2797: ...NG TIMING GEARS OPER ATION 12 Install the cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 13 Install the supercharger Refer to 9 ENGINE MANIFOLDS SUPERCHARGER INSTALLATION 14 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 15 Install and connect the radiator fan with the radiator Refer to 7 COOLING ENGINE RADIATOR...

Page 2798: ...ld 2 Tighten the screws 1 to 5 N m 44 in lbs 20 Lower the vehicle 21 Install the engine air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 22 Install the engine cover Refer to 9 ENGINE INSTALLATION 23 Fill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 24 Fill the engine oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE 25 Start...

Page 2799: ...ormation due to the retention of water vapor in the engine REMOVAL 1 Remove the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 2 Disconnect the ignition coil harness connectors 2 3 Disconnect the spark plug wires 1 at the spark plugs 4 Position aside the vacuum hoses at the cylinder head cover retainers 3 5 Disconnect the crankcase ventilation hose from the lef...

Page 2800: ...cover bolts 1 and tighten to 10 N m 7 ft lbs 3 Route the engine vacuum hoses on the cylinder head cover retainiers 3 4 Connect the crankcase ventilator hose to the left cylinder head cover the ignition coils 2 and the spark plug wires 1 5 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 9 876 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2801: ... scribe mark on timing chain cover Grooves in the camshafts must be toward the inside of the wedge 2 Positon the engine timing at 40 ATDC Refer to 9 ENGINE VALVE TIMING TIMING GEARS OPERATION 3 Using Special Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshafts by placing the tool flush on the cylinder head and inserting it into the groove in the camshaft 4 Remove the timing chain tens...

Page 2802: ...5 Use a cable tie 1 to secure the timing chains to the camshaft sprockets 6 Remove the camshaft sprocket bolt 1 and sprocket 9 878 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2803: ...rtially loosen the bolts in the sequence shown See diagram 8 Loosen and remove the bearing bridge bolts in the sequence shown Remove the camshaft bearing bridges ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 879 ...

Page 2804: ... Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshafts by placing the tool flush on the cylinder head and inserting it into the groove in the camshaft 4 Install but do not tighten the bearing bridge bolts 5 Tighten the bolts in the sequence shown to 15 N m 11 ft lbs 9 880 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2805: ...ence shown an addi tional 90 clockwise 7 Install the camshaft sprockets and bolts 1 Tighten the bolts to 50 N m 37 ft lbs 8 Tighten the camshaft sprocket bolts and additional 90 clockwise ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 881 ...

Page 2806: ... Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION ROCKER ARM ADJUSTER ASSY DISASSEMBLY REMOVAL 1 Remove the camshaft bearing bridge Refer to 9 ENGINE CYLINDER HEAD ROCKER ARMS REMOVAL Note Wear protective gloves protective clothing and eye protection Note If shaft is tapped too hard there is a risk of distorting the camshaft bearing bridge and da...

Page 2807: ...the bearing must be heated Do not exceed 160 C 1 Cool the rocker arm shaft 2 Insert the rocker arm shaft 1 into the camshaft bearing bridge 2 and through the rocker arms by tapping it gently with a mallet Ensure that the rocker arms are not crooked 3 Insert two camshaft bearing bridge bolts through the attachment holes in the camshaft bearing bridge to align and secure the rocker arm shaft The oil...

Page 2808: ...th a suitable solvent INSPECTION 1 Inspect the camshaft bearing journals for damage or binding If the journals are binding check the cylinder head for damage Also check the cylinder head oil holes for clogging 2 Check the camshaft lobe and the bearing surfaces for abnormal wear and damage Replace the camshaft if it is defective 3 Measure the lobe actual wear and replace the camshaft if it is out o...

Page 2809: ...ase 1 Remove the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 2 Remove the camshafts Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S REMOVAL 3 Remove one spark plug from the cylinder to be repaired 4 Position the cylinder to be repaired to TDC 5 Using Special Tool 9102 Flywheel Locking Tool lock the flywheel by inserting the tool into the starter opening 6 Pressurize the combustion cham...

Page 2810: ...l 1 Compress the valve spring 8 With the valve spring compressed remove the col lets 1 9 Release the valve spring and remove the valve spring retainer 2 the spring 3 and spring seat 4 9 886 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2811: ...replaced INSTALLATION Note Valves with nicked or burred stems must be replaced Note The tools used in these valve stem seal procedures are part of Special Tool 9106 Valve Assembly Tool Case 1 Lubricate the new seal 3 with clean engine oil 2 Install the protective sleeve 2 over the valve stem 3 Press the new seal over the sleeve on to the valve stem using the seal pliers 1 4 Remove the protective s...

Page 2812: ... the valve stem collets with the valve spring compressed 8 Release the valve spring slowly 9 Be sure that the collets are seated in the valve spring retainer 10 Remove the assembly tool Note Perform this procedure on one cylinder at a time 11 Repeat the procedure for each valve that is to be serviced 9 888 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2813: ...eight and maximum rigidity the compact rocker arms are pressure cast aluminum They pivot through roller bearings on rocker shafts bolted to the heads Using computer aided measurement and calculation techniques valve dynamics are equivalent to that achieved by direct valve actuation through in line tappets but with far less friction OPERATION The intake valve allows the air fuel mixture to enter th...

Page 2814: ...22 CF Valve Spring Com pressor compress the valve spring 3 Remove the collets 1 Release the valve spring compressor and remove the valve retainer 2 and the valve spring 3 with spacer 9 890 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2815: ...red CLEANING 1 Clean all valves thoroughly and discard burned warped and cracked valves INSTALLATION 1 Install the valve into the cylinder head 2 Install the protective sleeve 2 over valve stem 3 Lubricate the valve stem seal before installing 4 Using Special Tool 9106 1 Valve Assembly Tool Case press the valve stem seal 3 onto valve stem 5 Remove the protective sleeve 2 ZH ENGINE 3 2L SRT SERVICE...

Page 2816: ...the process for each valve 9 Install the cylinder head Refer to 9 ENGINE CYLINDER HEAD INSTALLATION VALVE SPRINGS DESCRIPTION Valve springs are conical to reduce spring and retainer weight and the exhaust valve heads are sodium filled to keep them cool for long life OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber 9 892 ENGINE 3 2L SRT SER...

Page 2817: ...nal rigidity CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent INSPECTION ENGINE BLOCK 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking 2 If new core plugs are to be installed Refer to 9 ENGINE STANDARD PROCEDURE 3 Examine block and cylinder bores for cracks or fractures 4 Check block deck surfaces for flatness Deck surface must be wi...

Page 2818: ...ENGINE BLOCK FLEX PLATE REMOVAL 2 Remove the crankshaft end cover bolts 2 3 Remove the end cover 3 4 Discard the end cover 3 and the rear crankshaft oil seal 1 5 Clean the engine block and the oil pan gasket surfaces INSTALLATION Note The rear crankshaft oil seal cannot be replaced separately The end cover and seal are assembled at the factory and must be replaced as a set 9 894 ENGINE 3 2L SRT SE...

Page 2819: ...t damaged or compressed Note The circumference and the sealing lip of the rear crankshaft oil seal as well as the mating con tact surface MUST be free of oil and grease Note The rear crankshaft oil seal must be posi tioned at right angles to the crankshaft to assure proper sealing 3 Using Special Tool 9100 Rear Seal Installer 1 install the rear crankshaft oil seal into the new end cover Note The d...

Page 2820: ...he accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 5 Protect the crankshaft with a rag then pry out the front crankshaft oil seal 1 with a suitable tool INSTALLATION 1 Remove any burrs from the seal s mounting surface 9 896 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2821: ...ot of the tool with the crankshaft key 4 Using a suitable tool tap the insertion tool until the vibration damper bolt can be installed through the insertion tool 5 Use the vibration damper bolt to push the seal into the timing chain cover until tight 6 Remove the Special Tools 7 Install the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 8 Install the accessory drive...

Page 2822: ...n the pins keeping the engine compact and reducing weight STANDARD PROCEDURE CONNECTING RODS AND BEARINGS CONNECTING ROD BEARINGS The bearing caps are not interchangeable and should be marked at removal to insure correct assembly The bearing shells must be installed with the tangs 1 inserted into the machined grooves in the rods and caps Install cap with the tangs on the same side as the rod Fit a...

Page 2823: ...num alloy to cope with the high temperatures created by dual ignition In addition the upper portions are hard anodized to pro tect the top ring For optimal wear protection the pis ton skirts receive an iron coating Three low tension piston rings provide compression control with low oil consumption Forged steel connecting rods 8 and crankshaft provide requisite strength with light weight Connecting...

Page 2824: ...70 F 21 C The piston and cylinder walls must be clean and dry Piston diameter should be measured 90 degrees to piston pin axis Cylinder bores should be measured halfway down the cylinder bore 2 and transverse to the engine crankshaft center line REMOVAL 1 Remove the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 9 900 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2825: ...nnecting rods and rod caps 1 for reassembly 3 Mark the pistons facing direction if arrows are not visible 4 Remove the connecting rod bolts 1 and the con necting rod caps ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 901 ...

Page 2826: ...ecting rod 3 11 Inspect all parts to be reused for damage Replace as required INSPECTION CONNECTING ROD 1 Check the connecting rods for any twisting or bending 2 Check the condition of the large end Use an oil stone to remove any nicks and burrs 3 Check the condition of the pin bore in the small end of the connecting rod Use an oil stone to remove all nicks and burrs PISTON PIN 1 Inspect for free ...

Page 2827: ...n and ring grooves for wear INSTALLATION 1 Fit the piston onto the connecting rod 3 2 Press in the piston pin 1 3 Install the snap rings 2 4 Replace the piston rings as required Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS REMOVAL ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 903 ...

Page 2828: ...d the piston connecting rod assembly 1 into a ring compressor 2 with light oil lubrication 6 Drive the piston into the cylinder using a wooden drift and a mallot 9 904 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2829: ...connecting rod caps with the marks 1 8 Install the connecting rod bolts 9 Tighten the connecting rod bolts in three stages Stage one 5 N m 44 in lbs Stage two 25 N m 18 ft lbs Stage three rotate bolts 90 clockwise 10 Test the engine for ease of rotation 11 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION PISTON RINGS REMOVAL 1 Remove the pistons ...

Page 2830: ...while cleaning 3 Use a ring grove cleaner or a broken ring to remove deposits in the ring grooves 4 Inspect the pistons for heat scoring and distortion at the piston pin openings and piston skirts Replace as required INSTALLATION 1 Measure the end gap 1 with rings at the bottom of the cylinder Ring 1 clearance is 20 mm to 35 mm Ring 2 clearance is 20 mm to 40 mm 9 906 ENGINE 3 2L SRT SERVICE INFOR...

Page 2831: ...on rings 1 3 Ring 1 clearance is 012 mm to 060 mm 4 Ring 2 clearance is 010 mm to 030 mm 5 Install the rings on the pistons as shown Compression ring 1 Sealing ring 2 Oil Ring Rail 3 Oil Ring Expander 4 ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 907 ...

Page 2832: ...ing material between the pins keeping the engine compact and reducing weight OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate REMOVAL 1 Remove the upper oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 2 Remove the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 3 Remove the rear crankshaft radial seal Refer to 9 ENGINE ...

Page 2833: ... the connecting rod bearing cap 1 on one side next to each other for this step 5 Remove the connecting rod bolts 1 Note Do not dislodge the connecting rod bearings from the connecting rods ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 909 ...

Page 2834: ...the crankshaft bearing caps before removing CAUTION Carefully pry out the crankshaft bearing caps 8 Remove the crankshaft main bearing journal cap side bolts 2 9 Remove and discard the crankshaft main bearing journal cap bolts 1 10 Remove the crankshaft main bearing journal cap bolts 3 9 910 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2835: ... engine block 12 Remove the crankshaft main bearing shells 1 and thrust washers 2 from the crankcase 13 Remove the crankshaft main bearing shells from the crankshaft main bearing journal caps ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 911 ...

Page 2836: ... engine block 3 Coat the surface of bearings lightly with engine oil 4 Position the crankshaft in the engine block 5 Fit the lower main bearing shells 5 into the main bearing journal caps 4 CAUTION The crankshaft main bearing journal cap bolts M8X75 and M10X90 must always be replaced oth erwise there is a risk of fracture 6 Install the main bearing journal caps 4 9 912 ENGINE 3 2L SRT SERVICE INFO...

Page 2837: ... 10 Install the oil pump Refer to 9 ENGINE LUBRI CATION OIL PUMP INSTALLATION 11 Install the upper oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 12 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 13 Install a new crankshaft rear radial seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION VIBRATION DAMPER REMOVA...

Page 2838: ...f signs of leakage are present 3 Inspect the sealing surface of the vibration damper Smooth any roughness with emery paper or an oil stone 4 Measure the vibration damper bolt Replace the bolt if length exceeds 78 mm 5 Position the vibration damper on the front of the crankshaft 6 Lubricate the bolt threads with engine oil before installing 7 Install the vibration damper bolt and tighten 1st to 200...

Page 2839: ... engine and check for leaks FLEX PLATE FLYWHEEL REMOVAL 1 Remove the transmission For manual Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL for automatic Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 REMOVAL 2 Remove the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 3 Using Special Tool 9102 Flywheel Locking Tool 1 lock the flywheel by inserting the tool in the starter openin...

Page 2840: ...New flywheel flexplate bolts must be used 1 Position the flywheel flexplate 3 and align on the cranshaft pin 2 Install the spacer and new flywheel flexplate bolts 1 Tighten bolts to 45 N m 33 ft lbs 3 Rotate the flywheel flexplate bolts an additional 90 clockwise 4 Install the clutch if equipped Refer to 6 CLUTCH CLUTCH DISC INSTALLATION 9 916 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2841: ...LLATION or Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION ENGINE MOUNT BRACKET REMOVAL REMOVAL LEFT 1 Remove the engine mount Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT REMOVAL 2 Remove and discard the engine mount bracket bolts 2 3 Remove the engine mount bracket 1 REMOVAL RIGHT 1 Remove the engine mount Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT REMOVAL ZH ENGINE 3 2L SRT SERVICE I...

Page 2842: ...NSTALLATION INSTALLATION LEFT 1 Position the engine mount brackets 1 on the engine block 2 Install the new bolts 2 Tighten to 20 N m 15 ft lbs plus 90 clockwise 3 Install the engine mounts Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION 9 918 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2843: ...e block 2 Install the new bolts 1 Tighten to 20 N m 15 ft lbs plus 90 clockwise 3 Install the engine mounts Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION FRONT MOUNT REMOVAL 1 Disconnect the negative battery cable ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 919 ...

Page 2844: ...he engine mount upper bolt 1 and the heat shield 2 CAUTION Do not stretch lines and hoses while lifting engine 5 Raise the engine slightly 6 Raise and support the vehicle 7 Remove the lower splash shield screws 1 and the splash shield 8 Remove the engine mount lower bolt 9 Remove the engine mount 9 920 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2845: ...the engine mount lower bolt 4 Tighten the bolt to 35 N m 26 ft lbs Note The recesses of the heat shield must be located in the anti twist slots of the engine bracket 3 Lower the engine onto the engine mount Install the heat shield 2 and the engine mount upper bolt 1 4 Tighten the engine mount upper bolt 1 to 55 N m 41 ft lbs ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 921 ...

Page 2846: ...IR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 9 Connect the negative battery cable REAR MOUNT REMOVAL 1 Raise and support the vehicle 2 Support the transmission with a transmission jack 3 Remove the rear mount lower bolts 3 4 Raise the transmission slightly off of the rear cross member 5 Remove the rear mount upper bolts 1 6 Remove the rear mount 9 922 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2847: ...with a bright yellow color under a black light 3 Using a black light inspect the entire engine for fluorescent dye particularly at the suspected area of oil leak If the oil leak is found and identified repair as necessary 4 If dye is not observed drive the vehicle at various speeds for approximately 24 km 15 miles and repeat inspec tion 5 If the oil leak source is not positively identified at this...

Page 2848: ...o not exceed 20 6 kPa 3 psi 5 If the leak is not detected very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when c...

Page 2849: ...cator tube 2 and install it in the crankcase 3 Install the bolt 1 in the cylinder head cover and tighten to 10 N m 89 in lbs 4 Position the wire harness loom at the oil level indicator tube and fasten with new cable tie 3 5 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTAL LATION 6 Start the engine and check for leaks OIL DESCRIPTION Use synthetic engin...

Page 2850: ...al 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 INTER NAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PRO...

Page 2851: ...en to 30 N m 22 ft lbs 10 Install the lower splash shield Tighten to 7 N m 5 ft lbs 11 Lower the vehicle and fill the crankcase with spec ified type and amount of engine oil 12 Install a new oil filter Refer to 9 ENGINE LU BRICATION OIL FILTER INSTALLATION 13 Install the oil filler cap 14 Start the engine and inspect for leaks 15 Turn off the engine and inspect the oil level USED ENGINE OIL DISPOS...

Page 2852: ...of the front of the engine It uses a replaceable element that can be incinerated REMOVAL 1 Use an oil filter wrench if necessary to remove the oil filter cap 1 2 Remove oil filter cap with the filter 3 Remove the oil filter 9 928 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2853: ...INSTALLATION 1 Replace the oil filter cap seal 2 Install a new filter 1 in the cap 3 Install the filter and cap 1 and tighten to 25 N m 18 ft lbs ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 929 ...

Page 2854: ... Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE 2 Remove the lower splash shield screws 1 and the splash shield 3 Remove the transmission oil cooler line retainer bolts 1 Position the cooler lines aside 9 930 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2855: ...N TRANSAXLE AUTOMATIC NAG1 REMOVAL or Refer to 21 TRANSMIS SION TRANSAXLE MANUAL REMOVAL 3 Remove the clutch if equipped Refer to 6 CLUTCH CLUTCH DISC REMOVAL 4 Mount the engine on an engine stand 5 Remove the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 6 Remove the 24 upper oil pan bolts 1 7 Separate the upper oil pan from the engine block ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 ...

Page 2856: ... gasket surfaces thoroughly 2 Apply a 1 5 mm to 2 mm bead of Loctite 5203 sealant or equivalent to the lower oil pan sealing surface 1 as shown 3 Install the lower oil pan and oil pan bolts Tighten the lower oil pan bolts to 14 N m 10 ft lbs 4 Position and install the transmission cooler lines and retainers 1 Tighten the bolts to 10 N m 7 ft lbs 9 932 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2857: ...nkcase to the specified oil level 9 Start the engine and check for leaks INSTALLATION UPPER OIL PAN 1 Clean the gasket surfaces thoroughly Note The components using sealant must be assembled within ten minutes of sealant applica tion 2 Apply a 1 5 to 2 mm bead of Loctite 5203 sealant 1 or equivalent to the oil pan sealing surface as shown ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 933 ...

Page 2858: ... oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 8 Install the clutch if equipped Refer to 6 CLUTCH CLUTCH DISC INSTALLATION 9 Install the transmission to the engine Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 INSTALLATION or Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION 10 Install the engine Refer to 9 ENGINE INSTALLATION OIL LEVEL TEMPERATURE SENSOR REMOVAL 1 Remove th...

Page 2859: ...vel temperature sensor INSTALLATION 1 Position the oil level temperature sensor in the upper oil pan with the screws 1 2 Position the harness retainer in the upper oil pan with the screws 2 3 Tighten all screws for the oil level temperature sen sor to 10 N m 89 in lbs ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 935 ...

Page 2860: ...il spray nozzles Note Do not use hard objects to clean the oil spray nozzles Replace the oil spray nozzles if they are blocked 4 Use compressed air only in the oil flow direction to clean the oil spray nozzles INSTALLATION Note Ensure the jet pipes of the oil spray nozzles are not damaged or bent during installation 1 Position the oil spray nozzles and bolts in the engine block 2 Tighten the oil s...

Page 2861: ...ler chain REMOVAL 1 Remove the lower oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 2 Remove the oil pump bolts 1 3 Release the oil pump chain tensioner 1 and remove the oil pump from the oil pump drive chain 2 CLEANING 1 Clean all of the parts thoroughly in a suitable solvent ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 937 ...

Page 2862: ... drive chain for wear Replace any worn or damaged parts 4 Position the oil pump driven sprocket in the drive chain Position and install the oil pump and bolts Tighten the bolts to 20 N m 15 ft lbs 5 Install the lower oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 6 Refill the engine with motor oil to specified level 7 Start the engine and check for leaks 9 938 ENGINE 3 2L SRT SERVICE ...

Page 2863: ...cessary INSTALLATION 1 Check the oil pump drive chain guide for wear and replace as necessary 2 Install the new oil pump drive chain and the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLATION 3 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER INSTALLATION OIL PRESSURE RELIEF VALVE DESCRIPTION The oil pressure relief valve cannot be adjusted or repaired If ...

Page 2864: ... to the side of the oil filter housing The engine oil is directed to the Oil Cooler through inlet and outlet passages machined into the housing The hot engine oil flows into the Oil Cooler the cooler engine coolant circulates through the Oil Cooler As the engine cool ant flows through the Oil Cooler the coolant extracts heat from the engine oil Through this flow process the engine oil is cooled an...

Page 2865: ...ver and pulling up firmly Remove the upper air cleaner housing assembly Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 3 Remove the lower air cleaner housing assembly Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Remove the air pump tubes 1 Refer to 25 EMISSIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE REMOVAL ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 941 ...

Page 2866: ...iner bolts 1 Refer to 9 ENGINE MANI FOLDS INTAKE MANIFOLD REMOVAL 6 Remove the vacuum line 3 7 Remove the air pump switchover valve 1 and gasket Refer to 25 EMISSIONS CONTROL AIR INJECTION SWITCHOVER VALVE REMOVAL 9 942 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2867: ... the upper radiator hose 1 9 Remove the cooler lines 2 10 Remove the four bolts attaching the oil cooler 1 to the engine 11 Remove the oil cooler 1 from the vehicle ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 943 ...

Page 2868: ...ighten bolts to 11 N m 97 in lbs 3 Install the cooler lines 2 4 Install the upper radiator hose from the thermostat housing 5 Install the air pump switchover valve 1 and gas ket Refer to 25 EMISSIONS CONTROL AIR INJECTION SWITCHOVER VALVE INSTALLA TION 6 Install the vacuum line 3 9 944 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2869: ...1 Refer to 25 EMIS SIONS CONTROL AIR INJECTION AIR PUMP INLET TUBE INSTALLATION 9 Install the lower air cleaner housing assembly Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 10 Install the upper air cleaner housing assembly Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 945 ...

Page 2870: ...In these tubes the air rotates 450 degrees from entry to cylinder head To achieve a similar effect at higher speeds a tube length of 18 3 inches 465 mm is used Butterfly valves in the walls of the long tubes operated by the engine control com puter switch the flow between long and short flow paths at approximately 3700 rpm The engine speed for switcho ver to the short tubes provides an imperceptib...

Page 2871: ...EANER HOUSING REMOVAL 3 Remove the lower air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Remove the intake plenum retaining bolts 1 5 Loosen plenum hose clamp 1 6 Remove the intake plenums and gaskets 7 Clean any gasket mating surfaces as necessary ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 947 ...

Page 2872: ...xhaust manifolds reduces underhood temperature by keeping heat in the exhaust stream This also allows the catalytic converter to be mounted in a more advantageous position for pack aging under the floor instead of close to the engine Stainless steel inner manifolds separated by an air space from two piece stainless steel outer shells reduce heat loss to the air in much the same way thermo pane gla...

Page 2873: ...pport the vehicle 4 Remove the lower splash shield screws 1 and the splash shield 5 Remove the left side catalytic converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 6 Remove the exhaust manifold nuts 3 7 Lower the vehicle 8 Remove the left side exhaust manifold 1 and gas kets 2 from the engine compartment ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 949 ...

Page 2874: ...NG REMOVAL 3 Raise and support the vehicle 4 Remove the lower splash shield screws 1 and the splash shield 5 Remove the right side catalytic converter Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 6 Remove exhaust manifold nuts 3 the exhaust manifold 2 and the gaskets 1 from below the vehicle 9 950 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2875: ...er Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 3 Install the lower splash shield and screws 1 Tighten the screws to 5 N m 44 in lbs 4 Lower the vehicle 5 Install the air cleaner Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 6 Connect the negative battery cable 7 Start the engine and check for exhaust leaks ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 951 ...

Page 2876: ...o 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 7 Connect the negative battery cable 8 Start the engine and check for exhaust leaks SUPERCHARGER DESCRIPTION A Lysholm helical style supercharger is used on all SRT engines OPERATION The supercharger used for the SRT has two helical style rotors that intermesh The supercharger is driven by the accessory drive belt through a electromechanical...

Page 2877: ...7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Disconnect the throttle body harness connector 2 7 Disconnect the vacuum line at the throttle body 4 8 Remove the intake manifold plenums Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 9 Remove the supercharger outlet tube Refer to 9 ENGINE MANIFOLDS SUPERCHARGER OUTLET TUBE REMOVAL 10 Release the fuel pressure through the service valve Refer to...

Page 2878: ...e 15 Disconnect the supercharger clutch harness connector 16 Remove the secondary air injection valves 5 17 Remove the supercharger to cylinder head bolts 1 and remove the supercharger 2 18 Remove the old supercharger gaskets 3 REMOVAL SUPERCHARGER OUTLET TUBE 1 Disconnect the negative battery cable 2 Remove the engine cover 1 Refer to 9 ENGINE REMOVAL 9 954 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2879: ...leaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Remove the lower air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 955 ...

Page 2880: ...right and left intake plenums Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 6 Remove the throttle body Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY REMOVAL 9 956 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2881: ... supercharger 2 and retaing bolts 1 onto the cylinder heads Tighten bolts to 23 N m 17 ft lbs 4 Install the secondary air injection valves 5 and retaining bolts Tighten bolts to 23 N m 17 ft lbs 5 Connect the supercharger harness connectors 6 Connect the charge air cooler coolant hoses at the right front of the engine 7 Install the fuel rail and retaining bolts Tighten bolts to 9 N m 80 in lbs Ref...

Page 2882: ...the throttle body 1 13 Connect the throttle body harness connector 2 14 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 15 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTAL LATION 16 Install the engine cover Refer to 9 ENGINE INSTALLATION 17 Refill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD...

Page 2883: ...the supercharger outlet tube 2 and tighten the retaining clamp 2 Install the throttle body and retaining bolts Tighten to 20 N m 15 ft lbs Refer to 14 FUEL SYS TEM FUEL INJECTION THROTTLE BODY INSTALLATION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 959 ...

Page 2884: ...e plenums Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 4 Install the lower air cleaner housings Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 9 960 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2885: ...ner housing 2 Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 6 Install the engine cover 1 Refer to 9 ENGINE COVER INSTALLATION 7 Connect the negative battery cable ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 961 ...

Page 2886: ...ensioner to 80 N m 59 ft lbs 2 Install the generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION TIMING CHAIN COVER REMOVAL 1 Remove the engine from the vehicle Refer to 9 ENGINE REMOVAL 2 Separate the engine from the transmission For manual Refer to 21 TRANSMISSION TRANS AXLE MANUAL REMOVAL for automatic Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 REMOVAL 9 962 ENGINE 3 2L SRT SER...

Page 2887: ...and the clutch 2 if equipped Refer to 6 CLUTCH CLUTCH DISC REMOVAL 4 Mount the engine on a stand 5 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 963 ...

Page 2888: ... 7 Remove the power steering pump Refer to 19 STEERING PUMP REMOVAL 8 Remove the idler pulley 9 Remove the bolt 1 and remove the vibration damper 2 Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 10 Remove the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR REMOVAL 9 964 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2889: ... 12 Remove the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 13 Using Special Tool 9102 1 Flywheel Locking Tool lock the flywheel by inserting the tool into the starter opening ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 965 ...

Page 2890: ...NGINE VALVE TIMING TMNG BELT CHAIN TENSIONER PULLEY REMOVAL 16 Remove the timing chain cover bolts as shown Remove the timing chain cover INSTALLATION Note Ensure all sealing surfaces have been cleaned and prepared properly for effective repair Multi Layer Steel MLS gaskets require a scratch free sealing surface 9 966 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2891: ... install the bolts 1 Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 2 Align the basic valve timing to 40 deg ATDC Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLA TION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 967 ...

Page 2892: ... 0 mm 0 5 mm bead assembled within 10 minutes and not be flattened or spread Note 3 Apply a 1 5 to 2 0 mm bead of Loctite 5203 or equivalent sealer to the area marked 1 as shown 4 Position the timing chain cover on the front of the engine Note Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly 5 Install the timing chain cover bolts and tighten to 20 N ...

Page 2893: ... 9102 Flywheel Locking Tool 1 from the engine 8 Install the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 9 Install a new front crankshaft radial oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL FRONT INSTALLATION 10 Install the generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 969 ...

Page 2894: ...TION DAMPER INSTAL LATION 12 Install the idler pulley Refer to 7 COOLING AC CESSORY DRIVE IDLER PULLEY INSTALLA TION 13 Install the power steering pump return hose 1 and pressure hose 2 Refer to 19 STEERING PUMP INSTALLATION 9 970 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2895: ...upper and lower 1 oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION 15 Install the accesory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 971 ...

Page 2896: ...ngine Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION or Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 INSTALLATION 19 Install the engine in the vehicle Refer to 9 ENGINE INSTALLATION TIMING CHAIN REMOVAL 1 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER REMOVAL 9 972 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2897: ...drive chain 2 and tensioner 1 Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 3 Remove the left and right camshaft sprocket bolts 1 4 Remove the timing chain and camshaft sprockets ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 973 ...

Page 2898: ...6 Clean and inspect all gasket surfaces chain guides and sprockets for wear or damage Repair or replace as necessary INSTALLATION 1 Invert the engine on the engine stand 2 Install the crankshaft sprocket 2 9 974 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2899: ...king 4 Align the balance shaft sprocket with the timing mark 3 and the copper teeth 1 of the timing chain 5 Insert the camshaft sprockets 6 into the timing chain and align the camshaft sprocket timing marks 4 and 5 with the copper teeth 1 of the timing chain ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 975 ...

Page 2900: ... timing chain with the sprockets and route within in the timing chain guides 1 7 Using Special Tools 9104 1 and 9105 Camshaft Locating Plates lock the camshaft sprockets 9 976 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2901: ...P INSTALLATION 9 Rotate the engine to the upright position 10 Install the timing chain cover Tighten the bolts to 20 N m 15 ft lbs Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER INSTALLA TION 11 Remove Special Tools 9104 and 9105 Camshaft Locating Plates from the camshaft sprockets ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 977 ...

Page 2902: ... 90 degree V 6 engine It rotates at engine speed in the opposite direction Mounted above the crankshaft in the cylinder block it is driven by the timing chain REMOVAL 1 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING GEAR HOUSING COVER REMOVAL 9 978 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2903: ...TARTER MOTOR REMOVAL 4 Using Special Tool 9102 Flywheel Locking Tool 1 lock the flywheel 5 Remove the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove the rear crankshaft oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 979 ...

Page 2904: ...ng bolt 2 8 Remove the balance shaft rear counter weight 1 from the balance shaft 9 Remove the balance shaft locking plate bolt 6 and locking plate at the front of the engine block 10 Remove the balance shaft 5 from the front of the engine 9 980 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2905: ...taining bolt 4 Tighten the bolt to 20 N m 15 ft lbs Rotate the bolt 4 an additional 90 3 Install the balance shaft locking plate and locking plate bolt 6 Tighten the balance shaft locking plate bolt to 20 N m 15 ft lbs 4 Install the crankshaft rear radial oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL 5 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT C...

Page 2906: ...GINE VALVE TIMING GEAR HOUSING COVER INSTALLATION 7 Remove the Special Tool 9102 Flywheel Locking Tool 1 from the engine and install the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 9 982 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2907: ...g chain guides 1 off of the mounting pins Inspect and replace worn or dam aged guides as required INSTALLATION 1 Install the timing chain guides on the mounting pins Lubricate surface with engine oil 2 Install the timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION ZH ENGINE 3 2L SRT SERVICE INFORMATION 9 983 ...

Page 2908: ...ins camshaft 6 and balance shaft 3 operation and timing Timing marks on the crankshaft 2 balance shaft 3 and camshafts 5 are aligned with copper links 1 in the timing chain to keep symetrical valve and ignition performance 9 984 ENGINE 3 2L SRT SERVICE INFORMATION ZH ...

Page 2909: ...UST PIPES 6 REMOVAL FRONT EXHAUST PIPES SRT 7 INSTALLATION INSTALLATION FRONT EXHAUST PIPES 9 INSTALLATION FRONT EXHAUST PIPES SRT 10 HEAT SHIELDS REMOVAL REMOVAL FRONT HEAT SHIELD 11 REMOVAL REAR HEAT SHIELD 12 INSTALLATION INSTALLATION FRONT HEAT SHIELD 12 INSTALLATION REAR HEAT SHIELD 13 MUFFLER REMOVAL REMOVAL 13 REMOVAL MUFFLER SRT 15 INSTALLATION INSTALLATION 17 INSTALLATION MUFFLER SRT 18 S...

Page 2910: ...st pipe leads to the three way catalytic converter which has an air gap insulated housing The air gap insulation whereby a steel shell is wrapped around the component limits heat loss to hasten the catalytic converter action The insulation also minimizes the need for insulation to protect the passenger com partment from excessive temperatures A large 812 cu in 13 3 L muffler is tuned to produce a ...

Page 2911: ...has an air gap insulated housing The air gap insulation whereby a steel shell is wrapped around the component limits heat loss to hasten the catalytic converter action The insulation also minimizes the need for insulation to protect the passenger com partment from excessive temperatures ZH EXHAUST SYSTEM 11 3 ...

Page 2912: ...e are the same for all markets but there is some difference in the software depending on local emissions requirements Dual ignition reduces hydrocarbon emissions unburned fuel released by the engine to the catalytic converter by 20 percent compared to single ignition systems This reduction is especially beneficial during the cold start and warm up phases of operation which is when a majority of th...

Page 2913: ...haust pipes catalytic converters muffler and resonators for cracked joints broken welds and corro sion damage that would result in a leaking exhaust system Inspect the clamps support brackets and insulators for cracks and corrosion damage ADJUSTMENTS EXHAUST SYSTEM ALIGNMENT A misaligned exhaust system is usually indicated by a vibration rattling noise or binding of exhaust system com ponents Thes...

Page 2914: ...AR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME 1 Raise and support the vehicle 2 Disconnect the oxygen sensor harness connectors 6 and 7 3 Support the exhaust system 4 Remove the bolts at the left and right side exhaust manifold flanges 8 and 9 5 Remove the center exhaust flange bolts 3 6 Remove the left and right sid...

Page 2915: ...PERATURE OF THE EXHAUST SYSTEM IS VERY HIGH THERE FORE NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED SPE CIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME ZH EXHAUST SYSTEM 11 7 ...

Page 2916: ...3 Support the exhaust system 4 Remove the bolts 1 at the left and right side exhaust manifold flanges 5 Remove the left and right side center exhaust flange bolts 6 Remove the left and right side exhaust pipe bolts 1 then remove the exhaust pipes from the vehicle 11 8 EXHAUST SYSTEM ZH ...

Page 2917: ...ehicle 3 Install bolts at the left and right exhaust manifold 8 and 9 flanges 4 Install bolts at the center exhaust manifold flange 3 5 Tighten exhaust manifold flange bolts to 20 N m 15 ft lbs 6 Tighten bolts at the center exhaust pipe flange to 20 N m 15 ft lbs 7 Connect oxygen sensor wiring harness connectors 6 and 7 8 Route oxygen sensor wire harness in harness retainer 9 Remove exhaust system...

Page 2918: ...front exhaust pipes in the vehicle 2 Install bolts at the left and right exhaust manifold flanges 3 Install bolts at the left and right center exhaust manifold flange 4 Tighten exhaust manifold flange bolts to 20 N m 15 ft lbs 5 Tighten bolts at the left and right center exhaust pipe flange to 20 N m 15 ft lbs 11 10 EXHAUST SYSTEM ZH ...

Page 2919: ...ess in harness retainer 8 Remove exhaust system support 9 Lower the vehicle HEAT SHIELDS REMOVAL REMOVAL FRONT HEAT SHIELD 1 Remove front exhaust section Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER REMOVAL 2 Remove the heat shield nuts 1 and the heat shield ZH EXHAUST SYSTEM 11 11 ...

Page 2920: ...at shield INSTALLATION INSTALLATION FRONT HEAT SHIELD 1 Position the heat shield on the floor pan 2 Install the heat shield nuts 1 Tighten the nuts to 10 N m 89 in lbs 3 Install the front exhaust section Refer to 11 EXHAUST SYSTEM CATALYTIC CONVERTER INSTALLATION 4 Start the engine and check for exhaust leaks 11 12 EXHAUST SYSTEM ZH ...

Page 2921: ...ER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED SPE CIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME 1 Raise and support vehicle 2 Remove the rear support bracket Convertible only Refer to 13 FRAME BUMPERS FRAME BRACKET REMOVAL 3 Support the rear section o...

Page 2922: ...ct the ground 1 strap at the muffler 6 Remove the pipe 1 from the exhaust hanger 2 7 Pry the rubber exhaust hangers 1 off of the bracket 8 Remove the muffler with the pipe from the vehicle 11 14 EXHAUST SYSTEM ZH ...

Page 2923: ...KEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME 1 Raise and support vehicle 2 Remove the rear support bracket Convertible only Refer to 13 FRAME BUMPERS FRAME BRACKET REMOVAL 3 Support the rear section of the exhaust system 4 Remove bolts from the right and left center connection flange ZH EXHAUST SY...

Page 2924: ...ct the ground 1 strap at the muffler 6 Remove the pipe 1 from the exhaust hanger 2 7 Pry the rubber exhaust hangers 1 off of the bracket 8 Remove the muffler with the pipe from the vehicle 11 16 EXHAUST SYSTEM ZH ...

Page 2925: ...INSTALLATION INSTALLATION 1 Position the muffler section in the rubber exhaust hangers 1 2 Install the bolts in the center exhaust flange 2 Tighten the bolts to 20 N m 15 ft lbs ZH EXHAUST SYSTEM 11 17 ...

Page 2926: ...il pipe Tighten the ground strap bolt to 10 N m 89 in lbs 4 Remove the support 5 Install the rear support bracket Convertible only Refer to 13 FRAME BUMPERS FRAME BRACKET INSTALLATION 6 Lower the vehicle INSTALLATION MUFFLER SRT 11 18 EXHAUST SYSTEM ZH ...

Page 2927: ...ange Tighten the bolts to 20 N m 15 ft lbs 3 Connect the ground strap 1 at the muffler and tail pipe Tighten the ground strap bolt to 10 N m 89 in lbs 4 Remove the support 5 Install the rear support bracket Convertible only Refer to 13 FRAME BUMPERS FRAME BRACKET INSTALLATION 6 Lower the vehicle ZH EXHAUST SYSTEM 11 19 ...

Page 2928: ...et bolt 1 3 Remove the bracket and the isolator 2 from the exhaust hanger 4 Remove the isolator from the bracket INSTALLATION 1 Position the bracket and bolt on the vehicle 2 Tighten the bolt to 20 N m 15 ft lbs 3 Install the isolator and hanger 4 Lower the vehicle 11 20 EXHAUST SYSTEM ZH ...

Page 2929: ...R SUPPORT BRACKET REMOVAL 9 INSTALLATION 10 FRONT FASCIA REMOVAL 1 Raise and support the vehicle 2 Remove the lower splash shield retaining screws 1 and the lower splash shield 2 Note Left side shown right side similar 3 Remove the left and right front fascia access panel retaining nuts and screws 1 4 Remove access panels from the vehicle ZH FRAME BUMPERS 13 1 ...

Page 2930: ...connect the ambient air temperature sensor wire harness connector 2 Note The front marker lamp harness connector can be reached through the access hole in the inner fender well 7 Disconnect the front marker lamp wire harness connectors 1 13 2 FRAME BUMPERS ZH ...

Page 2931: ...t fender to fascia retaining nuts and bolts Refer to 23 BODY EX TERIOR LEFT FRONT FENDER REMOVAL 10 Lower the vehicle 11 Remove the front grille assembly retaining bolts 1 12 Remove the upper fascia retaining bolts 1 13 Remove the fascia from the vehicle ZH FRAME BUMPERS 13 3 ...

Page 2932: ...y and install the retaining bolts 1 3 Raise and support the vehicle 4 Install the left and right front fender to fascia retain ing nuts and bolts Refer to 23 BODY EXTERI OR LEFT FRONT FENDER INSTALLATION 5 Install the lower fascia retaining nuts 1 6 Connect the ambient air temp sensor wire harness connector 2 13 4 FRAME BUMPERS ZH ...

Page 2933: ...nect the front marker lamp wire harness con nector 1 8 Connect the fog lamp wire harness connectors 1 9 Install the left and right front fascia access panel retaining nuts and screws 1 ZH FRAME BUMPERS 13 5 ...

Page 2934: ...10 Install the lower splash shield and the retaining screws 1 REAR FASCIA REMOVAL 1 Remove the rear fascia assembly retaining screws 1 2 and 3 2 Raise and support the vehicle 13 6 FRAME BUMPERS ZH ...

Page 2935: ...right and left lower fascia trim retain ing screws 1 4 Remove the rear fascia from the vehicle INSTALLATION 1 Position the rear fascia on the vehicle and install the retaining screws 1 2 and 3 ZH FRAME BUMPERS 13 7 ...

Page 2936: ...2 Install the lower fascia trim and the retaining screws 1 3 Lower the vehicle FRAME SPECIFICATIONS FRAME DIMENSIONS 13 8 FRAME BUMPERS ZH ...

Page 2937: ...REAR SUPPORT BRACKET REMOVAL 1 Raise and support the vehicle 2 Remove the bolts 2 from the support brace 3 Remove the brace 1 from the vehicle ZH FRAME BUMPERS 13 9 ...

Page 2938: ...ATION 1 Install the brace 1 to the vehicle 2 Install the bolts 2 to the vehicle Note Final torque must be made at curb weight 3 Lower the vehicle 4 Tighten the bolts to 60 N m 44 ft lbs 13 10 FRAME BUMPERS ZH ...

Page 2939: ...ION 9 FUEL FILTER PRESSURE REGULATOR DESCRIPTION 9 OPERATION 10 REMOVAL 11 INSTALLATION 12 FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION FUEL LEVEL SENDING UNIT SENSOR 13 OPERATION FUEL LEVEL SENDING UNIT SENSOR 13 DIAGNOSIS AND TESTING FUEL LEVEL SENDING UNIT 14 REMOVAL 15 INSTALLATION 15 FUEL LINES DESCRIPTION 16 FUEL PUMP DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING FUEL PUMP TEST 17 REMOVAL ...

Page 2940: ... partition The fuel delivery system consists of the following items Fuel Injector Rail Fuel Tank Filler Tube Cap Fuel Tank Filler Vent Tube Assembly Fuel Tubes Lines Hoses 3 In line Electric Fuel Pump 5 In line Fuel Filter Pressure Regulator 4 In tank Fuel Strainer 14 2 FUEL DELIVERY ZH ...

Page 2941: ...VR systems should also be considered part of the fuel system They are designed to reduce the emission of the fuel vapors into the atmosphere For complete operation and function of these systems refer to the Emission Controls section Refer to 25 EMISSIONS CON TROL OPERATION There are a total of four check type valves within the fuel tank fuel filler tube assembly Two tank vent rollover valves 1 are...

Page 2942: ... the test port on the test adapter tool 4 Start the engine and bring to normal operating temperature 5 Observe the test gauge Normal operating pressure should be 3 7 4 1 bar 54 60 psi 6 Shut engine off 7 Pressure should not fall below 2 5 bar 36 psi after 30 minutes 8 If pressure falls below 2 5 bar 36 psi within 30 minutes it must be determined if a fuel injector the check valve within the fuel p...

Page 2943: ...3 located next to the PCM 3 Start and run engine until it stalls 4 Attempt restarting engine until it will no longer run 5 Turn ignition key to OFF position 6 Return the fuel pump fuse to the relay control module 7 One or more Diagnostic Trouble Codes may have been stored in PCM memory due to fuel pump fuse removal The DRB IIIT scan tool must be used to erase any DTCs ZH FUEL DELIVERY 14 5 ...

Page 2944: ...EDURE 3 Disconnect negative battery cable 4 Raise and support the vehicle 5 Remove the fuel outlet hose 5 at the bottom of the fuel tank Note The fuel tank will be drained through this fitting WARNING WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE 6 Drain fuel tank into a holding tank or a properly labeled GASOLINE safety container CAUTION Gasoline or gasoline vapors are highly flamm...

Page 2945: ...28 FUEL SYSTEM Nominal working pressure is 3 7 4 1 bar 54 60 psi Allowable leak down engine off pressure after 30 minutes is 2 5 bar 36 psi Minimum fuel delivery rate is 1 liter 1 05 qt in a maximum of 35 seconds Fuel pump amperage draw range is 4 9 amps FUEL CAPACITY CAPACITY LITERS U S GALLONS Total 60 15 8 Reserve 8 2 1 Nominal refill capacities are shown A variation may be observed from vehicl...

Page 2946: ...SPECIAL TOOLS 9240 PIN WRENCH 14 8 FUEL DELIVERY ZH ...

Page 2947: ...ust be replaced as an assembly OPERATION When the fuel tank is full a float closes a flap at the bottom insert The fuel filler neck is filled rapidly and the gasoline pump nozzle switches off FUEL FILTER PRESSURE REGULATOR DESCRIPTION FUEL FILTER The combination Fuel Filter Fuel Pressure Regulator 4 consists of a housing with an integrated filter ele ment The fuel flows through the filter from the...

Page 2948: ...ely mounted to a chassis crossmember left to right OPERATION FUEL PRESSURE REGULATOR The Fuel Pressure Regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of between 3 7 4 1 bar 54 60 psi at the fuel injectors Fuel is supplied to the Fuel Filter Fuel Pressure Regulator by the Electric Fuel Pump directly 14 10 FUEL DELIVERY ZH ...

Page 2949: ... tank The Fuel Filter can not be serviced separately from the pressure regulator the entire Fuel Filter Fuel Pressure Reg ulator must be replaced as an assembly For complete Fuel Filter Fuel Pressure Regulator removal procedures refer to Fuel Filter Fuel Pressure Regulator removal in this section REMOVAL 1 Raise and support the vehicle 2 Remove the fuel pump splash shield WARNING THE FUEL SYSTEM I...

Page 2950: ...2 Install the following hoses lines in order 1 The fuel return hose 2 The fuel delivery hose 3 The fuel rail supply line 3 4 The fuel filter pressure regulator fuel line 1 3 Tighten the hoses lines to the fuel filter pressure regulator 4 Install the fuel pump splash shield 5 Lower the vehicle 14 12 FUEL DELIVERY ZH ...

Page 2951: ...The sending unit is a lever type sensor with sliding contacts potentiometer OPERATION FUEL LEVEL SENDING UNIT SENSOR The Fuel Level Sender produces a resistance value and changes it with the amount of fuel in the Fuel Tank The float arm attached to the sender moves as the fuel level changes The Fuel Pressure Sensor uses a transducer to determine a resistance value for the Emission Control System Z...

Page 2952: ...uges for Fuel Gauge testing To test the gauge sending unit only it must be removed from vehicle The sending unit is a part of the Fuel Level Sending Unit Sensor located and accessible at the top of the Fuel Tank Measure the resistance across the sending unit terminals With float 2 in up position resistance should be 20 ohms 5 With float 2 in down position resistance should be 270 ohms 5 14 14 FUEL...

Page 2953: ...rotate the fuel level sending unit sensor 2 counterclockwise 7 Remove the fuel level sending unit sensor 2 from the fuel tank 4 INSTALLATION 1 Install the fuel level sending unit sensor into the fuel tank 2 Install Special Tool 9240 and rotate the fuel level sending unit sensor clockwise fully to stop Remove the Special Tool 3 Connect the fuel level sending unit sensor harness connector 4 Install ...

Page 2954: ...the edge of the clamp from cutting into the hose Only these rolled edge type clamps may be used in this system All other types of clamps may cut into the hoses and cause high pressure fuel leaks Use new original equipment type hose clamps as replacements when necessary FUEL PUMP DESCRIPTION The Fuel Pump is a rotating spindle type pump The Fuel Pump moves fuel from the Fuel Tank through the Fuel F...

Page 2955: ...l rail 3 The DRB IIIT Scan Tool the 34 4 bar pressure trans ducer and the transducer to test port adapter may also be used in place of the fuel pressure gauge 2 Start and warm engine and note pressure gauge reading Fuel pressure should be 3 7 4 1 bar 54 60 psi at idle 3 If engine runs but pressure is below 3 7 bar 54 psi check for a kinked fuel supply line somewhere between fuel rail 3 and fuel pu...

Page 2956: ... leads into LCS adapter receptacles 3 Use 10 amp 10A receptacle and common receptacles 6 Gain access to MAIN MENU on DRB IIIT screen 7 Press DVOM button on DRB IIIT 8 Using left right arrow keys highlight CHANNEL 1 function on DRB IIIT screen 9 Press ENTER three times 10 Using up down arrow keys highlight RANGE on DRB IIIT screen screen will default to 2 amp scale 11 Press ENTER to change 2 amp sc...

Page 2957: ...e cavities immediately after testing REMOVAL WARNING PLACE A SHOP TOWEL AROUND THE FUEL LINES TO CATCH ANY EXCESS FUEL DURING DIS ASSEMBLY 1 Disconnect the negative battery cable 2 Raise and support the vehicle 3 Remove the fuel pump splash shield 4 Pinch off the fuel suction hose 6 and the fuel delivery hose 2 5 Disconnect the hoses from the fuel pump 4 6 Disconnect the fuel pump harness connecto...

Page 2958: ...the necessary fuel to each individual Fuel Injector and is located above the Intake Manifold and Fuel Injectors The Fuel Rail is also equipped with a service port The service port is used to connect a mechanical fuel pressure gauge to perform pressure tests OPERATION The Fuel Rail is designed to function in a semi returnless Fuel System The Fuel Pressure Regulator is no longer mounted to the fuel ...

Page 2959: ...LACE A SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL 3 Release the fuel pressure through the fuel rail service valve 7 4 Disconnect the fuel feed line 3 at the fuel rail 5 Remove the fuel injector harness connector retaining clips 5 then disconnect the fuel injector harness connec tors 6 from the fuel injectors 4 6 Remove the fuel rail bolts 8 attaching the fuel rail 2 to the intake manifo...

Page 2960: ...RVR is used to control vapor emissions during refueling OPERATION The Fuel Tank is designed to withstand a full 360 degree roll over test without fuel leakage To accomplish this fuel and vapor flow controls are required for all fuel tank connections An Evaporation Control System is connected to the roll over valve s control valve to reduce emissions of fuel vapors into the atmosphere when the tank...

Page 2961: ...m the bottom of the fuel tank 7 Remove the cargo area trim panels 8 Remove the fuel tank partition retaining bolts 2 and remove the fuel tank partition 9 Disconnect the fuel tank level and pressure sensor connectors 1 from the fuel sending unit 10 Disconnect the fuel tank filler neck cup seals from the body 11 Remove the fuel tank Note Inspect the strainer and O ring for damage and replace as nece...

Page 2962: ...uel tank 4 into the cargo area 3 Install the fuel tank retaining nuts 3 Tighten the retaining nuts to 10 N m 7 ft lbs 4 Position the fuel tank filler neck cup seal 9 around the filler neck 5 Connect the fuel tank level and pressure sensor connectors 1 to the fuel tank sending unit 6 Install the fuel tank partition into the cargo area 7 Install the fuel tank partition retaining bolts 2 Tighten the ...

Page 2963: ...el tank 11 Install the fuel pump splash shield 12 Lower the vehicle 13 Connect the negative battery cable FUEL TANK FILLER TUBE DESCRIPTION The Fuel Tank Filler Tube 1 is an integral part of the Fuel Tank Assembly and cannot be adjusted or repaired If faulty worn or damaged the entire Fuel Tank Assembly must be replaced as a complete unit ZH FUEL DELIVERY 14 25 ...

Page 2964: ... INSTALLATION INSTALLATION 40 INSTALLATION SRT 41 MANIFOLD AIR FLOW MAF SENSOR DESCRIPTION 42 OPERATION 42 REMOVAL 43 INSTALLATION 44 MANIFOLD TUNE VALVE DESCRIPTION 45 OPERATION 45 REMOVAL 45 INSTALLATION 46 MAP SENSOR DESCRIPTION DESCRIPTION 46 DESCRIPTION SRT 47 OPERATION OPERATION 47 OPERATION SRT 47 REMOVAL REMOVAL 47 REMOVAL SRT 48 INSTALLATION INSTALLATION 51 INSTALLATION SRT 51 O2 SENSOR D...

Page 2965: ... Bolt 8 6 71 Fuel Rail Bolt 9 7 80 Oxygen Sensor 55 41 487 Throttle Body Bolts 20 15 177 Tune Valve Rod Nut 6 4 44 ACCELERATOR PEDAL DESCRIPTION The Accelerator Pedal is integrated with the Accelera tor Pedal Position Sensor The Accelerator Pedal Posi tion Sensor and the Accelerator Pedal are serviced as an assembly ZH FUEL INJECTION 14 27 ...

Page 2966: ...tery cable 2 Remove the lower accelerator nut cover 1 and the nut 3 Lift the accelerator pedal off of the welded stud and out of the bracket 1 4 Disconnect the accelerator pedal harness connec tor from the accelerator pedal 14 28 FUEL INJECTION ZH ...

Page 2967: ...y cable 2 Remove the lower accelerator nut cover 1 and the nut 2 3 Lift the accelerator pedal off of the welded stud and out of the bracket 1 4 Disconnect the accelerator pedal harness connec tor from the accelerator pedal ZH FUEL INJECTION 14 29 ...

Page 2968: ...arness connector 2 Slide the accelerator pedal into the bracket 1 and then onto the welded stud 3 Install the accelerator pedal lower nut 1 Tighten to 15 N m 11 ft lbs 4 Install the plastic nut cover 5 Connect the negative battery cable 14 30 FUEL INJECTION ZH ...

Page 2969: ...ess connector 2 Slide the accelerator pedal into the bracket 1 and onto the welded stud 3 Install the accelerator pedal lower nut 2 Tighten to 15 N m 11 ft lbs 4 Install the plastic nut cover 1 5 Connect the negative battery cable ZH FUEL INJECTION 14 31 ...

Page 2970: ...ccelerator Pedal determines the opening angle of the throttle valve in the throttle body The data transfers over the CAN data bus Further functions are Idle speed control cruise control engine torque for ESP operation and short performance limitation for example for a higher coolant temperature The opening angle of the throttle valve will only be determined by the Accelerator Pedal signal when no ...

Page 2971: ...on CRANKSHAFT POSITION SENSOR DESCRIPTION The Crankshaft Position Sensor 1 is located on the left side of the engine just forward of the transmission housing The bottom of the sensor is positioned above the flywheel The sensor is a hall effect device combined with an internal magnet OPERATION The Crankshaft Position Sensor generates pulses that are the signal sent to the Powertrain Control Module ...

Page 2972: ... Disconnect the negative battery cable 2 Remove the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 3 Disconnect the crankshaft position sensor harness connector 4 Remove the retaining bolt and the crankshaft posi tion sensor 1 INSTALLATION 1 Install the crankshaft position sensor 1 to the engine Tighten to 8 N m 71 in lbs 2 Connect the crankshaft position senso...

Page 2973: ...tor the armature and needle move a short distance against a spring allowing fuel to flow out the orifice Because the fuel is under high pressure a fine spray is developed in the shape of a hollow cone or two streams The spraying action atomizes the fuel adding it to the air entering the combustion chamber The Engine Control Relay which is contained in the Relay Control Module provides battery volt...

Page 2974: ... a fuel pressure tester Collect the fuel in a suitable container 5 Disconnect the fuel feed line 3 6 Remove the fuel injector wire harness connector retaining clips and then disconnect the fuel injector harness 6 from the fuel injectors 4 7 Remove the fuel rail retaining bolts 8 8 Remove the fuel rail 2 with the fuel injectors 4 by moving the fuel rail 2 side to side while lifting upward 9 Remove ...

Page 2975: ... the fuel rail retaining bolts Tighten to 9 N m 80 in lbs 4 Install the fuel injector harness 6 to the fuel injectors 4 then install the fuel injector electrical connector retain ing clips 5 5 Connect the fuel feed line 3 Tighten to 38 N m 28 ft lbs 6 Install the wiring harness cover 1 then install the wiring harness cover retaining screw 7 Install the engine cover Refer to 9 ENGINE AIR INTAKE SYS...

Page 2976: ...mation The PCM controls the Fuel Pump Relay by switching the ground path for the coil side of the relay on and off The PCM turns the ground path off when the ignition switch is in the OFF position When the ignition switch is in the ON position the PCM energizes the Fuel Pump If the Crankshaft Position Sensor does not detect engine rotation the PCM de energizes the relay INTAKE AIR TEMPERATURE SENS...

Page 2977: ...or and cannot be serviced individually Refer to the MAF service procedures for removal and installation of the IAT MAF REMOVAL REMOVAL The normally aspirated 3 2L engine has the Intake Air Temperature IAT Sensor located inside the Mass Air Flow MAF Sensor The IAT Sensor can not be serviced separately The IAT Sensor and the MAF Sensor must be replaced as an assembly For proper removal procedure ref...

Page 2978: ...ATION INSTALLATION The normally aspirated 3 2L engine has the Intake Air Temperature IAT Sensor located inside the Mass Air Flow MAF Sensor The IAT Sensor can not be serviced separately The IAT Sensor and the MAF Sensor must be replaced as an assembly For proper installation procedure refer to MAF sensor installation Refer to 14 FUEL SYSTEM FUEL INJECTION MANIFOLD AIR FLOW MAF SENSOR INSTALLATION ...

Page 2979: ...NE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 4 Install the engine cover Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 5 Connect the negative battery cable ZH FUEL INJECTION 14 41 ...

Page 2980: ...trols the temperature of the heating resistor 6 by means of a variable voltage so its temperature is 160 C 320 F above the intake air temperature detected by the temperature resistor 1 The temperature of the heating resistor 6 is detected by the sensor resistor 2 If a temperature change occurs as a result of an increased or reduced air flow the PCM adapts the voltage at the heating resistor 6 unti...

Page 2981: ... the intake 2 away from their locked position 6 Press the locking tab 1 on the bottom right of the MAF down with a suitable tool unlocking it from the intake Press the locking tab on the upper left of the MAF upward with a suitable tool unlocking it from the intake manifold 7 Remove the MAF from the intake manifold 8 Inspect the sealing ring and replace if necessary 9 Inspect the sealing ring betw...

Page 2982: ...he intake then squeeze the locking ring 1 to lock the MAF onto the intake 4 Install the vent hose 2 to the MAF sensor 5 Connect the MAF IAT harness connector 1 6 Install the engine cover Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the ...

Page 2983: ...se torque REMOVAL 1 Disconnect the negative battery cable 2 Remove the engine cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 3 Remove the air injection pump Refer to 25 EMISSIONS CONTROL AIR INJECTION PUMP REMOVAL 4 Disconnect the manifold tune valve harness con nector at the manifold tune valve solenoid 5 Disconnect the vacuum line 6 Remove the left hand air pump switch ove...

Page 2984: ...ine and the manifold tune valve harness connector at the manifold tune valve solenoid 5 Install the air injection pump Refer to 25 EMIS SIONS CONTROL AIR INJECTION PUMP INSTALLATION 6 Install the engine cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 7 Connect the negative battery cable MAP SENSOR DESCRIPTION DESCRIPTION The Manifold Absolute Pressure MAP Sensor is mount...

Page 2985: ...es as infor mation to the PCM about the pressure in the intake manifold OPERATION SRT On the Supercharged 3 2L engine the MAP serves as a PCM input using a silicon based sensing unit to provide data on the manifold vacuum pressure that draws pushes the air fuel mixture into the combustion chambers The PCM use the map data combined with the intake air temperature to determine the volume of air ente...

Page 2986: ...gative battery cable 2 Remove the engine cover 1 Grasp both corners of the engine cover and pull up firmly 3 Remove the upper air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 14 48 FUEL INJECTION ZH ...

Page 2987: ...he lower air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 5 Remove the right and left intake plenums Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL ZH FUEL INJECTION 14 49 ...

Page 2988: ...TION THROTTLE BODY REMOVAL 7 Remove the supercharger outlet housing 2 by removing the supercharger outlet housing hose clamps 8 Disconnect the MAP sensor 1 harness connector 9 Remove the MAP sensor mounting bolts 10 Remove the MAP sensor 1 14 50 FUEL INJECTION ZH ...

Page 2989: ...ine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 5 Connect the negative battery cable INSTALLATION SRT 1 Install the MAP sensor 1 2 Install the MAP sensor mounting bolts Tighten to 4 5 N m 40 in lbs 3 Connect the MAP sensor 1 harness connector 4 Install the supercharger outlet housing 2 Tighten the supe...

Page 2990: ... the throttle body Refer to 14 FUEL SYS TEM FUEL INJECTION THROTTLE BODY INSTALLATION 6 Install both right and left intake plenums Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 14 52 FUEL INJECTION ZH ...

Page 2991: ...INE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 9 Install the engine cover Align the engine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 10 Connect the negative battery cable ZH FUEL INJECTION 14 53 ...

Page 2992: ...t injector pulse width to achieve the 14 7 to 1 air fuel ratio necessary for proper engine operation and to control emissions The O2 Sensor must have a source of oxygen outside the exhaust stream for comparison Current O2 Sensors receive their fresh oxygen outside air supply through the O2 Sensor case housing Four wires circuits are used on each O2 Sensor a 12 Volt feed circuit for the sensor heat...

Page 2993: ...OXYGEN SENSOR The input from the upstream heated O2 Sensor tells the PCM the oxygen content of the exhaust gas Based on this input the PCM fine tunes the air fuel ratio by adjusting injector pulse width The sensor output varies from 0 to 1 volt depending upon the oxygen content of the exhaust gas in the exhaust manifold When a large amount of oxygen is present caused by a lean air fuel mixture the...

Page 2994: ... corners of the engine cover and pull up firmly 3 Disconnect the O2 sensor harness connector 4 Remove the O2 sensor 1 REMOVAL DOWNSTREAM O2 1 Disconnect the negative battery cable Note The left side O2 sensor is shown The right side is similar 2 Raise and support the vehicle 3 Disconnect the O2 sensor harness connector 4 Remove the O2 sensor 1 14 56 FUEL INJECTION ZH ...

Page 2995: ...ush down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 5 Connect the negative battery cable INSTALLATION DOWNSTREAM O2 1 Apply anti seize compound to the threaded portion of the O2 sensor 2 Install the O2 sensor 1 Tighten to 50 N m 37 ft lbs 3 Connect the O2 sensor harness connec...

Page 2996: ...he Throttle Body The Throttle Position Sensor signal is used by the PCM to determine throttle position The PCM controls the Electronic Throttle Control of the Throttle Body The PCM monitors the Accelerator Pedal Position Sensor to determine the amount of throttle opening REMOVAL REMOVAL 1 Disconnect the negative battery cable 2 Remove the engine cover Grasp both corners of the engine cover and pul...

Page 2997: ...en lifting up on the inlet tube lever 3 and removing the inlet tube from the throttle body 3 Disconnect the throttle body harness connector 1 4 Disconnect the PCV hose 3 from the throttle body 5 Remove the throttle body retaining bolts 2 and PCV hose bracket 6 Remove the throttle body and the throttle body gasket from engine ZH FUEL INJECTION 14 59 ...

Page 2998: ...ine cover retaining clips to the rubber mounts and push down firmly to connect engine cover to rubber mounts Note To ease the installation of the engine cover apply a small amount of lubricant to the engine cover rubber mounts 7 Connect the negative battery cable INSTALLATION SRT 1 Connect the PCV hose 3 to the throttle body 2 Install the throttle body and gasket to engine 3 Install the throttle b...

Page 2999: ...rmly on the throttle body ensuring the inlet tube lever 3 is attached 6 Connect the negative battery cable THROTTLE POSITION SENSOR DESCRIPTION The Throttle Position Sensor TPS is a part of the Throttle Body The TPS cannot be serviced separately Refer to the Throttle Body removal and installation procedures Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY REMOVAL ZH FUEL INJECTION 14 61 ...

Page 3000: ...entiometer is designed to form a reference value The system will switch over to the second potentiometer if the first one fails The TPS cannot be serviced separately If the TPS fails the Throttle Body must be replaced Refer to the Throttle Body service procedures Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY REMOVAL 14 62 FUEL INJECTION ZH ...

Page 3001: ...PECIFICATIONS TORQUE 6 SPECIAL TOOLS STEERING 7 COLUMN 8 GEAR 35 LINKAGE 48 PUMP 67 STEERING DESCRIPTION STEERING SYSTEM The Power Steering Pump is a constant flow rate and displacement vane type pump The Pump Reservoir is attached to the pump body The pump is connected to the steering by the pressure and return hoses The Steering Gear used is a recirculating ball type gear A column provides steer...

Page 3002: ... piston teeth mesh with the pitman shaft Turn ing the worm shaft turns the pitman shaft which moves the steering linkage DIAGNOSIS AND TESTING POWER STEERING SYSTEM There is some noise in all Power Steering Systems One of the most common is a hissing sound evident at a stand still or at park with the engine running Or when the steering wheel is at the end of its travel Hiss is a high frequency noi...

Page 3003: ...tion hose 3 Internal pump noise 3 Replace pump 4 Air in the system 4 Perform pump initial operation SUCKING AIR SOUND 1 Loose return line clamp 1 Replace clamp 2 O ring missing or damaged on hose fitting 2 Replace o ring 3 Low fluid level 3 Fill to proper level 4 Air leak between pump and reservoir 4 Repair as necessary SCRUBBING OR KNOCKING 1 Wrong tire size 1 Verify tire size 2 Wrong gear 2 Veri...

Page 3004: ...repair as necessary Note Some roads will cause a vehicle to drift due to the crown in the road LOOSE STEERING AND VEHICLE LEADS DRIFTS CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING WHEEL 1 Worn or loose suspension or steering components 1 Repair as necessary 2 Worn or loose wheel bearings 2 Repair as necessary 3 Steering gear mounting 3 Tighten gear mounting bolts to specification...

Page 3005: ...the engine again and let it idle 10 The initial pressure reading should be 345 552 kPa 50 80 psi If the pressure is higher inspect the hoses for restrictions and repair as necessary 11 Increase the engine speed to 1500 RPM and read the flow meter The reading should be 2 4 2 8 GPM If the reading is below this specification the pump should be replaced CAUTION This next step involves testing maximum ...

Page 3006: ...5 18 216 Idler Arm Mounting Nut and Bolt 50 37 444 Idler Arm Pinch Bolt 30 22 264 Outer Tie Rod to Steering Knuckle Nut 50 37 444 Pittman Arm Pinch Bolt 55 41 492 Power Steering High Pressure Hose 30 22 264 Power Steering Pump Mounting Bolts 20 15 180 Power Steering Return Hose 40 30 360 Steering Column Lower Nuts 8 5 9 71 Steering Column Pinch Bolt 30 22 264 Steering Column Upper Bolts 20 15 180 ...

Page 3007: ...SPECIAL TOOLS STEERING C 3894 A Tie Rod Puller 9159 Steering Seal Installer 9168 Ball Joint Puller ZH STEERING 19 7 ...

Page 3008: ...PTING TO DIAGNOSE REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE SYSTEM CAPACITOR TO DISCHARGE FAILURE TO DO SO COULD RESULT IN ACCIDEN TAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COATINGS AND ARE ...

Page 3009: ...e Steering Wheel Switches or Airbag refer to the appropriate procedure REMOVAL REMOVAL WARNING BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS ARMED FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY 1 Disconnect the negative battery cable 2 Remove the left lower instrument panel 2 from under the steering column Refer to 23 BODY IN ST...

Page 3010: ...EMOVAL 4 Position the front wheels in the straight ahead position 5 Remove the steering wheel bolt 1 and remove the steering wheel Refer to 19 STEERING COL UMN STEERING WHEEL REMOVAL 6 Remove the clockspring screws 1 Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING REMOVAL 19 10 COLUMN ZH ...

Page 3011: ... Refer to 19 STEER ING COLUMN KEY LOCK CYLINDER REMOVAL 9 Remove the speed control switch 1 Refer to 8 ELECTRICAL SPEED CONTROL SWITCH REMOVAL 10 Remove the multifunction switch screws 1 2 Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL 11 Remove the column trim ring ZH COLUMN 19 11 ...

Page 3012: ...ttaching the steering column to the lower mount ing surface 14 Remove the upper bolts 1 on the steering col umn attaching it to the instrument panel support CAUTION DO NOT use force as the intermediate shaft is sensitive to the effects of side force 15 Pull the steering column out away from the instru ment panel 19 12 COLUMN ZH ...

Page 3013: ...ery cable 2 Remove the right lower I P panel from under the steering column Refer to 23 BODY INSTRU MENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Remove the driver airbag Refer to 8 ELECTRI CAL RESTRAINTS DRIVER AIRBAG REMOVAL 4 Position the front wheels in the straight ahead posi tion 5 Remove the steering wheel bolt 1 and remove the steering wheel Refer to 19 STEERING COL UMN STEERING WHEEL REM...

Page 3014: ...lock Refer to 19 STEER ING COLUMN KEY LOCK CYLINDER REMOVAL 9 Remove the speed control switch retaining screw 1 and the speed control switch Refer to 8 ELECTRICAL SPEED CONTROL SWITCH REMOVAL 10 Remove the multifunction switch retaining screws 1 2 and the multifunction switch Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH REMOVAL 11 Remove the column trim ring 19 14 COLUMN ZH ...

Page 3015: ...14 Remove the lower nuts on the steering column attaching the steering column to the lower mount ing surface 15 Remove the upper bolts 1 on the steering col umn attaching it to the instrument panel support CAUTION DO NOT use force as the intermediate shaft is sensitive to the effects of side force 16 Pull the steering column out away from the instru ment panel ZH COLUMN 19 15 ...

Page 3016: ...ntermediate shaft 9 2 Remove the retaining ring 6 disk spring 4 and the thrust ring 5 3 Push the intermediate shaft 9 out slightly remove the locking ring 13 and the thrust ring 10 4 Press the ball bearing out of the steering column using the intermediate shaft 9 19 16 COLUMN ZH ...

Page 3017: ...nevenly or it sticks The ball bearings are pressed into the bearing shells excessively Note If the preload is too low play is detectable at the steering wheel when the jacket tube is installed 5 Mount the retaining ring 6 on the intermediate shaft 9 and using a suitable tool push on until the disk spring 4 is fully preloaded 6 Attach the lower tube 1 to the upper tube by screwing in the countersun...

Page 3018: ...RY CAUTION DO NOT use force as the intermediate shaft is sensitive to the effects of side force 1 Install the steering column 2 Install the lower nuts on the steering column attaching the steering column to the lower mount ing surface Tighten to 8 N m 71 in lbs 3 Install the upper bolts 1 on the steering column attaching it to the instrument panel support Tighten to 20 N m 15 ft lbs 19 18 COLUMN Z...

Page 3019: ...steering gear Tighten to 16 20 N m 11 15 ft lbs 5 Connect the clockspring electrical connector 6 Install the column trim ring 7 Install the speed control switch screws 1 8 Install the multifunction switch screws 1 2 9 Reconnect the ignition switch connector ZH COLUMN 19 19 ...

Page 3020: ...8 ELECTRICAL INSTRUMENT CLUSTER INSTALLATION 11 Install the clockspring screws 1 Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING INSTALLATION 12 Install the steering wheel bolt 1 Refer to 19 STEERING COLUMN STEERING WHEEL INSTALLATION 19 20 COLUMN ZH ...

Page 3021: ...8 ELECTRICAL RESTRAINTS DRIVER AIRBAG INSTALLATION 14 Install the left lower instrument panel 2 under the steering column Refer to 23 BODY IN STRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 15 Connect the negative battery cable ZH COLUMN 19 21 ...

Page 3022: ...AUTION DO NOT use force as the intermediate shaft is sensitive to the effects of side force 1 Install the steering column 2 Install the lower nuts on the steering column attaching the steering column to the lower mount ing surface Tighten to 8 N m 71 in lbs 3 Install the upper bolts 1 on the steering column attaching it to the instrument panel support Tighten to 20 N m 15 ft lbs 19 22 COLUMN ZH ...

Page 3023: ...ness connectors up through the column 8 Install the speed control switch and retaining screw 1 9 Install the multifunction switch and retaining screws 1 2 10 Connect the ignition switch harness connector 11 Install the instrument cluster 1 Refer to 8 ELECTRICAL INSTRUMENT CLUSTER INSTALLATION 12 Install the clockspring and the retaining screws 1 Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING INSTALL...

Page 3024: ...RAINTS DRIVER AIRBAG INSTALLA TION 15 Install the right lower instrument panel 2 under the steering column Refer to 23 BODY IN STRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 16 Connect the negative battery cable IGNITION LOCK CABLE REMOVAL 1 Disconnect the negative battery cable 2 Remove the ashtray 2 at front of center console Refer to 23 BODY INTERIOR CENTER CON SOLE REMOVAL 19 24 COLUMN ZH ...

Page 3025: ... PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 4 Press the locking tabs together and push the igni tion lock cable 1 out of ignition starter switch in the direction of the arrows 5 Remove the shifter bezel 1 Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL ZH COLUMN 19 25 ...

Page 3026: ...n lock cable 1 to the shift lever assembly by inserting it into the mounting hole and then turning it 90 to the right 3 Turn the ignition switch to the OFF LOCK position It should only be possible to move the shift lever out of the Park position when the ignition switch is in the ON RUN position and the brake pedal is depressed It should only be possible to remove the ignition key when the shift l...

Page 3027: ...panel 2 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 5 Install the ash tray 2 in the front center console 6 Install the shifter cover 1 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION ZH COLUMN 19 27 ...

Page 3028: ... CAUTION The steering lock and lock cylinder can only be fitted in lock cylinder position 1 NEVER turn the steering lock when the ignition starter switch is not fitted 6 Remove the key cylinder Refer to 19 STEERING COLUMN IGNITION SWITCH REMOVAL 7 Disconnect the connector 8 from the warning buzzer contact 8 Disconnect the connector 1 from the ignition starter switch Note Vehicles with automatic tr...

Page 3029: ...nently 3 Install the ignition switch 2 4 Install the clamp 9 press in locking pin to install the steering lock 6 to the steering column 5 Install the parking lock interlock cable 7 6 Install the connector from the ignition starter switch 1 7 Install the connector from the warning buzzer contact 10 8 Install the key cylinder Refer to 19 STEERING COLUMN KEY LOCK CYLINDER INSTALLATION 9 Install the t...

Page 3030: ...D A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES IN LARGE DOSES THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES 1 Disconnect the negative battery cable 2 Push in the adjustable steering column fully 3 Position the steering wheel so that the front wheels are in the straight ahead position 4 Remove the ignition key and allow the s...

Page 3031: ...N REMOVING A DEPLOYED AIRBAG RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES IN LARGE DOSES THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES CAUTION If the steering wheel is offset by more than 1 tooth the turn signal indicator is no longer properly aligned CAUTION The SRS Malfunction Indicator Lam...

Page 3032: ...INSTALLATION KEY LOCK CYLINDER REMOVAL Note If the lock cylinder key is notched or jam ming spray the lock cylinder with lock cylinder grease If it is not possible to eliminate the com plaint replace the lock cylinder and key 1 Press out the escutcheon 2 with a suitable tool 19 32 COLUMN ZH ...

Page 3033: ...lock the lock cylinder 1 by turning the cap counter clockwise through 90 and then remove INSTALLATION 1 Spray the outside of the lock cylinder 1 with lock cylinder grease and insert it into the cap 2 Push the key through the cap as far as the stop in the lock cylinder 1 3 Turn the cap clockwise approx 90 until it can be felt or heard lock into position ZH COLUMN 19 33 ...

Page 3034: ...4 Turn the key to position 909 5 Press in the escutcheon 2 6 Install the transponder coil 3 on the lock cylinder 19 34 COLUMN ZH ...

Page 3035: ...curely mounted to the driver s side of the vehicle The steering linkage is attached to the pitman arm then attached to the idler arm OPERATION The Steering Gear acts as a rolling thread between the worm shaft and rack piston The worm shaft is supported by a thrust bearing at the lower end and a bearing assembly at the upper end When the worm shaft is turned the rack piston moves The rack piston te...

Page 3036: ...he fluid from the power steering pump reservoir 2 Raise and support the vehicle 3 Remove the drag link tie rod 1 from the pitman arm Refer to 19 STEERING LINKAGE DRAG LINK REMOVAL 4 Remove the left front cross brace 19 36 GEAR ZH ...

Page 3037: ...K SPRING CONTACT WILL BE DAMAGED BEYOND REPAIR 6 Remove the ignition key and allow the steering wheel to lock 7 Remove the pinch bolt 1 from the steering cou pling 8 Remove the steering shaft from the steering gear 9 Remove the engine ground strap from the frame member 10 Remove the lower engine mounting bolts 1 on the left and right of the engine mounts ZH GEAR 19 37 ...

Page 3038: ...ION DO NOT use force otherwise the lower steering shaft will be damaged on vehicles with a rigid steering column 12 Remove the three bolts 1 attaching the steering gear to the body of the vehicle carefully move steering gear out of the steering shaft then remove the steering gear from the vehicle 19 38 GEAR ZH ...

Page 3039: ...ing special tool 9168 remove the drag link tie rod 1 from the pitman arm Refer to 19 STEER ING LINKAGE DRAG LINK REMOVAL 4 Remove the right front body cross brace 5 Remove the power steering return line 3 and the high pressure line 2 6 Remove the ignition key and allow the steering wheel to lock ZH GEAR 19 39 ...

Page 3040: ...rom the steering gear 9 Remove the engine ground strap from the frame member 10 Remove the lower engine mounting bolts 1 on the left and right of the engine mounts 11 Safely install a support jack 1 under the right side of the engine Raise the engine 2 approx 40 mm 2 in 19 40 GEAR ZH ...

Page 3041: ...nter position by aligning the marking lines on the steering shaft and the housing cover CAUTION DO NOT use force otherwise the lower steering shaft collapsible tubing will be dam aged Ensure that the connection is assembled correctly 2 Carefully install the steering gear coupling onto the steering shaft 3 Push the lower steering shaft into the steering cou pling then bolt steering gear onto the ve...

Page 3042: ...ghten to 16 20 N m 11 15 ft lbs 7 Install the high pressure hose 2 Tighten to 30 N m 22 ft lbs 8 Install the return line 3 Tighten to 40 N m 30 ft lbs 9 Install the drag link tie rod Refer to 19 STEER ING LINKAGE DRAG LINK INSTALLATION 10 Install the left front cross brace 11 Fill and bleed the power steering pump Refer to 19 STEERING PUMP STANDARD PROCEDURE 19 42 GEAR ZH ...

Page 3043: ...tubing will be dam aged Insure that the connection is assembled cor rectly 2 Carefully install the steering gear coupling onto the steering shaft 3 Push the lower steering shaft into the steering cou pling then tighten the steering gear pinch bolt Tighten to 60 N m 44 ft lbs 4 Lower the engine and install the engine mount bolts 1 Tighten to 25 N m 18 ft lbs 5 Install the ground strap to the frame ...

Page 3044: ...hose 2 Tighten to 30 N m 22 ft lbs 8 Install the return line 3 Tighten to 40 N m 30 ft lbs 9 Install the drag link tie rod Refer to 19 STEER ING LINKAGE DRAG LINK INSTALLATION 10 Install the right front cross brace 11 Fill and bleed the power steering pump Refer to 19 STEERING PUMP STANDARD PROCEDURE 19 44 GEAR ZH ...

Page 3045: ... Adjust the steering gear by loosening the lock nut 4 Turn the adjusting screw 1 4 revolutions in stages Counterclockwise less play increased coeffi cient of friction Clockwise more play reduced coefficient of friction 5 Tighten the lock nut to 60 N m 44 ft lbs 6 Check the adjustment after tightening the lock nut repeat adjustment if necessary PITMAN SHAFT SEAL REMOVAL 1 Measure the distance of po...

Page 3046: ...rying tool INSTALLATION CAUTION DO NOT damage the sealing lip of the pitman shaft seal when sliding it on over the pit man shaft splines 1 Using Special Tool 9159 Steering Seal Installer 1 install a new pitman shaft seal into the steering gear 2 Install the upper snap ring 2 3 Remove any oil and grease from the splined sec tion of the pitman arm and the pitman arm shaft 4 Install the lower snap ri...

Page 3047: ... the pitman arm to the previously measured depth of measurement 9A9 Tighten the pinch bolt to 55 N m 41 ft lbs 6 Check the steering gear for any leaks 7 Check for correct power steering fluid level ZH GEAR 19 47 ...

Page 3048: ...ITMAN ARM REMOVAL REMOVAL 53 REMOVAL RHD 55 INSTALLATION INSTALLATION 57 INSTALLATION RHD 58 DAMPER REMOVAL REMOVAL 59 REMOVAL RHD 60 INSTALLATION INSTALLATION 60 INSTALLATION RHD 61 DRAG LINK REMOVAL REMOVAL 61 REMOVAL RHD 63 INSTALLATION INSTALLATION 64 INSTALLATION RHD 65 TIE ROD END REMOVAL 65 INSTALLATION 66 19 48 LINKAGE ZH ...

Page 3049: ... the idler arm nut 2 Remove the heat shield 2 3 Remove the nut and bolt and remove the idler arm 4 from the vehicle 4 Loosen the pinch bolt on the idler arm 4 5 Remove the idler arm bushing from the idler arm 4 6 Inspect the idler arm bushing Replace as necessary ZH LINKAGE 19 49 ...

Page 3050: ...idler arm nut 2 Remove the heat shield 4 3 Remove the nut and bolt 1 and remove the idler arm 1 from the vehicle 4 Loosen the pinch bolt on the idler arm 5 Remove the idler arm bushing 1 from the idler arm 6 Inspect the idler arm bushing Replace as necessary 19 50 LINKAGE ZH ...

Page 3051: ... the reference dimension 3 Install the idler arm pinch bolt Tighten to 30 N m 22 ft lbs 4 Install the idler arm to the vehicle 5 Install the nut and bolt on the idler arm Tighten to 50 N m 37 ft lbs 6 Install the heat shield 2 7 Install the drag link to the idler arm Tighten to 50 N m 37 ft lbs ZH LINKAGE 19 51 ...

Page 3052: ...erence dimension 3 Install the idler arm pinch bolt Tighten to 30 N m 22 ft lbs 4 Install the idler arm 2 to the vehicle 5 Install the nut and bolt 1 on the idler arm Tighten to 50 N m 37 ft lbs 6 Install the heat shield 4 7 Install the drag link 3 to the idler arm 2 Tighten to 50 N m 37 ft lbs 19 52 LINKAGE ZH ...

Page 3053: ... REMOVAL 1 Using Special Tool 9168 Ball Joint Puller remove the drag link from the pitman arm 2 Measure the distance of point 9A9 between the pit man arm 2 and the steering gear 1 using a cal iper gauge ZH LINKAGE 19 53 ...

Page 3054: ...emove the snap ring 2 that holds the pitman arm 1 on the shaft 4 Remove the pitman arm by loosening the pinch bolt 1 With a prying device remove the pitman arm from the pitman arm shaft 2 19 54 LINKAGE ZH ...

Page 3055: ...68 Ball Joint Puller 2 remove the drag link from the pitman arm Refer to 19 STEERING LINKAGE DRAG LINK REMOVAL 2 Measure the distance of point 9A9 between the pit man arm 2 and the steering gear 1 using a cal iper gauge ZH LINKAGE 19 55 ...

Page 3056: ...emove the snap ring that holds the pitman arm 1 on the shaft 2 4 Remove the pitman arm by loosening the pinch bolt 1 With a prying device remove the pitman arm from the pitman arm shaft 2 19 56 LINKAGE ZH ...

Page 3057: ...TION INSTALLATION 1 Remove any oil and grease from the splined sec tion of the pitman arm shaft and the pitman arm 2 Install the pitman arm 1 to the pitman arm shaft 2 3 Install the snap ring 2 ZH LINKAGE 19 57 ...

Page 3058: ...ighten the pinch bolt to 55 N m 41 ft lbs INSTALLATION RHD 1 Remove any oil and grease from the splined sec tion of the pitman arm shaft 2 and the pitman arm 1 2 Install the pitman arm 1 to the pitman arm shaft 2 3 Install the snap ring to the pitman arm shaft 2 19 58 LINKAGE ZH ...

Page 3059: ...f measurement 9A9 Tighten the pinch bolt to 55 N m 41 ft lbs DAMPER REMOVAL REMOVAL 1 Remove the nut and bolt 1 from the steering damper mounting bracket 2 Remove the nut and bolt from the drag link 3 Remove the steering damper from the vehicle ZH LINKAGE 19 59 ...

Page 3060: ...om the drag link 3 Remove the steering damper from the vehicle INSTALLATION INSTALLATION 1 Install the steering damper into the vehicle 2 Install the nut and bolt to the drag link Tighten to 40 N m 29 ft lbs 3 Install the bolt and nut 1 to the steering damper bracket Tighten to 40 N m 29 ft lbs 19 60 LINKAGE ZH ...

Page 3061: ...40 N m 29 ft lbs 3 Install the bolt and nut 1 to the steering damper bracket Tighten to 40 N m 29 ft lbs DRAG LINK REMOVAL REMOVAL 1 Remove the steering dampener from the drag link Refer to 19 STEERING LINKAGE DAMPER REMOVAL 2 Remove the nuts attaching the drag link 1 to the pitman arm and the idler arm ZH LINKAGE 19 61 ...

Page 3062: ... from the steering knuckles 5 Using Special Tool 9168 2 Ball Joint Puller remove the drag link 1 from the pitman arm and the idler arm Note The right hand drag link joint is a pivot joint with a swivelling range of max 2 This prevents the drag link from tilting 6 Inspect the tie rod ends for play or damage Repair as necessary 19 62 LINKAGE ZH ...

Page 3063: ...EERING LINKAGE DAMPER REMOVAL 2 Remove the nuts attaching the drag link 1 to the pitman arm and the idler arm 3 Remove the nuts attaching the tie rod ends to the steering knuckles 4 Using Special Tool C 3894 A remove the tie rod ends from the steering knuckles ZH LINKAGE 19 63 ...

Page 3064: ...k attaching points 1 2 Install the drag link and the attaching nuts 1 to the idler arm and pitman arm Tighten the drag link nuts to 50 N m 37 ft lbs 3 Install the tie rod ends into the steering knuckles 4 Install the nuts on the tie rod ends Tighten to 50 N m 37 ft lbs 5 Install the steering dampener Tighten to 40 N m 29 ft lbs 6 Adjust the front toe setting on the vehicle Refer to 2 SUSPENSION WH...

Page 3065: ...nstall the nuts on the tie rod ends Tighten to 50 N m 37 ft lbs 5 Install the steering dampener Tighten to 40 N m 29 ft lbs Refer to 19 STEERING LINKAGE DAMPER INSTALLATION 6 Adjust the front toe setting on the vehicle TIE ROD END REMOVAL 1 Loosen the tie rod end jam nut 1 2 Remove nut from the tie rod end at the steering knuckle 3 Using Special Tool C 3894 A 2 two jaw puller remove the tie rod en...

Page 3066: ... Install the tie rod end to the steering knuckle 4 Install the attaching nut on the tie rod end Tighten to 50 N m 37 ft lbs 5 Thread the jam nut down far enough to hold the tie rod end in place Do not tighten the jam nut 6 Adjust the front toe setting on the vehicle Refer to 2 SUSPENSION WHEEL ALIGNMENT STAN DARD PROCEDURE 19 66 LINKAGE ZH ...

Page 3067: ...e fluid settle for at least two minutes 2 Start the engine and let run for a few seconds then turn engine off 3 Add fluid if necessary Repeat the above procedure until the fluid level remains constant after running the engine 4 Raise the front wheels off the ground 5 Slowly turn the steering wheel right and left lightly contacting the wheel stops at least 20 times 6 Check the fluid level and add i...

Page 3068: ...he power steering supply line 6 from the reservoir 4 Remove the return hose from the power steering pump 5 Remove the high pressure hose 2 from the power steering pump 6 Remove the power steering pump by removing the two bolts 3 attaching it to the engine block 7 Remove the reservoir if necessary by pressing out the C clip 4 using a suitable tool 19 68 PUMP ZH ...

Page 3069: ...stall the high pressure hose 2 on the pump 4 Install the return hose on the pump 5 Install the power steering supply line 6 to the reservoir 6 Install the accessory drive belt 1 Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLA TION 7 Fill the power steering pump reservoir and then bleed the system by performing the initial operation Refer to 19 STEERING PUMP STANDARD PROCEDURE ZH PUMP 19 69...

Page 3070: ......

Page 3071: ...0 SLA CAN MESSAGE INCORRECT 65 P0700 SENSOR SUPPLY VOLTAGE 68 P0700 TRANSMISSION SLIPPING 72 P0702 CONTROL MODULE TCM IS NOT CODED 75 P0702 INTERNAL CONTROLLER 77 P0702 INVALID CONTROL MODULE VERSION 79 P0702 SOLENOID SUPPLY WATCHDOG 81 P0710 TRANS TEMP SENSOR SHORTED 85 P0714 TRANS TEMP SENSOR ERRATIC 89 P0715 INPUT SENSOR MISMATCH 92 P0715 INPUT SENSOR OVERSPEED 96 P0715 N2 INPUT SPEED SENSOR CI...

Page 3072: ...MESSAGE NOT VALID 188 RR WHEEL SPIN CAN MESSAGE NOT VALID 190 OVERVOLTAGE 192 UNDERVOLTAGE 194 TRANSMISSION VERIFICATION TEST 196 SCHEMATICS AND DIAGRAMS 197 NAG1 ELECTRICAL DIAGNOSTICS DIAGNOSIS AND TESTING 21 2 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3073: ... P0219 ENGINE OVERSPEED ZH NAG1 ELECTRICAL DIAGNOSTICS 21 3 ...

Page 3074: ...ion Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a ...

Page 3075: ...The Engine and Transmission must not have mechanical problems and be operating normally before proceeding with this test Turn the ignition off Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL With the DRB IIIT erase Transmission DTCs Road test the vehicle With the DRB IIIT read Transmission DTCs Did DTC P0219 ENGIN...

Page 3076: ... P0562 SYSTEM UNDERVOLTAGE 21 6 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3077: ... Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a gui...

Page 3078: ...0 RPM Measure the voltage of the Traction System Relay Output circuit at the TCM C1 harness connector Is the voltage above 9 0 volts Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Repair the Traction System Relay Output circuit for an open Perform NAG1 TRANSMISSION VERIF...

Page 3079: ... PO563 SYSTEM OVERVOLTAGE ZH NAG1 ELECTRICAL DIAGNOSTICS 21 9 ...

Page 3080: ... fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Re...

Page 3081: ... the TCM C1 harness connector Note Check connectors Clean repair as necessary Start the engine Increase the engine speed to 1500 RPM Measure the voltage of the Traction System Relay Output circuit in the TCM C1 harness connector Is the voltage below 16 9 volts Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NA...

Page 3082: ... P0600 ABS BRAKE MESSAGE 21 12 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3083: ...el can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the D...

Page 3084: ...ory and perform the appropriate symptom No Go To 4 4 CONTROLLER ANTILOCK BRAKE Turn the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase ABS DTCs Start the engine With the brakes firmly applied shift the gear selector into drive With the DRB IIIT read Transmission DTCs ...

Page 3085: ... P0600 ABS CAN MESSAGE INCORRECT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 15 ...

Page 3086: ... the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note C...

Page 3087: ...the DRB IIIT erase Transmission DTCs Start the engine and with the brakes firmly applied place the gear selector into Drive With the DRB IIIT read Transmission DTCs Did DTC P0600 ABS CAN MESSAGE INCORRECT set again Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Comp...

Page 3088: ... P0600 ABS CAN MESSAGE MISSING 21 18 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3089: ...IC NAG1 SCHEMATICS AND DIAGRAMS For a complete CAN BUS Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always...

Page 3090: ...00 ABS CAN MES SAGE MISSING DTC will set Erase DTC and return to customer No Test Complete 3 P0720 CAN BUS CIRCUIT DTC PRESENT With the DRB IIIT read Transmission DTCs Note If DTC P0720 CAN BUS CIRCUIT is present perform diag nostics on that symptom first Is DTC P0720 CAN BUS CIRCUIT present Yes Refer to the Transmission Electrical Diagnostics category and perform the appropriate symptom Perform N...

Page 3091: ...C BUS circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST No Go To 6 6 CAB BRAKE MESSAGE MISSING With the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selector into drive Wi...

Page 3092: ... P0600 ABS LEFT FRONT SENSOR MESSAGE 21 22 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3093: ... Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnost...

Page 3094: ...resent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 CONTROLLER ANTILOCK BRAKE Turn the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Road test the vehicle With the DRB IIIT read Transmi...

Page 3095: ... P0600 ABS LEFT REAR SENSOR MESSAGE ZH NAG1 ELECTRICAL DIAGNOSTICS 21 25 ...

Page 3096: ...Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnosti...

Page 3097: ...resent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 CONTROLLER ANTILOCK BRAKE Turn the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Road test the vehicle With the DRB IIIT read Transmi...

Page 3098: ... P0600 ABS RIGHT FRONT SENSOR MESSAGE 21 28 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3099: ...e Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnos...

Page 3100: ...resent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 CONTROLLER ANTILOCK BRAKE Turn the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Road test the vehicle With the DRB IIIT read Transmi...

Page 3101: ... P0600 ABS RIGHT REAR SENSOR MESSAGE ZH NAG1 ELECTRICAL DIAGNOSTICS 21 31 ...

Page 3102: ... Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnost...

Page 3103: ...resent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 CONTROLLER ANTILOCK BRAKE Turn the ignition off Replace the Controller Antilock Brake Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Road test the vehicle With the DRB IIIT read Transmi...

Page 3104: ... P0600 ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT 21 34 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3105: ...CAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB II...

Page 3106: ...Some of these conditions are displayed on the DRB IIIT at the same time the DTC is displayed Note Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist when check ing for an active DTC Turn the ignition on With the DRB IIIT erase Transmission DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmissio...

Page 3107: ...DTC P0600 ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT set again Yes Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 7 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness fo...

Page 3108: ... P0600 CAN MESSAGE FROM ECM FROM SLA 21 38 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3109: ... the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT r...

Page 3110: ...ver Assembly DTCs present Yes Refer to the Shift Lever Assembly category in this section and perform the appropriate symptom No Go To 4 4 CAN C BUS OR CIRCUIT S OPEN Turn the ignition off Disconnect the Shift Lever Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between the CAN C BUS circuit and the CAN C BUS circuit in the Shift Lever Assembly har...

Page 3111: ... P0600 ENGINE CAN MESSAGE INCORRECT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 41 ...

Page 3112: ...ion Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a ...

Page 3113: ...ion on With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selector into drive With the DRB IIIT read Transmission DTCs Did DTC P0600 ENGINE CAN MESSAGE INCORRECT set again Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST N...

Page 3114: ... P0600 ENGINE CAN MESSAGE MISSING 21 44 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3115: ...MATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repai...

Page 3116: ...to the Transmission Electrical Diagnostics category and perform the appropriate symptom Perform NAG1 TRANSMISSION VERIFICATION TEST No Go To 3 3 CHECK TO SEE IF ENGINE DTCS ARE PRESENT With the ignition on With the DRB IIIT read Engine DTCs Are any performance or BUS related Engine DTCs present Yes Refer to the Engine Electrical Diagnostics category and perform the appropriate symptom Perform NAG1...

Page 3117: ...measured above 5 0 ohms for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 PCM ENGINE CAN MESSAGE MISSING With the ignition off Reconnect the TCM C3 harness connector Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shi...

Page 3118: ... P0600 ENGINE RPM MESSAGE 21 48 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3119: ...n be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB II...

Page 3120: ...r to the Engine Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 PCM ENGINE RPM MESSAGE Turn the ignition off Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear...

Page 3121: ... P0600 ENGINE TEMPERATURE MESSAGE ZH NAG1 ELECTRICAL DIAGNOSTICS 21 51 ...

Page 3122: ...AGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transm...

Page 3123: ... to the Engine Electrical Diagnostics category and perform the appropriate symptom No Go To 4 4 PCM ENGINE TEMP MESSAGE Turn the ignition off Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear...

Page 3124: ... P0600 ENGINE TORQUE MESSAGE INCORRECT 21 54 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3125: ...vel can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the ...

Page 3126: ...rogram the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Drive the vehicle performing multiple aggressive upshifts and down shifts With the DRB IIIT read Transmission DTCs Did DTC P0600 ENGINE TORQUE MESSAGE INCORRECT set again Yes Replace the Transmission Control Module Re...

Page 3127: ... P0600 IC CAN MESSAGE INCORRECT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 57 ...

Page 3128: ... transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all...

Page 3129: ...rument Cluster DTCs present Yes Refer to the Instrument Cluster Electrical Diagnostics cat egory and perform the appropriate symptom No Go To 4 4 CAN C BUS OR CIRCUIT S OPEN Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance between the CAN C BUS circuit and the CAN C BUS circuit in the Instrument Clus...

Page 3130: ... P0600 IC HVAC CAN MESSAGE MISSING 21 60 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3131: ...D DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all eng...

Page 3132: ... TO SEE IF INSTRUMENT CLUSTER DTC PRESENT With the ignition on With the DRB IIIT read Instrument Cluster DTCs Are any Instrument Cluster DTCs present Yes Refer to the Instrument Cluster Electrical Diagnostics cat egory and perform the appropriate symptom No Go To 4 4 CHECK TO SEE IF A C HEATER CONTROL MODULE DTC PRESENT With the ignition on With the DRB IIIT read A C Heater Control Module DTCs Are...

Page 3133: ...ircuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 6 SERIAL COMMUNICATION K1 OR K2 CIRCUIT OPEN With the ignition off Disconnect the A C Heater Control Module harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Serial Communication K1 and K2 cir cuits from the Instrument Cluster C1 harness connector to the A C Heater Control Module harness co...

Page 3134: ...CONTROLS HEATER CONTROL REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST Turn the ignition on With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Replace the Instrument Cluster Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 21 64 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3135: ... P0600 SLA CAN MESSAGE INCORRECT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 65 ...

Page 3136: ...any transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record ...

Page 3137: ...Lever Assembly DTCs present Yes Refer to the Shift Lever Assembly category and perform the appropriate symptom No Go To 4 4 CAN C BUS OR CIRCUIT S OPEN Turn the ignition off Disconnect the Shift Lever Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance from the CAN C BUS circuit to the CAN C BUS circuit at the Shift Lever Assembly harness connector Is ...

Page 3138: ... P0700 SENSOR SUPPLY VOLTAGE 21 68 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3139: ...GNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmi...

Page 3140: ... It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 5 3 SENSOR SUPPLY VOLTAGE CIRCUIT SHORT TO OTHER CIRCUITS Turn the ignition off Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance from the Sensor Supply Voltage circ...

Page 3141: ...T No Repair the Sensor Supply Voltage circuit for a short to ground Perform NAG1 TRANSMISSION VERIFICATION TEST 5 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires whi...

Page 3142: ... P0700 TRANSMISSION SLIPPING 21 72 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3143: ...o 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms Wi...

Page 3144: ...v eline category for the proper procedures Were any problems found Yes Refer to the Differential Driveline category for proper repair procedures No Go To 4 4 INTERNAL TRANSMISSION Determine if the Transmission is mechanically slipping Is the transmission slipping Yes Repair internal transmission as necessary Refer to the Service Information for the proper repair proce dure Perform NAG1 TRANSMISSIO...

Page 3145: ... P0702 CONTROL MODULE TCM IS NOT CODED ZH NAG1 ELECTRICAL DIAGNOSTICS 21 75 ...

Page 3146: ...ol Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 TRANSMISSION CONTROL MODULE NOT CODED The Transmission Control Module was not coded and must be replaced View repair Repair Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFI...

Page 3147: ... P0702 INTERNAL CONTROLLER ZH NAG1 ELECTRICAL DIAGNOSTICS 21 77 ...

Page 3148: ...troller DTC sets again before replacing the TCM POSSIBLE CAUSES TRANSMISSION CONTROL MODULE For a complete Transmission Control Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 TRANSMISSION CONTROL MODULE The Transmission Control Module is reporting internal errors and must be replaced View repair Repair Replace the Transmission Co...

Page 3149: ... P0702 INVALID CONTROL MODULE VERSION ZH NAG1 ELECTRICAL DIAGNOSTICS 21 79 ...

Page 3150: ...ission Control Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 VALIDATE PART NUMBER AND CODING The Transmission Control Module was not coded or is the wrong part and must be replaced View repair Repair Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perfo...

Page 3151: ... P0702 SOLENOID SUPPLY WATCHDOG ZH NAG1 ELECTRICAL DIAGNOSTICS 21 81 ...

Page 3152: ...nce with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the w...

Page 3153: ...r Disconnect the TCM C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance from the Solenoid Voltage Supply circuit to each of the Solenoid Control circuits in the TCM C2 harness connec tor Note The resistances of the Solenoids should be Modulation Pressure Solenoid 2 5 6 5 ohms Shift Solenoid 4 0 8 0 ohms TCC Solenoid 2 0 4 0 ohms 1 2 4 5 Solenoid 2 5 6 5 ohm...

Page 3154: ...No Repair the Solenoid Supply Voltage circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 6 SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE Turn the ignition off Disconnect the TCM C2 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of each of the Solenoid Control circuits in the Transmission Solenoid Assembly harne...

Page 3155: ... P0710 TRANS TEMP SENSOR SHORTED ZH NAG1 ELECTRICAL DIAGNOSTICS 21 85 ...

Page 3156: ...level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set ...

Page 3157: ...oid Assembly harness connector and repair as necessary If no problems are found in the connector replace the Transmission Temperature Sensor P N Switch Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC NAG1 ELECTROHYDRAULIC UNIT REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST 4 TRANSMISSION TEMP SENSOR P N SWITCH Turn the ignition off Disconnect the Transmission Solenoid Assembly harness connector...

Page 3158: ...WITCH CIRCUIT SHORT TO OTHER CIRCUITS With the ignition off Disconnect the TCM C1 harness connector Note Check connectors Clean repair as necessary Measure the resistance from the Temp Sensor P N Switch circuit to all other circuits in the TCM C1 and C2 harness connectors Is the resistance above 100 kohms for all measurements Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTR...

Page 3159: ... P0714 TRANS TEMP SENSOR ERRATIC ZH NAG1 ELECTRICAL DIAGNOSTICS 21 89 ...

Page 3160: ...B IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must ...

Page 3161: ...ROHY DRAULIC UNIT REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST With the DRB IIIT read Transmission DTCs Did DTC P0714 TRANS TEMP SENSOR ERRATIC set again Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 91 ...

Page 3162: ... P0715 INPUT SENSOR MISMATCH 21 92 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3163: ...LE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engi...

Page 3164: ... the DRB IIIT read Transmission DTCs Did DTC P0715 INPUT SENSOR MISMATCH set again Yes Go To 4 No Go To 5 4 INTERNAL TRANSMISSION Turn the ignition off Remove the Transmission Oil Pan and inspect for debris or a plugged Transmission Oil Filter Is there any debris plugged Transmission Oil Filter or sign of an internal transmission problem Yes Repair the internal transmission as necessary Refer to t...

Page 3165: ...sible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 95 ...

Page 3166: ... P0715 INPUT SENSOR OVERSPEED 21 96 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3167: ... and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to termina...

Page 3168: ...ransmission Oil Filter Is there any debris plugged Transmission Oil Filter or signs of an internal transmission problem Yes Repair the internal transmission as necessary Refer to the Transmission Service Information for proper repair procedures Perform NAG1 TRANSMISSION VERIFICATION TEST No Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRANSMISSION CONTR...

Page 3169: ... P0715 N2 INPUT SPEED SENSOR CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 99 ...

Page 3170: ...SOR TRANSMISSION CONTROL MODULE For a complete Transmission Control Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service I...

Page 3171: ...ote It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 11 3 SENSOR SUPPLY VOLTAGE CIRCUIT OPEN Turn the ignition off Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sen...

Page 3172: ...5 0 ohms Yes Go To 5 No Repair the N2 Input Speed Sensor Signal circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 SENSOR GROUND CIRCUIT OPEN With the ignition off Measure the resistance of the Sensor Ground circuit from the TCM C2 harness connector to the Transmission Solenoid Assembly harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair the Sensor Ground circui...

Page 3173: ...ll measurements Yes Go To 7 No Repair the N2 Speed Sensor Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 7 N2 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the N2 Input Speed Sen sor Signal circuit Is the resistance above 100 kohms Yes Go To 8 No Repair the N2 Input Speed Sensor Signal ci...

Page 3174: ...e 100 kohms for all measurements Yes Go To 9 No Repair the Sensor Ground circuit for a short to other cir cuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 9 SENSOR GROUND CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Sensor Ground cir cuit Is the resistance above 100 kohms Yes Go To 10 No Repair the Sensor Ground circuit for a short to ground Perform...

Page 3175: ...tern match a typical 5 volt square wave signal scope pattern Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Replace the N2 Input Speed Sensor Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 ELECTROHYDRAULIC UNIT REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST 11 I...

Page 3176: ... P0715 N3 INPUT SPEED SENSOR CIRCUIT 21 106 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3177: ...RCUIT SHORT TO ANOTHER CIRCUIT N3 INPUT SPEED SENSOR TRANSMISSION CONTROL MODULE For a complete Transmission Control Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust...

Page 3178: ...ote It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 11 3 SENSOR SUPPLY VOLTAGE CIRCUIT OPEN Turn the ignition off Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Sen...

Page 3179: ...5 0 ohms Yes Go To 5 No Repair the N3 Input Speed Sensor Signal circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 SENSOR GROUND CIRCUIT OPEN With the ignition off Measure the resistance of the Sensor Ground circuit from the TCM C2 harness connector to the Transmission Solenoid Assembly harness connector Is the resistance below 5 0 ohms Yes Go To 6 No Repair the Sensor Ground circui...

Page 3180: ...ll measurements Yes Go To 7 No Repair the N3 Speed Sensor Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 7 N3 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the N3 Input Speed Sen sor Signal circuit Is the resistance above 100 kohms Yes Go To 8 No Repair the N3 Input Speed Sensor Signal ci...

Page 3181: ...0 kohms for all measurements Yes Go To 9 No Repair the Sensor Ground circuit for a short to other cir cuits Perform NAG1 TRANSMISSION VERIFICATION TEST 9 SENSOR GROUND CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Sensor Ground cir cuit Is the resistance above 100 kohms Yes Go To 10 No Repair the Sensor Ground circuit for a short to ground Perform NAG1...

Page 3182: ...es the scope pattern match a typical 5 volt square wave signal scope pattern Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Replace the N3 Input Speed Sensor Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 ELECTROHYDRAULIC UNIT REMOVAL Perform NAG1 TRANSMISSION VERIFI...

Page 3183: ... P0720 CAN BUS CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 113 ...

Page 3184: ...AMS For a complete CAN BUS Circuit Diagram Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a ...

Page 3185: ... C BUS circuit and the CAN C BUS circuit from the TCM C3 harness connector and to both the PCM C4 harness connector and to the CAB harness connec tor Is the resistance of each BUS circuit below 5 0 ohms Yes Go To 3 No Repair the faulty CAN C BUS circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 3 CAN C BUS SHORT TO CAN C BUS With the ignition off Measure the resistance between the CA...

Page 3186: ...a short to ground Perform NAG1 TRANSMISSION VERIFICATION TEST 5 CAN C BUS AND OR CAN C BUS CIRCUIT SHORT TO ANOTHER CIRCUIT With the ignition off Measure the resistance from both the CAN C BUS circuit and the CAN C BUS circuit to all other circuits in the TCM C3 and C2 har ness connector Is the resistance above 100 kohms for all measurements Yes Go To 6 No Repair the CAN C BUS and or CAN C BUS cir...

Page 3187: ...CAB TERMINATING RESISTOR With the ignition off Reconnect the PCM C4 harness connector Disconnect the CAB harness connector Note Check connectors Clean repair as necessary Measure the resistance from the CAN C BUS circuit to the CAN C BUS circuit at the CAB harness connector Is the resistance 120 ohms 2 0 ohms Yes Replace the Controller Antilock Brake Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODUL...

Page 3188: ... P0730 IMPROPER GEAR 21 118 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3189: ...sion Control Module Circuit Diagram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully...

Page 3190: ...1 TRANSMISSION TRANS AXLE AUTOMATIC NAG1 ELECTROHYDRAULIC UNIT REMOVAL Note This DTC is usually set due to an internal transmission problem such as but not limited to stuck solenoid valve and or contamination in the valve body broken springs leaking clutch seals dislodged or broken snap ring Inspect the internal transmission in accordance with the Service Information Where any problems found Yes R...

Page 3191: ... P0730 IMPROPER RATIO ZH NAG1 ELECTRICAL DIAGNOSTICS 21 121 ...

Page 3192: ...ram Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false ...

Page 3193: ...dures Is there any debris plugged Transmission Oil Filter or signs of an internal transmission problem Yes Refer to the Transmission Service Information for the proper repair procedure Pay particular attention to the valve body components and stuck solenoids Perform NAG1 TRANSMISSION VERIFICATION TEST No Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRAN...

Page 3194: ... P0740 TCC OVERTEMP 21 124 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3195: ...ne DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by drivin...

Page 3196: ... P0740 TCC STUCK ON 21 126 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3197: ...charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Transmission DTCs Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as...

Page 3198: ...TION TEST 4 TCC SOLENOID CONTROL CIRCUIT SHORT TO OTHER CIRCUITS With the ignition off Measure the resistance from the TCC Solenoid Control circuit to all other circuits in the Transmission Solenoid Assembly harness connec tor Is the resistance above 100 kohms for all measurements Yes Repair the TCC Solenoid Control circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST...

Page 3199: ... P0743 TCC SOLENOID CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 129 ...

Page 3200: ...vel can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the ...

Page 3201: ...cessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 TCC SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of ...

Page 3202: ...o To 6 No Repair the TCC Solenoid Control circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 6 TCC SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the TCC Solenoid Control circuit and the Solenoid Supply Voltage circuit at the Transmission Control Mod ule C2 harn...

Page 3203: ...ssible intermittent condition 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 Note Check for Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 133 ...

Page 3204: ... P0748 MODULATING PRESSURE SOLENOID CIRCUIT 21 134 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3205: ...st 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the service information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to perfor...

Page 3206: ...test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 MODULATING PRESSURE SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of ...

Page 3207: ...asurements Yes Go To 6 No Repair the Modulating Pressure Solenoid Control circuit for a short to other circuits Perform NAG1 TRANSMISSION VERIFICATION TEST 6 MODULATING PRESSURE SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the Modulating Pressure Solenoid Control circuit and the Solenoid Sup...

Page 3208: ...r a possible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 21 138 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3209: ... P0753 1 2 4 5 SOLENOID CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 139 ...

Page 3210: ...level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With th...

Page 3211: ...ssary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 1 2 4 5 SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance o...

Page 3212: ... Yes Go To 6 No Repair the 1 2 4 5 Solenoid Control circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 6 1 2 4 5 SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the 1 2 4 5 Solenoid Control circuit and the Solenoid Supply Voltage circuit at the Transmission Contr...

Page 3213: ...ssible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 143 ...

Page 3214: ... P0753 1 2 4 5 SOLENOID CIRCUIT SHORT TO GROUND 21 144 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3215: ...tion on With the DRB IIIT read Transmission DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0753 1 2 4 5 SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a ...

Page 3216: ... P0758 2 3 SOLENOID CIRCUIT 21 146 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3217: ...be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT...

Page 3218: ...cessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 2 3 SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of ...

Page 3219: ...To 6 No Repair the 2 3 Solenoid Control circuit for a short to the other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 6 2 3 SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the 2 3 Solenoid Control circuit and the Solenoid Supply Voltage circuit at the Transmission Control Mod ule C2 ha...

Page 3220: ...sible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 21 150 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3221: ... P0758 2 3 SOLENOID CIRCUIT SHORT TO GROUND ZH NAG1 ELECTRICAL DIAGNOSTICS 21 151 ...

Page 3222: ...n With the DRB IIIT read Transmission DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0758 2 3 SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide insp...

Page 3223: ... P0763 3 4 SOLENOID CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 153 ...

Page 3224: ...be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT...

Page 3225: ...ecessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 3 4 SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of...

Page 3226: ...o To 6 No Repair the 3 4 Solenoid Control circuit for a short to other circuits Perform NAG1 TRANSMISSION VERIFICATION TEST 6 3 4 SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the 3 4 Solenoid Control circuit and the Solenoid Supply Voltage circuit at the Transmission Control Mod ule C2 harne...

Page 3227: ...ible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 157 ...

Page 3228: ... P0763 3 4 SOLENOID CIRCUIT SHORT TO GROUND 21 158 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3229: ...on With the DRB IIIT read Transmission DTCs Is this DTC present Yes For complete diagnosis of this DTC refer to P0763 3 4 SOLENOID CIRCUIT No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide ins...

Page 3230: ... P0778 SHIFT PRESSURE SOLENOID CIRCUIT 21 160 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3231: ... 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performi...

Page 3232: ... road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 7 3 SHIFT PRESSURE SOLENOID CONTROL CIRCUIT OPEN Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of...

Page 3233: ...ements Yes Go To 6 No Repair the Shift Pressure Solenoid Control circuit for a short to other circuits Perform NAG1 TRANSMISSION VERIFICATION TEST 6 SHIFT PRESSURE SOLENOID RESISTANCE OUT OF TOLERANCE With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between the Shift Pressure Solenoid Control circuit and the Solenoid Supply Voltage circuit...

Page 3234: ...a possible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 21 164 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3235: ... P0778 SOLENOID SUPPLY VOLTAGE ZH NAG1 ELECTRICAL DIAGNOSTICS 21 165 ...

Page 3236: ...smission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRB IIIT read and record all Tran...

Page 3237: ...ehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 6 3 SOLENOID SUPPLY CIRCUIT SHORT TO ANOTHER CIRCUIT Turn the ignition off Disconnect the Transmission Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between the So...

Page 3238: ...D With the ignition off Reconnect the Transmission Solenoid Assembly harness connector Measure the resistance between ground and all Solenoid Control cir cuits at the Transmission Control Module C2 harness connector Is the resistance above 100 kohms Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE REMOVAL Perform NAG1 TRANSMIS...

Page 3239: ...ssible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete ZH NAG1 ELECTRICAL DIAGNOSTICS 21 169 ...

Page 3240: ... P0850 TRANS TEMP SENSOR P N SWITCH CIRCUIT 21 170 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3241: ...NOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to performing transmis...

Page 3242: ...nsmission DTCs Note It maybe necessary to road test the vehicle for this DTC to set With the DRB IIIT read Transmission DTCs Did this DTC set again Yes Go To 3 No Go To 9 3 SENSOR GROUND CIRCUIT OPEN Turn the ignition off Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance of ...

Page 3243: ...istance below 5 0 ohms Yes Go To 5 No Repair the Temp Sensor P N Switch circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 TEMP SENSOR P N SWITCH CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Temp Sensor P N Switch circuit Is the resistance above 100 kohms Yes Go To 6 No Repair the Temp Sensor P N Switch circuit for a short to ground Per...

Page 3244: ...k connectors Clean repair as necessary Measure the resistance between the Sensor Ground circuit and all other circuits in the TCM C1 and C2 harness connectors Is the resistance above 100 kohms for all measurements Yes Go To 7 No Repair the Sensor Ground circuit for a short to other cir cuit s Perform NAG1 TRANSMISSION VERIFICATION TEST 21 174 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3245: ...ect the Transmission Solenoid Assembly harness connector Reconnect the TCM C1 harness connector With the brakes firmly applied place the gear selector in Drive Measure the resistance between the Temp Sensor P N Switch circuit and the Sensor Ground circuit in the TCM C2 harness connector Is the resistance between 500 and 2500 ohms Yes Replace the Transmission Control Module Refer to 8 ELECTRICAL EL...

Page 3246: ...r a possible intermittent condition 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 Note Check for any Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST No Test Complete 21 176 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3247: ... P1793 ENGINE TORQUE REDUCTION ZH NAG1 ELECTRICAL DIAGNOSTICS 21 177 ...

Page 3248: ...tic Test 1 PRE DIAGNOSTIC CHECK OUT Note Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level in accordance with the Service Information Note Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB IIIT read Engine DTCs Check and repair all engine DTCs prior to ...

Page 3249: ... the Transmission Electrical Diagnostics category and perform the appropriate symptom No Go To 3 3 CHECK TO SEE IF ENGINE DTCS ARE PRESENT With the ignition on With the DRB IIIT read Engine DTCs Are any performance or BUS related Engine DTCs present Yes Refer to the Engine Electrical Diagnostics category and perform the appropriate symptom No Go To 4 ZH NAG1 ELECTRICAL DIAGNOSTICS 21 179 ...

Page 3250: ... faulty CAN C BUS circuit s for an open Perform NAG1 TRANSMISSION VERIFICATION TEST 5 PCM ENGINE TORQUE REDUCTION With the ignition off Replace and program the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE REMOVAL Turn the ignition on With the DRB IIIT erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selec...

Page 3251: ...CAN BUS CIRCUIT ZH NAG1 ELECTRICAL DIAGNOSTICS 21 181 ...

Page 3252: ...TIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 CHECK FOR CAN DTCS IN OTHER MODULES Turn the ignition on With the DRB IIIT read the stored and active DTCs for all modules on the CAN C BUS Are other modules reporting CAN BUS DTCs Yes Refer to the reporting category and perform the appropri ate symptom If the PCM is reporting a CAN BUS failure refer to the PCM tests first No Go To 2 21 182 NAG1 E...

Page 3253: ...N C BUS circuit and the CAN C BUS circuit from the PCM C4 harness connector to the SLA harness connector Is the resistance of both CAN C BUS circuits below 5 0 ohms Yes Replace the Shift Lever Assembly Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC NAG1 SHIFT MECHANISM REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST No Repair the faulty CAN C BUS circuit for an open Perform NAG1 TRANSMISSION VE...

Page 3254: ...INCORRECT CAN MESSAGE FROM ABS 21 184 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3255: ...Brake Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Turn the ignition on With the DRB IIIT erase SLA DTCs Start the engine With the brakes firmly applied place the shift lever into Drive With the DRB IIIT read SLA DTCs Did DTC INCORRECT CAN MESSAGE FROM ABS set again Yes Replace the Shift Lever Assembly Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC NAG1...

Page 3256: ...INTERNAL CONTROLLER 21 186 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3257: ...RANSAXLE AUTOMATIC NAG1 SCHEMATICS AND DIAGRAMS Diagnostic Test 1 SLA INTERNAL ERROR The Shift Lever Assembly is reporting internal errors View repair Repair Replace the Shift Lever Assembly Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 SHIFT MECHANISM REMOVAL Perform NAG1 TRANSMISSION VERIFICATION TEST ZH NAG1 ELECTRICAL DIAGNOSTICS 21 187 ...

Page 3258: ...LR WHEEL SPIN CAN MESSAGE NOT VALID 21 188 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3259: ...sent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 2 2 CAB ABS LR SENSOR MESSAGE Turn the ignition off Replace the Controller Antilock Brake Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Start the engine Road test the vehicle With the DRB IIIT read ABS DTCs Did DTC LR WHEEL SPIN CAN MESSAGE NOT ...

Page 3260: ...RR WHEEL SPIN CAN MESSAGE NOT VALID 21 190 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3261: ...sent Yes Refer to the Brakes ABS Electrical Diagnostics category and perform the appropriate symptom No Go To 2 2 CAB ABS RR SENSOR MESSAGE Turn the ignition off Replace the Controller Antilock Brake Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE REMOVAL Start the engine Road test the vehicle With the DRB IIIT read ABS DTCs Did DTC RR WHEEL SPIN CAN MESSAGE NOT ...

Page 3262: ...OVERVOLTAGE 21 192 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3263: ...GNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY OUTPUT CIRCUITS OVERVOLTAGE Turn the ignition off Disconnect the Shift Lever Assembly harness connector Note Check connectors Clean repair as necessary Start the engine and raise the engine speed to 1500 RPM Measure the voltage of the Fused Ignition Switch Output and Traction System Relay Output circuits at the SLA harness connector Is the voltage abo...

Page 3264: ...UNDERVOLTAGE 21 194 NAG1 ELECTRICAL DIAGNOSTICS ZH ...

Page 3265: ...SED IGNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY OUTPUT LOW AT SLA Turn the ignition off Disconnect the Shift Lever Assembly harness connector Note Check connectors Clean repair as necessary Start the engine and raise the engine speed to 1500 RPM Measure the voltage of the Fused Ignition Switch Output and Traction System Relay Output circuits at the SLA harness connector Is the voltage below 9 ...

Page 3266: ...parts perform the TCM Quick Learn procedure Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE Note If internal repairs were performed and the shift quality is still poor it may be necessary to check the internal repair ROAD TEST PROCEDURE Road test the vehicle Make fifteen to twenty 1 2 2 3 3 4 and 4 5 upshifts Perform these shifts from a standing star...

Page 3267: ...SCHEMATICS AND DIAGRAMS AUTOMATIC TRANSMISSION CIRCUIT DIAGRAM ZH NAG1 ELECTRICAL DIAGNOSTICS 21 197 ...

Page 3268: ...ION 305 OPERATION 306 DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 306 DIAGNOSIS AND TESTING CAUSES OF BURNT FLUID 306 DIAGNOSIS AND TESTING FLUID CONTAMINATION 306 STANDARD PROCEDURE CHECK OIL LEVEL 307 STANDARD PROCEDURE TRANSMISSION FILL 309 STANDARD PROCEDURE FILTER CHANGE 309 FREEWHEELING CLUTCH DESCRIPTION 311 OPERATION 311 DISASSEMBLY 312 ASSEMBLY 313 HOLDING CLUTCHES DESCRIPTION ...

Page 3269: ...ar is designed as an overdrive with a high speed ratio The gears are actuated electronically hydraulically The gears are shifted by means of an appropriate combination of three multi disc holding clutches three multi disc driving clutches and two freewheeling clutches Electronic transmission control enables precise adaptation of pressures to the respective operating conditions and to the engine ou...

Page 3270: ...ed with lubricating oil The parking lock gear 11 is connected to the output shaft 10 via splines Freewheel F1 18 and F2 13 are used to optimize the shifts The front freewheel F1 18 is supported on the extension of the stator shaft 19 on the transmission side and in the locking direction connects the sun gear of the front planetary gear set 17 to the transmission housing In the locking direction th...

Page 3271: ...gine variants EMERGENCY RUNNING FUNCTION In order to ensure a safe driving state and to prevent damage to the automatic transmission the TCM control mod ule switches to limp home mode in the event of critical faults A DTC assigned to the fault is stored in memory All solenoid and regulating valves are thus de energized The net effect is The last engaged gear remains engaged The modulating pressure...

Page 3272: ...5 The sun gear 21 is held against the housing by the locked freewheel F1 20 during acceleration and via the engaged multi disc holding clutch B1 4 during deceleration The planetary pinion gears 17 turn on the fixed sun gear 21 and increase the torque from the annulus gear 8 to the planetary carrier 13 The planetary carrier 13 moves at a reduced speed in the running direction of the engine 21 202 A...

Page 3273: ...11 turns at a reduced speed due to the mechanical connection to the front planetary carrier 15 The sun gear 23 is held against the housing by the engaged multi disc holding clutch B2 6 by the locked free wheel F2 24 during acceleration and by the engaged driving clutch K3 12 during deceleration The rear planetary gears 19 turn on the fixed sun gear 23 and increase the torque from the annulus gear ...

Page 3274: ... to the planetary carrier 14 turns at a reduced speed in the running direction of the engine Rear Planetary Gear Set The annulus gear 11 turns at the input speed as a result of the mechanical connection to the front planetary carrier 13 The sun gear 23 is held against the housing by the engaged multi disc holding clutch B2 6 by the locked freewheel F2 24 during acceleration and by the engaged driv...

Page 3275: ...tary Gear Set The annulus gear 10 turns at the input speed as a result of the engaged driving clutch K2 9 The sun gear 22 is held against the housing by the multi disc holding clutch B2 6 The planetary pinion gears 18 turn on the fixed sun gear 22 and increase the torque from the annulus gear 10 to the planetary carrier 14 The output shaft 26 connected to the planetary carrier 14 turns at a reduce...

Page 3276: ...e planetary carrier 15 due to the mechanical connection with the locked front planetary gearset This planetary gearset is therefore locked and turns as a closed unit FOURTH GEAR POWERFLOW Speed and torque are not converted by the direct gear ratio of the 4th gear Power is transferred from the driveshaft 25 to the output shaft 26 via three locked planetary gearsets 21 206 AUTOMATIC NAG1 SERVICE INF...

Page 3277: ...e planetary gearset is locked by the same speeds of the annulus gear 10 and the sun gear 22 and it turns as a closed unit Rear Planetary Gear Set The driving clutch K2 9 is engaged and transfers the input speed of the driveshaft 25 to the planetary carrier 15 via the annulus gear 10 The annulus gear 11 turns in the same way as the planetary carrier 15 due to the mechanical connection with the lock...

Page 3278: ...ears 18 turn between the annulus gear 10 and the sun gear 22 The speed of the center planetary carrier 14 and the output shaft 26 connected to the center planetary carrier lies between that of the annulus gear 10 and the sun gear 22 This provides a step up ratio Rear Planetary Gear Set The driving clutch K2 9 is engaged and transfers the input speed of the driveshaft 25 to the planetary carrier 15...

Page 3279: ...duced speed in the running direction of the engine Center Planetary Gear Set The annulus gear 10 is held against the housing by the multi disc holding clutch B3 5 via the mechanical con nection to the planetary carrier 15 The sun gear 22 turns backwards due to the engaged driving clutch K3 12 The planetary gears 18 turn on the fixed annulus gear 10 and increase the torque from the sun gear 22 to t...

Page 3280: ...gear 23 The direction is reversed by the held planetary carrier 15 so that the sun gear 23 turns in the opposite direction to the running direction of the engine SHIFT GROUPS SHIFT SEQUENCE 1 2 Shift First Gear Engaged The end face of the command valve 5 is kept unpressurized via the solenoid valve for 1 2 and 4 5 shift 1 Via the holding pressure shift valve 4 the working pressure p A is present a...

Page 3281: ...d by the working pressure p A The rising shift pressure p S at driving clutch K1 6 acts on the annular face of the overlap regulating valve 2 and reduces the overlap pressure regulated by the overlap regulating valve 2 When a corresponding pressure level is reached at the holding pressure shift valve 4 this valve switches over Second Gear Engaged After the gearchange is complete the pressure on th...

Page 3282: ...The multi disc holding clutch B1 7 is deactivated unpressurized The spring of the shift pressure shift valve 3 pushes the valve back to its basic position 21 212 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3283: ...the gearshift lever in the NEUTRAL or PARK positions holding clutch B1 1 and driving clutch K3 4 are applied and the various valves in the 1 2 4 5 shift group are positioned to apply pressure to the multi disc holding clutch B2 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 213 ...

Page 3284: ...alve B2 9 in the upper position shift pressure p S travels behind the piston B2 5 and simulta neously to the opposing face of the piston B2 6 The multi disc holding clutch B2 begins to close The pressure on the opposing face of the piston B2 6 ensures a soft activation of the multi disc holding clutch B2 21 214 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3285: ...e 16 to driving clutch K3 4 and via the 3 4 command valve 13 to the end face of the 3 4 shift pressure shift valve 14 The 3 4 shift pressure shift valve 14 is moved against the force of the spring towards the right At the same time the 3 4 solenoid valve 10 is energized This allows shift valve pressure p SV to enter the spring chamber of the shift valve B2 9 and to reach the end face of the 3 4 co...

Page 3286: ...owing a If the propeller shaft turns but the wheels do not inspect the differential and axle shafts b If the propeller shaft does not turn and the transmission is noisy stop the engine Remove the transmission oil pan and check for debris If the pan is clear remove the transmission and check for a damaged flexplate torque converter oil pump or input shaft c If the propeller shaft does not turn and ...

Page 3287: ...amp Switch Replace Switch if Necessary GRUMBLING DRONING JERKING WHEN TCC IS ENGAGED 1 Slip Speed TCC too Low 1 Switch Off Torque Converter Lock Up Using DRBIIIT If Complaint is Not Reproduced Afterwards Replace PWM Valve Set Adaption Values to Zero HOWLING HUMMING ABOVE 4000 RPM IN EACH GEAR 1 Oil Filter Blocked 1 Replace Oil Filter 2 Oil Pump 2 Replace Oil Pump WHINING SINGING 1 Gear Set Noises ...

Page 3288: ...eplace Gear Recognition Switch NO UPSHIFT INTO 5TH GEAR WHEN FULL THROTTLE OR KICK DOWN ACTIVATION 1 The Upshift 4 5 at Full Throttle or Kick Down Never Occurs Until Reaching Cut Off Speed Under These Conditions the High Powered Vehicle Will Never Shift Into 5th Gear Below 250 km h 1 Instruct Customer NO KICK DOWN SHIFTING 1 Accelerator Pedal Value 95 1 Check Engine Control Adjust as Necessary ENG...

Page 3289: ... PLUG TO THE CONDUCTOR PLATE 1 Deformation O rings 1 Replace O rings 2 Deformation Adapter 2 Replace Adaptor 3 The Conductor Plate is not Fitted Surface to Surface on the Valve Body in One Corner the Plug Is not Centered in the Socket and the O ring Will Not Seal 3 Remove Nose of Conductor Plate 4 Contacting At The Conductor Plate Leaky Oil In Harness Sometimes In The Control Module 4 Replace Cond...

Page 3290: ...lling a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppliers REMOVAL 1 Disconnect the negative battery cable 2 Remove the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT REMOVAL 3 Remove the lower splash shield screws 1 and the lower s...

Page 3291: ...suitable drain pan beneath the transmis sion drain 6 Remove the transmission drain plug 2 and drain the transmission 7 Disconnect the transmission shift selector rod 1 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 221 ...

Page 3292: ... line banjo fit tings 1 from the left and right sides of the tran mission housing 9 Remove the transmission oil cooler line retainer bolts 1 from the left and right side of the engine lower oil pan 21 222 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3293: ...e Rotate the engine at the vibration damper bolt 11 Remove the torque converter bolts 2 12 Disconnect and remove the oxygen sensor har ness connectors 1 13 Remove the heat shield bolts 2 and the heat shield ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 223 ...

Page 3294: ...ve the starter Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 17 Remove the transmission to engine retaining bolts 18 Lower and remove the transmission from the vehicle DISASSEMBLY 1 Remove the torque converter 1 Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 TORQUE CONVERTER REMOVAL 21 224 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3295: ... maximum travel for assembly reference 4 Loosen the guide bushing 12 and remove it from the transmission housing 5 Remove the oil pan 5 6 Remove the oil filter 4 7 Unscrew the bolts 3 and remove the electrohy draulic unit 2 8 Place the transmission in the PARK position before attempting to remove the output shaft nut 9 Remove the output shaft nut holding the propeller shaft flange to the output sh...

Page 3296: ...13 Remove the transmission rear output shaft bear ing retaining ring 1 14 Position Special Tool 9082 1 over the inner race of the output shaft bearing 3 21 226 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3297: ... the transmission hous ing to the torque converter housing from inside the converter housing 19 Stand the transmission upright on the converter housing Be sure to use suitable spacers between the bench surface and the torque converter hous ing since the input shaft protrudes past the front surface of the housing 20 Remove the remaining bolts holding the transmis sion housing to the torque converte...

Page 3298: ...ear gear set and clutch K3 3 23 Remove the thrust needle bearing 4 and the thrust washer 5 24 Remove the drive shaft with driving clutch K2 and front planetary gear set 6 25 Remove the driving clutch K1 1 21 228 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3299: ...ue converter hub seal and the oil pump outer o ring seal from the oil pump 28 Unscrew the bolts 1 and remove the multi disc brake B1 5 from the torque converter housing Screw two opposed bolts into the multi disc brake B1 5 and separate from the torque converter housing by applying light blows with a plastic hammer 29 Detach the intermediate plate 3 from torque converter housing 2 ZH AUTOMATIC NAG...

Page 3300: ... holding clutch B3 discs 2 from the transmission housing 6 The externally toothed disc carrier for the multi disc holding clutch B2 4 is also the piston for the multi disc holding clutch B3 discs 2 32 Remove the parking lock gear 5 21 230 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3301: ... 4 and multi disc holding clutch pack B3 2 6 a Put the multi discs for multi disc holding clutch B3 together in the sequence shown in the illus tration and insert individually b Using a feeler gauge determine the play L at three points between the snap ring 7 and outer multi disc 1 B3 clutch clearance should be 1 0 1 4 mm 0 039 0 055 in Adjust the clearance as necessary c Adjust with snap ring 7 i...

Page 3302: ...is free before installing multi disc holding clutch B1 7 Install the multi disc holding clutch B1 5 onto the converter housing 2 and intermediate plate 3 Installed position of clutch B1 5 in relation to converter housing 2 is specified by a plain dowel pin arrow in clutch B1 5 8 Install the bolts to multi disc holding clutch B1 5 to the converter housing 2 21 232 AUTOMATIC NAG1 SERVICE INFORMATION...

Page 3303: ...hten Tighten the oil pump bolts to 20 N m 177 in lbs 13 Using grease insert the teflon rings 7 in the groove so that the joint remains together 14 Install the driving clutch K1 1 onto multi disc holding clutch B1 15 Install the drive shaft with driving clutch K2 6 and front planetary gear set 1 16 Install the front washer 5 and the thrust needle bearing 4 17 Install the output shaft with the cente...

Page 3304: ...ousing Using a depth gauge measure from the gauge bar 1 to the parking lock gear 2 b Using a depth gauge measure from the Spe cial Tool 6311 1 to the contact surface of the output shaft bearing 2 in the transmission housing c Subtract the first figure from the second figure to determine the current end play of the trans mission Select a shim such that the end play will be 0 3 0 5 mm 0 012 0 020 in...

Page 3305: ...lay between the bear ing 2 and the retaining ring 1 using a feeler gauge d There must be no play between the retaining ring 1 and the bearing 2 If the ring cannot be installed a thinner ring must be used If there is play between the ring 1 and the bear ing 2 a thicker ring must be installed Retain ing rings are available in thicknesses of 2 0 mm 0 079 in 2 1 mm 0 083 in and 2 2 mm 0 087 in 24 Rota...

Page 3306: ...haft d Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Move the input shaft in and out and record reading End play should be 0 3 0 5 mm 0 012 0 020 in Adjust as necessary 26 Install the output shaft washer onto the output shaft 27 Install a new transmission rear seal into the trans mission case 2 with Special Tool 8902A 1 28 Install the propel...

Page 3307: ...c Press downward on the staking tool 1 until the staking pin 3 contacts the output shaft nut flange 2 d Strike Special Tool C 4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft 32 Install the electrohydraulic unit 2 Tighten the bolts to 8 N m 71 in lbs 33 Install the oil filter 4 34 Install the oil pan 5 Tighten the bolts to 8 N m 71 in lbs ZH AUTOMATIC N...

Page 3308: ...ully seated in the transmission Mount the transmission on the transmission jack 3 Position the transmission in the vehicle on the engine block dowels 4 Install the transmission retaining bolts and the ground cable Tighten the bolts to 38 N m 28 ft lbs Note Rotate the engine at the vibration damper bolt 5 Install the torque converter bolts Tighten the bolts to 50 N m 37 ft lbs 6 Install the torque ...

Page 3309: ... transmission controller harness connector 2 9 Install the heat shield and harness retainer with bolts 2 Tighten the bolts to 20 N m 15 ft lbs 10 Route the oxygen sensor wire harness in the retainer and connect the oxygen sensors 1 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 239 ...

Page 3310: ... cooler lines Install the fittings on the left and right sides of the transmission case Tighten the fittings to 34 N m 25 ft lbs 12 Install the transmission oil cooler line retainers and bolts at the left and right sides of the oil pan Tighten the bolts to 20 N m 15 ft lbs 21 240 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3311: ...l the retaining clip 1 14 Install the transmission drain plug 2 with a new gasket 1 Tighten the drain plug to 20 N m 15 ft lbs 15 Install the propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 241 ...

Page 3312: ...Lower the vehicle 18 Connect the negative battery cable 19 Fill the transmission to the specified level with the specified transmission fluid 20 Start the engine and check for leaks 21 Check the transmission fluid level using Special Tool 8863 A 21 242 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3313: ...SCHEMATICS AND DIAGRAMS ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 243 ...

Page 3314: ...21 244 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3315: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 245 ...

Page 3316: ...21 246 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3317: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 247 ...

Page 3318: ...21 248 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3319: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 249 ...

Page 3320: ...21 250 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3321: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 251 ...

Page 3322: ...21 252 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3323: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 253 ...

Page 3324: ...21 254 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3325: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 255 ...

Page 3326: ...21 256 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3327: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 257 ...

Page 3328: ...21 258 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3329: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 259 ...

Page 3330: ...21 260 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3331: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 261 ...

Page 3332: ...21 262 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3333: ...ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 263 ...

Page 3334: ...5 B2 Clutch Snap rings 2 9 3 2 3 5 3 8 and 4 1 0 114 0 126 0 138 0 150 0 162 B3 Clutch Clearance 1 0 1 4 0 039 0 055 B3 Clutch Snap rings 3 2 3 5 3 8 4 1 4 4 and 4 7 0 126 0 138 0 150 0 162 0 173 0 185 K1 Clutch Clearance 3 Disc 2 7 3 1 0 106 0 122 4 Disc 3 0 3 4 0 118 0 134 5 Disc 3 3 3 7 0 13 0 146 6 Disc 3 6 4 0 0 142 0 158 K1 Clutch Snap rings 2 6 2 9 3 2 3 5 3 8 and 4 1 0 102 0 114 0 126 0 13...

Page 3335: ...opeller Flange 120 88 5 Bolt Electrohydraulic Unit 8 71 Bolt Transmission Housing to Converter Housing 20 177 Bolts Oil Pan 8 71 Screws Valve Body Housing Side Cover 4 35 Bolt Shift Plate 8 71 Bolt Solenoid Leaf Spring 8 71 Plug Oil Pan Drain 20 177 Nut Shifter Mechanism to Floor Pan 7 65 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 265 ...

Page 3336: ...SPECIAL TOOLS NAG1 AUTOMATIC TRANSMISSION C 3339 DIAL INDICATOR C 4171 HANDLE 6311 BAR GAUGE 8266 END PLAY SET 82 ADAPTER GEARTRAIN END PLAY 8863A DIPSTICK 21 266 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3337: ...8900 Compressor Multi use Spring 8901 TOOL PRESSING 8902A INSTALLER SEAL 9078 TOOL STAKING 9082 REMOVER BEARING 9287 INSTALLER BEARING ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 267 ...

Page 3338: ...consists of a number of internally toothed discs 4 on an internally toothed disc carrier and externally toothed discs 3 on an externally toothed disc carrier OPERATION The driving clutches 1 2 and 5 produce a non positive locking connection between two elements of a planetary gear set or between one element from each of two planetary gear sets in order to transmit the drive torque 21 268 AUTOMATIC...

Page 3339: ...planetary gear set is locked with the annulus gear 11 of the center planetary gear set via the externally toothed disc carrier 13 and the center planetary carrier 10 on which the internally toothed discs are seated Annu lus gear 16 and annulus gear 11 turn at the same speed as the input shaft 21 If the driving clutch K3 5 is actuated via the piston 7 the piston compresses the disc set The sun gear...

Page 3340: ... carrier 1 3 Place Special Tool 8900 on the spring plate 8 and compress the spring until the snap ring 10 is exposed 4 Remove the snap ring 10 5 Take out the disc spring 7 and remove the piston 6 by carefully blowing compressed air into the bore 6 Remove the snap ring 3 and take out the freewheel F1 2 21 270 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3341: ...he sun gear Check the sealing ring 9 replace if necessary 4 Place Special Tool 8900 on spring plate 8 and compress the spring until the groove of the snap ring is exposed 5 Insert the snap ring 10 After installing check the snap ring for correct seat Note Pay attention to the sequence of the discs Place new friction multiple discs in ATF fluid for one hour before installing 6 Insert the multiple d...

Page 3342: ... the upper bearing surface of the groove in the outer multiple disc carrier e The correct clutch clearance is 2 7 3 1 mm 0 106 0 122 in for three friction disc versions 3 0 3 4 mm 0 118 0 134 in for four disc ver sions 3 3 3 7 mm 0 130 0 146 in for five disc versions and 3 6 4 0 mm 0 142 0 158 in for six disc versions f Adjust with snap ring 6 if necessary Snap rings are available in thicknesses o...

Page 3343: ...9 Insert the front freewheel F1 2 and fit the snap ring 3 The freewheel F1 2 must be installed in the direction of the arrow ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 273 ...

Page 3344: ...rated front gear set 1 and take off the hollow gear 14 2 Remove the input shaft and K2 clutch 3 3 Remove the thrust bearing 2 4 Remove the snap ring 13 from K2 outer multiple disc carrier 5 Take out the multiple disc pack 12 6 Take out the disc spring 11 21 274 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3345: ... 1 onto spring retainer and press until snap ring 2 is released 8 Remove the snap ring 10 9 Take out the disc spring 7 and pull the piston 6 out of the outer multiple disc carrier ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 275 ...

Page 3346: ...toward the spring retainer 9 Inspect the seal 8 replace if necessary 3 Place Special Tool 8900 on the spring plate 1 and press until the groove of the snap ring is exposed 4 Insert the snap ring 2 5 Insert the disc spring Note Pay attention to the sequence of the discs Place new friction multiple discs in ATF fluid for one hour before installing 6 Insert the multiple disk set into the outer multip...

Page 3347: ...ng 6 must contact the upper bearing surface of the groove in the outer multiple disc carrier e The correct clutch clearance is 2 3 2 7 mm 0 091 0 106 in for three friction disc versions 2 4 2 8 mm 0 095 0 110 in for four disc ver sions 2 5 2 9 mm 0 099 0 114 in for five disc versions and 2 7 3 1 mm 0 106 0 122 in for six disc versions f Adjust with snap ring 6 if necessary Snap rings are available...

Page 3348: ...st bearing 2 with a little grease to prevent it from slipping 10 Install the input shaft and k2 clutch in the K1 inner disc carrier with integrated front gear set 1 11 Fit the hollow gear 14 Pay attention to the installation position 21 278 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3349: ...sc pack 2 and the disc spring 3 from the outer disc carrier 3 Place Special Tool 8900 9 on the spring plate 5 and compress the spring until the snap ring 4 is exposed 4 Remove the snap ring 4 5 Remove the spring plate 5 and the piston 6 from the outer disc carrier 8 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 279 ...

Page 3350: ...ol 8900 9 on the spring plate 5 and clamp until the snap ring groove is exposed 4 Insert the snap ring 4 The collar of the snap ring 4 must point towards the disc pack 2 Note Pay attention to the sequence of the discs Place new friction multiple discs in ATF fluid for one hour before installing 5 Install the disc spring 3 and the multiple disc pack 2 in the outer disc carrier 8 6 Insert the snap r...

Page 3351: ...essary Snap rings are available in thicknesses of 2 0 mm 0 079 in 2 3 mm 0 091 in 2 6 mm 0 102 in 2 9 mm 0 114 in 3 2 mm 0 126 in and 3 5 mm 0 138 in ELECTROHYDRAULIC UNIT DESCRIPTION The electrohydraulic control unit comprises the shift plate made from light alloy for the hydraulic control and an electrical control unit The electrical control unit comprises of a supporting body made of plastic in...

Page 3352: ...ed amounts to lubricate and cool the mechanical transmission components and the torque converter Furthermore the lubrication pressure p Sm is also used to limit the pressure in the torque converter Shift Pressure p S The shift pressure is determined by the shift pressure regulating solenoid valve and the shift pressure regulating valve The shift pressure Regulates the pressure in the activating sh...

Page 3353: ...essure p Ü The overlap pressure controls the shift component pressure reduction during a shift phase The pressure in a shift element as it disengages is controlled during the shift phase depending on engine load modulating pressure and the pressure in the shift element as it engages The adjusted pressure is inversely proportional to the transmission capability of the shift element being engaged co...

Page 3354: ...orque converter lockup clutch and distribution of the lubricating oil Overlap Regulating Valve Each shift group is assigned one overlap regulating valve 1 The 1 2 4 5 overlap regulating valve is installed in the shift valve housing the 2 3 and 3 4 overlap regulating valves are installed in the valve housing The overlap regulating valve regulates the pressure reduction during a shift phase 21 284 A...

Page 3355: ... stationary phase to the shift phase and back again Holding Pressure Shift Valve Each shift group possesses one holding pressure shift valve 1 The 1 2 4 5 and 2 3 holding pressure shift valves are installed in the shift valve housing the 3 4 holding pressure shift valve is installed in the valve housing The holding pressure shift valve allocates the working pressure to one actuator of a shift grou...

Page 3356: ...ure p S to the activating actuator and the overlap pressure p Ü regulated by the overlap regulating valve to the deactivating actuator Lubrication Pressure Regulating Valve The lubrication pressure regulating valve 1 is located in the valve housing of the electrohydraulic control module The valve controls the fluid to lubricate and cool the mechanical part of the transmission and lim its the press...

Page 3357: ...he shift plate It regulates the shift pressure p S Regulating Valve Pressure Regulating Valve The regulating valve pressure regulating valve 1 is located in the valve housing of the electrohydraulic control module It regulates the regulating valve pres sure p RV ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 287 ...

Page 3358: ...ONTROL UNIT Signals from the transmission control module TCM are converted into hydraulic functions in the electrical control unit 7 The RPM sensors 1 12 starter inter lock contact 9 and transmission oil temperature sen sor 8 of the electrical control unit 7 supply the TCM with input signals The solenoid valves are controlled by the TCM and trigger the hydraulic functions 21 288 AUTOMATIC NAG1 SER...

Page 3359: ...re According to the size of the working pressure the torque converter lockup clutch is either Engaged Disengaged or Slipping When the regulat ing valve 6 is in the lower position lubricating oil flows through the torque converter and oil cooler 8 into the transmission torque converter lockup clutch unpressurized In its regulating position slipping torque converter lockup clutch pressurized a reduc...

Page 3360: ...ransfer capacity of the activating shift actuator regulated overlap Command Valve When the end face is unpressurized stationary phase the working pressure is directed to the actuated shift ele ment If the end face of the command valve is subjected to the shift valve pressure p SV shift phase then the shift pressure is switched to the activating element and the overlap pressure is switched to the d...

Page 3361: ... the shift pressure p S Shift Pressure Shift Valve When the multiple disc brake B1 3 is activated the working pressure pa is applied to the end face of the 1 2 4 5 shift pressure shift valve 4 via the command valve 1 Its shift state is maintained during the shift phase by substituting the shift element pressure acting on its end face and which is variable during the shift phase with a correspondin...

Page 3362: ...ansmission lubrication system including the torque converter Shift Pressure Regulating Valve The shift pressure is determined by the shift pressure regulating solenoid valve and the shift pressure regu lating valve 3 In addition pressure from the driving clutch K2 1 is also present at the annular surface 2 of the shift pressure regulating valve 3 This reduces the shift pressure in 2nd gear 21 292 ...

Page 3363: ...s far as the maximum pressure Shift Valve Pressure Regulating Valve The non constant regulating valve pressure p RV is regulated to a constant shift valve pressure p SV at the shift valve pressure regulating valve 1 and is used to supply the 1 2 and 4 5 3 4 2 3 solenoid valves and the torque converter lockup clutch PWM solenoid valve ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 293 ...

Page 3364: ...he transmission housing 5 Disconnect the 13 pin plug connector 1 Turn the bayonet lock of the guide bushing 2 anti clockwise Note If the transmission fluid is burnt or contains abraded particles the oil cooler lines and oil cooler must be flushed out 6 Remove the transmission filter Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 FLUID STANDARD PROCEDURE 21 294 AUTOMATIC NAG1 SERVICE INFORMATION...

Page 3365: ...e solenoid valves 6 11 from the shift plate 13 Note Check O rings on solenoid valves for dam age and replace if necessary 6 Bend away the retaining lug on the stiffening rib on the transmission oil temperature sensor 7 Remove the electrohydraulic control module 12 from the shift plate 13 Note Pay great attention to cleanliness for all work on the shift plate Fluffy cloths must not be used Leather ...

Page 3366: ... 2 from the valve body 4 11 Remove the strainers 1 for the modulating pres sure and shift pressure control solenoid valves from the valve housing 12 Note the locations of the major shift valve group components for assembly reference 21 296 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3367: ...13 Remove the strainer in the inlet to torque con verter lock up control solenoid valve 1 14 Remove the sealing plate 3 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 297 ...

Page 3368: ...lls 1 3 4 and the central strainer 2 for re installation Remove all check balls 1 3 4 and the central strainer 2 16 Remove the screws holding the side covers to the valve body and valve housing 17 Remove all the valves and springs from the valve body 1 Check all valves for ease of movement and shavings 21 298 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3369: ...e housing 2 Check all valves for ease of movement and shavings Note The sleeves and pistons of the overlap regulating valves must not be mixed up 19 Remove the pressure supply valve from the valve body ASSEMBLY ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 299 ...

Page 3370: ...ed and blown out with compressed air noting that parts may be blown away 2 Install the pressure supply valve 1 into the valve body Note The sleeves and pistons of the overlap regulating valves must not be mixed up 3 Install all of the valves and springs into the valve housing 2 Check all valves for ease of movement and shav ings 4 Install the screws to hold the side covers to the valve body and va...

Page 3371: ...ody four made from plastic 4 and eight from steel 1 3 5 Install all of the check balls 1 3 4 and the central strainer 2 6 Install the strainer in the inlet to the torque con verter lock up control solenoid valve 1 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 301 ...

Page 3372: ...lve body 4 and sealing plate 3 9 Install the shift plate bolts 1 Tighten the bolts to 8 N m 71 in lbs 10 Install the leaf spring 5 11 Install the strainers 1 for the modulating pressure and shift pressure control solenoid valves into the valve housing 21 302 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3373: ...the bolts to 8 N m 71 in lbs Note Pay attention to the different lengths of the bolts 17 Install the solenoid caps 1 2 18 Install the electrohydraulic unit into the vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 ELECTROHYDRAULIC UNIT INSTALLATION INSTALLATION 1 Position the electrohydraulic unit in the transmis sion housing 2 Insert the selector valve 1 in the driver of the detent plate...

Page 3374: ... Torque the drain plug to 20 N m 177 in lbs 7 Install the guide bushing 12 into the transmission housing and install the bolt 11 to hold the guide bushing in place 8 Check the O ring on the plug connector 1 and replace if necessary 9 Install the plug connector 1 into the guide bushing 2 Turn the bayonet lock of the guide bushing 2 clockwise to connect plug connector 1 21 304 AUTOMATIC NAG1 SERVICE...

Page 3375: ...ic Dexron IIIT Automatic Transmission Fluid may be substituted The oil level control is located on the electrohydraulic unit and consists of the float 5 which is integrated into the electrohydraulic control unit The float is posi tioned to plug the opening between the oil gallery and gearset chamber so that the rotating gearsets do not splash about in oil as the oil level rises The oil level contr...

Page 3376: ...en for a leak if inspection is not careful DIAGNOSIS AND TESTING CAUSES OF BURNT FLUID Burnt discolored fluid is a result of overheating which has four primary causes 1 Internal clutch slippage usually caused by low line pressure inadequate clutch apply pressure or clutch seal failure 2 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usually the result ...

Page 3377: ...shing procedures will not remove all contaminants STANDARD PROCEDURE CHECK OIL LEVEL 1 Verify that the vehicle is parked on a level surface 2 Remove locking pin 1 Remove the plate of the locking pin with a suitable tool and press out the pin remaining in the cap downwards 3 Remove the cap 2 from the fill tube 3 WARNING RISK OF ACCIDENT FROM VEHICLE STARTING OFF BY ITSELF WHEN ENGINE RUNNING RISK O...

Page 3378: ...indicator marks every 10mm Determine the height of the oil level on the dipstick and using the height the transmission temperature and the Transmission Fluid Graph determine if the transmission oil level is correct 9 Add or remove oil as necessary and recheck the oil level 10 Once the oil level is correct install a new dipstick tube cap 2 and lock pin 1 21 308 AUTOMATIC NAG1 SERVICE INFORMATION ZH...

Page 3379: ...d to the transmission b If the transmission was completely overhauled the torque converter was replaced or drained and the cooler was flushed add 7 7 L 16 3 pts of transmission fluid to the transmission 5 Check the transmission fluid level Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 FLUID STANDARD PROCEDURE and adjust as required STANDARD PROCEDURE FILTER CHANGE 1 Raise and support the vehic...

Page 3380: ...or swollen 10 Install the transmission pan 1 and bolts 3 Tighten the bolts to 8 N m 71 in lbs 11 Install the drain plug 2 with a new gasket 1 Tighten the drain plug to 20 N m 15 lbs ft 12 Install the heat shield and the bolts 2 Tighten the bolts to 8 N m 71 in lbs 13 Route the oxygen sensor wire harness 1 in the heat shield Connect the oxygen sensor wire har ness connectors 14 Lower the vehicle 15...

Page 3381: ...l elements of a planetary gear set together or against the transmission housing in one direction of rotation to allow the torque to be transmit ted If the inner race 7 of the freewheeling clutch is locked and the outer race 4 turns counter clockwise 1 the locking elements 3 adopt a diagonal position on account of their special contours allowing the free wheel function The outer race 4 slides over ...

Page 3382: ...ear planetary sun gear 4 with the K3 internally toothed disk carrier and the rear freewheel F2 3 3 Remove the snap ring 2 for freewheel 4 Press the freewheel out of the K3 inner disc carrier and rear planetary sun gear 4 5 Check the O rings 6 replace if necessary 21 312 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3383: ...c carrier and rear planetary sun gear for dam age Replace as necessary ASSEMBLY 1 Press the freewheel F2 3 into the K3 inner disc carrier and rear planetary sun gear 4 2 Install the snap ring 2 for the freewheel ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 313 ...

Page 3384: ... CLUTCHES DESCRIPTION Three multi disc holding clutches the front middle and rear multi disc holding clutches B1 1 B3 4 and B2 5 are located in the planetary gear sets in the transmission housing A multi disc holding clutch consists of a number of internally toothed discs 10 on an internally toothed disc carrier and externally toothed discs 9 on an externally toothed disc carrier which is rigidly ...

Page 3385: ...r 15 locks the sun gear 14 against the housing The planetary pinion gears 13 turn on the sun gear 14 If the multi disc holding clutch B2 5 is actuated via the piston 7 the piston compresses the disc set The inter nally toothed disc carrier 8 locks the sun gear 12 against the housing The planetary pinion gears 11 turn on the sun gear 12 If the multi disc holding clutch B3 4 is actuated via the pist...

Page 3386: ... disc holding clutch B1 outer carrier 3 Place Special Tool 8900 on the disc spring and compress the spring until the snap ring 4 is exposed 4 Remove the snap ring 4 5 Remove the piston 2 from the multi disc holding clutch B1 carrier by carefully blowing compressed air into the bore 21 316 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3387: ...rt the snap ring 4 Note The collar of the snap ring must point towards the multiple disc pack After installing check the snap ring for correct seat 3 Insert the disc spring 5 and the multiple disc pack 6 in the multi disc holding clutch B1 outer carrier 4 Insert the snap ring 7 Note Pay attention to the sequence of discs Place the new friction multiple discs in ATF fluid for one hour before instal...

Page 3388: ...asure ment the snap ring 6 must contact the upper bearing surface of the groove in the outer mul tiple disc carrier 5 The correct clearance is 2 3 2 7 mm 0 091 0 106 in for 2 friction disc versions 2 7 3 1 mm 0 106 0 122 in for 3 disc versions and 3 0 3 4 mm 0 118 0 134 in for 4 disc versions d Adjust with snap ring 6 if necessary Snap rings are available in thicknesses of 2 6 mm 0 102 in 2 9 mm 0...

Page 3389: ...re spring disc 14 and compress the spring until the groove for the snap ring is exposed 4 Remove the snap ring 16 5 Remove the spring plate 15 and the piston back pressure disc spring 14 6 Separate the piston guide ring 13 and the B2 piston 10 from the B3 piston B2 outer disc carrier 8 by blowing compressed air into the bore 7 Press the piston guide ring 13 out of the B2 piston 10 8 Separate the B...

Page 3390: ... disc carrier 8 in the correct position 2 Check all of the sealing rings replace if necessary The rounded off edges on the sealing rings 6 11 and 12 must point outwards The rounded off edges on the sealing ring 9 must point inwards 21 320 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3391: ...Insert the piston guide ring 2 The valve 1 in the piston guide ring must be on top 5 Insert the piston back pressure disc spring 14 and the spring plate 15 Insert the disc spring with the curvature towards the spring plate ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 321 ...

Page 3392: ...isc carrier 10 Measure the B2 clutch pack clearance a Mount Special Tool 8901 1 on the B3 B2 outer disc carrier 2 b Using a lever press compress the pressing tool as far as the stop then the marking ring is still visible see small arrow c Using a feeler gauge determine the play L at three points between the snap ring 8 and outer multiple disc 7 d The correct clutch clearance is 1 9 2 3 mm 0 075 0 ...

Page 3393: ...gine speeds and other information and are processed into an input signal for electronic control Input speed sensor N2 6 records the speed of the front sun gear via the externally toothed disc carrier of the multiple disc clutch K1 10 and input speed sen sor N3 8 records the speed of the front planet carrier via the internally toothed disc carrier of driving clutch K1 3 OIL PUMP DESCRIPTION The oil...

Page 3394: ...he meshing of the teeth prevents oil flowing from the delivery side to the intake side An external gear 3 eccentrically mounted in the pump housing is located on the internal gear 4 which is connected to the drive flange The crescent 1 drives the exter nal wheel DISASSEMBLY 1 Remove the pump gears 1 and 2 from the pump housing 21 324 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3395: ... inner oil pump seal 1 3 Remove the outer oil pump o ring 2 ASSEMBLY 1 Install a new inner oil pump seal 1 with Special Tool 8902 A 2 Replace the outer oil pump o ring 2 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 325 ...

Page 3396: ...PARK position before attempting to remove the output shaft nut 4 Remove the output shaft nut holding the propeller shaft flange to the output shaft 5 Remove the propeller shaft flange 6 Remove the transmission rear oil seal with a suit able slide hammer and screw 7 Remove the transmission output shaft washer Be sure to tag the washer since it is very similar to the geartrain end play shim and they...

Page 3397: ...tion Special Tool 9082 1 over the inner race of the output shaft bearing 3 10 Slide the collar 3 on the Special Tool 9082 1 downward over the fingers 4 of the tool ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 327 ...

Page 3398: ...nd install over the output shaft and against the park gear INSTALLATION CAUTION Verify that the geartrain end play shim is properly installed over the output shaft and against the park gear 1 Install the output shaft bearing in the rear transmission housing a Using Special Tool 9287 1 install the output shaft bearing 2 into the transmission housing 3 The closed side of the plastic cage 21 328 AUTO...

Page 3399: ... ring and the bearing a thicker ring must be installed Retaining rings are available in thicknesses of 2 0 mm 0 079 in 2 1 mm 0 083 in and 2 2 mm 0 087 in 2 Install the output shaft washer onto the output shaft 3 Install a new transmission rear seal into the trans mission case 2 with Special Tool 8902A 1 4 Install the propeller shaft flange onto the output shaft 5 Place the transmission in the PAR...

Page 3400: ...ecurely staked to the output shaft 8 Install the propeller shaft Refer to 3 DIFFEREN TIAL DRIVELINE PROPELLER SHAFT INSTALLATION OUTPUT SHAFT SEAL REMOVAL 1 Remove the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT REMOVAL Move propeller shaft to the right and tie up 2 Place the transmission in the PARK position before attempting to remove the output shaft nut 3 Remove the outpu...

Page 3401: ...ssion in the PARK position before attempting to tighten the output shaft nut 5 Install a new output shaft nut Tighten the output shaft nut to 120 N m 88 5 ft lbs 6 Stake the output shaft nut to the output shaft as follows a Place the Special Tool 9078 2 and Special Tool C 4171 onto the output shaft b Rotate the Special Tool 9078 2 until the align ment pin 3 engages the output shaft notch ZH AUTOMA...

Page 3402: ...ooth walled cylinder which is closed at one end and converts fluid pressure into mechanical movement The fluid pressure exerted on the piston is contained within the system through the use of piston rings or seals OPERATION The principal which makes this operation possible is known as Pascal s Law Pascal s Law can be stated as Pres sure on a confined fluid is transmitted equally in all directions ...

Page 3403: ...re created equals 10 PSI Another interpretation of Pascal s Law is that regardless of container shape or size the pressure will be maintained through out as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container FORCE MULTIPLICATION Using the 10 PSI example used in the illustration a force of 1000 lbs can be moved with a force of only 100...

Page 3404: ...chanical part of the transmission as the front middle and rear planetary gear sets OPERATION The annulus gear 1 and sun gear 3 elements of a planetary gear system are alternately driven and braked by the actuating elements of the multi plate clutch and multiple disc brake The planetary pinion gears 2 can turn on the internal gearing of the annu lus gear 1 and on the external gearing of the sun gea...

Page 3405: ...m the output shaft with center planetary carrier 2 3 Remove the driving clutch K3 7 4 Remove the rear hollow shaft freewheel F2 6 from the output shaft with center planetary carrier 2 5 Remove the rear planetary gear set 5 with integrated tubular shaft of center gear set from the output shaft with center planetary carrier 2 6 Remove the thrust washer 4 ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 335 ...

Page 3406: ... S between shim 10 and retaining ring 1 using a feeler gauge Clearance should be 0 15 0 6 mm 0 006 0 024 in Shims are available in thicknesses of 3 0 mm 0 118 in 3 4 mm 0 134 in and 3 7 mm 0 146 in Adjust as necessary Note During the test apply a contact force by hand to K3 in the direction of the output shaft SHIFT INTERLOCK SOLENOID DESCRIPTION The typical electrical solenoid used in automotive ...

Page 3407: ...e coil or 2 Increase the number of turns of wire in the coil The most common practice is to increase the number of turns by using thin wire that can completely fill the available space within the solenoid housing The strength of the spring and the length of the plunger also contribute to the response speed possible by a particular solenoid design A solenoid can also be described by the method by w...

Page 3408: ...t in the conductor tracks 3 The force of the contact springs 2 ensures secure contacts TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE The torque converter lockup clutch PWM solenoid valve 1 is located in the shell of the electric valve control unit and is pressed against the shift plate by a spring The PWM solenoid valve 1 for the torque converter lockup controls the pressure for the torque con...

Page 3409: ...s normally directly attached to the valve which it is to operate When the cur rent is removed from the coil the attraction is removed and the plunger will return to its original position due to spring pressure The plunger is made of a conductive material and accomplishes this movement by providing a path for the magnetic field to flow By keeping the air gap between the plunger and the coil to the ...

Page 3410: ...tral contact consists of the plunger 2 the permanent magnet 3 the dry reed contact 4 DESCRIPTION TRANSMISSION TEMPERATURE SENSOR The transmission oil temperature sensor 1 is located in the shell of the electric valve control unit and is fixed to the conductor tracks Its purpose is to measure the temperature of the transmission oil and pass the temperature to the TCM as an input signal It is a temp...

Page 3411: ...smission oil has a consid erable effect on the shifting time and therefore the shift quality By measuring the oil temperature shift operations can be optimized in all temperature ranges The transmission oil temperature sensor 1 is switched in series with the park neutral contact The temperature signal is transferred to the TCM only when the dry reed contact of the park neutral contact is closed in...

Page 3412: ...40 104 1 37 1109 0 45 113 1 40 1149 0 50 122 1 44 1189 0 55 131 1 48 1231 0 60 140 1 51 1273 0 65 149 1 55 1316 0 70 158 1 58 1360 0 75 167 1 62 1405 0 80 176 1 65 1450 0 85 185 1 69 1497 0 90 194 1 72 1545 0 95 203 1 76 1594 0 100 212 1 79 1644 0 105 221 1 83 1695 0 110 230 1 86 1747 0 115 239 1 90 1800 0 120 248 1 93 1855 0 125 257 1 97 1911 0 130 266 2 00 1968 0 135 275 2 04 2027 0 140 284 2 08...

Page 3413: ...s reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmis sion fluid temperatures The converter clutch engages in third gear The torque converter 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 CAUTION The torque converter must be replaced if a transmiss...

Page 3414: ...curved blades placed radially along the inside of the housing on the transmission side of the converter As the converter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system 21 344 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3415: ...te the impeller but is not attached to the housing The input shaft is inserted 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 STATOR ZH AUTOMATIC NAG1 SERVICE INFORMATION 21 345 ...

Page 3416: ... up solenoid to achieve a smooth application of the torque converter clutch This function referred to as Electronically Modulated Converter Clutch EMCC can occur at various times depend ing on the following variables Shift lever position Current gear range Transmission fluid temperature Engine coolant temperature Input speed Throttle angle Engine speed OPERATION The converter impeller driving memb...

Page 3417: ...heeling providing no torque multiplica tion By applying the turbine s piston and friction mate rial to the front cover a total converter engagement can be obtained The result of this engagement is a direct 1 1 mechanical link between the engine and the transmission The clutch can be engaged in second third fourth and fifth gear ranges The TCM controls the torque converter by way of internal logic ...

Page 3418: ... The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter 1 forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the transmis sion 2 INSTALLATION Check the converter hub and drive flats for sharp edges burrs scratches or nicks Polish the hub and flats with 320 400 grit paper or cro...

Page 3419: ...ion in the vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 INSTALLATION 9 Fill the transmission with the recommended fluid TORQUE CONVERTER HUB SEAL REMOVAL 1 Remove the torque converter Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC NAG1 TORQUE CONVERTER REMOVAL 2 Remove the torque converter hub seal with suitable screw and slide hammer INSTALLATION 1 Position the torque converter hub sea...

Page 3420: ...fer to 21 TRANS MISSION TRANSAXLE AUTOMATIC NAG1 TORQUE CONVERTER INSTALLATION SHIFT INTERLOCK SOLENOID DESCRIPTION The shift interlock solenoid is not serviced separately If the shift interlock solenoid becomes inoperable the shift mechanism must be replaced 21 350 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3421: ...o nuetral Lever must be touching the slot arrow 5 Energize the interlock solenoid 3 6 Loosen the bolts 1 7 Adjust the gap between the locking lever 4 and the cam plate 5 to 02 mm using the adjusting screw 2 8 Tighten the bolts 1 to 3 5 N m 31 in lbs 9 Install the shifter outer cover 10 Install the console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION ZH AUTOMATIC NAG1 SERVICE INFORMATION 2...

Page 3422: ...digital and analog input signals controls various components and transfers information to various modules via the Con troller Area Network CAN bus The Shift Lever Assembly has input and output signals to the Data Link Connector The Shift Lever Assembly receives input signals from the selector lever the W S switch the upshift downshift Autostick switch the shift gate illumination the kickdown switc...

Page 3423: ...LATION 1 Connect the shift rod to the shift mechanism and install the retainer clip 2 Position the shift mechanism 1 in the vehicle 3 Install the retaining bolts 3 Tighten the bolts to 7 N m 65 in lbs 4 Connect the wire harness 2 connectors at the rear of the shift mechanism 5 Install the front center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 6 Install the gear shift lever hand...

Page 3424: ...rod from the vehicle INSTALLATION 1 Position the shift rod on the transmission shift arm an install the clip 2 Position the shift rod on the shifter and install the clip 3 Lower the vehicle and check the operation of the shift mechanism 21 354 AUTOMATIC NAG1 SERVICE INFORMATION ZH ...

Page 3425: ...SHAFT DISASSEMBLY 397 ASSEMBLY 401 SYNCHRONIZER DESCRIPTION 404 ASSEMBLY 405 GEAR SHIFT LEVER HANDLE REMOVAL 405 INSTALLATION 406 REVERSE LOCKOUT CABLE DESCRIPTION 406 STANDARD PROCEDURE REVERSE LOCKOUT CABLE ADJUSTMENT 406 SHIFT MECHANISM DESCRIPTION 412 REMOVAL 412 INSTALLATION 414 MANUAL SERVICE INFORMATION DESCRIPTION The manual transmission is a fully synchronized two shaft transmission with ...

Page 3426: ...s well as the use of roller sleeves DIAGNOSIS AND TESTING LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak inadequate lubricant fill or an incorrect lubricant level check Leaks can occur at the mating surfaces of the gear case and adaptor or from the front rear seals A suspected leak could also be the result of an overfill condition Leaks at the rear of the ...

Page 3427: ...If the clutch problem is advanced gear clash during shifts can result Worn or damaged synchro rings can cause gear clash when shifting into any forward gear In some new or rebuilt transmissions new syn chronizer rings may tend to stick slightly causing hard or noisy shifts In most cases this condition will decline as the rings wear in TRANSMISSION NOISE Most manual transmissions make some noise du...

Page 3428: ...he backup lamp switch harness con nector 1 7 Disconnect the pressure line 1 at the clutch slave cylinder Remove the retaining bolt 2 and the pressure line 1 from the transmission 21 358 MANUAL SERVICE INFORMATION ZH ...

Page 3429: ...ble 1 by turning the locking nut counter clockwise Remove the cable end from the ball stud and position the cable aside 9 Disconnect the shift rod 1 from the ball stud 2 Position the shift rod 1 aside ZH MANUAL SERVICE INFORMATION 21 359 ...

Page 3430: ... such as Mopar degreasing solvent Gunk or similar solvents Do not dry the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels INSTALLATION 1 Position the transmission on the jack 2 Install the transmission to the rear of the engine block Align the transmission dowels to the engine block dowel holes 3 Connect the ground cable 1 to the transmissi...

Page 3431: ... install the bolts Tighten the transmission mount bolts 1 to the transmis sion to 30 N m 22 ft lbs Tighten the rear cross member retaining bolts 2 to the body to 40 N m 30 ft lbs 7 Connect the shift rod 1 to the transmission ball stud 2 ZH MANUAL SERVICE INFORMATION 21 361 ...

Page 3432: ...nect the reverse lockout cable 1 and turn the nut clockwise to lock in place Connect the cable end to the ball stud 9 Connect the backup lamp switch harness connec tor 1 21 362 MANUAL SERVICE INFORMATION ZH ...

Page 3433: ...OCEDURE 13 Lower the vehicle 14 Check the brake fluid level in master cylinder fluid reservoir 15 Bleed the clutch slave cylinder Refer to 6 CLUTCH STANDARD PROCEDURE 16 Recheck the brake fluid level 17 Connect the negative battery cable 18 Start the engine and check for leaks 19 Check for proper clutch operation SPECIFICATIONS SPECIFICATIONS GEAR RATIOS GEAR RATIOS DESCRIPTION SPECIFICATION 1st G...

Page 3434: ...Pinion Flange Collared Nut 180 133 1593 Rear Crossmember Bolts 40 30 354 Release Bearing Slave Cylinder Bolts 9 7 80 Reverse Idler Shaft Retaining Bolt 23 17 204 Reverse Lockout Cable Bracket Bolts 20 15 177 Slave Cylinder Pressure Line Bolt 10 7 3 89 Transmission To Engine Bolts 40 30 354 Transmission Ground Bolt 40 30 354 Transmission Mount Bolts 30 22 266 SPECIFICATIONS FLUID CAPACITY FLUID CAP...

Page 3435: ...SPECIAL TOOLS DRIFT 9122 DRIFT 9123 SPLITTER 1126 PULLER 1026 Wrench C 3281 SLIDE HAMMER C 3752 ZH MANUAL SERVICE INFORMATION 21 365 ...

Page 3436: ...ADAPTOR 8870 8019 9078 9120 938 21 366 MANUAL SERVICE INFORMATION ZH ...

Page 3437: ...n completely 4 Install the drain plug 2 and tighten to 60 N m 44 ft lbs 5 Remove the drain pan Fill the transmission with the specified fluid 6 Install and tighten the fill plug 1 to 50 N m 37 ft lbs 7 Lower the vehicle STANDARD PROCEDURE CHECKING FLUID LEVEL 1 Raise and support the vehicle 2 Remove the transmission fill plug 1 3 The full fluid level should be at the base of the fill plug threaded...

Page 3438: ...the transmission in reverse 3 Raise and support the vehicle 4 Disconnect the backup lamp switch harness con nector 1 5 Remove the backup lamp switch retaining bolt 1 6 Remove the backup lamp switch 2 and o ring seal from the transmission 21 368 MANUAL SERVICE INFORMATION ZH ...

Page 3439: ... N m 89 in lbs 3 Connect the backup lamp switch harness connec tor 1 4 Lower the vehicle 5 Connect the negative battery cable 6 Check the operation of the backup lamps OUTPUT FLANGE SEAL REMOVAL 1 Support the transmission 2 Remove the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT REMOVAL ZH MANUAL SERVICE INFORMATION 21 369 ...

Page 3440: ...3281 2 Flange Wrench while removing the collared nut 1 4 Remove the output flange 3 from output shaft 1 Note Do not score the transmission seal bore 5 Pry out transmission output flange seal 2 with a screwdriver 21 370 MANUAL SERVICE INFORMATION ZH ...

Page 3441: ... 3 with Special Tool C 3281 Flange Wrench 2 Tighten the nut to 180 N m 133 ft lbs Note The Special Tool 9078 has two possible locations for the beveled staking pin The pin must be installed in the hole labeled Transmission for this operation This hole is located directly across from the spring loaded alignment pin ZH MANUAL SERVICE INFORMATION 21 371 ...

Page 3442: ...taking tool 1 until the staking pin 3 contacts the output shaft nut flange 2 d Strike Special Tool 9078 Staking Tool with a suitable hammer until the output shaft nut is securely staked to the output shaft 4 Install the propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 5 Check the transmission fluid level Refer to 21 TRANSMISSION TRANSAXLE MANUAL FLUID STANDARD PROCEDU...

Page 3443: ...Slide Hammer and 8870 Adaptor to remove the detent plug 1 INSTALLATION 1 Smooth any burrs or nicks in the detent plug bore 2 Use a plastic mallet to drive in and fully seat the detent plug 1 3 Install the transmission in the vehicle Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION ZH MANUAL SERVICE INFORMATION 21 373 ...

Page 3444: ...ER REMOVAL 3 Use a screwdriver 1 to pry out the input shaft seal 2 INSTALLATION 1 Use Special Tool 9123 Drift 1 and a mallet to drive in the new seal 2 2 Install the clutch release bearing slave cylinder Refer to 6 CLUTCH SLAVE CYLINDER INSTALLATION 3 Install the transmission in the vehicle Refer to 21 TRANSMISSION TRANSAXLE MANUAL INSTALLATION 21 374 MANUAL SERVICE INFORMATION ZH ...

Page 3445: ... 1 6 Remove the guide sleeves 6 ASSEMBLY 1 Drive in the sleeves 6 using a mallet 2 Install the shift shaft bearing 1 Note The input and counter shaft bearings must be fully seated before installing the locking plates 3 Install the input shaft bearing 2 and the countershaft bearing 3 4 Install the locking plates 5 and bolts 4 Tighten the bolts to 9 N m 7 ft lbs 5 Assemble the front and rear transmi...

Page 3446: ...l 12 ASSEMBLY 1 Install a new output flange seal 12 using Special Tool 9123 Drift 2 Use a suitable deep socket to drive in the shift shaft bearing 11 3 Install the mainshaft bearing 7 locking plates 10 and retaining bolts 9 Tighten the bolts to 9 N m 7 ft lbs 4 Drive in the countershaft bearing 8 5 Install the reverse gear idler shaft 3 6 Install the bearing shell 2 7 Install the bearings 4 revers...

Page 3447: ... the transmission Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL 2 Remove the clutch release bearing slave cylinder Refer to 6 CLUTCH SLAVE CYLINDER REMOVAL 3 Remove the sealing ring 6 from countershaft bore 4 using a screwdriver 4 Remove the input shaft seal 1 using a screw driver 5 Remove the countershaft bolt 5 6 Remove the input shaft snap ring 2 ZH MANUAL SERVICE INFORMATION 21 377 ...

Page 3448: ...T PLUG REMOVAL 10 Remove the rear section retaining bolts 4 11 Separate the rear section from the front section Note The countershaft input shaft and shift unit can only be removed as an assembly from the rear section 12 Remove the four bolts 1 attaching the shifter plate 2 to the rear section 13 Use special tools 1126 and 938 to press the shafts and shift unit out of the rear section of the trans...

Page 3449: ...ISSION TRANSAXLE MANUAL TRANSMISSION HOUSING DISASSEMBLY ASSEMBLY 1 Assemble the rear section housing Refer to 21 TRANSMISSION TRANSAXLE MANUAL TRANSMISSION HOUSING ASSEMBLY Note Be certain that the shift forks are aligned in the shifting sleeves on the shafts 2 Fit the shifter assembly 2 on to the main and counter shafts 1 ZH MANUAL SERVICE INFORMATION 21 379 ...

Page 3450: ...e main shaft and shift shaft Align the reverse gear 1 to the gear sets as shown 4 Use the output flange 3 and the collared nut 1 to draw in the output shaft Remove the nut and flange when the rear section is in place 21 380 MANUAL SERVICE INFORMATION ZH ...

Page 3451: ...tall the snap ring 2 on the input shaft 8 Use Special Tool 9123 Drift to drive in a new input shaft seal 9 Install a new sealing ring 6 in the counter shaft bolt opening 4 10 Install the clutch release bearing slave cylinder Refer to 6 CLUTCH SLAVE CYLINDER REMOVAL 11 Apply a 1 5 to 2mm bead of Loctite 5203 sealer or equivalent to the front section as shown ZH MANUAL SERVICE INFORMATION 21 381 ...

Page 3452: ...ve the roll pin 8 in until flush 15 Drive the reverse gear detent 1 in until fully seated 16 Install the oil filler plug 2 Tighten the plug to 50 N m 37 ft lbs 17 Install the oil drain plug 3 Tighten the plug to 60 N m 44 ft lbs 18 Install the output flange 6 and collared nut 5 Tighten the nut to 180 N m 133 ft lbs 21 382 MANUAL SERVICE INFORMATION ZH ...

Page 3453: ...ssemble the geartrain housing Refer to 21 TRANSMISSION TRANSAXLE MANUAL GEARTRAIN HOUSING DISASSEMBLY 2 Mount the main shaft in a vise with protective jaws 3 Remove first gear idler gear using special tool 938 and 1126 ZH MANUAL SERVICE INFORMATION 21 383 ...

Page 3454: ...4 Remove the reverse gear synchronizer assembly 1 5 Remove the synchronizer ring 1 and idler gear 2 for reverse gear 21 384 MANUAL SERVICE INFORMATION ZH ...

Page 3455: ...6 Remove first gear needle bearing 1 and sleeve 2 7 Remove the thrust washer 1 first gear idler gear 2 and first gear idler needle bearing 3 ZH MANUAL SERVICE INFORMATION 21 385 ...

Page 3456: ...e the friction ring 1 cone ring 2 and the synchronizer ring 3 9 Remove the locking ring 1 using pliers Remove the 1st 2nd gear synchronizer using special tool 938 and 1126 21 386 MANUAL SERVICE INFORMATION ZH ...

Page 3457: ...10 Remove the synchronizer ring 1 cone ring 2 and friction ring 3 11 Remove the second gear idler gear 1 and nee dle bearing 2 ZH MANUAL SERVICE INFORMATION 21 387 ...

Page 3458: ...emove the cylindrical roller bearing 3 from the input shaft 2 15 Remove the input shaft 2 from the vise 16 Clamp the main shaft 3 in the vise with input end up 17 Remove the locking ring 1 pull off the synchro nizer cone 2 and the clutch body using special tool 938 and 1126 21 388 MANUAL SERVICE INFORMATION ZH ...

Page 3459: ...18 Remove the synchronizer ring 1 and the clutch body 2 19 Remove the 6th gear idler gear 1 and needle bearing 2 20 Remove the main shaft 3 from the vise ZH MANUAL SERVICE INFORMATION 21 389 ...

Page 3460: ...haft 3 2 Install the clutch body 2 and the synchronizer ring 1 Note The inscription on the synchronizer body must face upwards towards the input end The drivers on the synchronizer ring must engage in the grooves in the synchronizer body 21 390 MANUAL SERVICE INFORMATION ZH ...

Page 3461: ...SION TRANS AXLE MANUAL SYNCHRONIZER ASSEMBLY 4 Press on the 5th 6th gear synchronizer assembly 1 Note Snap rings that are bent or otherwise dam aged must be replaced 5 Install the snap ring 1 on the mainshaft 2 Check that it is fully seated ZH MANUAL SERVICE INFORMATION 21 391 ...

Page 3462: ...sure the drivers on the synchronizer ring are engaged in the grooves of the synchronizer body 7 Oil the cylindrical bearing 2 and place it in the input shaft 1 8 Place the input shaft 1 on the mainshaft 21 392 MANUAL SERVICE INFORMATION ZH ...

Page 3463: ... the col lar facing upwards 11 Install the friction ring 4 the cone ring 3 and the synchronizer ring 2 The lobes in the friction ring 4 must engage in the recesses of the syn chronizer ring 3 12 Assemble the 1st 2nd gear synchronizer if it is not being replaced Refer to 21 TRANSMISSION TRANS AXLE MANUAL SYNCHRONIZER ASSEMBLY ZH MANUAL SERVICE INFORMATION 21 393 ...

Page 3464: ...13 Install the 1st 2nd gear synchronizer assembly 1 Note Do not over expand the snap ring 14 Install the snap ring 1 21 394 MANUAL SERVICE INFORMATION ZH ...

Page 3465: ...in the recesses in the synchronizer ring 3 15 Install the synchronizer ring 3 the cone ring 2 and the friction ring 1 16 Install the first gear needle bearing 3 first gear 2 and press on the 1st gear thrust washer 1 ZH MANUAL SERVICE INFORMATION 21 395 ...

Page 3466: ...7 Press on the sleeve 2 and the reverse gear needle bearing 1 Note The reverse gear collar must face upwards 18 Install the reverse gear 2 and the synchronizer ring 1 21 396 MANUAL SERVICE INFORMATION ZH ...

Page 3467: ...he geartrain housing Refer to 21 TRANSMISSION TRANSAXLE MANUAL GEARTRAIN HOUSING ASSEMBLY COUNTERSHAFT DISASSEMBLY 1 Remove the transmission Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL 2 Disassemble the geartrain housing Refer to 21 TRANSMISSION TRANSAXLE MANUAL GEARTRAIN HOUS ING DISASSEMBLY ZH MANUAL SERVICE INFORMATION 21 397 ...

Page 3468: ...e constant mesh gear 2 and the 6th gear drive gear 3 5 Clamp the countershaft in a vise with protective jaws with the output end pointing downwards 6 Remove the 3rd gear idler gear 1 and needle bearing 2 21 398 MANUAL SERVICE INFORMATION ZH ...

Page 3469: ...7 Remove the 3rd 4th gear clutch body 1 and the friction ring 2 8 Remove the 3rd 4th gear cone ring 1 the syn chronizer ring 2 and the locking ring 3 using pli ers ZH MANUAL SERVICE INFORMATION 21 399 ...

Page 3470: ... Use the jaw puller to remove the 4th gear 2 together with the 3rd 4th gear synchronizer 1 10 Remove the 4th gear synchronizer ring 1 cone ring 2 and friction ring 3 21 400 MANUAL SERVICE INFORMATION ZH ...

Page 3471: ... 1 gear 2 and needle bearing 3 12 Release the countershaft from the vise ASSEMBLY 1 Clamp the countershaft in a vise with input end up 2 Install the 4th gear needle bearing 3 gear 2 and clutch body 1 ZH MANUAL SERVICE INFORMATION 21 401 ...

Page 3472: ...ring 1 4 Unless a new synchronizer is being used the syn chronizer unit must be properly assembled Refer to 21 TRANSMISSION TRANSAXLE MANUAL SYNCHRONIZER ASSEMBLY 5 Install the 4th gear 2 and the 3rd 4th gear syn chronizer unit 1 21 402 MANUAL SERVICE INFORMATION ZH ...

Page 3473: ...6 Install the snap ring 3 the 3rd 4th gear synchro nizer ring 2 and cone ring 1 7 Install the friction ring 2 and clutch body 1 ZH MANUAL SERVICE INFORMATION 21 403 ...

Page 3474: ...LE MANUAL GEARTRAIN HOUSING ASSEMBLY 14 Install the transmission Refer to 21 TRANS MISSION TRANSAXLE MANUAL INSTALLATION SYNCHRONIZER DESCRIPTION When shifting high torque transmission and frequent shift work with a reduced shift force at the same time require a powerful synchronization unit The multiple cone synchronization in gears 1 to 6 meets these requirements and therefore offers the followi...

Page 3475: ...LEVER HANDLE REMOVAL 1 Lift the shift boot 2 to expose the retainer nut 3 2 Rotate the retainer nut 3 clockwise and down to remove the shift handle 1 3 Pull straight up on the handle 1 ZH MANUAL SERVICE INFORMATION 21 405 ...

Page 3476: ...ental selection by the lockout cable The lockout cable requires that the knob must be lifted before selecting reverse or the movement will be blocked The reverse gear lockout cable is serviced only with the shift mechanism If the cable becomes inoperable the shift mechanism must be replaced Refer to 21 TRANS MISSION TRANSAXLE MANUAL SHIFT MECHANISM REMOVAL STANDARD PROCEDURE REVERSE LOCKOUT CABLE ...

Page 3477: ...ter bezel 1 by using a plastic wedge to release the bezel from the console 2 4 Slide the shifter bezel 1 over the leather shifter boot 2 and lay the bezel on the side of the console ZH MANUAL SERVICE INFORMATION 21 407 ...

Page 3478: ...5 Depress the locking tabs 1 of the rubber shifter boot 6 Pull the rubber shifter boot 2 up over the leather shifter boot 1 21 408 MANUAL SERVICE INFORMATION ZH ...

Page 3479: ...e Special Tool 9120 1 onto the shifter alignment slot at the base of the shifter housing 2 Ensure that the recessed portion of the tool is facing upward 8 Raise and support the vehicle 9 Depress the detent lock 1 on the reverse lock out cable The cable should automatically adjust when the lock is depressed 10 The adjustment procedure is now complete ZH MANUAL SERVICE INFORMATION 21 409 ...

Page 3480: ...wer the vehicle 12 Pull up on the shifter knob and remove the Spe cial Tool 9120 1 from the alignment slot 13 Install the rubber shifter boot back into the locking tabs 1 21 410 MANUAL SERVICE INFORMATION ZH ...

Page 3481: ... 1 over the leather shifter boot 2 Carefully press firmly down in all four corners of the shifter bezel until it locks into place 15 Install the leather shifter boot 1 onto the shifter bezel 2 ZH MANUAL SERVICE INFORMATION 21 411 ...

Page 3482: ...nner shift module 12 in the transmission by the selector cable 4 and the shift movement is transmitted by the shift rod 1 Both transmission components are maintenance free This type of shift mechanism has the following advantages Precise and easy to operate shift No transmission of component movements to the shift lever and tunnel The swivel lever 3 and rubber mounts allow the engine transmission ...

Page 3483: ...ver 4 and the boot 3 from the shift mechanism 4 Remove the propeller shaft Refer to 21 TRANSMISSION TRANSAXLE MANUAL REMOVAL 5 Lower the engine and transmission slightly with the support 6 Loosen the cable lock nut 2 and press In on the release button 3 to remove the reverse lockout cable 1 from the bracket ZH MANUAL SERVICE INFORMATION 21 413 ...

Page 3484: ...shift mechanism 3 from the vehicle INSTALLATION Note Be sure that the foam insulation remains in position around the opening in the floor pan 1 Position the shift mechanism 3 in the vehicle above the transmission and install the retaining pin 1 Connect the shift rod 2 to the ball stud 21 414 MANUAL SERVICE INFORMATION ZH ...

Page 3485: ...OPELLER SHAFT INSTALLATION 4 Lower the vehicle 5 Install the boot 3 the cover 4 the spring 5 and washer 6 on the shift mechanism 6 Press down on the washer 6 and install the retaining pin 2 7 Install the gear shift lever handle 1 Refer to 21 TRANSMISSION TRANSAXLE MANUAL GEAR SHIFT KNOB INSTALLATION 8 Connect the negative battery cable ZH MANUAL SERVICE INFORMATION 21 415 ...

Page 3486: ......

Page 3487: ...1 LEFT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED 13 RIGHT FRONT TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED 15 RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED 17 TIRE PRESSURE SENSOR TRANSMITTER 19 TRANSMITTER FAILURE 22 LEFT FRONT TIRE PRESSURE SENSOR TRANSMITTER 24 LEFT REAR TIRE PRESSURE SENSOR TRANSMITTER 26 RIGHT FRONT TIRE PRESSURE SENSOR TRANSMITTER 28 RIGHT REAR TIRE...

Page 3488: ...NO TIRES TRAINED 22 2 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3489: ...agnostic Test 1 PROGRAMMING TIRE PRESSURE MONITOR Turn the ignition on With the DRB IIIT and a calibration magnet program the Tire Pressure Monitor module for all four tire pressure sensor transmitters Disconnect the DRB IIIT and prepare the vehicle for a road test Road test the vehicle above 33 km h 20 MPH for a minimum of two minutes With the DRB IIIT read the last 32 transmissions received by t...

Page 3490: ...TIRE PRESSURE MONITOR MODULE FAILURE 22 4 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3491: ...eels for the Tire Pressure Sensor Transmitters being present Do all the wheels have tire pressure sensor transmitters Yes Go to 2 No Install the Tire Pressure Sensor Transmitters and program module Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR INSTALLATION Perform TIRE PRESSURE MONITOR VERIFICATION TEST 2 PROGRAMMING TIRE PRESSURE MONITOR Turn the ignition on With the DRB IIIT and a cal...

Page 3492: ...TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED 22 6 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3493: ...pressure sensor trans mitters approximately once a minute 60 68 seconds when the vehicle speed is above 33 km h 20 MPH Set Condition If the Tire Pressure Monitor TPM module cannot process the frequency transmission from the right front tire pressure sensor transmitter the DTC will be set RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED When Monitored With the ignition on the Tire Pressure...

Page 3494: ...ignal Jammed DTC Yes Replace the Tire Pressure Sensor Transmitter at the affected wheel Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR REMOVAL Perform TIRE PRESSURE MONITOR VERIFICATION TEST No The condition that caused this DTC is currently not present Check for tire pressure sensor transmitter low bat tery code Perform TIRE PRESSURE MONITOR VERIFICATION TEST 22 8 TIRES WHEELS ELECTRICA...

Page 3495: ...SIGNAL JAMMED ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 9 ...

Page 3496: ... of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER SIGNAL JAMMED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires ...

Page 3497: ...LEFT FRONT TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 11 ...

Page 3498: ...his DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER SIGNAL JAMMED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connecto...

Page 3499: ...LEFT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 13 ...

Page 3500: ...is DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER SIGNAL JAMMED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connector...

Page 3501: ...RIGHT FRONT TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 15 ...

Page 3502: ...this DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER SIGNAL JAMMED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connect...

Page 3503: ...RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 17 ...

Page 3504: ...his DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER SIGNAL JAMMED No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connecto...

Page 3505: ...TIRE PRESSURE SENSOR TRANSMITTER ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 19 ...

Page 3506: ...ters approximately once a minute 60 68 seconds when the vehicle speed is above 33 km h 20 MPH Set Condition If the Tire Pressure Monitor TPM module receives a transmission from the right front tire pres sure sensor transmitter that the battery is low the DTC will be set RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER When Monitored With the ignition on the Tire Pressure Monitor TPM monitors the tire p...

Page 3507: ...ire Pressure Sensor Transmitter DTC Yes Replace the Tire Pressure Sensor Transmitter at the affected wheel Perform TIRE PRESSURE MONITOR VERIFICATION TEST No The condition that caused this DTC is currently not present Inspect the related wiring harness for a possible intermittent condition Perform TIRE PRESSURE MONITOR VERIFICATION TEST ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 21 ...

Page 3508: ...TRANSMITTER FAILURE 22 22 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3509: ...s For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle ...

Page 3510: ...LEFT FRONT TIRE PRESSURE SENSOR TRANSMITTER 22 24 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3511: ... this DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific ...

Page 3512: ...LEFT REAR TIRE PRESSURE SENSOR TRANSMITTER 22 26 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3513: ...this DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific t...

Page 3514: ...RIGHT FRONT TIRE PRESSURE SENSOR TRANSMITTER 22 28 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3515: ...s this DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific...

Page 3516: ...RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER 22 30 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3517: ... this DTC preset Yes For complete diagnosis of this DTC refer to TIRE PRES SURE SENSOR TRANSMITTER No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors specific ...

Page 3518: ...TIRE PRESSURE SENSOR TRANSMITTER LOW BATTERY 22 32 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3519: ...sensor trans mitters approximately once a minute 60 68 seconds when the vehicle speed is above 33 km h 20 MPH Set Condition If the Tire Pressure Monitor TPM module receives a transmission from the right front tire pres sure sensor transmitter that the battery is low the DTC will be set RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER LOW BATTERY When Monitored With the ignition on the Tire Pressure Mon...

Page 3520: ...ery DTC Yes Replace the Tire Pressure Sensor Transmitter at the affected wheel Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR REMOVAL Perform TIRE PRESSURE MONITOR VERIFICATION TEST No The condition that caused this DTC is currently not present Inspect the related wiring harness for a possible intermittent condition Perform TIRE PRESSURE MONITOR VERIFICATION TEST 22 34 TIRES WHEELS ELECT...

Page 3521: ...le at 40 km h 25 MPH for at least 2 minutes With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If a DTC is present refer to the appropriate category and select the corresponding symptom Are any DTCs present YES Repair is not complete refer to appropriate symptom NO Repair is complete ZH TIRES WHEELS ELECTRICAL DIAGNOSTICS 22 35 ...

Page 3522: ...SCHEMATICS AND DIAGRAMS 22 36 TIRES WHEELS ELECTRICAL DIAGNOSTICS ZH ...

Page 3523: ...PROGRAMMING 49 REMOVAL 50 INSTALLATION 50 SENSOR DESCRIPTION 50 OPERATION 51 REMOVAL 51 INSTALLATION 53 TIRES DESCRIPTION TIRES 54 RADIAL PLY TIRES 55 TIRE INFLATION PRESSURES 55 TIRE PRESSURE FOR HIGH SPEED 57 REPLACEMENT TIRES 57 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 57 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 58 DIAGNOSIS AND TESTING TIRE NOISE OR VIBRATION 58 DIAGNO...

Page 3524: ...nce between the high and low points on the wheel This is measured by using a dial indicator 1 on the inner portion of the wheel 6 Lateral runout 2 is the side to side movement of the wheel This is measured by using a dial indicator 1 on the inner portion of the wheel 6 rim 22 38 TIRES WHEELS SERVICE INFORMATION ZH ...

Page 3525: ... acceptable level the tire can be rotated on the wheel See Method 2 METHOD 1 RELOCATE WHEEL ON HUB 1 Drive the vehicle a short distance to eliminate tire flat spotting from a parked position 2 Check the wheel bearings and adjust or replace if necessary 3 Check the rear wheel mounting surface of the wheel hub 4 Relocate the wheel on the mounting surface of the wheel hub 1 two bolts over from the or...

Page 3526: ...ive when there is runout in both tire and wheel 1 Remove the tire from the wheel and mount the wheel on a service dynamic balance machine 2 Check the wheel radial runout and the lateral runout Radial runout 1 This is measured by using a dial indicator 1 on the inner portion of the wheel 6 Lateral runout 1 This is measured by using a dial indicator 1 on the inner portion of the wheel 6 rim 22 40 TI...

Page 3527: ...should be used only when a two plane balancer is not available Note Aluminum wheels require coated balance weights and special alignment equipment Wheel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balancing find the location of the heavy spot 1 causing ...

Page 3528: ...t colored adhesive label on the outboard sidewall The low spot on the rim is identified with a label on the outside of the rim and a dot on the inside of the rim If the outside label has been removed the tire will have to be removed to locate the dot on the inside of the rim Before dismounting a tire from its wheel a reference mark should be placed on the tire at the valve stem location This refer...

Page 3529: ... mm 4 0 in of the first spot and is still excessive replace the tire If the high spot is within 101 6 mm 4 0 in of the first spot on the wheel the wheel may be out of specifications Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING If the high spot is NOT within 101 6 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the tire and remount it 90 degrees ...

Page 3530: ...tterns These effects can be reduced by rotating the tires at regular intervals The benefits of tire rotation are Increase tread life Maintain traction levels A smooth quiet ride STANDARD PROCEDURE TIRE AND WHEEL INSTALLATION The wheel bolts are designed for specific applications They must be replaced with equivalent parts Do not use replacement parts of lesser quality or a substitute design Before...

Page 3531: ... the sequence shown Tighten the wheel bolts to 110 N m 81 ft lbs TIRE PRESSURE MONITORING DESCRIPTION This vehicle has a Tire Pressure Monitoring TPM system It is there to alert the driver when air pressure in any of the vehicle s four tires falls below a prede termined threshold It alerts the driver with a lamp in the Instrument Cluster ZH TIRES WHEELS SERVICE INFORMATION 22 45 ...

Page 3532: ...the valve stem 1 of each tire 2 to communicate the tire pressure condition to the module If a tire has low air pressure an indicator light on the instrument cluster is illuminated The vehicle operator must check the tire pressure of each tire in order to determine which tire has a low pressure con dition The low tire pressure warning system utilizes these main components Tire Pressure Monitoring M...

Page 3533: ...tatus to the body control module BCM When the module determines there is a fault the low tire pressure indicator lamp circuit is grounded and the BCM turns on the Low Tire pressure indicator lamp The TPM module 1 also stores its own identification number each of the four sensor transmitter identifica tion numbers module version and the date of manufacture CAUTION CAUTION The use of tire sealants i...

Page 3534: ...smitter Mounting Nut Torque 4 N m 35 in Lbs MODULE DESCRIPTION The Tire Pressure Monitoring TPM System utilizes a control module 1 to control the system The TPM module 1 is located in the headliner between the dome lamp and the rear view mirror OPERATION The Universal Garage Door Opener Tire Pressure Monitor TPM module has a microprocessor controller that can monitor the transmissions from the sen...

Page 3535: ...trument panel near the steer ing column 2 Access the Chassis System using the DRB IIIT 3 Once in the Chassis System select Tire Pressure Monitor then select Miscellaneous Functions 4 Select Train All Mode from the System Test screen displaying the following options Tire Set Train All Mode Stop Train Mode 5 Place the magnet Special Tool 8821 at the valve stem for that wheel as directed by the DRB I...

Page 3536: ...eadliner SENSOR DESCRIPTION CAUTION The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Mon itoring system Tire sealants can clog tire pressure 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 o...

Page 3537: ...in the vehicle Approximately every 60 seconds or if tire pressure changes by one psi or more between transmissions The system operates by monitoring a radio frequency transmission from the sensor transmitters located in each wheel When the vehicle reaches a speed of approximately 32 km h 20 MPH centrifugal force created by the rotating wheels closes a roll switch inside each sensor transmitter pow...

Page 3538: ...and dismounting the tire Failure to do this will greatly increase the risk of damaging the transmitter when servicing the tire 6 Remove the nut 1 mounting the valve stem 4 of the pressure sensor transmitter to the wheel 2 Drop sensor transmitter into the tire 3 CAUTION When breaking the top and bottom bead of the tire off the wheel care must be used so the bead breaking mechanism on the tire chang...

Page 3539: ...alve stem base before installing the pressure transmitter in the wheel Also be sure that the surface of the wheel that the grommet seals are against is clean and not damaged 1 Install the tire pressure sensor transmitter 1 on the wheel 2 2 Install the special sensor mounting nut 3 When tightening the tire pressure sensor transmitter nut hold the sensor so it does not rotate Once tight ened the gap...

Page 3540: ... transmitter using the DRB IIIT scan tool If the identification code and tire pressure thresholds from the new tire pressure transmitter are present in the receivers memory the new tire pressure transmitter has been cor rectly programmed to the receiver TIRES DESCRIPTION TIRES Tires are designed and engineered for each specific vehicle They provide the best overall performance for normal operation...

Page 3541: ...t always printed on the tire sidewall These ratings are Q up to 100 MPH S up to 112 MPH T up to 118 MPH U up to 124 MPH H up to 130 MPH V up to 149 MPH Z more than 149 MPH consult the tire manufacturer for the specific speed rating An All Season type tire will have either M S M S or M S indicating mud and snow traction imprinted on the side wall RADIAL PLY TIRES Radial ply tires improve handling t...

Page 3542: ...he label also lists the cold inflation pressure for these tires at full load operation Tire pressures have been chosen to provide safe operation vehicle stability and a smooth ride Tire pressure should be checked cold once a month Tire pressure decreases as the ambient temperature drops Check tire pres sure frequently when ambient temperature varies widely Tire inflation pressures are cold inflati...

Page 3543: ...inflation pressure recommendations REPLACEMENT TIRES WARNING FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE The original equipment tires provide a proper balance of many characteristics such as Ride Noise Handling Durability Tread Life Traction Rolling Resistance Speed Capability It is recommended that tires equivalent to the original equ...

Page 3544: ... differential and exhaust noises will change as speed varies while the tire noise will usually remain constant DIAGNOSIS AND TESTING TIRE VEHICLE LEAD Use the following vehicle lead diagnosis and correction procedure to diagnose and correct a vehicle lead or drift problem VEHICLE LEAD DIAGNOSIS AND CORRECTION 1 Adjust tire pressure to correct specifications Road test OK If vehicle still leads go t...

Page 3545: ...MEDIATELY THE TIRE SEALANT MUST NOT COME INTO CONTACT WITH THE SKIN EYES OR CLOTHING RINSE IMMEDIATELY WITH CLEAN WATER TIREFIT sealant can be used on the roadside to seal minor punctures in particular in the tread The tire can then continue to be used to a limited extent until it can be replaced After using TIREFIT tire sealant the customer is required to find the nearest authorized DaimlerChrysl...

Page 3546: ...soft bristle brush Steam cleaning may also be used to remove the coating SPECIFICATIONS TIRES SPECIFICATIONS DESCRIPTION SPECIFICATION FRONT TIRES 225 40ZR18 REAR TIRES 255 35ZR19 WHEELS DESCRIPTION WHEELS The rim size is located on the Vehicle Safety Certifi cation Label located on the driver s door shut face The size of the rim is determined by the drivetrain package Original equipment wheels ri...

Page 3547: ...RD PROCEDURE WHEEL REPLACEMENT The wheel bolts are designed for specific applications They must be replaced with equivalent parts Do not use replacement parts of lesser quality or a substitute design All aluminum wheels have wheel bolts which feature an enlarged head This enlarged head is necessary to ensure proper retention of the aluminum wheels Note Do not use chrome plated lug bolts with chrom...

Page 3548: ...els from any other source should be equivalent in Load Carrying Capacity Diameter Width Offset Mounting Configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle Replacement with used wheels is not recommended Their service history may have included severe treatment SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Wheel M...

Page 3549: ...REAR SPOILER SWITCH SENSE CIRCUIT 4 REAR SPOILER LIMIT SWITCH SIGNAL UP CIRCUIT 7 REAR SPOILER LIMIT SWITCH SIGNAL DOWN CIRCUIT 10 REAR SPOILER DRIVER UP CIRCUIT 13 REAR SPOILER DRIVER DOWN CIRCUIT 16 REAR SPOILER LIMIT SWITCH FAILURE 19 REAR SPOILER MOTOR FAILURE 22 REAR SPOILER INOPERATIVE 26 REAR SPOILER VERIFICATION TEST 29 SCHEMATICS AND DIAGRAMS 30 CONVERTIBLE TOP 31 BODY ELECTRICAL DIAGNOST...

Page 3550: ...BODY CONTROL MODULE INTERNAL FAILURE 23 2 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3551: ...AMS Diagnostic Test 1 FUSED B CIRCUIT Turn the ignition off Disconnect the BCM C4 harness connector Note Check connectors Clean repair as necessary Measure the voltage of the Fused B circuit at the BCM C4 harness connector Is the voltage above 10 0 volts Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform REAR SPOI...

Page 3552: ...REAR SPOILER SWITCH SENSE CIRCUIT 23 4 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3553: ...POILER SWITCH BODY CONTROL MODULE For a complete Rear Spoiler Circuit Diagram Refer to 23 BODY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 REAR SPOILER SWITCH SENSE CIRCUIT SHORT TO B Turn the ignition off Disconnect the BCM C4 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Spoiler Switch Sense circuit at the BCM C4 harness conn...

Page 3554: ...AR SPOILER VERIFICATION TEST 3 REAR SPOILER SWITCH SENSE CIRCUIT SHORT TO GROUND With the ignition off Disconnect the Rear Spoiler Switch harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Rear Spoiler Switch Sense circuit at the BCM C4 harness connector Is the resistance below 100K ohms Yes Repair the Rear Spoiler Switch Sense circuit f...

Page 3555: ...REAR SPOILER LIMIT SWITCH SIGNAL UP CIRCUIT ZH BODY ELECTRICAL DIAGNOSTICS 23 7 ...

Page 3556: ...lete Rear Spoiler Circuit Diagram Refer to 23 BODY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 REAR SPOILER LIMIT SWITCH SIGNAL UP CIRCUIT SHORT TO B Turn the ignition off Disconnect the BCM harness connector Disconnect the Rear Spoiler Limit Switch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Spoiler Limit Switch Signal Up ci...

Page 3557: ...n open Perform REAR SPOILER VERIFICATION TEST 3 OPEN REAR SPOILER LIMIT SWITCH GROUND CIRCUIT With the ignition off Measure the resistance between ground and the Rear Spoiler Limit Switch Ground circuit at the Rear Spoiler Limit Switch harness con nector Is the resistance below 5 0 ohms Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIME...

Page 3558: ...REAR SPOILER LIMIT SWITCH SIGNAL DOWN CIRCUIT 23 10 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3559: ...omplete Rear Spoiler Circuit Diagram Refer to 23 BODY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 REAR SPOILER LIMIT SWITCH SIGNAL DOWN CIRCUIT SHORT TO B Turn the ignition off Disconnect the BCM harness connector Disconnect the Rear Spoiler Limit Switch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Spoiler Limit Switch Signal ...

Page 3560: ...r an open Perform REAR SPOILER VERIFICATION TEST 3 OPEN REAR SPOILER LIMIT SWITCH GROUND CIRCUIT With the ignition off Measure the resistance between ground and the Rear Spoiler Limit Switch Ground circuit at the Rear Spoiler Limit Switch harness con nector Is the resistance below 5 0 ohms Yes Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL T...

Page 3561: ...REAR SPOILER DRIVER UP CIRCUIT ZH BODY ELECTRICAL DIAGNOSTICS 23 13 ...

Page 3562: ...complete Rear Spoiler Circuit Diagram Refer to 23 BODY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 OPEN REAR SPOILER DRIVER UP CIRCUIT Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Rear Spoiler Motor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Rear Spoiler Driver Up circuit from the BCM C4 harness connector to the Rea...

Page 3563: ... Go to 3 3 REAR SPOILER DRIVER UP CIRCUIT SHORT TO GROUND Turn the ignition off Measure the resistance between ground and the Rear Spoiler Driver Up circuit at the Rear Spoiler Motor harness connector Is the resistance below 100k ohms Yes Repair the Rear Spoiler Driver Up circuit for a short to ground Perform REAR SPOILER VERIFICATION TEST No Replace the Body Control Module Refer to 8 ELECTRI CAL ...

Page 3564: ...REAR SPOILER DRIVER DOWN CIRCUIT 23 16 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3565: ... Disconnect the BCM C4 harness connector Disconnect the Rear Spoiler Motor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Rear Spoiler Driver Down circuit from the BCM C4 harness connector to the Rear Spoiler Motor harness connector Is the resistance below 5 0 ohms Yes Go to 2 No Repair the Rear Spoiler Driver Down circuit for an open Perform REAR S...

Page 3566: ...uit at the Rear Spoiler Motor harness connector Is the resistance below 100k ohms Yes Repair the Rear Spoiler Driver Down circuit for a short to ground Perform REAR SPOILER VERIFICATION TEST No Replace the Body Control Module Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform REAR SPOILER VERIFICATION TEST 23 18 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3567: ...REAR SPOILER LIMIT SWITCH FAILURE ZH BODY ELECTRICAL DIAGNOSTICS 23 19 ...

Page 3568: ... SPOILER LIMIT SWITCH SIGNAL UP CIRCUIT Turn the ignition off Disconnect the Rear Spoiler Limit Switch harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Spoiler Limit Switch Signal Up circuit at the Spoiler Limit Switch harness connector Is the voltage above 10 0 volts Yes Go to 2 No Go to 4 2 SPOILER LIMIT SWITCH SIGNAL DOWN CIRCUIT ...

Page 3569: ... ELECTRONIC CONTROL MODULES BODY CON TROL CENTRAL TIMER MODUL REMOVAL Perform REAR SPOILER VERIFICATION TEST 4 SPOILER LIMIT SWITCH SIGNAL UP CIRCUIT SHORT TO GROUND Turn the ignition off Disconnect the BCM C4 harness connector Measure the resistance between ground and the Spoiler Limit Switch Up circuit Is the resistance below 100k ohms Yes Repair the Spoiler Limit Switch Signal Up circuit for a ...

Page 3570: ...REAR SPOILER MOTOR FAILURE 23 22 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3571: ...CUIT OPEN REAR SPOILER MOTOR For a complete Rear Spoiler Circuit Diagram Refer to 23 BODY SCHEMATICS AND DIAGRAMS Diagnostic Test 1 OPEN REAR SPOILER DRIVER UP CIRCUIT Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Rear Spoiler Motor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Rear Spoiler Driver Up circuit from the ...

Page 3572: ...TO B Turn the ignition on Measure the voltage of the Rear Spoiler Driver Up circuit at the Rear Spoiler Motor harness connector Is the voltage above 1 0 volt Yes Repair the Rear Spoiler Driver Up circuit for a short to B Perform REAR SPOILER VERIFICATION TEST No Go to 4 4 REAR SPOILER DRIVER DOWN CIRCUIT SHORT TO B With the ignition on Measure the voltage of the Rear Spoiler Driver Down circuit at...

Page 3573: ...orm REAR SPOILER VERIFICATION TEST No Go to 6 6 REAR SPOILER DRIVER DOWN CIRCUIT SHORT TO GROUND With the ignition off Measure the resistance between ground and the Rear Spoiler Driver Down circuit at the Rear Spoiler Motor harness connector Is the resistance below 100k ohms Yes Repair the Rear Spoiler Driver Down circuit for a short to ground Perform REAR SPOILER VERIFICATION TEST No Replace the ...

Page 3574: ... REAR SPOILER INOPERATIVE 23 26 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3575: ...Measure the resistance between ground and the Rear Spoiler Switch Sense at the BCM C4 harness connector Is the resistance below 5 0 ohms Yes Go to 4 No Go to 2 2 OPEN REAR SPOILER SWITCH SENSE CIRCUIT With the ignition off Disconnect the Rear Spoiler Switch harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Rear Spoiler Switch Sense circuit from the BCM...

Page 3576: ...h Ground circuit for an open 4 REAR SPOILER SWITCH With the ignition off Press and hold the Rear Spoiler Switch in the direction to lower the Rear Spoiler Measure the resistance between ground and the Rear Spoiler Switch Sense at the BCM C4 harness connector Is the resistance between 190 0 210 0 ohms Yes Replace the Body Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES BODY CONTROL ...

Page 3577: ...er Switch to fully retract the spoiler Drive the vehicle at 89 km h 55 MPH and verify the spoiler operation With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If a DTC is present refer to the appropriate category and select the corresponding symptom Are any DTCs present YES Repair is not complete refer to appropriate symptom NO Repair is complete ZH...

Page 3578: ...SCHEMATICS AND DIAGRAMS 23 30 BODY ELECTRICAL DIAGNOSTICS ZH ...

Page 3579: ...TO B 97 9652 TONNEAU COVER CYLINDER TRAVEL SENSOR CIRCUIT SHORT TO B 99 9701 9702 THERMO PROTECTION ACTIVE 101 9710 RIGHT ROTATION RELAY CONTROL CIRCUIT SHORT TO GROUND 103 9711 RIGHT ROTATION RELAY CONTROL CIRCUIT OPEN SHORT TO B 104 9710 LEFT ROTATION RELAY CONTROL CIRCUIT SHORT TO GROUND 108 9721 LEFT ROTATION RELAY CONTROL CIRCUIT OPEN SHORT TO B 110 9810 HYDRAULIC SOLENOID S1 SUPPLY VOLTAGE C...

Page 3580: ...R TOP SWITCH ROOF OPEN CLOSE CIRCUIT SHORT TO B 193 9930 UNKNOWN TOP POSITION 195 9931 TOP POSITION UNKNOWN MAIN CYLINDER TRAVEL SENSORS ROD SIDE MAIN CYLINDER TRAVEL SENSORS BASE SIDE 197 9932 TOP POSITION UNKNOWN MAIN TRAVEL SENSORS BASE LATCH RETAINER SWITCH 199 9933 TOP POSITION UNKNOWN REAR BOW UP REAR BOW DOWN 201 9934 TOP POSITION UNKNOWN REAR BOW CYLINDER BASE SIDE REAR BOW SWITCH 203 9935...

Page 3581: ...9004 POWER TOP CONTROL MODULE PTCM EEPROM TIMING ZH CONVERTIBLE TOP 23 33 ...

Page 3582: ...not indicate a fatal error in the PTCM and should not be replaced The Power Top will work as designed with the DTC set With the DRBIIIT read and record the PTCM DTCs and then erase the PTCM DTCs Perform 3 ignition key cycles leaving the ignition key on for a mini mum of 90 seconds per cycle Erase this DTC from the PTCM after any other PTCM DTC s have been repaired PTCM Diagnostic Information compl...

Page 3583: ...9003 9004 POWER TOP CONTROL MODULE EEPROM ERROR ZH CONVERTIBLE TOP 23 35 ...

Page 3584: ...internal PTCM fault With the DRBIIIT read and record the PTCM DTCs and then erase the PTCM DTCs Perform 3 ignition key cycles leaving the ignition key on for a mini mum of 30 seconds per cycle With the DRBIIIT read the PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL...

Page 3585: ...9009 9010 POWER TOP CONTROL MODULE PTCM LOW VOLTAGE ZH CONVERTIBLE TOP 23 37 ...

Page 3586: ...Does the DRBIIIT display Battery Voltage above 10 0 volts Yes Go To 2 No Check and repair the Charging System Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Open Fused B Circuit Turn the ignition off Disconnect the PTCM C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Fused Ignition Switch Output circuit at the PTCM C1 harn...

Page 3587: ...9011 POWER TOP CONTROL MODULE PTCM OVER VOLTAGE ZH CONVERTIBLE TOP 23 39 ...

Page 3588: ...iagnostic Test 1 PTCM Turn the ignition off Disconnect the PTCM C1 harness connector Note Check connectors Clean repair as necessary Start the engine and allow the engine to idle Measure the voltage of the Fused B circuit at the PTCM C1 har ness connector Is the voltage above 16 0 volts Yes Check and repair the Charging System Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Replace the Powe...

Page 3589: ...9012 STOP MODE LONGER THAN 10 MINUTES ZH CONVERTIBLE TOP 23 41 ...

Page 3590: ...itting idle in a mid position for more than 9 minutes Turn the Ignition off and manually lower the Convertible Top into the cargo compartment so the Power Top Control Module can relearn the location of the top Erase this DTC from the PTCM after any other PTCM DTC s have been repaired PTCM Diagnostic Information complete Continue Test Complete 23 42 CONVERTIBLE TOP ZH ...

Page 3591: ...9076 NO COMMUNICATION WITH BODY CONTROL MODULE BCM ZH CONVERTIBLE TOP 23 43 ...

Page 3592: ...ors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the PTCM C1 harness connector to the BCM harness connector Is the resistance below 5 0 ohm Yes Go To 2 No Repair the PTCM CAN B Bus circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Open CAN B Bus circuit With the ignition off Measure the resistance of the CAN B Bus circuit from the PTCM C1 h...

Page 3593: ...9078 NO COMMUNICATION WITH CENTRAL LOCKING PUMP SECURITY SYSTEM MODULE CPL SSM ZH CONVERTIBLE TOP 23 45 ...

Page 3594: ...c Troubleshooting procedure before proceeding Diagnostic Test 1 Open CAN B Bus circuit Turn the ignition off Disconnect the Power Top Control Module PTCM C1 harness con nector Disconnect the Central Locking Pump Security System Module CLP SSM harness connector Note Check connectors Clean repair as necessary Measure the resistance of the CAN B Bus circuit from the PTCM C1 harness connector to the C...

Page 3595: ...arness connector to the CLP SSM harness connector Is the resistance below 5 0 ohm Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Repair the PTCM CAN B Bus circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST ZH CONVERTIBLE TOP 23 47 ...

Page 3596: ...9610 MAIN CYLINDER TRAVEL SENSOR ROD SIDE CIRCUITS OPEN SHORT TO GROUND 23 48 CONVERTIBLE TOP ZH ...

Page 3597: ...IT TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR POWER TOP CONTROL MODULE Always perform the Pre Diagnostic Troubleshooting procedure before proceeding Diagnostic Test 1 Monitor the Main Cylinder Travel Sensor Rod Side Turn the ignition on The Convertible Top must be up and locked With the DRB IIIT select Sensor Display and monitor the MN CYL TRVL SE...

Page 3598: ...el Sensor Rod Side circuit and the Main Cylinder Travel Sen sor Rod Side circuit With the jumper connected does the DRB IIIT display MN CYL TRVL SEN ROD above 100 Counts Yes Replace the Main Cylinder Travel Sensor Note Travel Sensors are replaced as a set of four Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 3 3 Main Cylinder Travel Sensor Rod Side circuit Remove the jumper wire Wit...

Page 3599: ...he Main Cylinder Travel Sensor Rod Side cir cuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Main Cylinder Travel Sensor Rod Side Circuit Shorted to Ground With the ignition off Measure the resistance between ground and the Main Cylinder Travel Sensor Rod Side circuit Is resistance below 100 komhs Yes Repair the Main Cylinder Travel Sensor Rod Side cir cuit for a short to gro...

Page 3600: ...E VERIFICA TION TEST No Go To 7 7 Main Cylinder Travel Sensor Rod Side Circuit Shorted to Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Measure the resistance between ground and the Main Cylinder Travel Sensor Rod Side circuit Is resistance below 100 komhs Yes Repair the Main Cylinder Travel Sensor Rod Side cir cuit for a short to ground Perform POWER TO...

Page 3601: ... connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform CONVERTIBLE TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC t...

Page 3602: ...9611 MAIN CYLINDER TRAVEL SENSOR ROD SIDE CIRCUIT SHORT TO B 23 54 CONVERTIBLE TOP ZH ...

Page 3603: ...N ROD Does the DRB IIIT display the MN CYL TRVL SEN ROD between 10 25 Counts Yes Go To 3 No Go To 2 2 Main Cylinder Travel Sensor Rod Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Main Cylinder ...

Page 3604: ...onnections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set is...

Page 3605: ...9612 MAIN CYLINDER TRAVEL SENSOR ROD SIDE CIRCUIT TO B ZH CONVERTIBLE TOP 23 57 ...

Page 3606: ...D Does the DRB IIIT display the MN CYL TRVL SEN ROD between 10 25 Counts Yes Go To 3 No Go To 2 2 Main Cylinder Travel Sensor Rod Side Circuit Short To B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Main Cylin...

Page 3607: ...ections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set is cu...

Page 3608: ...9620 MAIN CYLINDER TRAVEL SENSOR BASE SIDE CIRCUIT OPEN SHORT TO GROUND 23 60 CONVERTIBLE TOP ZH ...

Page 3609: ...IT TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR POWER TOP CONTROL MODULE Always perform the Pre Diagnostic Troubleshooting procedure before proceeding Diagnostic Test 1 Monitor the Main Cylinder Travel Sensor Base Side Turn the ignition on The Convertible Top must be up and locked With the DRB IIIT select Sensor Display and monitor the MN CYL TRVL S...

Page 3610: ...l Sensor Base Side circuit and the Main Cylinder Travel Sensor Base Side circuit With the jumper connected does the DRB IIIT display MN CYL TRVL SEN BSE above 100 Counts Yes Replace the Main Cylinder Travel Sensor Note Travel Sensors are replaced as a set of four Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 3 3 Main Cylinder Travel Sensor Base Side circuit Remove the jumper wire Wi...

Page 3611: ...e Main Cylinder Travel Sensor Base Side cir cuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Main Cylinder Travel Sensor Base Side Circuit Shorted to Ground With the ignition off Measure the resistance between ground and the Main Cylinder Travel Sensor Base Side circuit Is resistance below 100 kohms Yes Repair the Main Cylinder Travel Sensor Base Side cir cuit for a short to ...

Page 3612: ...LE VERIFICA TION TEST No Go To 7 7 Main Cylinder Travel Sensor Base Side Circuit Shorted to Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Measure the resistance between ground and the Main Cylinder Travel Sensor Base Side circuit Is resistance below 100 kohms Yes Repair the Main Cylinder Travel Sensor Base Side circuit for a short to ground Perform POWER...

Page 3613: ... connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform CONVERTIBLE TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC t...

Page 3614: ...9621 MAIN CYLINDER TRAVEL SENSOR BASE SIDE CIRCUIT SHORT TO B 23 66 CONVERTIBLE TOP ZH ...

Page 3615: ... SEN BAS Does the DRB IIIT display the MN CYL TRVL SEN BAS between 70 85 Counts Yes Go To 3 No Go To 2 2 Main Cylinder Travel Sensor Base Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Main Cylin...

Page 3616: ...onnections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set is...

Page 3617: ...9622 MAIN CYLINDER TRAVEL SENSOR BASE SIDE SHORT CIRCUIT TO B ZH CONVERTIBLE TOP 23 69 ...

Page 3618: ... TRVL SEN BSE Does the DRB IIIT display the MN CYL TRVL SEN BSE between 70 85 Counts Yes Go To 3 No Go To 2 2 Main Cylinder Travel Sensor Base Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Main ...

Page 3619: ...onnections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set is...

Page 3620: ...9630 REAR BOW TRAVEL SENSOR ROD SIDE CIRCUIT OPEN SHORT TO GROUND 23 72 CONVERTIBLE TOP ZH ...

Page 3621: ...CUIT TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR CIRCUIT SHORTED TO GROUND TRAVEL SENSOR POWER TOP CONTROL MODULE Always perform the Pre Diagnostic Troubleshooting procedure before proceeding Diagnostic Test 1 Monitor the Rear Bow Travel Sensor Rod Side Turn the ignition on The Convertible Top must be up and locked With the DRB IIIT select Sensor Display and monitor the RR BOW TRVL SEN R...

Page 3622: ...avel Sensor Rod Side circuit and the Rear Bow Travel Sensor Rod Side circuit With the Jumper connected does the DRB IIIT display the RR BOW TRVL SEN ROD above 100 Counts Yes Replace the Rear Bow Travel Sensor Note Travel Sensors are replaced as a set of four Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 3 3 Rear Bow Travel Sensor Rod Side circuit Remove jumper wire With the ignition...

Page 3623: ...pair the open Rear Bow Travel Sensor Rod Side circuit Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Rear Bow Travel Sensor Rod Side Circuit Shorted to Ground With the ignition off Measure the resistance between ground and the Rear Bow Travel Sensor Rod Side circuit Is resistance below 100 kohms Yes Repair the Rear Bow Travel Sensor Rod Side circuit for a short to ground Perform POWER TOP C...

Page 3624: ...POWER TOP CONTROL MODULE VERIFICA TION TEST No Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 8 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note ...

Page 3625: ...9631 REAR BOW TRAVEL SENSOR ROD SIDE CIRCUIT SHORT TO B ZH CONVERTIBLE TOP 23 77 ...

Page 3626: ... TRVL SEN ROD Does the DRB IIIT display the RR BOW TRVL SEN ROD between 10 25 Counts Yes Go To 3 No Go To 2 2 Rear Bow Travel Sensor Rod Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Bow Tr...

Page 3627: ...ections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set is cu...

Page 3628: ...9632 REAR BOW CYLINDER TRAVEL SENSOR ROD SIDE SHORT CIRCUIT TO B 23 80 CONVERTIBLE TOP ZH ...

Page 3629: ... TRVL SEN ROD Does the DRB IIIT display the RR BOW TRVL SEN ROD between 10 25 Counts Yes Go To 3 No Go To 2 2 Rear Bow Cylinder Travel Sensor Rod Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Re...

Page 3630: ... connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set ...

Page 3631: ...9640 REAR BOW TRAVEL SENSOR BASE SIDE CIRCUIT OPEN SHORT TO GROUND ZH CONVERTIBLE TOP 23 83 ...

Page 3632: ...ocked With the DRB IIIT select Sensor Display and monitor the RR BOW TRVL SEN Does the DRB IIIT display RR BOW TRVL SEN BAS between 70 85 Counts Yes Go To 8 No Go To 2 2 Rear Bow Travel Sensor Base Side Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT select Sensor Display and monit...

Page 3633: ...es Go To 4 No Go To 6 4 Open Rear Bow Travel Sensor Base Side Circuit Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Measure the resistance of the Rear Bow Travel Sensor Base Side circuit from the Power Top Travel Sensor harness connector to the Power Top Control Module C1 harness connector Is the resistance below 5 0 ohms Yes Go To 5 No Repair the Rear Bow Trav...

Page 3634: ... VERIFICA TION TEST No Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 6 Open Rear Bow Travel Sensor Base Side Circuit With the ignition on Measure the voltage of the Rear Bow Travel Sensor Base Side circuit by backprobing from the Power Top Control Module C1 harness connector...

Page 3635: ...TOP CONTROL MODULE VERIFICA TION TEST 8 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram sche...

Page 3636: ...9641 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE CIRCUIT SHORT TO B 23 88 CONVERTIBLE TOP ZH ...

Page 3637: ... TRVL SEN BSE Does the DRB IIIT display the RR BOW TRVL SEN BSE between 70 85 Counts Yes Go To 3 No Go To 2 2 Rear Bow Cylinder Travel Sensor Base Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the R...

Page 3638: ... connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set ...

Page 3639: ...9642 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE SHORT CIRCUIT TO B ZH CONVERTIBLE TOP 23 91 ...

Page 3640: ...RVL SEN BSE Does the DRB IIIT display the RR BOW TRVL SEN BSE between 70 85 Yes Go To 3 No Go To 2 2 Rear Bow Cylinder Travel Sensor Base Side Short to B Turn the ignition off Disconnect the Power Top Travel Sensor harness connector Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Rear Bow C...

Page 3641: ... connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to set ...

Page 3642: ...9650 TONNEAU COVER CYLINDER TRAVEL SENSOR CIRCUIT OPEN SHORT TO GROUND 23 94 CONVERTIBLE TOP ZH ...

Page 3643: ...VR TRL SEN ROD between 70 85 Counts Yes Go To 3 No Go To 2 2 Power Top Control Module Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors Clean repair as necessary Turn the ignition on With the DRB IIIT select Sensor Display and monitor the TON CVR TRL SEN ROD With a fused jumper wire momentarily connect the jumper between the Tonneau Cover Cyli...

Page 3644: ...nal connections can set DTCs Note Check for any Technical Service Bulletins that may apply Using the wiring diagram schematic as a guide inspect the wiring and connectors specific to this DTC Wiggle the wires while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform POWER TOP CONTROL MODULE VERIFICATION TEST No The condition that caused this DTC to s...

Page 3645: ...9651 TONNEAU COVER CYLINDER TRAVEL SENSOR CIRCUIT SHORT TO B ZH CONVERTIBLE TOP 23 97 ...

Page 3646: ... Short to B Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Tonneau Cover Cylinder Travel Sensor circuit at the Power Top Control Module C2 harness connector Is the voltage above 1 0 volt Yes Repair the Tonneau Cover Cylinder Travel Sensor cir cuit for a short to B Per...

Page 3647: ...9652 TONNEAU COVER CYLINDER TRAVEL SENSOR CIRCUIT SHORT TO B ZH CONVERTIBLE TOP 23 99 ...

Page 3648: ...Short to B Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Tonneau Cover Cylinder Travel Sensor circuit at the Power Top Control Module C2 harness connector Is the voltage above 1 0 volt Yes Repair the Tonneau Cover Cylinder Travel Sensor cir cuit for a short to B Perf...

Page 3649: ...9701 9702 THERMO PROTECTION ACTIVE ZH CONVERTIBLE TOP 23 101 ...

Page 3650: ...osed three times within a short period of time The PTCM will disable the Top operation to allow the hydraulic system to cool down Allow the Power Top system to cool off for 30 minutes before operat ing the Top again With the DRB IIIT erase this DTC from the PTCM after any other PTCM DTC s have been repaired PTCM Diagnostic Information complete Continue Test Complete 23 102 CONVERTIBLE TOP ZH ...

Page 3651: ...ower Top Control Module C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Right Rotation Relay Control circuit Is the resistance above 100 kohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 Ri...

Page 3652: ...9711 RIGHT ROTATION RELAY CONTROL CIRCUIT OPEN SHORT TO B 23 104 CONVERTIBLE TOP ZH ...

Page 3653: ...oting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both Right Left Relay Control Circuit Open Short to B DTCs set Yes Go To 6 No Go To 2 2 Right Rotation Relay Control Circuit For Short To B Turn the ignition off Disconnect the PTCM C2 harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measur...

Page 3654: ...ER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 4 4 Open Right Rotation Relay Control Circuit With the ignition off Disconnect the Right Rotation Relay harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Right Rotation Relay Control circuit from the Right Rotation Relay harness connector and the PTCM C2 har ness...

Page 3655: ...OP CONTROL MODULE VERIFICA TION TEST 6 Rotation Relay Ground Circuit Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Measure the resistance between the Rotation Relay Ground circuit and the Right Rotation Relay Control circuit at the Power Top Control Module C2 harness connector Is the resistance between 60 0 90 0 ohms Yes Replace the Power Top Control Module Ref...

Page 3656: ...9710 LEFT ROTATION RELAY CONTROL CIRCUIT SHORT TO GROUND 23 108 CONVERTIBLE TOP ZH ...

Page 3657: ...he Power Top Control Module C2 harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Left Rotation Relay Control circuit Is the resistance above 100k ohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2...

Page 3658: ...9721 LEFT ROTATION RELAY CONTROL CIRCUIT OPEN SHORT TO B 23 110 CONVERTIBLE TOP ZH ...

Page 3659: ... Diagnostic Troubleshooting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both Right Left Relay Control Circuit Open Short to B DTCs set Yes Go To 6 No Go To 2 2 Left Rotation Relay Control Circuit For Short To B Turn the ignition off Disconnect the PTCM C2 harness connector Note Check connectors Clean repair as necessary Turn t...

Page 3660: ... POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 4 4 Left Rotation Relay Control Circuit With the ignition off Disconnect the Left Rotation Relay harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Left Rotation Relay Control circuit from the Left Rotation Relay harness connector and the PTCM C2 harness conne...

Page 3661: ...P CONTROL MODULE VERIFICA TION TEST 6 Rotation Relay Ground Circuit Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Measure the resistance between the Rotation Relay Ground circuit and the Left Rotation Relay Control circuit at the Power Top Control Module C2 harness connector Is the resistance between 60 0 90 0 ohms Yes Replace the Power Top Control Module Refer...

Page 3662: ...9810 HYDRAULIC SOLENOID S1 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 23 114 CONVERTIBLE TOP ZH ...

Page 3663: ...nector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Hydraulic Solenoid S1 Supply Voltage circuit Is the resistance above 100 kohms Yes Go To 2 No Repair the Hydraulic Solenoid S1 Supply Voltage circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Hydraulic Solenoid S1 With the ignition off Reconnect the Hydraulic Solen...

Page 3664: ...9811 HYDRAULIC SOLENOID S1 SUPPLY VOLTAGE CIRCUIT OPEN SHORT TO B 23 116 CONVERTIBLE TOP ZH ...

Page 3665: ...nostic Troubleshooting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both Hydraulic Solenoid S1 S2 Supply Circuit Open Short to B DTCs set Yes Go To 6 No Go To 2 2 Hydraulic Solenoid S1 Supply Voltage circuit For Short To B Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors C...

Page 3666: ...ONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 4 4 Open Hydraulic Solenoid S1 Supply Voltage circuit With the ignition off Disconnect the Hydraulic Solenoid S1 harness connector Measure the resistance of the Hydraulic Solenoid S1 Supply Voltage circuit from the Power Top Control Module C2 harness connector to the Hydraulic Solenoi...

Page 3667: ...L MODULE VERIFICA TION TEST No Repair the Hydraulic Solenoid S1 S2 Ground circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 6 PTCM Turn the ignition off Measure the resistance between ground and the Hydraulic Solenoid S1 S2 Ground circuit by backprobing from the Power Top Control Mod ule C2 harness connector Is the resistance below 5 0 ohms Yes Repair the Hydraulic Solenoid S...

Page 3668: ...9820 HYDRAULIC SOLENOID S2 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 23 120 CONVERTIBLE TOP ZH ...

Page 3669: ...nector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Hydraulic Solenoid S2 Supply Voltage circuit Is the resistance above 100 kohms Yes Go To 2 No Repair the Hydraulic Solenoid S2 Supply Voltage circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Hydraulic Solenoid S2 With the ignition off Reconnect the Hydraulic Solen...

Page 3670: ...9821 HYDRAULIC SOLENOID S2 SUPPLY VOLTAGE CIRCUIT OPEN SHORT TO B 23 122 CONVERTIBLE TOP ZH ...

Page 3671: ...ostic Troubleshooting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both Hydraulic Solenoid S1 S2 Supply Circuit Open Short to B DTCs set Yes Go To 6 No Go To 2 2 Hydraulic Solenoid S2 Supply Voltage circuit For Short To B Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors Cl...

Page 3672: ...ONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 4 4 Open Hydraulic Solenoid S1 Supply Voltage circuit With the ignition off Disconnect the Hydraulic Solenoid S2 harness connector Measure the resistance of the Hydraulic Solenoid S2 Supply Voltage circuit from the Power Top Control Module C2 harness connector to the Hydraulic Solenoi...

Page 3673: ...TROL MODULE VERIFICA TION TEST No Repair the Hydraulic Solenoid S1 S2 Ground circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 6 PTCM Turn the ignition off Measure the resistance between ground and the Hydraulic Solenoid S1 S2 Ground circuit by backprobing the Power Top Control Module C2 harness connector Is the resistance below 5 0 ohms Yes Repair the Hydraulic Solenoid S1 S...

Page 3674: ...9830 HYDRAULIC SOLENOID S3 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 23 126 CONVERTIBLE TOP ZH ...

Page 3675: ...ote Check connectors Clean repair as necessary Measure the resistance between ground and the Hydraulic Solenoid S3 Supply Voltage circuit Is the resistance above 100 kohms Yes Go To 2 No Repair the Hydraulic Solenoid S3 Supply Voltage circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Hydraulic Solenoid S3 With the ignition off Reconnect the Hydraulic Solenoid S3 h...

Page 3676: ...9831 HYDRAULIC SOLENOID S3 SUPPLY VOLTAGE CIRCUIT OPEN SHORT TO B 23 128 CONVERTIBLE TOP ZH ...

Page 3677: ...nostic Troubleshooting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both Hydraulic Solenoid S3 S4 Supply Circuit Open Short to B DTCs set Yes Go To 6 No Go To 2 2 Hydraulic Solenoid S3 Supply Voltage circuit For Short To B Turn the ignition off Disconnect the Power Top Control Module C2 harness connector Note Check connectors C...

Page 3678: ...ONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 4 4 Open Hydraulic Solenoid S3 Supply Voltage circuit With the ignition off Disconnect the Hydraulic Solenoid S3 harness connector Measure the resistance of the Hydraulic Solenoid S3 Supply Voltage circuit from the Power Top Control Module C2 harness connector to the Hydraulic Solenoi...

Page 3679: ...TROL MODULE VERIFICA TION TEST No Repair the Hydraulic Solenoid S3 S4 Ground circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 6 PTCM Turn the ignition off Measure the resistance between ground and the Hydraulic Solenoid S3 S4 Ground circuit by backprobing the Power Top Control Module C2 harness connector Is the resistance below 5 0 ohms Yes Repair the Hydraulic Solenoid S3 S...

Page 3680: ...9840 HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 23 132 CONVERTIBLE TOP ZH ...

Page 3681: ...tor Note Check connectors Clean repair as necessary Measure the resistance between ground and the Hydraulic Solenoid S4 Supply Voltage circuit Is the resistance above 100 kohms Yes Go To 2 No Repair the Hydraulic Solenoid S4 Supply Voltage circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 2 Hydraulic Solenoid S4 With the ignition off Reconnect the Power Top Control ...

Page 3682: ...9841 HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT OPEN SHORT TO B 23 134 CONVERTIBLE TOP ZH ...

Page 3683: ...circuit Possible Causes POWER TOP HYDRAULIC ASSEMBLY OPEN HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT SHORT TO B OPEN HYDRAULIC SOLENOID S3 S4 GROUND CIRCUIT POWER TOP CONTROL MODULE Always perform the Pre Diagnostic Troubleshooting procedure before proceeding Diagnostic Test 1 Read DTCs Turn the ignition on With the DRBIIIT read Current DTCs Are both ...

Page 3684: ...low 1 0 volts Yes Go To 3 No Repair the Hydraulic Solenoid S4 Supply Voltage circuit for a short to B Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 3 Hydraulic Solenoid S4 With the ignition off Measure the resistance between the Hydraulic Solenoid S4 Supply Voltage circuit and the Hydraulic Solenoid S3 S4 Ground circuit from the Power Top Control Module C2 harness connector Is the resistance...

Page 3685: ... Supply Voltage circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Open Hydraulic Solenoid S3 S4 Ground circuit With the ignition off Measure the resistance of the Hydraulic Solenoid S3 S4 Ground circuit from the Power Top Control Module C2 harness connector to the Hydraulic Solenoid S4 harness connector Is the resistance below 5 0 ohms Yes Replace the Power Top Hydraulic As...

Page 3686: ...ng the Power Top Control Module C2 harness connector Is the resistance below 5 0 ohms Yes Repair the Hydraulic Solenoid S3 S4 Ground circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 23 138 CONVERTIBLE TO...

Page 3687: ...9860 TRUNK LATCH ACTUATOR UNLOCK CONTROL CIRCUIT SHORT TO GROUND ZH CONVERTIBLE TOP 23 139 ...

Page 3688: ...before proceeding Diagnostic Test 1 Trunk Latch Assembly Turn the ignition off Disconnect the Trunk Latch Assembly C2 harness connector Note Check connectors Clean repair as necessary Using a 12 volt test light connected to between the Trunk Latch Actua tor Lock Control circuit and the Trunk Latch Actuator Unlock Control circuit at the Trunk Latch Assembly C2 harness connector With the DRB IIIT se...

Page 3689: ...ecessary Measure the resistance between ground and the Trunk Latch Actuator Unlock Control circuit Is the resistance below 100 kohms Yes Repair the Trunk Latch Actuator Unlock Control circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWE...

Page 3690: ...9861 TRUNK LATCH ACTUATOR UNLOCK CONTROL CIRCUIT SHORT TO B 23 142 CONVERTIBLE TOP ZH ...

Page 3691: ...Troubleshooting procedure before proceeding Diagnostic Test 1 Trunk Latch Assembly Turn the ignition off Disconnect the Trunk Latch Assembly C2 harness connector Note Check connectors Clean repair as necessary Using a 12 volt test light connected to between the Trunk Latch Actua tor Lock Control circuit and the Trunk Latch Actuator Unlock Control circuit at the Trunk Latch Assembly C2 harness conn...

Page 3692: ...Unlock Control circuit for a short to B Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 3 3 Trunk Latch Actuator Turn the ignition off Reconnect the Trunk Latch Assembly C2 harness connector Measure the resistance between the Trunk Latch Actuator Unlock Con trol circuit and the Trunk Latch Actuator Lock Control circuit from the Power Top Control Module C1 harness connector Is the resi...

Page 3693: ...the Trunk Latch Actuator Lock Control circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Open Trunk Latch Actuator Unlock Control Circuit With the ignition off Measure the resistance of the Trunk Latch Actuator Unlock Control cir cuit from the Trunk Latch Assembly C2 harness connector to the Power Top Control Module C1 harness connector Is the resistance below 5 0 ohms Yes R...

Page 3694: ...9870 TRUNK LATCH ACTUATOR LOCK CONTROL CIRCUIT SHORT TO GROUND 23 146 CONVERTIBLE TOP ZH ...

Page 3695: ...efore proceeding Diagnostic Test 1 Trunk Latch Assembly Turn the ignition on Disconnect the Trunk Latch Assembly C2 harness connector Note Check connectors Clean repair as necessary Using a 12 volt test light connected to between the Trunk Latch Actua tor Lock Control circuit and the Trunk Latch Actuator Unlock Control circuit at the Trunk Latch Assembly C2 harness connector With the DRB IIIT sele...

Page 3696: ...ecessary Measure the resistance between ground and the Trunk Latch Actuator Lock Control circuit Is the resistance below 100 kohms Yes Repair the Trunk Latch Actuator Lock Control circuit for a short to ground Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TO...

Page 3697: ...9871 TRUNK LATCH ACTUATOR LOCK CONTROL CIRCUIT SHORT TO B ZH CONVERTIBLE TOP 23 149 ...

Page 3698: ...roubleshooting procedure before proceeding Diagnostic Test 1 Trunk Latch Assembly Turn the ignition off Disconnect the Trunk Latch Assembly C2 harness connector Note Check connectors Clean repair as necessary Using a 12 volt test light connected to between the Trunk Latch Actua tor Lock Control circuit and the Trunk Latch Actuator Unlock Control circuit at the Trunk Latch Assembly C2 harness conne...

Page 3699: ...ck Control circuit for a short to B Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 3 3 Trunk Latch Actuator Turn the ignition off Reconnect the Trunk Latch Assembly C2 harness connector Measure the resistance between the Trunk Latch Actuator Unlock Con trol circuit and the Trunk Latch Actuator Lock Control circuit from the Power Top Control Module C1 harness connector Is the resistan...

Page 3700: ...he Trunk Latch Actuator Lock Control circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 5 Open Trunk Latch Actuator Unlock Control Circuit With the ignition off Measure the resistance of the Trunk Latch Actuator Unlock Control cir cuit from the Trunk Latch Assembly C2 harness connector to the Power Top Control Module C1 harness connector Is the resistance below 5 0 ohms Yes Re...

Page 3701: ...9901 MAIN CYLINDER TRAVEL SENSOR ROD SIDE INOPERATIVE ZH CONVERTIBLE TOP 23 153 ...

Page 3702: ...p Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermitten...

Page 3703: ...9902 MAIN CYLINDER TRAVEL SENSOR ROD SIDE STUCK ZH CONVERTIBLE TOP 23 155 ...

Page 3704: ...ower Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible inte...

Page 3705: ...9903 MAIN CYLINDER TRAVEL SENSOR BASE SIDE INOPERATIVE ZH CONVERTIBLE TOP 23 157 ...

Page 3706: ...Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermitt...

Page 3707: ...9904 MAIN CYLINDER TRAVEL SENSOR BASE SIDE STUCK ZH CONVERTIBLE TOP 23 159 ...

Page 3708: ...Power Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible int...

Page 3709: ...9905 REAR BOW CYLINDER TRAVEL SENSOR ROD SIDE INOPERATIVE ZH CONVERTIBLE TOP 23 161 ...

Page 3710: ...wer Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible inter...

Page 3711: ...9906 REAR BOW CYLINDER TRAVEL SENSOR ROD SIDE STUCK ZH CONVERTIBLE TOP 23 163 ...

Page 3712: ... read the Power Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a po...

Page 3713: ...9907 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE INOPERATIVE ZH CONVERTIBLE TOP 23 165 ...

Page 3714: ...ower Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible inte...

Page 3715: ...9908 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE STUCK ZH CONVERTIBLE TOP 23 167 ...

Page 3716: ... read the Power Top Control Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a po...

Page 3717: ...9909 REAR BOW SWITCH SENSE CIRCUIT OPEN ZH CONVERTIBLE TOP 23 169 ...

Page 3718: ...r Switch Open DTCs set Yes Check and repair the Switches common ground circuit for a loose damaged or corroded ground circuit Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Rear Bow Switch Turn the ignition off Disconnect the Rear Bow Switch harness connector Note Check connectors Clean repair as necessary Connect a fused jumper wire between the Rear Bow Switch Sense cir cuit and...

Page 3719: ...e below 5 0 ohms Yes Go To 4 No Repair the Rear Bow Switch Sense circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 4 Open Rear Bow Switch Ground circuit With the ignition off Measure the resistance between ground and the Rear Bow Switch ground circuit Is the resistance below 5 0 ohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW...

Page 3720: ...9910 REAR BOW SWITCH SENSE CIRCUIT SHORT TO GROUND 23 172 CONVERTIBLE TOP ZH ...

Page 3721: ...utput Display and monitor the REAR BOW SW SENSE Does the REAR BOW SW SENSE read UNLOCKED Yes Replace the Rear Bow Switch Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Rear Bow Switch Sense Circuit Shorted To Ground Turn the ignition off Disconnect the Power Top Control Module PTCM C1 harness con nector Note Check connectors Clean repair as necessary Measure the resistance betwee...

Page 3722: ...9911 9912 TONNEAU COVER SWITCH SENSE CIRCUIT OPEN 23 174 CONVERTIBLE TOP ZH ...

Page 3723: ...r Switch Open DTCs set Yes Check and repair the Switches common ground circuit for a loose damaged or corroded ground circuit Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Tonneau Cover Switch Turn the ignition off Disconnect the Tonneau Cover Switch harness connector Note Check connectors Clean repair as necessary Connect a fused jumper wire between the Tonneau Cover Switch sen...

Page 3724: ...ance below 5 0 ohms Yes Go To 4 No Repair the Tonneau Cover Switch Sense circuit for an open Perform POWER TOP CONTROL MODULE VERIFICA TION TEST 4 Open Tonneau Cover Switch Ground circuit With the ignition off Measure the resistance between ground and the Tonneau Cover Switch ground circuit Is the resistance below 5 0 ohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC C...

Page 3725: ...9913_9914 TONNEAU COVER SWITCH SENSE CIRCUIT SHORT TO GROUND ZH CONVERTIBLE TOP 23 177 ...

Page 3726: ... select Input Output Display and monitor the TON COVER SW SENSE Does the DRBIIIT display TON COVER SW SENSE UNLOCKED Yes Replace the Tonneau Cover Switch Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Tonneau Cover Switch Sense Circuit Shorted To Ground Turn the ignition off Disconnect the Power Top Control Module PTCM C1 harness con nector Note Check connectors Clean repair as n...

Page 3727: ...9915 TRUNK LATCH LOCKED SIGNAL CIRCUIT OPEN ZH CONVERTIBLE TOP 23 179 ...

Page 3728: ...s set Yes Check the Trunk Latch Assembly ground circuit for a loose damaged or corroded ground circuit If the ground circuit is OK replace the Trunk Latch Assembly Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Trunk Latch Assembly Turn the ignition off Disconnect the Trunk Latch Assembly C1 harness connector Note Check connectors Clean repair as necessary Connect a fused jumper ...

Page 3729: ...ocked signal circuit from the Trunk Latch Assembly C1 harness connector to the Power Top Control Module C1 harness connector Is the resistance below 5 0 ohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Repair the Trunk Latch Locked circuit for an open Perform POWER ...

Page 3730: ...9916 TRUNK LATCH LOCKED SIGNAL CIRCUIT STUCK OR SHORT TO GROUND 23 182 CONVERTIBLE TOP ZH ...

Page 3731: ... the DRB IIIT select Input Output Display and monitor the TRUNK LTCH LOCK SW Does the DRBIIIT display TRUNK LTCH LOCK SW NOT ACTIVE Yes Replace the Trunk Latch Assembly Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Trunk Latch Locked Signal Circuit For Short to Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean r...

Page 3732: ...9917 TRUNK LATCH UNLOCKED SIGNAL CIRCUIT OPEN 23 184 CONVERTIBLE TOP ZH ...

Page 3733: ...s set Yes Check the Trunk Latch Assembly ground circuit for a loose damaged or corroded ground circuit If the ground circuit is OK replace the Trunk Latch Assembly Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Trunk Latch Assembly Turn the ignition off Disconnect the Trunk Latch Assembly C1 harness connector Note Check connectors Clean repair as necessary Connect a fused jumper ...

Page 3734: ...nlocked signal circuit from the Trunk Latch Assembly C1 harness connector to the Power Top Control Module C1 harness connector Is the resistance below 5 0 ohms Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Repair the Trunk Latch Unlocked circuit for an open Perform PO...

Page 3735: ...9918 TRUNK LATCH UNLOCKED SIGNAL CIRCUIT SHORT TO GROUND ZH CONVERTIBLE TOP 23 187 ...

Page 3736: ...DRB IIIT select Input Output Display and monitor the TRUNK LTCH UNLCK SW Does the DRBIIIT display TRUNK LTCH UNLCK SW UNLOCKED Yes Replace the Trunk Latch Assembly Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Trunk Latch Unlocked Signal Circuit for Short to Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repa...

Page 3737: ...9919 POWER TOP SWITCH OPEN CIRCUIT SHORT TO GROUND ZH CONVERTIBLE TOP 23 189 ...

Page 3738: ...Output Display and monitor the POWER TOP SW OPEN Does the DRBIIIT display POWER TOP SW OPEN NOT ACTIVE Yes Replace the Power Top Switch Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Power Top Switch Open Circuit For Short To Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Measure the resist...

Page 3739: ...9920 POWER TOP SWITCH CLOSE CIRCUIT SHORT TO GROUND ZH CONVERTIBLE TOP 23 191 ...

Page 3740: ...put Output Display and monitor the POWER TOP SW CLOSE Does the DRBIIIT display POWER TOP SW CLOSE NOT ACTIVE Yes Replace the Power Top Switch Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Power Top Switch Close Circuit for Short to Ground Turn the ignition off Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary Measure the...

Page 3741: ...9921 POWER TOP SWITCH ROOF OPEN CLOSE CIRCUIT SHORT TO B ZH CONVERTIBLE TOP 23 193 ...

Page 3742: ...h Signal circuit and the Power Top Switch Indicator Driver circuit from the Power Top Switch connector Is the resistance below 5 0 ohms Yes Replace the Power Top Switch Perform POWER TOP CONTROL MODULE VERIFICA TION TEST No Go To 2 2 Power Top Switch Circuit Short To B With the ignition off Disconnect the Power Top Control Module C1 harness connector Note Check connectors Clean repair as necessary...

Page 3743: ...9930 UNKNOWN TOP POSITION ZH CONVERTIBLE TOP 23 195 ...

Page 3744: ...wer Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors Clean repair as necessary Poor pin...

Page 3745: ...9931 TOP POSITION UNKNOWN MAIN CYLINDER TRAVEL SENSORS ROD SIDE MAIN CYLINDER TRAVEL SENSORS BASE SIDE ZH CONVERTIBLE TOP 23 197 ...

Page 3746: ...ule PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition N...

Page 3747: ...9932 TOP POSITION UNKNOWN MAIN TRAVEL SENSORS BASE LATCH RETAINER SWITCH ZH CONVERTIBLE TOP 23 199 ...

Page 3748: ...TCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check ...

Page 3749: ...9933 TOP POSITION UNKNOWN REAR BOW UP REAR BOW DOWN ZH CONVERTIBLE TOP 23 201 ...

Page 3750: ...s DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check connectors ...

Page 3751: ...9934 TOP POSITION UNKNOWN REAR BOW CYLINDER BASE SIDE REAR BOW SWITCH ZH CONVERTIBLE TOP 23 203 ...

Page 3752: ...DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note Check...

Page 3753: ...9935 TOP POSITION UNKNOWN TONNEAU COVER LATCHED TONNEAU COVER TRAVEL SENSOR ZH CONVERTIBLE TOP 23 205 ...

Page 3754: ...TCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note C...

Page 3755: ...9936 TOP POSITION UNKNOWN TRUNK LATCH UNLOCK SIGNAL TRUNK LATCH LOCK SIGNAL ZH CONVERTIBLE TOP 23 207 ...

Page 3756: ...e PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Not...

Page 3757: ...9937 TOP POSITION UNKNOWN REAR BOW SWITCH LATCHED MAIN CYLINDER TRAVEL SENSOR BASE SIDE ZH CONVERTIBLE TOP 23 209 ...

Page 3758: ...l Module PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condit...

Page 3759: ...9938 TOP POSITION UNKNOWN REAR BOW SWITCH LATCHED TONNEAU COVER TRAVEL SENSOR ZH CONVERTIBLE TOP 23 211 ...

Page 3760: ...PTCM DTCs Did this DTC set again Yes Replace the Power Top Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWER TOP CONTROL MODULE REMOVAL Perform POWER TOP CONTROL MODULE VERIFICATION TEST No Go To 2 2 INTERMITTENT WIRING AND CONNECTORS The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Note ...

Page 3761: ...he Power Top completely Operate the Power Top Switch to raise the Power Top completely With the DRB IIIT confirm that no DTCs are present and that all components are functioning properly If a DTC is present refer to the appropriate category and select the corresponding DTC Are any DTCs present YES Repair is not complete refer to appropriate DTC NO Repair is complete ZH CONVERTIBLE TOP 23 213 ...

Page 3762: ...ere conditions can cause premature seal wear and excessive closing or latching effort After completing a repair water test vehicle to verify leak has stopped before returning vehicle to use VISUAL INSPECTION BEFORE WATER LEAK TESTS Verify that floor and body plugs are in place body drains are clear and body components are properly aligned and sealed If component alignment or sealing is necessary r...

Page 3763: ...age to the blower With interior pressurized apply dish detergent solution to suspected leak area on the exterior of the vehicle Apply detergent solution with spray device or soft bristle brush If soap bubbles occur at a body seam joint seal or gasket the leak entry point could be at that location WIND NOISE Wind noise is the result of most air leaks Air leaks can be caused by poor sealing improper...

Page 3764: ...n After lubrication any excess lubricant should be removed 4 The hood latch latch release mechanism latch striker and safety latch should be lubricated periodically 5 The door lock cylinders should be lubricated twice each year preferably autumn and spring a Spray a small amount of lock cylinder lubricant directly into the lock cylinder b Apply a small amount to the key and insert it into the lock...

Page 3765: ...rpose Grease NLGI GC LB 2 EP 2 Liftgate Hinge As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Liftgate Support Arms As Required Engine Oil Liftgate Latches As Required White Spray Lubricant 3 Liftgate Release Handle Pivot and Slide Contact Surfaces As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Window System Components As Required White Spray Lubricant 3 Lock Cylinders Twice a Year Lock Cyl...

Page 3766: ...inge to Liftgate 25 18 221 Liftgate Latch to Liftgate 8 6 71 Liftgate Striker to Frame 10 7 88 Power Window Motor to Door 13 10 115 Liftgate Release Handle Retaining Bolt 8 6 71 Liftgate Latch Assembly to Liftgate 8 6 71 Rear Cross Strut to Frame 60 44 531 Seat Adjustment Motor 4 3 35 Seat Height Adjustment to Frame 24 18 212 Seat Rail to Seat 50 37 443 Seat Track to Floor 50 37 443 Seatback to Fr...

Page 3767: ...SPECIAL TOOLS 9108 ASSEMBLY AID ZH BODY SERVICE INFORMATION 23 219 ...

Page 3768: ...30 INSTALLATION 232 TRIM PANEL REMOVAL REMOVAL COUPE 234 REMOVAL ROADSTER 236 INSTALLATION INSTALLATION COUPE 236 INSTALLATION ROADSTER 238 BUMPER REMOVAL 238 INSTALLATION 238 DECKLID REMOVAL 239 INSTALLATION 240 EXTERIOR HANDLE REMOVAL 1 Disconnect the negative battery cable 2 Remove the rear liftgate trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 3 Disconnect the ...

Page 3769: ...en rear latch support bracket retaining nuts and bolts 1 5 Remove the bracket from vehicle 6 Remove the four rear latch retaining bolts 1 and remove the latch assembly from the rear liftgate ZH DECKLID LIFTGATE 23 221 ...

Page 3770: ...ctor 1 and the harness connector 2 from the rear latch assembly DISASSEMBLY 1 Disconnect the rear liftgate release handle linkage by pushing the arm 1 up off the linkage and then pulling the linkage out of the latch 23 222 DECKLID LIFTGATE ZH ...

Page 3771: ...olt 1 and remove the handle assembly from the latch assem bly bracket INSTALLATION ASSEMBLY 1 Install the liftgate release handle assembly on the latch bracket Install the retaining bolt 1 Tighten to 8 N m 71 in lbs ZH DECKLID LIFTGATE 23 223 ...

Page 3772: ...2 Connect the rear liftgate release handle linkage 1 INSTALLATION 1 Connect the pneumatic harness connector 2 and the harness connector 1 to the rear latch assembly 23 224 DECKLID LIFTGATE ZH ...

Page 3773: ...ly into the rear liftgate Install the retaining bolts 1 Tighten to 8 N m 71 in lbs 3 Install the rear latch assembly bracket and then install the seven retaining nuts and bolts 1 Tighten to 8 N m 71 in lbs ZH DECKLID LIFTGATE 23 225 ...

Page 3774: ...D HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 6 Connect the negative battery cable GAS PROP REMOVAL 1 Open the rear liftgate 2 Support the liftgate with a suitable propping device 3 Remove the gas prop lock cap 1 on the upper end Then pull the gas prop 2 off of its mounting point 23 226 DECKLID LIFTGATE ZH ...

Page 3775: ...lower end Then pull the gas prop 2 off of its mounting point INSTALLATION 1 Place the gas prop on its upper and lower mount ing points and push it in until it clicks 2 Install the upper lock cap 1 on the gas prop 2 ZH DECKLID LIFTGATE 23 227 ...

Page 3776: ...fy the rear liftgate operation HINGE REMOVAL 1 Remove the liftgate Refer to 23 BODY DECK LID HATCH LIFTGATE TAILGATE LIFTGATE REMOVAL 2 Remove the remaining two bolts 1 from the hinges and then remove the hinges from the liftgate 23 228 DECKLID LIFTGATE ZH ...

Page 3777: ...LIFTGATE INSTALLATION LATCH REMOVAL 1 For removal of the latch Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE EXTERIOR HANDLE REMOVAL INSTALLATION For installation of the latch Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE EXTERIOR HANDLE INSTALLATION LATCH STRIKER REMOVAL 1 Remove the trunk rear trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 2 Remove the bolts...

Page 3778: ...ls an upper and a lower Both trim panels must be removed to access the liftgate s harness connectors Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 3 Disconnect the following harness connections Right and left defroster harness connections Right and left license plate lamp harness con nections Ground lug G302 Antenna amplifier harness connector Rear liftgate lock switch Pneuma...

Page 3779: ...e Then pull the harness through the access hole 5 Remove the headliner Refer to 23 BODY INTE RIOR HEADLINER REMOVAL 6 Using a suitable propping device prop the liftgate up and remove the gas prop 2 from its mount point 1 ZH DECKLID LIFTGATE 23 231 ...

Page 3780: ...leaving the hinge bolts 1 attached to the liftgate 8 Carefully lift the liftgate off the body and then set it down on a clean dry surface INSTALLATION 1 Have a helper lift the liftgate and install the two bolts 1 for each hinge from inside the roof panel Tighten to 25 N m 18 ft lbs 23 232 DECKLID LIFTGATE ZH ...

Page 3781: ...nections Right and left defroster harness connections Right and left license plate lamp harness con nections Ground lug G302 Antenna amplifier harness connector Rear liftgate lock switch Pneumatic lock air line Center High Mounted Stop Lamp CHMSL har ness connector Rear spoiler limit switch and motor harness connectors 4 Install the rubber grommet 1 to the liftgate ZH DECKLID LIFTGATE 23 233 ...

Page 3782: ...Y DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 6 Align the liftgate Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS TRIM PANEL REMOVAL REMOVAL COUPE LOWER LIFTGATE TRIM PANEL 1 Remove the handle trim screw 1 23 234 DECKLID LIFTGATE ZH ...

Page 3783: ...PPER LIFTGATE TRIM PANEL 1 Remove the lower trim panel Refer to Lower Lift gate Trim Panel 2 Remove the two screws 1 attaching the upper lift gate trim panel 2 to the liftgate 3 Pull down on the upper liftgate trim panel 2 to release it from the liftgate ZH DECKLID LIFTGATE 23 235 ...

Page 3784: ...im panel 1 INSTALLATION INSTALLATION COUPE UPPER LIFTGATE TRIM PANEL 1 Push up on the upper liftgate trim panel 2 to attach it to the liftgate 2 Install the two screws 1 attaching the upper lift gate trim panel 2 to the liftgate 3 Install the lower trim panel Refer to Lower Liftgate Trim Panel 23 236 DECKLID LIFTGATE ZH ...

Page 3785: ...LOWER LIFTGATE TRIM PANEL 1 Push on the lower liftgate trim panel 1 to attach the retainers to the liftgate 2 Install the handle trim screw 1 ZH DECKLID LIFTGATE 23 237 ...

Page 3786: ... REMOVAL 1 Open the liftgate 2 Remove the bolt 1 attaching the bumper to the liftgate INSTALLATION 1 Position the bumper then install the bolt attaching the bumper to the liftgate Do not tighten the bolt at this time 2 Close the liftgate and align it with the quarter panels Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 3 Tighten the liftgate bumper bolt 23 238 DECKLID LIFTGATE ZH ...

Page 3787: ...ect the wiring harness connector 2 attached to the decklid CAUTION To avoid paint damage have an assis tant help while removing the decklid bolts 3 Remove the right side decklid retaining bolts 1 CAUTION To avoid paint damage have an assis tant help while removing the decklid bolts 4 Remove the left side decklid retaining bolts 1 5 With the aid of an assistant remove the decklid from the vehicle S...

Page 3788: ...ant position the decklid on the vehicle 2 Loosely install the two right side decklid retaining bolts 3 Align the decklid with the previously outlined wit ness marks 4 Connect the wiring harness connector 2 to the decklid 5 Loosely install the two left side decklid retaining bolts 6 Verify fit of decklid to vehicle body Adjust as nec essary 7 Tighten decklid retaining bolts to 23 N m 203 in lbs 23 ...

Page 3789: ...ODY GAP MEASUREMENTS 242 OPENING DIMENSIONS SPECIFICATIONS BODY DIMENSIONS 244 SEALER LOCATIONS SPECIFICATIONS SEALER LOCATIONS 247 WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS 264 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVES 277 ZH BODY STRUCTURE 23 241 ...

Page 3790: ...GAP AND FLUSH SPECIFICATIONS BODY GAP MEASUREMENTS FRONT AND SIDE GAP DIMENSIONS 23 242 BODY STRUCTURE ZH ...

Page 3791: ...REAR AND SIDE GAP AND FLUSH DIMENSIONS ZH BODY STRUCTURE 23 243 ...

Page 3792: ...OPENING DIMENSIONS SPECIFICATIONS BODY DIMENSIONS 23 244 BODY STRUCTURE ZH ...

Page 3793: ...ZH BODY STRUCTURE 23 245 ...

Page 3794: ...23 246 BODY STRUCTURE ZH ...

Page 3795: ...SEALER LOCATIONS SPECIFICATIONS SEALER LOCATIONS ZH BODY STRUCTURE 23 247 ...

Page 3796: ...23 248 BODY STRUCTURE ZH ...

Page 3797: ...ZH BODY STRUCTURE 23 249 ...

Page 3798: ...23 250 BODY STRUCTURE ZH ...

Page 3799: ...ZH BODY STRUCTURE 23 251 ...

Page 3800: ...23 252 BODY STRUCTURE ZH ...

Page 3801: ...ZH BODY STRUCTURE 23 253 ...

Page 3802: ...23 254 BODY STRUCTURE ZH ...

Page 3803: ...ZH BODY STRUCTURE 23 255 ...

Page 3804: ...23 256 BODY STRUCTURE ZH ...

Page 3805: ...ZH BODY STRUCTURE 23 257 ...

Page 3806: ...23 258 BODY STRUCTURE ZH ...

Page 3807: ...ZH BODY STRUCTURE 23 259 ...

Page 3808: ...23 260 BODY STRUCTURE ZH ...

Page 3809: ...ZH BODY STRUCTURE 23 261 ...

Page 3810: ...23 262 BODY STRUCTURE ZH ...

Page 3811: ...ZH BODY STRUCTURE 23 263 ...

Page 3812: ...WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS 23 264 BODY STRUCTURE ZH ...

Page 3813: ...ZH BODY STRUCTURE 23 265 ...

Page 3814: ...23 266 BODY STRUCTURE ZH ...

Page 3815: ...ZH BODY STRUCTURE 23 267 ...

Page 3816: ...23 268 BODY STRUCTURE ZH ...

Page 3817: ...ZH BODY STRUCTURE 23 269 ...

Page 3818: ...23 270 BODY STRUCTURE ZH ...

Page 3819: ...ZH BODY STRUCTURE 23 271 ...

Page 3820: ...23 272 BODY STRUCTURE ZH ...

Page 3821: ...ZH BODY STRUCTURE 23 273 ...

Page 3822: ...23 274 BODY STRUCTURE ZH ...

Page 3823: ...ZH BODY STRUCTURE 23 275 ...

Page 3824: ...23 276 BODY STRUCTURE ZH ...

Page 3825: ...STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVES ZH BODY STRUCTURE 23 277 ...

Page 3826: ...23 278 DOOR ZH ...

Page 3827: ...290 WINDOW REGULATOR REMOVAL 292 INSTALLATION 293 LATCH REMOVAL 294 INSTALLATION 295 LOCK CYLINDER REMOVAL 296 INSTALLATION 297 TRIM PANEL REMOVAL 299 INSTALLATION 300A CHECK STRAP REMOVAL 1 Remove the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Remove the door speaker by removing the screws 1 attaching it to the door 3 Remove the door foil from the inner door panel front area...

Page 3828: ... through the installa tion opening in the inner door panel INSTALLATION Note Lubricate the door check strap below the plastic cover 1 Install the door check strap through the installation opening in the inner door panel 2 Install the screw 3 then install the seal 5 to the door check strap Note Tighten the bolts on the end first 3 Install the two bolts 1 attaching the door check strap 2 to the door...

Page 3829: ...FRONT TRIM PANEL INSTALLATION DOOR REMOVAL CAUTION Use care when removing any compo nent that is attached to the vehicles painted sur face Take the necessary precautions to avoid paint damage while servicing the vehicle 1 Remove the check strap Refer to 23 BODY DOOR FRONT CHECK STRAP REMOVAL 2 Disconnect and remove the lock air line 1 from the door lock Then remove the air line from the door ZH DO...

Page 3830: ...nt door and lay down on secure clean area INSTALLATION CAUTION To avoid paint damage have an assis tant help while installing the door 1 Install the protective hose on the front door and thread all electrical leads as well as the air line lead into the door 2 Slowly position the door onto the A pillar then install the bolts to the bottom and top hinge Tighten to 32 N m 24 ft lbs 3 Connect the rear...

Page 3831: ... front door up down front and back then tighten to 32 N m 24 ft lbs 4 Loosen the bolts on the hinge side adjust then tighten with the centering screw on the hinge Adjust contour of driver s door at the hinge side Tighten to 32 N m 24 ft lbs 5 Install the lock striker Tighten to 28 N m 21 ft lbs 6 Insert a centering gauge into the door lock until lock completely catches catch stage 2 7 Position a d...

Page 3832: ...aling rail off of the inner door with a plastic wedge and remove from the door Check the clips for wear or damage 5 each 3 Remove the outer window sealing rail by removing the two chrome cover screws 1 then pull the rub ber door seal off at the separation point which is about 3 4 inches down the back of the door seal 4 Remove the cover on the door escutcheon with a plastic wedge then remove the ex...

Page 3833: ...ved 10 Loosen the mounting bolt only until the window 5 can be lifted out of the slider 11 Remove the window by pulling it upward while guiding the slider through the opening in the door shaft 12 Put the window down on a secure and dry surface INSTALLATION WARNING WHEN WORKING ON THE POWER WINDOWS OR THE WINDOWS IN THE VEHICLE DOORS THE UNSECURED WINDOW CAN FALL DOWN AND CAN CAUSE INJURY BY PINCHI...

Page 3834: ...nward while guiding the slider through the opening in door shaft 2 Tighten the mounting bolts 2 4 Tighten to 9 N m 79 in lbs 3 Connect the connector for the power window motor 3 4 Install the door foil on the inner door 5 Install the door speaker 1 Tighten to 4 N m 35 in lbs 23 286 DOOR ZH ...

Page 3835: ... BODY DOOR FRONT DOOR GLASS ADJUST MENTS 9 Install the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION ADJUSTMENTS ADJUSTMENT 1 Check the front door adjustment and adjust if nec essary Refer to 23 BODY DOOR FRONT DOOR ADJUSTMENTS 2 Remove the door trim panel on the front door Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Remove the door speaker 1 4 Remove the door foil from ...

Page 3836: ... can be increased or reduced by loosening the nut the sliding jaw must be moved for this purpose 8 Adjust the window so that the upper glass edge makes contact with the inner rubber sealing lip 1 over the entire length when the door lock is in the first catch position then tighten bolts and nuts 3 on the guide rail 9 Tighten the bolts and nut if they were loosened 10 Install the bolt plug Note Gre...

Page 3837: ...om the door in the area of the door lock 2 Loosen the screw 1 pull door handle out to the stop and hold it in place Retighten the screw 1 lightly with the handle in this position Left front door Right hand thread Right front door Left hand thread ZH DOOR 23 289 ...

Page 3838: ...Note The screw will not fall out 3 Remove the 4 mm Allen screw 1 on the face of the door 4 Remove the lock cylinder INSTALLATION 23 290 DOOR ZH ...

Page 3839: ...ut pulling or holding the door handle 3 Check the door lock release for proper function by closing the catch in the door latch with a suitable tool and releasing it with the door handle 4 Insert the door weatherstrip 2 into the channel 5 Check for proper door and handle function ZH DOOR 23 291 ...

Page 3840: ...n be moved out of bracket 3 Loosen the upper regulator bolt 7 which is between the inner and outer door panel on the face of the door 4 Remove the upper window regulator nut 1 5 Remove the lower door nuts 4 from the door bottom Nuts are located behind the rubber plugs 6 Unclip power window motor cable from the door 7 Lift the window regulator up then turn it and lift the regulator out through the ...

Page 3841: ...ect the power window motor 6 4 Install the lower door nuts 4 in the door bottom 3 then install the rubber plugs 5 Install the upper window regulator nut 1 6 Install the upper window regulator nut 1 between the inner and outer door panels 7 Install the door glass in the front door Refer to 23 BODY DOOR FRONT DOOR GLASS INSTALLATION ZH DOOR 23 293 ...

Page 3842: ...to 23 BODY DOOR FRONT EXTERIOR HANDLE REMOVAL 3 Remove the foil from the door 4 Remove the rubber plug 3 remove the window channel bolts 2 and remove the window run channel 1 down ward through installation opening 5 Remove the latch cable 8 from the clip 6 Disconnect the latch air line 9 7 Remove the assembly screw 7 and remove the door lock module 6 23 294 DOOR ZH ...

Page 3843: ...ble 8 to the clip 4 Install the nuts 2 and window run channel 1 through installation opening then install the rubber plug 3 5 Install the foil on the front door 6 Install the exterior door handle on the front door Refer to 23 BODY DOOR FRONT EXTERIOR HANDLE INSTALLATION 7 Install the door trim panel on the front door Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION ZH DOOR 23 295 ...

Page 3844: ...m the door in the area of the door lock 2 Loosen the screw 1 pull door handle out to the stop and hold it in place Retighten the screw 1 lightly with the handle in this position Left front door Right hand thread Right front door Left hand thread 23 296 DOOR ZH ...

Page 3845: ...Note The screw will not fall out 3 Remove the 4 mm Allen screw 1 on the face of the door 4 Remove the lock cylinder INSTALLATION ZH DOOR 23 297 ...

Page 3846: ...ut pulling or holding the door handle 3 Check the door lock release for proper function by closing the catch in the door latch with a suitable tool and releasing it with the door handle 4 Insert the door weatherstrip 2 into the channel 5 Check for proper door and handle function 23 298 DOOR ZH ...

Page 3847: ...trim panel by prying the cover from the door panel using a trim stick 2 3 Remove the eschutcheon cover 3 using a trim stick 4 Remove the pull handle cover 1 by separating it with a trim stick 2 ZH DOOR 23 299 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 299 October 2004 ...

Page 3848: ... using a trim stick while pulling the trim panel away from the door 10 Disconnect the front door speaker electrical connector 11 Disconnect the door lock cable from the plastic retainer clip located on the back side of the inside of the trim panel 12 Check the sheet metal clip nuts on the door trim panel If necessary replace any damaged sheet metal clip nuts 13 Check the door foil on the door and ...

Page 3849: ...panel clips Then swing the door trim panel down and push in the clips on the bottom of the door panel 4 Install the door trim panel retaining screws 2 5 Install the screw behind the SRS cover 3 and then install the cover 6 Install the door end cover 1 and the door latch cover 2 7 Install the escutcheon cover 8 Install the pull handle cover 9 Install the release handle bezel ZH DOOR 23 300A 2005 ZH...

Page 3850: ... REMOVAL SRT ROADSTER 316 REMOVAL SRT COUPE 318 REMOVAL SPOILER MOTOR HARNESS 318A REMOVAL DRIVESHAFT 318B REMOVAL MOTOR BRACKET 318B REMOVAL SPOILER DAMPENERS 318C INSTALLATION INSTALLATION SPOILER WING 318C INSTALLATION MOUNTING PLATE 318D INSTALLATION MOTOR 318G INSTALLATION SRT ROADSTER 318H INSTALLATION SRT COUPE 318J INSTALLATION SPOILER MOTOR HARNESS 318K INSTALLATION DRIVESHAFT 318K INSTAL...

Page 3851: ...ws 1 3 Close the hood FRONT FENDERS REMOVAL 1 Open the hood 7 and raise it to its upright position Refer to 23 BODY HOOD HOOD STANDARD PRO CEDURE 2 Remove the front fascia 6 Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA REMOVAL 3 Remove the bolts 2 on the fender attaching it to the A pillar 23 302 EXTERIOR ZH ...

Page 3852: ...stall the four bolts 1 attaching the fender to the inner support 3 Install the screw 5 on the top front of the fender 4 Install the bolts 3 on the lower portion of the rear of the fender 5 Install the bolts 2 on the fender attaching it to the A pillar 6 Install the front fascia 6 Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA INSTALLATION 7 Close the hood 7 8 Align the fender Refer to 23 BODY BODY...

Page 3853: ...the lower side of the rocker panel 4 Remove the splash shield from the vehicle INSTALLATION 1 Install the splash shield onto the vehicle 2 Install the two retaining screws from the lower side of the rocker panel 3 Install the five plastic retainer nuts and the five retainer screws from the wheelhouse splash shield 4 Install the left front tire and wheel assembly Refer to 22 TIRES WHEELS STANDARD P...

Page 3854: ...retaining screws from the lower side of the rocker panel 4 Remove the splash shield from the vehicle INSTALLATION 1 Install the splash shield onto the vehicle 2 Install the two retaining screws from the lower side of the rocker panel 3 Install the five plastic retainer nuts and the five retainer screws from the wheelhouse splash shield 4 Install the right front tire and wheel assembly ZH EXTERIOR ...

Page 3855: ...e hoses and connections from the underside of the cowl grille then remove the cowl grille from the vehicle INSTALLATION 1 Install the hoses and connections to the underside of the cowl grille then install the cowl grille to the vehicle engaging the clips on the back side of the cowl grille 2 Install the seven screws to the front of the cowl grille 3 Install the windshield wiper arms nuts and plast...

Page 3856: ...ntly apply heat in a circular motion to loosen the adhesive bond 3 With a fingernail lift up and peel away badging tape from the panel using a heat gun as you go 4 Clean off all traces of adhesive from the panel s with a general purpose adhesive remover INSTALLATION INSTALLATION WITH DOUBLE SIDED TAPE 1 Prep the painted surface for the application of the new adhesive Note Use a commercially availa...

Page 3857: ... bolts 2 3 Remove the fuel filler door INSTALLATION 1 Install the fuel filler door 1 to the vehicle 2 Install the two bolts 2 3 Verify correct alignment of the fuel filler door and the body Refer to 23 BODY BODY STRUC TURE GAP AND FLUSH SPECIFICATIONS 23 308 EXTERIOR ZH ...

Page 3858: ...ed by an electric motor it deploys auto matically when the vehicle speed reaches 62 MPH 102 km h to provide 40 Lbs 356 Newtons of aero dynamic downforce to the rear of the vehicle at 80 MPH 129 km h ZH EXTERIOR 23 309 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 309 October 2004 ...

Page 3859: ...wing 1 is attached to the liftgate 5 by a mounting plate 2 mounting studs 4 and mounting nuts 3 1 Spoiler wing 2 Mounting plate 3 Mounting nuts 4 Mounting studs 5 Liftgate 23 310 EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 310 October 2004 ...

Page 3860: ... in defined steps to allow time to pull any hands or foreign objects that may be in the path of the rear spoiler before it is all the way down If the rear spoiler gets disturbed while retracting automatically or while retracting man ually the rear spoiler is automatically driven up again and will lock in the up position During manual retrac tion if you let up on the switch the rear spoiler will be...

Page 3861: ... by pushing the top of the manual override switch 1 2 Remove the mounting bolt covers from both sides of the rear spoiler 3 Remove the four screws 1 then remove the rear spoiler wing 2 from the rear spoiler linkage 23 312 EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 312 October 2004 ...

Page 3862: ...ERIOR SPOILER REMOVAL 2 Open the rear liftgate 3 Remove the lower trim panel 1 Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 4 Disconnect the spoiler electrical connectors 1 ZH EXTERIOR 23 313 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 313 October 2004 ...

Page 3863: ...Remove the mounting plate nuts 2 from the rear liftgate 8 Lower the liftgate down and pull the mounting plate out of the rear liftgate 9 Remove the mounting bracket from the mounting plate by removing the retaining nuts 1 23 314 EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 314 October 2004 ...

Page 3864: ...NEL REMOVAL 3 Disconnect the electrical connectors from the motor 4 Remove any tie straps if equipped securing the motor to the motor bracket 1 LINKAGE BOLTS 2 LINKAGE 3 TORQUE SHAFT 4 MOTOR 5 GEAR DRIVE 6 FINAL REDUCTION GEAR 7 MOTOR BRACKET 8 SPOILER WING ZH EXTERIOR 23 315 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 315 October 2004 ...

Page 3865: ...the bracket REMOVAL SRT ROADSTER 1 Open the decklid and remove the decklid trim panel 1 Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 23 316 EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 316 October 2004 ...

Page 3866: ...the retaining nuts 1 securing the spoiler assembly to the decklid 3 Remove the spoiler assembly 2 from the decklid 1 ZH EXTERIOR 23 317 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 317 October 2004 ...

Page 3867: ...n removing the spoiler wing The spoiler wing studs will be removed with the spoiler wing 6 Carefully separate the spoiler wing from the mount ing plate REMOVAL SRT COUPE 1 Open the liftgate and remove the lower liftgate trim panel 1 Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 23 318 EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318 October 2004 ...

Page 3868: ...emove the lower liftgate trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 3 Disconnect the spoiler motor electrical connectors 3 and separate the connectors from the bracket 1 4 Remove the 4 spoiler motor bracket nuts 2 to gain access to the microswitch retainers 5 Remove the retainers from the rear of the microswitches 4 6 Disconnect the harness 6 from the spoiler mo...

Page 3869: ... plate 4 Using a roll pin punch remove the roll pin 2 5 Remove the spoiler wing frame nuts 1 and rotate the spoiler wing frame 4 up and out from the driveshaft 3 6 Release the driveshaft 3 from the spoiler trans mission and remove the driveshaft REMOVAL MOTOR BRACKET 1 Remove the spoiler motor Refer to 23 BODY EX TERIOR SPOILER REMOVAL 2 Remove the driveshafts Refer to 23 BODY EX TERIOR SPOILER RE...

Page 3870: ... motor Refer to 23 BODY EX TERIOR SPOILER REMOVAL 3 Remove the spoiler dampeners 1 from the spoiler wing frame 2 INSTALLATION INSTALLATION SPOILER WING 1 Install the rear spoiler wing 2 onto the spoiler link age 2 Install the four screws 1 attaching the rear spoiler wing the linkage Tighten to 8 N m 71 in lbs 3 Install the mounting screws covers on both sides of the rear spoiler ZH EXTERIOR 23 318...

Page 3871: ...ler wing alignment to the vehicle body INSTALLATION MOUNTING PLATE 1 Install the mounting bracket to the mounting plate Tighten the retaining nuts to 8 N m 71 in lbs 23 318D EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318D October 2004 ...

Page 3872: ...r liftgate Tighten to 2 5 N m 19 in lbs 4 Install the mounting nuts 2 attaching the mounting plate to the rear liftgate Tighten to 2 5 N m 19 in lbs 5 Install the two drain tubes 6 Connect the spoiler electrical connectors 1 ZH EXTERIOR 23 318E 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318E October 2004 ...

Page 3873: ...ODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 8 Install the spoiler wing 2 to the linkage 1 Refer to 23 BODY EXTERIOR SPOILER INSTALLATION 23 318F EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318F October 2004 ...

Page 3874: ... bracket 2 Connect the electrical connectors 3 Install tie straps as necessary to secure the wiring harness to the motor 4 Install the lower liftgate trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE DECKLID INSTALLATION 5 Connect the negative battery cable 6 Operate the rear wing spoiler and check for proper operation ZH EXTERIOR 23 318G 2005 ZH Service Manual Publication No 81 270 0503...

Page 3875: ... mounting plate 3 2 Install the two bolts 1 attaching the spoiler wing 2 to the mounting plate 3 Tighten to 8 N m 71 in lbs 3 Install the spoiler assembly 2 the decklid 23 318H EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318H October 2004 ...

Page 3876: ...assembly to the decklid Tighten to 2 5 N m 19 in lbs 5 Install the decklid trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION ZH EXTERIOR 23 318I 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318I October 2004 ...

Page 3877: ...poiler wing studs 2 through the holes installing the spoiler wing 1 onto the liftgate 4 2 Install the four nuts 3 Tighten to 8 N m 71 in lbs 3 Install the lower liftgate trim panel Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL INSTALLATION 23 318J EXTERIOR ZH 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 318J October 2004 ...

Page 3878: ... cable 8 Operate the spoiler and check for proper operation INSTALLATION DRIVESHAFT NOTE Only one side is shown The procedure is the same for both sides 1 Insert the driveshaft end through the hole in the mounting plate then connect it to the spoiler transmission 2 Position the spoiler wing frame 4 over the drive shaft end 3 and install the nuts 1 3 Rotate the spoiler wing frame to access the roll...

Page 3879: ...NERS NOTE Left side is shown Right side is similar NOTE With the spoiler motor removed the spoiler wing frame can be moved as needed to access the spoiler dampeners 1 Install the spoiler dampeners 1 onto the spoiler wing frame 2 2 Install the spoiler motor Refer to 23 BODY EX TERIOR SPOILER INSTALLATION 3 Install the spoiler wing Refer to 23 BODY EXTE RIOR SPOILER INSTALLATION 4 Operate the spoile...

Page 3880: ...t wheel liner 3 Lower the vehicle 4 Remove the screws attaching the rocker panel 2 to the vehicle 5 Remove the screws attaching the lift pads 1 to the vehicle 6 Remove the rocker panel 2 ZH EXTERIOR 23 319 2005 ZH Service Manual Publication No 81 270 05036 05ZH23 319 October 2004 ...

Page 3881: ...hicles painted sur face Take the necessary precautions to avoid paint damage while servicing the vehicle Note The side louvers are attached to the fender using a combination of plastic retaining clips and adhesive strips 1 Carefully insert a plastic trim stick between the end of the louver and the fender 2 Gently pry the louver away from the fender to break the adhesive bond between the louver and...

Page 3882: ...3 Using two trim sticks carefully insert the trim sticks and compress the louver retaining clip 4 Depress the louver retaining clips as illustrated ZH EXTERIOR 23 321 ...

Page 3883: ...ll the entire louver assembly away from the fender with the front edge acting as a hinge 8 Remove the louver from the fender INSTALLATION 1 Inspect the fender for any remaining adhesive and remove any old adhesive 2 Prep the painted surface for the application of the new louver adhesive strips Note Use a commercially available and approved Wax and Grease remover to prep the painted surface 23 322 ...

Page 3884: ... into the front fender holes 5 Rotate the louver toward the fender and insert the retaining clips into the clip holes in the fender 6 Press the retaining clips into the clip holes in the fender 7 Apply pressure to the tips of the louver assembly and adhere the louver to the fender ZH EXTERIOR 23 323 ...

Page 3885: ...8 Remove the protective covering from the forward adhesive strip 1 9 Apply pressure to the front of the louver assembly and adhere the louver to the fender 23 324 EXTERIOR ZH ...

Page 3886: ...N 329 REMOVAL 330 INSTALLATION 332 ADJUSTMENTS ADJUSTMENT HOOD 333 INSULATION REMOVAL 335 INSTALLATION 335 LATCH REMOVAL 336 INSTALLATION 337 LATCH RELEASE CABLE REMOVAL 338 INSTALLATION 339 LATCH STRIKER REMOVAL 340 INSTALLATION 340 GAS PROP REMOVAL 1 Open the hood 2 Support the hood with a suitable prop device 3 Remove the gas prop lock 1 on the upper end 2 ZH HOOD 23 325 ...

Page 3887: ...4 Remove the gas prop lock 1 on the lower end 2 5 Remove gas prop from vehicle INSTALLATION 1 Place gas prop 2 in position on the vehicle 2 Install the lower lock cap 1 on the gas prop 2 23 326 HOOD ZH ...

Page 3888: ... upper lock caps 1 on the gas prop 2 4 Verify hood lid operation HINGE REMOVAL 1 Remove the hood from the hinge by removing the upper bolts 1 then the lower bolts 2 Refer to 23 BODY HOOD HOOD REMOVAL ZH HOOD 23 327 ...

Page 3889: ... the position of the hood hinge on the inner panel 4 Remove the bolts 2 and then remove the hood hinge INSTALLATION 1 Install the hood hinge then install the bolts 2 Tighten to 8 N m 70 in lbs 2 Install the inner front fender 1 23 328 HOOD ZH ...

Page 3890: ...CEDURE MOVING THE HOOD TO ITS FULLY UPRIGHT POSITION OPENING CAUTION The locking button symbol PRESS must be completely visible in the opening of the gas prop rod cover tube 1 Press the gas prop rod locking button in the open ing of the gas prop rod cover tube and then move the hood to its fully upright position until locking button catches on the detent ZH HOOD 23 329 ...

Page 3891: ...rop rod cover tube and then slowly allow the hood to come down against the pressure of the gas pressure strut REMOVAL CAUTION Use care when removing any compo nent that is attached to the vehicles painted sur face Take the necessary precautions to avoid paint damage while servicing the vehicle 1 Open the hood by pulling the handle 1 and move it to the full upright position 23 330 HOOD ZH ...

Page 3892: ...e by the safety hooks on the hood hinges 2 Remove the two lower bolts 2 from the left and right hood hinges 3 Remove the gas prop rod retainer 1 and remove the gas prop rod 2 from the hood at the top retaining hook 3 ZH HOOD 23 331 ...

Page 3893: ...LLATION CAUTION To avoid paint damage have an assis tant help while installing the hood 1 With the aid of an assistant position the hood on the safety hooks on the hood hinges 2 Loosely install the lower bolts 2 on the hood 3 Loosely install the upper bolts 1 on the hood 4 Align the hood with the bolts 1 2 to coincide with the witness marks 5 With the aid of an assistant tighten the hood hinge bol...

Page 3894: ...rger adjustment path see steps 4 10 1 Open the hood 2 Loosen the bolts 1 2 on the hood hinges and adjust the hood 3 Tighten the bolts Tighten to 10 N m 88 in lbs 4 Move the hood to its fully upright position Refer to 23 BODY HOOD HOOD STANDARD PROCE DURE 5 Remove the gas prop rod from the hood at the top and lay it down in the engine compartment 6 Close the hood 7 Remove the inner fender from the ...

Page 3895: ...d 3 Center the top section of hood latch 2 in the lat eral and longitudinal directions in relation to the bottom section of the hood latch and then tighten the bolts 2 Tighten to 8 N m 70 in lbs 4 Install the inner fender in the front fender Note For this purpose close the hood release and ensure that hook is caught in upper frame cross member 5 Check the function of the safety hook 6 Close the ho...

Page 3896: ...OVAL 1 Open the hood 2 Remove the twelve plastic anchors 1 3 Remove the insulation INSTALLATION 1 Install the insulation to the hood 2 Install the twelve plastic anchors 1 to the hood 3 Close the hood ZH HOOD 23 335 ...

Page 3897: ...Remove the bolts 1 and then remove hood latch 2 lower section 3 Remove the hood pull cable 2 from the hood striker 3 Note Mark installation position of the hood catch upper section on the hood 4 Remove the hood latch 3 23 336 HOOD ZH ...

Page 3898: ...ch release cable 2 3 Note the correct routing of hood latch release cable 2 4 Install the hood latch release cable 2 to the hood latch 3 5 Position the bolts 1 and install the hood latch 2 Tighten to 8 N m 71 in lbs 6 Close the hood and test for proper alignment and fit ZH HOOD 23 337 ...

Page 3899: ... the cover and then remove the hood pull cable from the handle 1 4 Remove the cable grommet from the bulkhead just below the fuse box 5 Remove the upper frame cross member 6 Remove the clip on the frame cross member 7 Remove the cover 8 Remove the hood latch 6 9 Remove the hood latch release cable 1 from between the headlamp and the upper frame cross member 23 338 HOOD ZH ...

Page 3900: ...ember 5 Install the upper frame cross member 6 Install the wire to the grommet 3 on the hood latch release cable 2 Note Insure that hood latch release cable grom met is properly seated in the bulkhead 7 Push the cable grommet into the bulkhead below the fuse box 8 Install the handle 1 to the arresting mechanism in the cover and hook the hood latch release cable to the handle 9 Install the screw on...

Page 3901: ...ttaching the latch striker 1 to the hood 2 Remove the latch striker 1 from the hood INSTALLATION 1 Install the latch striker 1 to the hood 2 Install the two bolts 2 attaching the latch striker 1 to the hood Tighten to 10 N m 88 in lbs 23 340 HOOD ZH ...

Page 3902: ...MENT CLUSTER COVER 361 REMOVAL INSTRUMENT CLUSTER COVER RHD 362 INSTALLATION INSTALLATION INSTRUMENT PANEL TOP SECTION 363 INSTALLATION INSTRUMENT PANEL TOP SECTION RHD 367 INSTALLATION LOWER INSTRUMENT PANEL LEFT 370 INSTALLATION LOWER INSTRUMENT PANEL RIGHT RHD 371 INSTALLATION LOWER INSTRUMENT PANEL RIGHT 373 INSTALLATION LOWER I P PANEL RHD 373 INSTALLATION INSTRUMENT CLUSTER COVER 375 INSTALL...

Page 3903: ...at the top 3 Loosen the hinge screws 2 and adjust the gap width and transition at the bottom and sides 4 Unscrew both stop buffers until the glove compart ment lid makes contact and can still be closed eas ily 5 Check for easy motion and proper function 23 342 INSTRUMENT PANEL ZH ...

Page 3904: ...strument panel 1 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Open the glove compartment 4 Remove the cover at the top of the glove compart ment opening 2 5 Remove the glove compartment lamp 1 and dis connect the electrical connection ZH INSTRUMENT PANEL 23 343 ...

Page 3905: ...el 7 Remove the glove compartment from the vehicle REMOVAL DRAWER 1 Open the glove compartment drawer 3 2 Disconnect the retaining rail for the interior cover ing 1 at the top with a plastic wedge 3 Disconnect the insert clip from the damper shock 2 4 Remove the damper shock 23 344 INSTRUMENT PANEL ZH ...

Page 3906: ...the hinges 6 Pull the glove compartment drawer out of the hinges 2 7 Remove the clip at the bottom of the retaining strap and unhook the retaining strap 3 8 Remove the glove compartment drawer from the vehicle ZH INSTRUMENT PANEL 23 345 ...

Page 3907: ...nections for the glove compartment illumination and route through the opening 1 Install glove compartment 2 Install the screws 1 2 4 and 5 around the opening 3 Connect the glove compartment lamp electrical connector and install 4 Install the cover 2 at the top of the glove compart ment opening 23 346 INSTRUMENT PANEL ZH ...

Page 3908: ...ALLATION 6 Install the side air nozzle INSTALLATION DRAWER 1 Install the glove compartment drawer on the hinges 2 2 Install the clip at the bottom of the retaining strap 3 and hook the retaining strap 3 Install the damper shock 1 4 Install the insert clip to the damper shock 1 ZH INSTRUMENT PANEL 23 347 ...

Page 3909: ... the interior cover ing at the top 6 Close the glove compartment door 7 Check the adjustment of the glove compartment door and adjust if necessary Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX STANDARD PROCEDURE 23 348 INSTRUMENT PANEL ZH ...

Page 3910: ... pillar trim 1 CAUTION Damage to the top section of instru ment panel can occur if the A pillar sheet metal clips are not removed when removing and install ing the top section of the instrument panel 2 Remove the sheet metal clips 1 on left and right A pillars ZH INSTRUMENT PANEL 23 349 ...

Page 3911: ...1 on the left and the I P cover on the right 4 Remove the right and left air deflectors 5 Remove the screw located behind the right and left air deflectors 2 6 Remove the screws 1 on left and right of the instrument panel located on the inside of the fuse cover and the I P cover 23 350 INSTRUMENT PANEL ZH ...

Page 3912: ...e glove compartment and remove the screws 1 attaching it to the top section of the instrument panel 8 Remove the defroster grille screws 1 and the defroster grille pulling it outwards ZH INSTRUMENT PANEL 23 351 ...

Page 3913: ...e the bolts 1 on left and right under the defroster grille 10 Lift the top section 1 of the instrument panel and remove toward rear 11 Lay the top section down on a suitable surface 23 352 INSTRUMENT PANEL ZH ...

Page 3914: ...REMOVAL INSTRUMENT PANEL TOP SECTION RHD 1 Remove both right and left A pillar trim 1 panels 2 Remove the sheet metal clips 1 on left and right A pillars ZH INSTRUMENT PANEL 23 353 ...

Page 3915: ...ight air outlet deflector by removing the deflector to reveal the screw 5 Remove the screw 2 on right of the I P located on the inside of the fuse cover 6 Remove the I P panel on the left side of the I P 7 Remove the screw 1 attaching the top section to the side panel 23 354 INSTRUMENT PANEL ZH ...

Page 3916: ...he I P 10 Remove the defroster grille screws 1 and the defroster grille pulling it outwards 11 Remove the bolts on left and right under the defroster grille CAUTION Damage to the top section of I P can occur if the A pillar sheet metal clips were not removed 12 Lift the top section of the I P and remove toward rear 13 Lay the top section of I P down on a suitable surface ZH INSTRUMENT PANEL 23 355...

Page 3917: ...tru ment cover 5 to the illumination control module 4 and the side of the instrument panel to the sup port bar 6 Remove the screw at the top of lower cover to cluster cover 5 Remove the illumination control module 7 6 Pull the lower instrument cover 2 off of the cluster cover 7 Remove the screw 2 attaching the hood latch release handle bezel to the lower instrument panel and then guide the handle ...

Page 3918: ...ector from the I P then remove the screw 4 from behind the deflector 2 Open the glove compartment and disconnect the shock and the limiter strap from the door of the glove compartment 3 Remove the screws from the hinge of the glove compartment door removing the glove compart ment from the vehicle 4 Remove the screws 1 2 and 3 ZH INSTRUMENT PANEL 23 357 ...

Page 3919: ...emove the I P side cover 6 Remove the screw 1 attaching the lower I P to the upper panel 7 Remove the two screws 2 from the lower panel then remove the lower I P from the vehicle 23 358 INSTRUMENT PANEL ZH ...

Page 3920: ...ttaching the steering col umn panel under the steering column then remove the steering column panel 3 Remove the fuse panel side cover 4 Remove the two screws 4 attaching the lower I P to the illumination control module and the screw 3 on the side of the I P to the illumination control module support bar 5 Disconnect the illumination control module harness connector then remove the illumination co...

Page 3921: ...ing wheel has been omitted so that the I P screws can be clearly seen 7 Remove the screws 1 4 in the lower I P 8 Remove the screw 1 attaching the hood latch release handle to the lower I P 23 360 INSTRUMENT PANEL ZH ...

Page 3922: ...el Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Remove the sentry key antenna ring from the key cylinder 4 Remove the screws attaching the instrument clus ter cover to the lower instrument panel 5 Disconnect the instrument cluster cover 1 from the top with a plastic wedge 6 Tip the instrument cluster cover toward the rear at the top Lift it over the jacket tube covering an...

Page 3923: ... SKREEM antenna ring from the key cylinder 4 Remove the screws attaching the instrument cluster cover to the I P 5 Disconnect the instrument cluster cover from the I P top with a plastic wedge 6 Tip the instrument cluster cover toward the rear at the bottom Lift the instrument cluster cover over the steering column and simultaneously pull down releasing the cover from the I P 23 362 INSTRUMENT PAN...

Page 3924: ...nel in relation to the driver and passenger door trim panels Note When installing check for proper installation of the insulating mat sheet metal clips and expanding anchors 1 Install the top section 1 to the vehicle 2 Install the sheet metal clips 1 on left and right A pillars ZH INSTRUMENT PANEL 23 363 ...

Page 3925: ...3 Install the bolts 1 on left and right under the defroster grille 4 Position the defroster grille 2 and install the screws 1 23 364 INSTRUMENT PANEL ZH ...

Page 3926: ...e top section 6 Install the screws 1 on left and right of the instru ment panel located on the inside of the fuse cover and the I P cover 7 Install the screws 2 located behind the air deflec tors 8 Install both right and left air deflectors ZH INSTRUMENT PANEL 23 365 ...

Page 3927: ...9 Install the fuse cover 1 on the left and the I P cover on the right 10 Install the A pillar trim 1 23 366 INSTRUMENT PANEL ZH ...

Page 3928: ...D 1 Install the top section of I P 2 Install the sheet metal clips 1 on left and right A pillars 3 Install the bolts on left and right under the defroster grille 4 Position the defroster grille and install the screws 1 ZH INSTRUMENT PANEL 23 367 ...

Page 3929: ... to the top section of the I P 6 Install the screw 4 located in the air outlet deflector 7 Install the screw 1 located in the air outlet deflec tor 8 Install the screw 2 on right of the I P panel located on the inside of the fuse cover 23 368 INSTRUMENT PANEL ZH ...

Page 3930: ...tall the screw 1 on left of the I P panel located on the inside of the I P cover 10 Install the fuse cover on the right and the I P cover on the left 11 Install the A pillar trim 1 ZH INSTRUMENT PANEL 23 369 ...

Page 3931: ...below the floor cov ering 1 Install the lower instrument panel 2 upward into the cluster cover lining up the holes in the lower section and the sides 2 Guide the hood latch release handle 2 through the lower instrument panel 1 then install the screw attaching it to the lower instrument panel 1 23 370 INSTRUMENT PANEL ZH ...

Page 3932: ... attaching the illumination control module 7 to the instrument panel and to the sup port bar 6 on the side 7 Install the cover 2 under the steering column Then install the screw 3 8 Install the screw behind the air deflector then install the side air deflector INSTALLATION LOWER INSTRUMENT PANEL RIGHT RHD 1 Install the two screws 2 to the lower I P ZH INSTRUMENT PANEL 23 371 ...

Page 3933: ... 4 Install the screws 1 2 and 3 5 Install the screws to the hinge of the glove com partment door 6 Connect the shock and the limiter strap to the door of the glove compartment 7 Install the screw 4 behind the air outlet deflector then install the air outlet deflector 23 372 INSTRUMENT PANEL ZH ...

Page 3934: ...n toward the front 2 Install the screws attaching the lower instrument panel to the glove compartment 3 Fold back the carpet INSTALLATION LOWER I P PANEL RHD 1 Guide the handle through the lower panel as you install the lower I P 2 into the cluster bezel 1 ZH INSTRUMENT PANEL 23 373 ...

Page 3935: ...2 Install the screw attaching the hood latch release handle bezel to the lower I P 3 Install the screws 1 4 in the lower I P 23 374 INSTRUMENT PANEL ZH ...

Page 3936: ...g column 9 Install the right side I P air outlet deflector 1 INSTALLATION INSTRUMENT CLUSTER COVER 1 Tip the instrument cluster cover toward the rear at the top then lift it over the jacket tube covering and simultaneously guide the adjustment knobs through the cover 2 Connect the instrument cluster cover 1 to the instrument panel top section 3 Install the screws attaching the instrument cluster c...

Page 3937: ...over firmly into the I P 2 Install the screws attaching the instrument cluster cover to the lower instrument panel 3 Install the SKREEM antenna ring to the key cylinder 4 Install the right side lower instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 5 Connect the negative battery cable 23 376 INSTRUMENT PANEL ZH ...

Page 3938: ...HTRAY 398 REMOVAL SHIFT LEVER ASSEMBLY COVER 400 INSTALLATION INSTALLATION CENTER CONSOLE FRONT 401 INSTALLATION CENTER CONSOLE COVER 405 INSTALLATION REAR CENTER CONSOLE 407 INSTALLATION ASH TRAY 409 INSTALLATION SHIFT LEVER ASSEMBLY COVER 411 DOOR SILL TRIM PLATE REMOVAL 413 INSTALLATION 413 HEADLINER REMOVAL 414 INSTALLATION 417 SPORT BAR REMOVAL 419 INSTALLATION 421 A PILLAR TRIM REMOVAL 1 Pre...

Page 3939: ...3 Remove the retaining clips 1 if doing any service to the instrument panel INSTALLATION 1 Install the retaining clips on the A pillar and attach the electric wire 23 378 INTERIOR ZH ...

Page 3940: ...L 3 Remove the cover on center console Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 4 Remove the ashtray housing with the stowage compartment in the front of the center console Refer to 23 BODY INTERIOR CENTER CON SOLE REMOVAL 5 Remove the air outlet cover in the footwell 6 Remove the door sill trim plate 4 Refer to 23 BODY INTERIOR DOOR SILL TRIM PLATE REMOVAL 7 Remove the kick panel 2 in the...

Page 3941: ... the accelerator pedal to the instrument panel structural duct 10 Remove the nut 1 attaching the accelerator pedal to the floor Disconnect the electrical con nector and remove the pedal from the welded stud 23 380 INTERIOR ZH ...

Page 3942: ... then remove the rear edge guard 2 in the lower area Note Cut the single piece carpet 1 along dotted lines in order to avoid time consuming removal of the heater or air conditioning systems CAUTION Do not damage the electrical and pneu matic lines 14 Cut the carpet 1 in the transmission tunnel area along the dotted lines with a sharp knife ZH INTERIOR 23 381 ...

Page 3943: ...hift lever assembly area CAUTION Do not damage the electrical and pneu matic lines 16 Cut the carpet 1 in the footwell area under the front center console 17 Lift at the rear while removing the carpet 1 from below the center console and then remove it from the vehicle 23 382 INTERIOR ZH ...

Page 3944: ...utlet cover in the footwell 6 Remove lower instrument panel right Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 7 Removing the door sill trim plate 4 Refer to 23 BODY INTERIOR DOOR SILL TRIM PLATE REMOVAL 8 Remove the kick panel 2 in the right footwell Pull the edge guard 1 off in the area of the kick panel 2 Remove the cap 3 with a suitable tool then remove the screw 9 Unhoo...

Page 3945: ... and pneu matic lines 12 Cut the carpet 1 in the transmission tunnel area along the dotted lines with a sharp knife CAUTION Do not damage electrical and pneu matic lines 13 Cut the carpet 1 in the shift lever module 23 384 INTERIOR ZH ...

Page 3946: ...t the rear and then remove it from vehicle INSTALLATION INSTALLATION CARPET LEFT SIDE Note Before installing the carpet 1 clean the vehicle passenger compartment in the area of the floor covering 1 Prepare the carpet 1 for installation by cutting the new carpet along the dotted line with a suitable cutting device and remove the section below the heater cross hatched ZH INTERIOR 23 385 ...

Page 3947: ...he carpet by inserting the cut edge in the front area below the center console while simulta neously guiding the parking brake lever kick down switch welded pin for the accelerator pedal and the electrical leads for the driver s seat through the carpet arrows 23 386 INTERIOR ZH ...

Page 3948: ...ith clips 1 along the cutting line For this purpose cut slits in both carpet halves 2 with a blade and then insert the clips 1 5 Install the plugs 3 and then install the rear edge guard 2 in the lower area 6 Connect the electrical connector 4 to the parking brake 5 switch 7 Install the storage pocket 1 ZH INTERIOR 23 387 ...

Page 3949: ... 1 attaching the accelerator pedal to the floor then install the electrical connector 9 Install nut 1 attaching the accelerator pedal to the instrument panel structural duct 10 Install the pedal cover 23 388 INTERIOR ZH ...

Page 3950: ...DY INTERIOR CENTER CONSOLE INSTALLATION 15 Install the cover on center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTAL LATION 16 Install the rear center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTAL LATION 17 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION INSTALLATION CARPET RIGHT SIDE Note Before installing floor covering clean vehi cle passenger compartment in ...

Page 3951: ... cross hatched 3 Install the carpet by inserting the cut edge in the front area below the center console while simulta neously guiding the parking brake lever 2 and the electrical leads 1 for the passenger s seat through the carpet 23 390 INTERIOR ZH ...

Page 3952: ...Y INTERIOR DOOR SILL TRIM PLATE INSTALLATION Install the edge guard 1 in the area of the paneling 2 Install the screw 3 then install the cap 10 Install the cover below instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 11 Install the air outlet cover in the footwell 12 Install the ashtray housing with the stowage com partment in the front center console Refer...

Page 3953: ...AL 2 Remove the instrument cluster cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Remove the shifter cover and bezel Disconnect the power window harness connectors 4 Remove the rear center console Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 5 Remove the radio 1 Refer to 8 ELECTRICAL AUDIO RADIO REMOVAL 23 392 INTERIOR ZH ...

Page 3954: ...ve the A C heater control module by remov ing the screws 3 and disconnecting the harness connector from behind 8 Remove the screws 4 and 2 from the sides of the center console the I P 9 Remove the center console 2 from the vehicle REMOVAL CENTER CONSOLE COVER 1 Remove the radio Refer to 8 ELECTRICAL AU DIO RADIO REMOVAL ZH INTERIOR 23 393 ...

Page 3955: ...2 Remove the screws 1 in the radio cutout attach ing it to the center console cover 3 Pull the cover 1 toward the rear and pull it out at the top of the instrument panel 2 hooks 23 394 INTERIOR ZH ...

Page 3956: ...e switch group at the catch lugs 2 5 Remove the console switch group 1 from the cover REMOVAL REAR CENTER CONSOLE 1 Remove the cover 1 around the shift lever Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL ZH INTERIOR 23 395 ...

Page 3957: ...2 Pull the handle 1 off the parking brake lever 3 Remove the screws 1 attaching the center con sole to the rear center console 23 396 INTERIOR ZH ...

Page 3958: ...compartment 6 Remove the nuts 1 7 Lift the rear center console 2 up uniformly while moving it out at the front disconnecting it from the arresting hook at the separating point of the front 1 and rear center consoles 2 8 Guide the parking brake handle through the open ing in the retractable cover 9 Disconnect all electrical connectors 10 Remove the rear center console 2 from the vehicle ZH INTERIOR...

Page 3959: ...REMOVAL ASHTRAY 1 Remove the cover 1 on the center console Refer to 23 BODY INTERIOR CENTER CON SOLE REMOVAL 2 Remove the screws 1 3 attaching the ashtray 2 to the center console 23 398 INTERIOR ZH ...

Page 3960: ...3 Press the ashtray housing 1 to the left and remove it toward the right arrows 4 Disconnect the ashtray harness connector for the courtesy light 1 ZH INTERIOR 23 399 ...

Page 3961: ...AL SHIFT LEVER ASSEMBLY COVER 1 Remove the chrome plastic frame 1 with a plastic wedge 2 Press the cover 1 out of the catch in the center console at the rear and side with a plastic wedge 23 400 INTERIOR ZH ...

Page 3962: ...rt the insulating mat expose the electric wires and insert the panel into the side insert tabs on the center console 1 Install the center console 4 upward into the top section of the instrument panel 2 Install the screws attaching the center console to the rear center console 3 air duct 2 and instru ment panel top section 1 ZH INTERIOR 23 401 ...

Page 3963: ...eater control module 2 Refer to 24 HEATING AIR CONDITIONING CON TROLS HEATER CONTROL INSTALLATION 4 Install the glove compartment to the hinges 2 Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX INSTALLATION 23 402 INTERIOR ZH ...

Page 3964: ...ay with the stowage compartment 1 on the center console Refer to 23 BODY IN TERIOR CENTER CONSOLE INSTALLATION 6 Install the center console cover 1 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION ZH INTERIOR 23 403 ...

Page 3965: ...the rear center console 2 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 8 Install the instrument cluster cover 1 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 23 404 INTERIOR ZH ...

Page 3966: ...el 2 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION INSTALLATION CENTER CONSOLE COVER 1 Install the console switch group 1 to the cover 2 Connect the cockpit switch group to the catch lugs 2 ZH INTERIOR 23 405 ...

Page 3967: ...ush the cover 2 toward the front at top on the instrument panel top section 4 Install the screws 1 in the radio cutout 5 Install the radio Refer to 8 ELECTRICAL AUDIO RADIO INSTALLATION 23 406 INTERIOR ZH ...

Page 3968: ...arking brake handle through opening in the retractable cover 3 Install the rear center console 2 uniformly while moving in at front 1 arresting hook at the separat ing point 4 Install the nuts 1 5 Install the carpeting 2 6 Close the cover on the stowage compartment ZH INTERIOR 23 407 ...

Page 3969: ...ews 1 attaching the front and the rear center consoles 8 Instal the handle on the parking brake lever 9 Install the cover 1 around the shift lever Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 23 408 INTERIOR ZH ...

Page 3970: ...INSTALLATION ASH TRAY 1 Connect the ashtray courtesy light harness connec tor 1 2 Install the ashtray housing 1 to the right and push it toward the left ZH INTERIOR 23 409 ...

Page 3971: ...3 Install the screws 1 3 attaching the ashtray 2 to the center console 4 Install the cover 1 on the center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION 23 410 INTERIOR ZH ...

Page 3972: ...the cover around the shift lever Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION INSTALLATION SHIFT LEVER ASSEMBLY COVER 1 Connect the electrical connectors 1 to the power window switches ZH INTERIOR 23 411 ...

Page 3973: ...2 Press cover 1 into the catch in the center console at the rear and the side 3 Install the chrome plastic frame 1 23 412 INTERIOR ZH ...

Page 3974: ...DOOR SILL TRIM PLATE REMOVAL 1 Pull up on the door sill trim plate releasing it from the body clips INSTALLATION 1 Push the door sill trim down until it locks into place ZH INTERIOR 23 413 ...

Page 3975: ...REMOVAL 1 Remove the dome lamp assembly 2 by gently prying off the lens using a trim stick 1 or equivalent 2 Remove the two retaining screws 1 and pull the dome lamp assembly from the headliner 23 414 INTERIOR ZH ...

Page 3976: ...e dome lamp assembly 4 Remove the universal garage door opener TPM module 1 from the headliner using a trim stick or equivalent Pull the module from the headliner and disconnect the harness connector 5 Remove both the right and left sun visor assemblies ZH INTERIOR 23 415 ...

Page 3977: ... 7 Tilt both seats all the way forward and all the way down 8 Disengage rear interior trim panel 2 retaining clips near headliner 9 Remove the rear headliner retaining clips 1 10 Remove the headliner from the passenger door opening 23 416 INTERIOR ZH ...

Page 3978: ...is will hold the headliner into the correct position 3 Install the rear headliner retainers 2 4 Connect the rear interior trim panel retaining clips 1 near headliner 5 Install the right and left A pillar trim panels 1 6 Using a trim stick reinstall head liner into upper window weather strips ZH INTERIOR 23 417 ...

Page 3979: ...onnect the universal garage door opener TPM module 1 harness connector and install into the headliner 8 Connect the dome lamp assembly harness connec tor 1 and install into the headliner 23 418 INTERIOR ZH ...

Page 3980: ...stall the dome lamp assembly lens SPORT BAR REMOVAL 1 Tilt both of the seats forward 2 Remove the umbrella hooks 1 by removing the screws 3 Remove the front sports bar trim panel 3 by removing the two plastic retainers 2 ZH INTERIOR 23 419 ...

Page 3981: ...4 Remove the cargo pouch 1 by pulling it out and down from the rear cargo carpet 5 Remove the rear sports bar trim panel by removing the bolt 1 from both sides 23 420 INTERIOR ZH ...

Page 3982: ...ss the sports bar mounting bolts then remove the sports bar mounting bolts 1 2 7 Pull straight up on the sports bar removing it from vehicle INSTALLATION 1 Install the sports bar then install the sports bar mounting bolts 1 2 ZH INTERIOR 23 421 ...

Page 3983: ...hen install the sports bar trim panel bolts 1 3 Reposition the rear cargo carpet to the correct position and then install the front sports bar trim panel 3 by installing the plastic retainers 2 4 Install the umbrella hooks 1 23 422 INTERIOR ZH ...

Page 3984: ...5 Install the cargo pouch 1 6 Tilt both of the seats back ZH INTERIOR 23 423 ...

Page 3985: ... Gray and Medium Slate Gray two tone XDV BD5 Dark Slate Gray monotone XDV PAINT CODE DESCRIPTION Exterior vehicle body colors are identified on the Body Code Plate The plate is located on the in the engine com partment and attached to the top of the right frame rail Refer to the Introduction Section at the front of this manual for Body Code Plate description The first digit of the paint code liste...

Page 3986: ... hard 4 Cover the filler primer with color touch up paint Do not overlap the touch up color onto the original color coat around the scratch or chip Butt the new color to the original color if possible Do not stroke the applicator brush on the body surface Allow the touch up paint to dry hard 5 On vehicles without clear coat the touch up color can be lightly finesse sanded 1500 grit and polished wi...

Page 3987: ...e key is removed only when the door is open The power adjuster provides 7 6 inches 194 mm of longitudinal adjustment and 1 7 inches 43 mm of vertical adjustment Standard heated seats have two heating levels and a timed automatic shutoff Separate rocker switches for the driver and passenger heaters mount in the center console Pressing the top of the switch turns on the normal heat ing level and pre...

Page 3988: ...the way forward to its lock posi tion 5 Remove the bolt 2 on the seat track for the seat belt mounting 6 Remove the belt end from the seat adjuster 7 Remove the rear two bolts 1 attaching the seat track to the floor 8 Disconnect the electrical connectors for the seat heater and the electrical seat adjustment 9 Move the seat backward lift up and then remove from the vehicle ZH SEATS 23 427 ...

Page 3989: ...rear seat track bolts 1 Tighten to 50 N m 37 ft lbs 5 Install the belt end fitting to the seat adjuster Note Tighten the bolt for the belt end fitting only so that it can be moved 6 Install the bolt 2 at the belt end fitting Tighten to 35 N m 26 ft lbs 7 Move the seat all the way backwards 8 Install the two front seat track bolts 2 Tighten to 50 N m 37 ft lbs 9 Install the plastic covering 3 to th...

Page 3990: ...the bolts 1 from the seat back 5 Disconnect the seat back heater and adjustment electrical connectors 6 Remove the seat back from the frame REMOVAL PLASTIC BACK COVER 1 Remove the cover on the seat back only down to step 6 Refer to 23 BODY SEATS SEAT BACK COVER REMOVAL Note Use T25 Torx socket 2 Remove the screws 1 on left and right sides 3 Unhook the plastic back cover at the top of the seat back...

Page 3991: ...lling the left and right bolts 2 Tighten to 24 N m 18 ft lbs 5 Install the seat cushion Refer to 23 BODY SEATS SEAT CUSHION INSTALLATION 6 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION INSTALLATION PLASTIC BACK COVER 1 Install the plastic back cover on the top of the seat back frame 2 2 Install the screws 1 on left and right sides 3 Install the cover on the seat back Refer to 23 ...

Page 3992: ...fer to 23 BODY SEATS SEAT BACK REMOVAL 2 Lay the seat back 1 down on a suitable surface with the cover 2 down 3 Unhook the cover 2 all the way around on the clip groove in the rear shell 4 Remove seat back frame 3 from the foam rubber pad 2 ZH SEATS 23 431 ...

Page 3993: ...strip in area of seat back 1 hinge area 6 Pull the cover 1 over the foam rubber pad 3 in the upper area 7 Remove the longitudinal retainers by turning the upholstery clips 2 90 8 Remove the cover 1 from the foam rubber pad 3 23 432 SEATS ZH ...

Page 3994: ...9 Pull the upholstery wires 2 out of the fabric sleeves 3 in the cover 1 10 Remove the upholstery clips 2 on the rear of the foam rubber pad 1 ZH SEATS 23 433 ...

Page 3995: ...INSTALLATION 1 Insert the upholstery wires 2 into the fabric sleeves 3 in the cover 1 2 Attach the upholstery clips 2 to the rear of the foam rubber pad 1 23 434 SEATS ZH ...

Page 3996: ...foam rubber pad 4 4 Connect the upholstery clips 2 with the upholstery wires starting with the center upholstery wire 3 5 Draw the cover 2 over the foam rubber pad 1 6 Attach the cover to the VelcroT strip in the area of the seat back hinge area ZH SEATS 23 435 ...

Page 3997: ...7 Position the seat back frame 3 on the foam rub ber pad 2 8 Hook in the cover 2 all the way around in the clip groove in the seat back shell and align 9 Install the front seat back 1 23 436 SEATS ZH ...

Page 3998: ...SEAT CUSHION REMOVAL 1 Remove the seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Remove the bolt 2 on the front seat 1 to the frame 3 3 Remove the panel 2 ZH SEATS 23 437 ...

Page 3999: ...4 Pull the two expanding anchors 2 out of the front left and right bearing brackets 1 5 Remove the bearing brackets 1 from the seat cushion 2 23 438 SEATS ZH ...

Page 4000: ...l both springs 1 into the plate springs with the narrow coils pointing downward at an angle and insert into humps on cushion shell 2 Push the seat cushion toward the rear below the seat back 2 Install the seat cushion at front and install to the seat frame Note Insert the connection leads into connector with present leads 3 Connect the leads for the heated seat cushion to the 4 pin connector ZH SE...

Page 4001: ...are deleted parts and must be reordered for installation 4 Install the two expanding anchors 2 into the front left and right bearing bracket 1 5 Install the front bolt 2 6 Install the front seat Refer to 23 BODY SEATS SEAT INSTALLATION 23 440 SEATS ZH ...

Page 4002: ...er to 23 BODY SEATS SEAT CUSHION REMOVAL 2 Lay the seat cushion on a suitable surface with the cover facing down 3 Unhook the two fabric tabs on the cushion shell 1 4 Unhook the cover 2 all the way around the clip groove in the seat cushion shell 1 ZH SEATS 23 441 ...

Page 4003: ... the cover 1 to the side and unhook the upholstery straps from the wire insert in the foam rubber pad 2 7 Pull the lateral upholstery wire 2 out of the fabric sleeve in the cover 6 and unhook the upholstery straps 1 5 from the foam rubber pad 4 23 442 SEATS ZH ...

Page 4004: ...dle upholstery straps 2 from the wire insert 3 in the foam rubber pad 4 9 Remove the cover 1 from the foam rubber pad 2 10 Unhook the upholstery straps and pull the longitu dinal upholstery wires out of the fabric sleeves in the cover 1 ZH SEATS 23 443 ...

Page 4005: ...eral upholstery wire into the fabric sleeve in the cover 3 5 Install the side longitudinal retainers and the rear lateral retainers 6 Pull the cover 3 to the side over the foam rubber pad 1 Note Insert one additional retaining clip in clip groove at front center arrow 7 Position the seat cushion shell 1 align the cover 2 and hook the cover into the cushion shell 1 all the way around 8 Hook fabric ...

Page 4006: ...9 Ensure that the contour of the cover is positioned correctly 10 Install the seat cushion 1 Refer to 23 BODY SEATS SEAT CUSHION INSTALLATION ZH SEATS 23 445 ...

Page 4007: ...of tools and adhesive systems that are recommended for use in this procedure Refer to 23 BODY STATIONARY GLASS WINDSHIELD REMOVAL 1 Remove liftgate trim panels Refer to 23 BODY DECKLID HATCH LIFTGATE TAILGATE TRIM PANEL REMOVAL 2 Disconnect wire connectors 3 from rear window defogger 2 3 Disconnect and remove CHMSL lamp Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR CENTER HIGH MOUNTED STOP LAMP RE...

Page 4008: ...ds or repair screws at bottom of backlight opening Refer to the Windshield Removal procedure for a description of tools and adhesive systems that are recommended for use in this procedure Refer to 23 BODY STATIONARY GLASS WINDSHIELD REMOVAL 1 Apply a 12 mm 0 5 in bead of urethane 2 around the perimeter of the glass 1 2 Place backlight glass 1 into position 3 Install the glass 1 in the same manner ...

Page 4009: ...ld be cleaned and properly installed on weld studs or repair screws at bottom of quarter window opening The window opening fence should be cleaned of old urethane bonding material 1 Refer to the Windshield Removal procedure for a description of tools cleaning procedures and adhe sive systems that are recommended for use in this procedure Refer to 23 BODY STATIONARY GLASS WINDSHIELD REMOVAL 1 Clean...

Page 4010: ...amage body or trim finish when cutting out glass or applying fence primer 5 Cut urethane bonding from around windshield 2 using a suitable sharp cold knife 1 A pneumatic cutting device can be used if available 6 Separate windshield 2 from vehicle INSTALLATION WARNING DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE IF IT...

Page 4011: ...ce replacement windshield 1 into windshield opening 2 Position glass in the center of the opening against the support spacers 2 Note There are 4 support spacers one in each corner of the fence opening 3 Mark the glass at the support spacers 2 with a grease pencil or masking tape and ink pen to use as a reference for installation 4 Remove replacement windshield 1 from wind shield opening 5 Position...

Page 4012: ... perim eter of windshield along the inside of the moldings Apply two beads along the bottom edge 10 Apply fence primer around the perimeter of the windshield opening fence 1 Allow at least 18 minutes drying time 11 With aid of a helper position windshield 3 over windshield opening Align reference marks at bot tom of windshield to support spacers 2 12 Slowly lower windshield glass to windshield ope...

Page 4013: ...cover and wipers Refer to 23 BODY EXTERIOR COWL GRILLE INSTALLA TION 16 Install inside rear view mirror Refer to 8 ELEC TRICAL POWER MIRRORS AUTOMATIC DAY NIGHT MIRROR INSTALLATION 17 After urethane has cured water test windshield to verify repair 23 452 STATIONARY GLASS ZH ...

Page 4014: ...YDRAULIC PUMP MOTOR 516 INSTALLATION PUMP RESERVOIR 517 SWITCH REMOVAL REMOVAL POWER TOP SWITCH 518 REMOVAL CARGO DIVIDER SWITCH 518 REMOVAL LATCH RETAINER SWITCH 518 REMOVAL ROOF OPEN SWITCH 519 INSTALLATION INSTALLATION POWER TOP SWITCH 523 INSTALLATION CARGO COMPARTMENT DIVIDER SWITCH 524 INSTALLATION LATCH RETAINER SWITCH 524 INSTALLATION ROOF OPEN SWITCH 524 LATCH REMOVAL REMOVAL REAR BOW LAT...

Page 4015: ...e The roof will then fold itself back into a storage compartment behind the seats The motion of the roof and the positioning of its different parts is completely determined by the geometry of the roof structure A scissors like linkage is formed by a set of metal arms and brackets that are linked together by pins The linkage folds down into itself when the roof is open and expands to form the struc...

Page 4016: ...OPERATION ZH CONVERTIBLE TOP 23 455 ...

Page 4017: ...sors and Limit Switches throughout the Power Top Control System to determine hydraulic fluid flow Hydraulically the Power Top Hydraulic Assembly is a self contained unit The Power Top Hydraulic Assembly includes the motor pump and fluid reservoir The Power Top Hydraulic Assembly operates the various hydraulic cylinders and hydraulic latches that work to raise and lower the convertible top The Powe...

Page 4018: ...UNLOCK REAR BOW OPEN TOP ZH CONVERTIBLE TOP 23 457 ...

Page 4019: ...tate of the top When the PTCM senses that the latch retainer switch is open and the roof open switch is open the PTCM will energize the Right Rotation Relay and the Hydraulic Solenoid S3 The Power Top Hydraulic Assembly delivers hydraulic fluid to the following areas Hydraulic fluid is delivered through Hydraulic Solenoid S3 to the base side of both main cylinders to stabilize the top while the re...

Page 4020: ...LIFT REAR BOW OPEN TOP ZH CONVERTIBLE TOP 23 459 ...

Page 4021: ...h Hydraulic Solenoids S2 and S3 to the rod and base side of the main cyl inders to stabilize the top while the rear bow cylinders raise the rear bow Hydraulic fluid is delivered through Hydraulic Solenoid S2 to the rod side of the tonneau cover cylinder to stabilize the cover while the rear bow cylinders raise the rear bow Hydraulic fluid is delivered through Hydraulic Solenoids S3 and S2 to both ...

Page 4022: ...UNLOCK AND OPEN TONNEAU COVER OPEN TOP ZH CONVERTIBLE TOP 23 461 ...

Page 4023: ...e rod side of both rear bow cylinders to stabilize the rear bow while the tonneau cover opens Hydraulic fluid is delivered through Hydraulic Solenoids S2 and S3 to the rod and base side of both main cylinders to stabilize the top while the tonneau cover opens Hydraulic fluid is delivered through Hydraulic Solenoids S2 and then S1 to the base side of the tonneau cover latch cylinder to unlock the t...

Page 4024: ...LOWER REAR BOW OPEN TOP ZH CONVERTIBLE TOP 23 463 ...

Page 4025: ...cylinder to keep the latch unlocked Hydraulic fluid is delivered through Hydraulic Solenoid S3 to the base side of the main cylinders to stabilize the top while the rear bow moves into the cargo compartment Hydraulic Solenoid S1 is activated and holds the hydraulic fluid in the base of both tonneau cover and latch cylinders to stabilize the tonneau cover while the rear bow is being lowered into th...

Page 4026: ...OPENING CONVERTIBLE TOP OPEN TOP ZH CONVERTIBLE TOP 23 465 ...

Page 4027: ...ollowing areas Hydraulic fluid is delivered through Hydraulic Solenoid S2 and then S1 to the rod and base side of the tonneau cover cylinder and the base side of the tonneau cover latch cylinder to stabilize the tonneau cover and latch cylinder while the main cylinders lower the top into the cargo compartment Hydraulic fluid is delivered through Hydraulic Solenoid S2 to the rod side of both main c...

Page 4028: ...CLOSE AND LOCK TONNEAU COVER OPEN TOP ZH CONVERTIBLE TOP 23 467 ...

Page 4029: ...lic fluid The Power Top Hydraulic Assembly delivers hydraulic fluid to the following areas Hydraulic fluid is delivered to the rod side of both main cylinders to stabilize the top in the cargo compartment as the tonneau cover is lowered and locked Hydraulic fluid is delivered to the rod side of the tonneau cover cylinder and the tonneau cover latch cylinder to lower and lock down the tonneau cover...

Page 4030: ...CONVERTIBLE TOP OPEN ZH CONVERTIBLE TOP 23 469 ...

Page 4031: ... lowered and locked by the tonneau cover cylinder travel sensor and the tonneau cover switch the PTCM sends a signal over the CAN B BUS to the instrument cluster to chime indicating that lowering the convertible top is complete 23 470 CONVERTIBLE TOP ZH ...

Page 4032: ...UNLOCK AND OPEN TONNEAU COVER CLOSE ZH CONVERTIBLE TOP 23 471 ...

Page 4033: ...eau cover unlocks and opens Hydraulic fluid is delivered through Hydraulic Solenoid S2 and then S1 to the base side of the tonneau cover latch cylinder to unlock the tonneau cover Hydraulic fluid is delivered through Hydraulic Solenoid S2 and then S1 to both sides of the tonneau cover cylinder to lift the tonneau cover Even though there is hydraulic pressure on both sides of the tonneau cover cyli...

Page 4034: ...CLOSING CONVERTIBLE TOP CLOSE TOP ZH CONVERTIBLE TOP 23 473 ...

Page 4035: ...The PTCM actuates Hydraulic Solenoid S1 to stabilize the tonneau cover cylinder and latch cylinder by locking the hydraulic fluid on the base side of the cylinders Hydraulic fluid is delivered through Hydraulic Solenoid S3 to the base side of the rear bow latch cylinder to keep the latch unlocked Hydraulic fluid is delivered through Hydraulic Solenoid S3 to the base side of both main cylinders to ...

Page 4036: ...LIFT REAR BOW CLOSE TOP ZH CONVERTIBLE TOP 23 475 ...

Page 4037: ...aulic Solenoids S2 and S3 to both sides of the main cylinders to sta bilize the top while the rear bow cylinders raise the rear bow Hydraulic fluid is delivered through Hydraulic Solenoids S2 and then S1 to the rod side and base side of the tonneau cover cylinder and the base side of the tonneau cover latch cylinder to stabilize the cover while the rear bow cylinders raise the rear bow out of the ...

Page 4038: ...CLOSE AND LOCK TONNEAU COVER CLOSE TOP ZH CONVERTIBLE TOP 23 477 ...

Page 4039: ...uid to the following areas Hydraulic Solenoids S2 and S3 are activated to lock hydraulic fluid to both sides of the Main cylinders the base side of the Rear Bow Latch cylinder and the rod side of both Rear Bow cylinders to stabilize the top while the tonneau cover is lowered and locked Hydraulic fluid is delivered to the rod side of the tonneau cover cylinder and tonneau cover latch cylinder to lo...

Page 4040: ...LOWER AND LATCH REAR BOW CLOSE TOP ZH CONVERTIBLE TOP 23 479 ...

Page 4041: ...draulic Solenoid S4 The Power Top Hydraulic Assembly delivers hydraulic fluid to the following areas Hydraulic fluid is delivered through Hydraulic Solenoid S4 to the base side of both rear bow cylinders to lower the rear bow onto the tonneau cover Hydraulic fluid is delivered through Hydraulic Solenoid S4 to the rod side of the rear bow latch cylinder to lock down the rear bow 23 480 CONVERTIBLE ...

Page 4042: ...CONVERTIBLE TOP CLOSED ZH CONVERTIBLE TOP 23 481 ...

Page 4043: ...he ignition OFF and continue to push down on the switch 5 seconds 4 After 5 seconds the hydraulic system pressure will be relieved STANDARD PROCEDURE MANUALLY LOWER TOP Note The pressure from the top hydraulic system must be relieved before attempting to manually lower top Refer to 23 BODY CONVERTIBLE TOP STANDARD PROCEDURE Note Make sure the rear cargo compartment divider is secured in its vertic...

Page 4044: ... header and top of approximately 8 inches 200 mm Once the top is free rotate the release handle back to its stored position 4 Open the decklid and unlock the rear bow by inserting an allen wrench into the rear bow latch 1 and turning counterclockwise ZH CONVERTIBLE TOP 23 483 ...

Page 4045: ...n the rear bow and secure in the vertical position 7 Insert the multifunction tool supplied with vehicle into gap in front of the tonneau cover and rotate counterclockwise until the tonneau cover is released 23 484 CONVERTIBLE TOP ZH ...

Page 4046: ...8 Lift the tonneau cover up and support in the verti cal position 9 Lower the top assembly into the top storage com partment 10 Lower the tonneau cover ZH CONVERTIBLE TOP 23 485 ...

Page 4047: ...rotate clockwise until the tonneau cover is locked STANDARD PROCEDURE MANUALLY RAISE TOP 1 Lower the windows and open the doors 2 Insert the multifunction tool supplied with vehicle into gap in front of the tonneau cover and rotate counterclockwise until the tonneau cover is released 3 Lift the tonneau cover up and support in the verti cal position 23 486 CONVERTIBLE TOP ZH ...

Page 4048: ...rtible top to move it out of its storage area until top is fully extended 5 Lift the rear bow until it is in its vertical position CAUTION The tonneau cover flaps will automati cally extend while lowering the tonneau cover The flaps can be damaged if not allowed to extend automatically 6 Lower the tonneau cover ZH CONVERTIBLE TOP 23 487 ...

Page 4049: ... the multifunction tool supplied with vehicle into gap in front of the tonneau cover and rotate clockwise until the tonneau cover is locked 8 Lower the rear bow into the tonneau cover 23 488 CONVERTIBLE TOP ZH ...

Page 4050: ...bow latch 1 and turning counterclockwise 10 Press the button on the release handle and fold down 11 Turn the release just past one quarter turn clock wise and pull the convertible top frame carefully down until it meets the windshield header attach ment points ZH CONVERTIBLE TOP 23 489 ...

Page 4051: ...nvertible top 13 Fold the latch handle up until the release button engages The convertible top is now locked onto the windshield header 14 Open the decklid and lock the rear bow by insert ing an allen wrench into the rear bow latch 1 and turning clockwise 23 490 CONVERTIBLE TOP ZH ...

Page 4052: ...e Top The cylinders are pressurized with oil from the hydraulic pump assembly through the hydraulic lines 1 and 4 The Main Bow Cylinders have travel sensors 2 and 3 mounted on both the rod side 6 and the base side 10 of the cylinder Rear Bow Cylinders The Rear Bow Hydraulic Cylinders are used to control the movement of the rear bow of the Convertible Top The cylinders are pressurized with oil from...

Page 4053: ...essurized oil through the hydraulic line 1 and into the hydraulic cylinder on the base side of the cylinder The pressurized oil enters the hydraulic cylinder where it fills the cavity 6 and forces the piston 5 to move the rod 3 to a fully extended position 23 492 CONVERTIBLE TOP ZH ...

Page 4054: ...rized oil through the hydraulic line 2 and into the hydraulic cylinder on the rod side of the cylinder The pressurized oil enters the hydraulic cylinder where it fills the cavity 5 and forces the piston 6 to move the rod 3 to a fully retracted position ZH CONVERTIBLE TOP 23 493 ...

Page 4055: ...ut the PTCM can determine the positioning sequence of the convertible top There are two sensors located on the left main hydraulic cylinder and the left rear bow hydraulic cylinder Only the tonneau cover hydraulic cylinder has one sensor The sensors are defined as either the base side 10 or the rod side 6 The travel sensors for the main cylinder and the rear bow cylinder are serviced together The ...

Page 4056: ...RTIBLE TOP HYDRAULIC CYLINDER REMOVAL 6 Remove the cylinder lower retainer 3 and remove the cylinder 1 from the pump bracket 2 REMOVAL MAIN CYLINDER Note Left side shown right side similar 1 Disconnect the negative battery cable 2 Manually raise tonneau cover and support Refer to 23 BODY CONVERTIBLE TOP STANDARD PROCEDURE 3 Remove the upper and lower cylinder retainers 2 4 Remove the main cylinder...

Page 4057: ...wer the convertible top 3 into the stor age area Refer to 23 BODY CONVERTIBLE TOP STANDARD PROCEDURE 3 Secure the tonneau cover 2 in the upright posi tion 4 Remove the front cover retaining screws 1 and retainer 4 5 Remove the front side weather strips 1 23 496 CONVERTIBLE TOP ZH ...

Page 4058: ...assembly in the upright position 8 Remove the top cover from the front bow and fold back to gain access to the front cover retaining strap rivets 1 9 Drill out the front cover retaining strap rivets 1 one on each side left side shown right side similar ZH CONVERTIBLE TOP 23 497 ...

Page 4059: ...isconnect both cover support cables 2 from the front bow 1 left side shown right side similar 11 Remove the top support cable 1 from the cover 2 left side shown right side similar 23 498 CONVERTIBLE TOP ZH ...

Page 4060: ...e retainer left side shown right side similar 13 Drill out the cover side retaining rivets 1 14 Release the cover side retainers from the rear bow support by sliding the cover down and then out left side shown right side similar ZH CONVERTIBLE TOP 23 499 ...

Page 4061: ...or rear bow cylinder travel sensor is faulty all of the main and rear bow cyl inder travel sensors must be replaced 1 Remove the plastic tie wrap 3 from the hydraulic cylinder 2 Rotate the hydraulic line 1 on the hydraulic cylin der in order to gain access to the travel sensor Note The travel sensor is retained by a pressed fit To remove the travel sensor grasp the sensor and gently pry the sensor...

Page 4062: ...Refer to 23 BODY CONVERTIBLE TOP HYDRAULIC PUMP MOTOR INSTALLATION 5 Install the left side trunk trim panel 6 Connect the negative battery cable INSTALLATION MAIN CYLINDER 1 Install the travel sensors on the cylinder left side only 2 Connect the hydraulic lines to the cylinder with a new O rings and retainers 3 Position the main cylinder 1 into the top frame assembly and install the retainers 2 4 ...

Page 4063: ...l sensors to the cylinder 4 left side only 3 Connect the hydraulic lines to the cylinder using new O rings and retainers 4 Install the cover side retainers to the top frame by sliding the retainer into the frame and pushing up to lock into place left side shown right side simi lar 5 Install new retaining rivet 1 left side shown right side similar 23 502 CONVERTIBLE TOP ZH ...

Page 4064: ...6 Install both rear side weather strips 1 left side shown right side similar 7 Install the cover support cables 1 into the cover 2 left side shown right side similar ZH CONVERTIBLE TOP 23 503 ...

Page 4065: ...t cover support cables 2 to the front bow 1 9 Manually place the top in the upright position 10 Attach the front cover retaining straps with new rivets 1 one each side left side shown right side similar 23 504 CONVERTIBLE TOP ZH ...

Page 4066: ...2 Lower the top assembly into the storage area 13 Install the front bow side cover retainer screws 1 left side shown right side similar 14 Install the front side weather strips 1 right side shown left side similar ZH CONVERTIBLE TOP 23 505 ...

Page 4067: ... TRAVEL SENSOR 1 Install the travel sensor 2 to the hydraulic cylin der Note The travel sensor is retained by a pressed fit To install the travel sensor gently press the sensor into the hydraulic cylinder housing 2 Rotate the hydraulic line 1 on the hydraulic cylin der and tuck the line into the groove on the cylin der housing 3 Tie wrap the hydraulic line to cylinder housing using a plastic tie w...

Page 4068: ...e cylinder side of the hydraulic line is a 90 elbow coupler 1 and the pump side of the hydraulic line is a straight coupler 3 The hydraulic lines are identified by a number printed on the outer casing of the line Each line is numbered and must always be placed in the proper cavity in the line retainer plate When replacing the convertible top hydraulic lines always replace as a set ZH CONVERTIBLE T...

Page 4069: ...Top The Main Bow Cylinders 2 Rear Bow Cylinders 1 Ton neau Cover Cylinder 5 Tonneau Cover Latch 6 and the Rear Bow Latch 3 Each hydraulic cylinder has two hydraulic lines one at the base side to raise the cylinder and one at the rod side to lower the cylinder REMOVAL Note The hydraulic lines to the hydraulic cylin ders must be replaced in pairs 23 508 CONVERTIBLE TOP ZH ...

Page 4070: ...e hydraulic cylinder 3 Note If necessary use a small pick to remove the O ring from the hydraulic cylinder 3 Remove the O ring from the hydraulic cylinder 3 4 Remove the bolts 1 from the hydraulic line retain ing plate 2 5 Carefully separate the hydraulic lines from the power top hydraulic assembly 3 ZH CONVERTIBLE TOP 23 509 ...

Page 4071: ...e Always replace all O rings and metal snap rings when servicing the hydraulic lines 1 Starting from the pump side of the hydraulic line straight coupler insert the new hydraulic line through the proper hole location on the line reten tion plate Note The hydraulic line must be inserted into the proper cavity of the pump 2 Slide the cone mechanism of Special Tool 9108 2 onto the coupling end of the...

Page 4072: ...metal snap ring 3 over the cone mechanism of Special Tool 9108 2 4 Using the Special Tool 9108 snap ring installer 4 push the metal snap ring 3 onto the coupling end of the hydraulic line 1 ZH CONVERTIBLE TOP 23 511 ...

Page 4073: ...lic pump 2 Refer to 23 BODY CON VERTIBLE TOP HYDRAULIC PUMP MOTOR REMOVAL 6 At the cylinder side of the hydraulic line install a new O ring 2 onto the hydraulic line coupling 1 7 Insert the hydraulic line into the hydraulic cylinder 3 23 512 CONVERTIBLE TOP ZH ...

Page 4074: ...AULIC PUMP MOTOR DESCRIPTION The Convertible Top is equipped with a stand alone Power Top Hydraulic Assembly The Power PackerT Electrohy draulic Pump consists of a 12 volt DC reversible permanent magnet motor 3 Reservoir 1 Gear Pump 2 Sole noids and Rotational Relays ZH CONVERTIBLE TOP 23 513 ...

Page 4075: ...10 bar 1668 psi 145 psi The left rotation pressure relief valve is set at 140 bar 10 bar 2030 psi 145 psi Rotational Relays The right Rotation Relay 5 and left Rotation Relay 4 control the direction of the pump motor 3 The default of the relays are at ground potential The PTCM controls the battery voltage to energize one of the relays to feed battery voltage to one side of the pump motor 2 and the...

Page 4076: ...er hydraulic cylinder at the tonneau cover hinge 1 5 Disconnect the power top hydraulic assembly har ness connector 2 6 Remove the power top hydraulic assembly retain ing nuts 3 and lift the pump assembly out of the trunk well 7 Remove the three bolts 1 from the hydraulic line retaining plate 8 Separate the hydraulic line retaining plate from the power top hydraulic assembly 9 Remove the power top...

Page 4077: ...OR REMOVAL 3 Remove the reservoir plug 1 and drain fluid 4 Remove the reservoir retaining clamp 3 and remove reservoir 2 from the hydraulic pump assembly INSTALLATION INSTALLATION HYDRAULIC PUMP MOTOR 1 Connect the hydraulic lines and retaining plate 2 to the pump assembly 3 Torque the bolts 1 to 10 N m 89 in lbs using Loctite 270 23 516 CONVERTIBLE TOP ZH ...

Page 4078: ...ONTROL MOD ULES POWER TOP CONTROL MODULE INSTALLATION 6 Install the left trunk trim panel 7 Connect the negative battery cable INSTALLATION PUMP RESERVOIR 1 Install the reservoir 2 onto the hydraulic pump assembly 2 Install the reservoir retaining clamp 3 3 Install the hydraulic pump assembly into the vehi cle 4 Remove the reservoir plug 1 and fill to appropri ate level with the recommended fluid ...

Page 4079: ...onsole 2 REMOVAL CARGO DIVIDER SWITCH Note The cargo compartment divider latch 2 and switch 3 are serviced as an assembly 1 Disconnect the negative battery cable 2 Disconnect the cargo compartment divider switch harness connector 1 3 Remove the cargo compartment divider latch assembly retaining bolt REMOVAL LATCH RETAINER SWITCH The latch retainer switch and the latch retainer are serviced as an a...

Page 4080: ...tch 1 Disconnect the negative battery cable 2 Manually lower the convertible top 3 into the cargo compartment Refer to 23 BODY CON VERTIBLE TOP STANDARD PROCEDURE 3 Secure the tonneau cover 2 in the upright posi tion 4 Remove the front cover retaining screws 1 and retainer 4 5 Remove the front side weather strips 1 right side shown left side similar ZH CONVERTIBLE TOP 23 519 ...

Page 4081: ...ly place the top assembly in the upright position 8 Remove the top cover from the front bow and fold back to gain access to the front cover retaining strap rivets 1 9 Drill out the front cover retaining strap rivets 1 one on each side left side shown right side similar 23 520 CONVERTIBLE TOP ZH ...

Page 4082: ...isconnect both cover support cables 2 from the front bow 1 left side shown right side similar 11 Remove the top support cable 1 from the cover 2 left side shown right side similar ZH CONVERTIBLE TOP 23 521 ...

Page 4083: ...e retainer left side shown right side similar 13 Drill out the cover side retaining rivets 1 14 Release the cover side retainers from the rear bow support by sliding the cover down and then out left side shown right side similar 23 522 CONVERTIBLE TOP ZH ...

Page 4084: ... roof open switch retaining screw from the inside and remove the switch from the top frame 2 INSTALLATION INSTALLATION POWER TOP SWITCH 1 Install the power top switch 1 into the center con sole 2 Connect the power top switch harness connector 3 Install the center console 2 Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION ZH CONVERTIBLE TOP 23 523 ...

Page 4085: ... the negative battery cable INSTALLATION LATCH RETAINER SWITCH The latch retainer switch and the latch retainer are serviced as an assembly Refer to 23 BODY CONVERTIBLE TOP LATCH INSTALLATION INSTALLATION ROOF OPEN SWITCH 1 Install the roof open switch 1 into the top frame 2 and install the retaining screw 2 Connect the latch retainer switch harness connec tor 3 23 524 CONVERTIBLE TOP ZH ...

Page 4086: ...e and pushing up to lock into place 4 Install new retaining rivets 1 left side shown right side similar 5 Install both rear side weather strips 1 left side shown right side similar 6 Connect both of the front cover support cables left side shown right side similar ZH CONVERTIBLE TOP 23 525 ...

Page 4087: ... into the cover 2 left side shown right side similar 8 Manually place the top in the upright position 9 Attached the front cover retaining straps with new rivets 1 one each side left side shown right side similar 23 526 CONVERTIBLE TOP ZH ...

Page 4088: ... front bow 1 left side shown right side similar 11 Install the top to the front bow 12 Lower the top assembly into the storage area 13 Install the front bow side cover retainer screws 1 left side shown right side similar ZH CONVERTIBLE TOP 23 527 ...

Page 4089: ...ips 1 15 Install the front cover retainer 4 and retaining screws 1 16 Lower tonneau cover down and manually lock into place Refer to 23 BODY CONVERTIBLE TOP STANDARD PROCEDURE 17 Connect the negative battery cable 23 528 CONVERTIBLE TOP ZH ...

Page 4090: ...5 Remove the rear bow latch retaining screws 2 and remove the latch assembly from the tonneau cover REMOVAL TONNEAU COVER LATCH 1 Disconnect the negative battery cable 2 Manually open the tonneau cover 3 Disconnect the tonneau cover latch harness con nector 4 Disconnect the hydraulic lines 3 from the tonneau cover latch assembly 2 5 Remove the latch assembly retaining screws 1 and remove the latch...

Page 4091: ... BODY CONVERTIBLE TOP FOLDING TOP COVER REMOVAL 2 Remove the release handle Refer to 23 BODY CONVERTIBLE TOP RELEASE HANDLE REMOVAL 3 Disconnect the latch linkage 1 from the latch assembly 4 Remove the linkage assembly retaining bolts 1 and remove the linkage assembly from the front bow 2 23 530 CONVERTIBLE TOP ZH ...

Page 4092: ...r the convertible top 2 Remove the top catch cover 2 from the front bow 3 3 Disconnect the linkage assembly from the top catch 4 Remove the top catch retaining screws 1 and remove from the front bow 2 ZH CONVERTIBLE TOP 23 531 ...

Page 4093: ... harness connec tor 6 Remove the upper windshield trim panel 7 Disconnect the latch retainer switch harness con nector 5 8 Remove the latch retainer bolts 4 and remove the shim 3 and retainer 2 from the windshield header 1 INSTALLATION INSTALLATION REAR BOW LATCH 1 Install the rear bow latch to the tonneau cover Tighten screws 2 to 8 N m 71 in lbs 2 Connect the hydraulic lines 1 to the rear bow la...

Page 4094: ...t the hydraulic lines 3 to the latch assem bly 3 Connect the tonneau cover latch harness connec tor 4 Manually lower and lock the tonneau cover 5 Connect the negative battery cable INSTALLATION LINKAGE ASSEMBLY 1 Install the linkage assembly to the front bow 2 Tighten screws 1 to 10 N m 89 in lbs ZH CONVERTIBLE TOP 23 533 ...

Page 4095: ...ERTIBLE TOP RELEASE HANDLE INSTALLATION 4 Reassemble the top cover Refer to 23 BODY CONVERTIBLE TOP FOLDING TOP COVER INSTALLATION INSTALLATION TOP CATCH 1 Attach the top catch to the front bow 2 Tighten screws 1 to 10 N m 89 in lbs 2 Connect the linkage assembly to the top catch 23 534 CONVERTIBLE TOP ZH ...

Page 4096: ... m 89 in lbs 2 Connect the latch retainer switch harness connec tor 5 3 Install the upper windshield trim panel 4 Connect the universal transmitter harness connec tor and install the lower windshield trim panel 5 Install the dome lamp assembly 6 Install the right and left sun visors 7 Install both A pillar trim panels Refer to 23 BODY INTERIOR A PILLAR TRIM INSTALLA TION 8 Raise the convertible to...

Page 4097: ...tive battery cable 2 Manually lower the convertible top 3 into the cargo compartment Refer to 23 BODY CON VERTIBLE TOP STANDARD PROCEDURE 3 Secure the tonneau cover 2 in the upright posi tion 4 Remove the front cover retaining screws 1 and retainer 4 5 Remove the front side weather strips 1 right side shown left side similar 23 536 CONVERTIBLE TOP ZH ...

Page 4098: ...ly place the top assembly in the upright position 8 Remove the top cover from the front bow and fold back to gain access to the front cover retaining strap rivets 1 left side shown right side similar 9 Drill out the front cover retaining strap rivets 1 one on each side ZH CONVERTIBLE TOP 23 537 ...

Page 4099: ...10 Disconnect both cover support cables 2 from the front bow 1 11 Remove the top support cable 1 from the cover 2 23 538 CONVERTIBLE TOP ZH ...

Page 4100: ...cover side retainer left side shown right side similar 13 Drill out the cover side retaining rivets 1 one on each side 14 Release the cover side retainers from the rear bow support by sliding the cover down and then out ZH CONVERTIBLE TOP 23 539 ...

Page 4101: ...rew 3 and remove the cable 4 from the top frame REMOVAL DETENT CABLE 1 Partially disassemble the top cover assembly to gain access to the detent cable 2 Refer to 23 BODY CONVERTIBLE TOP FOLDING TOP COVER REMOVAL 2 Remove the detent cable retaining bolt 1 3 Remove the detent cable 2 from the center bow 23 540 CONVERTIBLE TOP ZH ...

Page 4102: ... frame with the retaining screw 3 Tighten screw to 5 N m 44 in lbs 2 Install the cover side retainers to the top frame by sliding the retainer into the frame and pushing up to lock into place one on each side 3 Install the new retaining rivets 1 one on each side ZH CONVERTIBLE TOP 23 541 ...

Page 4103: ...Install both rear side weather strips 1 left side shown right side similar 5 Connect both of the front cover support cables 6 Install the cover support cables 1 into the cover 2 23 542 CONVERTIBLE TOP ZH ...

Page 4104: ...ng straps with new riv ets 1 one on each side 9 Install the top to the front bow 10 Lower the top assembly into the storage area 11 Install the front bow side cover retainer screws 1 left side shown right side similar Tighten the screws to 2 5 N m 22 in lbs ZH CONVERTIBLE TOP 23 543 ...

Page 4105: ...milar 13 Install the front cover retainer 4 and retaining screws 1 Tighten screws to 5 N m 44 in lbs 14 Lower tonneau cover down and manually lock into place Refer to 23 BODY CONVERTIBLE TOP STANDARD PROCEDURE 15 Connect the negative battery cable 23 544 CONVERTIBLE TOP ZH ...

Page 4106: ...e filled at the factory with Pentosin CHF 11S Use Pentosin CHF 11S Mopar part number 05127381AA Pump noise and reduced component life may result if an unapproved fluid is used REAR WINDOW DESCRIPTION The Rear Window is permanently fixed to the Convertible Top cover The Rear Window is made of glass and is equipped with a defogger grid The defogger grid can be repaired but if the Rear Window is dama...

Page 4107: ...lease handle set screw 3 Rotate the release handle back to its normal posi tion and remove the release handle INSTALLATION 1 Install the release handle 2 and rotate clockwise 2 Tighten the release handle set screw 1 3 Rotate the release handle counter clockwise to its normal position 23 546 CONVERTIBLE TOP ZH ...

Page 4108: ...nto the cargo compartment Refer to 23 BODY CON VERTIBLE TOP STANDARD PROCEDURE 3 Secure the tonneau cover 2 in the upright posi tion 4 Remove the front cover retaining screws 1 and retainer 4 5 Remove the left and right front side weather strips 1 right side shown left side similar ZH CONVERTIBLE TOP 23 547 ...

Page 4109: ...own right side similar 7 Manually place the top assembly in the upright position 8 Remove the top cover from the front bow and fold back to gain access to the front cover retaining strap rivets 1 9 Drill out the front cover retaining strap rivets 1 one on each side 23 548 CONVERTIBLE TOP ZH ...

Page 4110: ... right and left cover support cables 2 from the front bow left side shown right side similar 11 Remove the right and left top support cable 1 from the cover 2 left side shown right side similar ZH CONVERTIBLE TOP 23 549 ...

Page 4111: ...e retainer left side shown right side similar 13 Drill out the right and left cover side retaining riv ets 1 left side shown right side similar 14 Release the cover side retainers from the rear bow support by sliding the cover down and then out 23 550 CONVERTIBLE TOP ZH ...

Page 4112: ...ess to the rear cover retaining straps 3 16 Drill out the right and left rear cover retaining strap rivets 2 left side shown right side similar 17 Lift up the rear bow and disconnect the rear defogger harness connectors 1 ZH CONVERTIBLE TOP 23 551 ...

Page 4113: ...Note Use caution when removing the weather strip from the rear bow 18 Remove the rear bow weather strip 2 from the rear bow 1 19 Remove the cover 1 from the rear bow 2 23 552 CONVERTIBLE TOP ZH ...

Page 4114: ...ad rivet 1 from either side of the center bow and reposition the stay pad 3 so the top cover can be removed Note The cover must be removed from the side that the stay pad rivet was removed from 22 Remove the cover assembly 2 by sliding the top cover off the remaining bows ZH CONVERTIBLE TOP 23 553 ...

Page 4115: ...f the cover 1 Align the cover supports with the two center bows Install the cover assembly 1 into the two center bows and guide into the bows slowly Pull the cover assembly slowly until the cover supports are all the way into the center bows 2 Attach the cover stay strap 3 to the center bow with a new rivet 1 23 554 CONVERTIBLE TOP ZH ...

Page 4116: ...The new cover will have a center mark that needs to be aligned with the rear bow latch 3 Install the cover 1 onto the rear bow 2 Push the cover into the rear bow firmly until the cover retain ing clips are engaged into the rear bow 4 Install the rear bow weather strip 2 onto the rear bow 1 ZH CONVERTIBLE TOP 23 555 ...

Page 4117: ... up the rear bow and connect the rear defogger harness connectors 1 6 Install the right and left cover 1 rear retaining straps 3 with new rivets 2 left side shown right side similar 23 556 CONVERTIBLE TOP ZH ...

Page 4118: ...the frame and pushing up to lock into place 8 Install the right and left new retaining rivets 1 left side shown right side similar 9 Install both rear side weather strips 1 10 Connect both of the front cover support cables left side shown right side similar ZH CONVERTIBLE TOP 23 557 ...

Page 4119: ...into the cover 2 left side shown right side similar 12 Manually place the top in the upright position 13 Attached the front cover retaining straps with new rivets 1 one each side left side shown right side similar 23 558 CONVERTIBLE TOP ZH ...

Page 4120: ... shown right side similar 15 Install the top to the front bow 16 Lower the top assembly into the cargo compart ment 17 Install the right and left front bow side cover retainer screws 1 two on each side Tighten the screws to 2 5 N m 22 in lbs ZH CONVERTIBLE TOP 23 559 ...

Page 4121: ...de similar 19 Install the front cover retainer 4 and retaining screws 1 Tighten screw to 5 N m 44 in lbs 20 Lower tonneau cover down and manually lock cover into place Refer to 23 BODY CONVERT IBLE TOP STANDARD PROCEDURE 21 Connect the negative battery cable 23 560 CONVERTIBLE TOP ZH ...

Page 4122: ...TRIP REMOVAL 564 INSTALLATION 565 REAR BOW WEATHERSTRIPS REMOVAL 565 INSTALLATION 566 TONNEAU COVER WEATHERSTRIP REMOVAL 566 INSTALLATION 567 HEADER A PILLAR WEATHERSTRIP REMOVAL 1 Using a trim stick or other suitable device carefully pry up the inner edge 2 Grasp the edge of the weatherstrip and pull out ward to remove the seal from the a pillar and header ZH WEATHERSTRIP SEALS 23 561 ...

Page 4123: ...n the header and pillar 2 Firmly press downward to seat the weatherstrip in the flange CONVERTIBLE RAIL WEATHERSTRIP REMOVAL 1 Open the convertible top half way 2 Remove the convertible top side rail weatherstrip 1 23 562 WEATHERSTRIP SEALS ZH ...

Page 4124: ...3 Pull the rear weatherstrip away from the bow INSTALLATION 1 Firmly press the rear weatherstrip 1 into the bow ZH WEATHERSTRIP SEALS 23 563 ...

Page 4125: ...the bow 3 Lower the convertible top TRUNK OPENING WEATHERSTRIP REMOVAL 1 Using a trim stick or other suitable device carefully pry up the inner edge 2 Grasp the edge of the weatherstrip 1 and pull out ward to remove the seal from the trunk 23 564 WEATHERSTRIP SEALS ZH ...

Page 4126: ...ward to install the seal to the trunk REAR BOW WEATHERSTRIPS REMOVAL 1 Using a trim stick or other suitable device carefully pry up the inner edge 2 Grasp the edge of the weatherstrip and pull out ward to remove the seal from the rear bow ZH WEATHERSTRIP SEALS 23 565 ...

Page 4127: ...erstrip in the rear bow TONNEAU COVER WEATHERSTRIP REMOVAL 1 Open the convertible top half way 2 Using a trim stick or other suitable device carefully pry up the inner edge 3 Grasp the edge of the weatherstrip 1 and pull out ward to remove the seal from the tonneau opening 23 566 WEATHERSTRIP SEALS ZH ...

Page 4128: ...INSTALLATION 1 Position the weatherstrip 1 on the tonneau cover opening 2 Firmly press downward to seat the weatherstrip in the flange 3 Close the convertible top ZH WEATHERSTRIP SEALS 23 567 ...

Page 4129: ......

Page 4130: ...ND DIAGRAMS 60 HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS DESCRIPTION To maintain the performance level of the heating air conditioning system the engine cooling system must be prop erly maintained Any obstructions in front of the radiator or condenser will reduce the performance of the air con ditioning and engine cooling systems The heating system includes the radiator heater core and the h...

Page 4131: ...mines the discharge air temperature by energizing the blend door actuator which operates the blend door This allows an almost immediate control of the output air temperature of the system The mode control on the A C heater control panel is used to direct the conditioned air to the selected system out lets The mode control uses engine vacuum to control the mode doors which are operated by vacuum ac...

Page 4132: ...AMBIENT TEMPERATURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 3 ...

Page 4133: ...IR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Ambient Temperature Sensor voltage Does the DRB IIIT display AMBIENT TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Ambient Tempe...

Page 4134: ...R CONDITIONING CONTROLS AMBIENT TEMP SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Instrument Cluster C1 harness connector Note Check connector Clean repair as necessary Measure the resistance of the Ambient Temperature Sensor Signal cir cuit from the Instrument Cluster harness connector ...

Page 4135: ...LECTRI CAL INSTRUMENT CLUSTER REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Ambient Temperature Sensor harness connector Note Check connector Clean repair as necessary Turn the ignition on With the DRB IIIT read the Ambient Temperature...

Page 4136: ... BODY VERIFICATION TEST No Go to 8 8 READ A C HEATER CONTROL MODULE DTC S WITH DRB IIIT Ensure the Ambient Temperature Sensor is connected at this time Start the engine Turn the A C system on and run for at least five minutes With the DRB IIIT read A C Heater Control Module DTC s Does the DRB IIIT display Ambient Temperature Sensor Failure DTC Yes Replace the Ambient Temperature Sensor Perform BOD...

Page 4137: ... Perform BODY VERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE FROM THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance from the Ambient Temperature Sensor Signal circuit to the Sensor Ground circuit at the Ambient Temperature Sen sor connector Is the resistance below 1000 0 ohms Yes Repair the Ambient Temperature Sensor Si...

Page 4138: ...LEFT HEATER CORE TEMPERATURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 9 ...

Page 4139: ...ICS AND DIA GRAMS Diagnostic Test 1 READ LEFT HEATER CORE TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Left Heater Core Temperature Sensor volt age Does the DRB IIIT display LEFT HEATER CORE TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF THE LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the...

Page 4140: ... AIR CONDITIONING CONTROLS TEM PERATURE SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Left Heater Core Temperature Sensor Signal circuit from the A C Heater Co...

Page 4141: ...ONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ LEFT HEATER CORE TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Heater Core Temperature Sensor harness connector Note Check connector Clean repair as necessary Turn the ignition on With the DRB IIIT read the ...

Page 4142: ...EMOVAL Perform BODY VERIFICATION TEST No Go to 8 8 READ A C HEATER CONTROL MODULE DTC S WITH DRB IIIT Ensure the Heater Core Temperature Sensor is connected at this time Start the engine Turn the A C system on With the DRB IIIT read A C Heater Control Module DTC s Does the DRB IIIT display Left Heater Core Temperature Sensor Failure DTC Yes Replace the Heater Core Temperature Sensor Refer to 24 HE...

Page 4143: ...BODY VERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE FROM THE LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance from the Left Heater Core Temperature Sensor Signal circuit to the Sensor Ground circuit at the Heater Core Temper ature Sensor connector Is the resistance below 1000 0 ohms Yes Repair the Left Heater Core...

Page 4144: ...RIGHT HEATER CORE TEMPERATURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 15 ...

Page 4145: ...TICS AND DIA GRAMS Diagnostic Test 1 READ RIGHT HEATER CORE TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Right Heater Core Temperature Sensor voltage Does the DRB IIIT display Right HEATER CORE TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF THE RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect...

Page 4146: ...G AIR CONDITIONING CONTROLS TEM PERATURE SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Right Heater Core Temperature Sensor Signal circuit from the A C Heater...

Page 4147: ...ONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ RIGHT HEATER CORE TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Heater Core Temperature Sensor harness connector Note Check connector Clean repair as necessary Turn the ignition on With the DRB IIIT read the...

Page 4148: ...REMOVAL Perform BODY VERIFICATION TEST No Go to 8 8 READ A C HEATER CONTROL MODULE DTC S WITH DRB IIIT Ensure the Heater Core Temperature Sensor is connected at this time Start the engine Turn the A C system on With the DRB IIIT read A C Heater Control Module DTC s Does the DRB IIIT display Right Heater Core Temperature Sen sor Failure DTC Yes Replace the Heater Core Temperature Sensor Refer to 24...

Page 4149: ...BODY VERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE FROM THE RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance from the Right Heater Core Temperature Sen sor Signal circuit to the Sensor Ground circuit at the Heater Core Tem perature Sensor connector Is the resistance below 1000 0 ohms Yes Repair the Right Heater ...

Page 4150: ...EVAPORATOR TEMPERATURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 21 ...

Page 4151: ...TICS AND DIA GRAMS Diagnostic Test 1 READ EVAPORATOR TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Evaporator Temperature Sensor voltage Does the DRB IIIT display EVAP TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF THE EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Evaporator Temperature Sensor...

Page 4152: ...NG CONTROLS EVAPO RATOR TEMPERATURE SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Evaporator Temperature Sensor Signal circuit from the A C Heater Control Module har...

Page 4153: ...TING AIR CONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ EVAPORATOR TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Evaporator Temperature Sensor harness connector Note Check connector Clean repair as necessary Turn the ignition on With the DRB IIIT read t...

Page 4154: ...8 READ A C HEATER CONTROL MODULE DTC S WITH DRB IIIT Ensure the Evaporator Temperature Sensor is connected at this time Start the engine Turn the A C system on and run for at least five minutes so water will form on the Evaporator Temperature Sensor With the DRB IIIT read A C Heater Control Module DTC s Does the DRB IIIT display an Evaporator Temperature Sensor Failure DTC Yes Replace the Evaporat...

Page 4155: ...ERIFICATION TEST No Go to 10 10 MEASURE THE RESISTANCE FROM THE EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance from the Evaporator Temperature Sensor Sig nal circuit to the Sensor Ground circuit at the Evaporator Temperature Sensor harness connector Is the resistance below 1000 0 ohms Yes Repair the Evaporator Temperature Sens...

Page 4156: ...ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 27 ...

Page 4157: ... CONTROL MODULE For a complete HVAC Circuit Diagram Refer to 24 HEATING AIR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 READ ENGINE COOLANT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition on With the DRB IIIT read the Engine Coolant Temperature Sensor volt age Does the DRB IIIT display ENGINE COOLANT TEMP 5 0 VOLTS or greater Yes Go to 2 No Go to 6 2 MEASURE THE VOLTAGE OF T...

Page 4158: ...LING ENGINE ENGINE COOLANT TEMP SENSOR REMOVAL Perform BODY VERIFICATION TEST 4 MEASURE THE RESISTANCE OF THE ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off Disconnect the Powertrain Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Engine Coolant Temperature Sensor Signal circuit from the Powertrain Control Module...

Page 4159: ...IC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform BODY VERIFICATION TEST No Repair the Sensor Ground circuit for an open Perform BODY VERIFICATION TEST 6 READ ENGINE COOLANT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT Turn the ignition off Disconnect the Engine Coolant Temperature Sensor harness connec tor Note Check connector Clean repair as necessary Turn the ignition on With the DRB II...

Page 4160: ...r Control Module DTC s Does the DRB IIIT display an Engine Coolant Temperature Sen sor Failure DTC Yes Replace the Engine Coolant Temperature Sensor Refer to 7 COOLING ENGINE ENGINE COOLANT TEMP SENSOR REMOVAL Perform BODY VERIFICATION TEST No The condition that caused this DTC to set is currently not present Inspect the related wiring harness for a possible intermittent condition Perform BODY VER...

Page 4161: ... the Sensor Ground circuit at the Engine Coolant Tem perature Sensor harness connector Is the resistance below 1000 0 ohms Yes Repair the Engine Coolant Temperature Sensor Signal cir cuit for a short to the Sensor Ground circuit Perform BODY VERIFICATION TEST No Replace the Powertrain Control Module Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POW ERTRAIN CONTROL MODULE REMOVAL Perform BODY VE...

Page 4162: ...A C PRESSURE SENSOR CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 33 ...

Page 4163: ...D TO SENSOR GROUND CIRCUIT A C PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT OPEN A C PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND A C PRESSURE SENSOR A C PRESSURE SENSOR SIGNAL CIRCUIT OPEN A C PRESSURE SENSOR GROUND CIRCUIT OPEN A C HEATER CONTROL MODULE For a complete HVAC Circuit Diagram Refer to 24 HEATING AIR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 READ A C PRESSURE SENSOR...

Page 4164: ...TEST No Go to 3 3 MEASURE THE VOLTAGE ON THE A C PRESSURE SENSOR SIGNAL CIRCUIT Turn the ignition on Measure the voltage on the A C Pressure Sensor Signal circuit at the A C Pressure Sensor harness connector Is the voltage above 5 2 volts Yes Repair the A C Pressure Sensor Signal circuit for a short to battery voltage Perform BODY VERIFICATION TEST No Go to 4 4 MONITOR A C PRESSURE SENSOR VOLTAGE ...

Page 4165: ...n open Perform BODY VERIFICATION TEST 6 MEASURE THE RESISTANCE BETWEEN GROUND AND THE A C PRESSURE SENSOR GROUND CIRCUIT With the ignition off Measure the resistance between ground and the A C Pressure Sensor Ground circuit at the A C Pressure Sensor harness connector Is the resistance below 30 ohms Yes Replace the A C Heater Control Module Refer to 24 HEATING AIR CONDITIONING CONTROLS HEATER CONT...

Page 4166: ...isconnect the A C Pressure Sensor harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of the 5 Volt Supply circuit at the A C Pressure Sensor harness connector Is the voltage between 4 5 and 5 0 volts Yes Go to 9 No Go to 12 9 MONITOR A C PRESSURE SENSOR VOLTAGE WITH DRB IIIT With the ignition on With the DRB IIIT monitor the A C Pressure Senso...

Page 4167: ...C Pressure Sensor Signal circuit to the Sensor Ground circuit at the A C Pressure Sensor harness con nector Is the resistance below 100 ohms Yes Repair the A C Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform BODY VERIFICATION TEST No Replace the A C Heater Control Module Refer to 24 HEATING AIR CONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION T...

Page 4168: ...e Sensor harness connector to the A C Heater Control Module har ness connector Is the resistance below 5 0 ohms Yes Replace the A C Heater Control Module Refer to 24 HEATING AIR CONDITIONING CONTROLS HEATER CONTROL REMOVAL Perform BODY VERIFICATION TEST No Repair the A C Pressure Sensor 5 Volt Supply circuit for an open Perform BODY VERIFICATION TEST ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOST...

Page 4169: ...COOLANT CIRCULATION PUMP CIRCUIT 24 40 HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS ZH ...

Page 4170: ...IONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 MEASURE COOLANT CIRCULATION PUMP VOLTAGE Note Inspect Fuse 15 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Coolant Circulation Pump harness connector Note Check connector Clean repair as necessary Measure the voltage of the Fused B circuit ...

Page 4171: ... Circulation Pump Control circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE VOLTAGE OF THE COOLANT CIRCULATION PUMP CONTROL CIRCUIT With the ignition off Reconnect the Coolant Circulation Pump harness connector Measure the voltage of the Coolant Circulation Pump Control circuit at the A C Heater Control Module harness connector Is the voltage above 10 volts Yes Replace the A C Heate...

Page 4172: ...LEFT COOLANT CIRCULATION VALVE CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 43 ...

Page 4173: ...AIR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 MEASURE COOLANT CIRCULATION VALVE VOLTAGE Note Inspect Fuse 15 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Coolant Circulation Valve harness connector Note Check connector Clean repair as necessary Measure the voltage of the Fuse...

Page 4174: ...air the Left Coolant Circulation Valve Control circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE VOLTAGE OF THE LEFT COOLANT CIRCULATION VALVE CONTROL CIRCUIT With the ignition off Reconnect the Coolant Circulation Valve harness connector Measure the voltage of the Left Coolant Circulation Valve Control cir cuit at the A C Heater Control Module harness connector Is the voltage above...

Page 4175: ...RIGHT COOLANT CIRCULATION VALVE CIRCUIT 24 46 HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS ZH ...

Page 4176: ...G AIR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 MEASURE COOLANT CIRCULATION VALVE VOLTAGE Note Inspect Fuse 15 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Turn the ignition off Disconnect the Coolant Circulation Valve harness connector Note Check connector Clean repair as necessary Measure the voltage of the Fu...

Page 4177: ...air the Right Coolant Circulation Valve Control circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE VOLTAGE OF THE RIGHT COOLANT CIRCULATION VALVE CONTROL CIRCUIT With the ignition off Reconnect the Coolant Circulation Valve harness connector Measure the voltage of the Right Coolant Circulation Valve Control cir cuit at the A C Heater Control Module harness connector Is the voltage ab...

Page 4178: ...A C COMPRESSOR CLUTCH CIRCUIT ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 49 ...

Page 4179: ...MODULE For a complete HVAC Circuit Diagram Refer to 24 HEATING AIR CONDITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 TEST THE A C COMPRESSOR CLUTCH Turn the ignition off Disconnect the inline connector C106 in the underhood relay control module compartment Note Check connector Clean repair as necessary Using a jumper wire to battery power energize the A C Compressor clutch Does the A C Compr...

Page 4180: ...CATION TEST No Repair the A C Compressor Clutch signal circuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE RESISTANCE OF THE A C COMPRESSOR CLUTCH SIGNAL CIRCUIT With the ignition off Disconnect the A C Compressor Clutch connector Note Check connector Clean repair as necessary Measure the resistance of the A C Compressor Clutch signal circuit from the inline connector C106 to the A C ...

Page 4181: ...RECIRCULATED AIR SWITCHOVER VALVE CIRCUIT 24 52 HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS ZH ...

Page 4182: ...ITIONING SCHEMATICS AND DIA GRAMS Diagnostic Test 1 MEASURE RECIRCULATED AIR SWITCHOVER VALVE VOLTAGE Note Inspect Fuse 37 located in the Underhood Accessory Fuse Block If the fuse is open repair the cause of the open fuse before continuing Disconnect the Recirculated Air Switchover Valve harness connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage of t...

Page 4183: ... 0 ohms Yes Go to 3 No Repair the Recirculated Air Switchover Valve Control cir cuit for an open Perform BODY VERIFICATION TEST 3 MEASURE THE VOLTAGE OF THE RECIRCULATED AIR SWITCHOVER VALVE CONTROL CIRCUIT Reconnect the Recirculated Air Switchover Valve connector Turn the ignition on Measure the voltage of the Recirculated Air Switchover Valve Control circuit at the A C Heater Control Module harn...

Page 4184: ...NO COMMUNICATION FROM INSTRUMENT CLUSTER ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 55 ...

Page 4185: ... Turn the ignition off Disconnect the Instrument Cluster harness connector Note Check connector Clean repair as necessary Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Serial Communication K1 circuit from the Instrument Cluster harness connector to the A C Heater Control Module harness connector Is the resist...

Page 4186: ...NO COMMUNICATION TO INSTRUMENT CLUSTER ZH HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS 24 57 ...

Page 4187: ...Turn the ignition off Disconnect the Instrument Cluster harness connector Note Check connector Clean repair as necessary Disconnect the A C Heater Control Module harness connector Note Check connector Clean repair as necessary Measure the resistance of the Serial Communication K2 circuit from the Instrument Cluster harness connector to the A C Heater Control Module harness connector Is the resista...

Page 4188: ...rs and other options as necessary With the DRB IIIT erase all Diagnostic Trouble Codes DTCs from ALL modules Start the engine and allow it to run for 2 minutes Operate all functions of the system that caused the original complaint Ensure that all accessories are turned off and the battery is fully charged Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRB IIIT read DTC...

Page 4189: ...SCHEMATICS AND DIAGRAMS 24 60 HEATING AIR CONDITIONING ELECTRICAL DIAGNOSTICS ZH ...

Page 4190: ...VERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST EXPOSURE MAY IRRI TATE THE EYES NOSE AND OR THROAT WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDI TIONING REFRIGERANT SYSTEM SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT IF EYE ...

Page 4191: ...he refrigerant system seal the open fittings with a cap or plug Before connecting an open refrigerant fitting always install a new seal or gasket Coat the fitting and seal with clean refrigerant oil before connecting Do not remove the sealing caps from a replacement component until it is to be installed When installing a refrigerant line avoid sharp bends that may restrict refrigerant flow Positio...

Page 4192: ...t System REST system enables the vehicle to be heated with the Ignition OFF The REST switch 4 in the Heater A C Con trols activates this system DESCRIPTION REFRIGERANT SYSTEM SERVICE PORT Note Unique service port coupler sizes are used on the R 134a system to ensure that the refrigerant sys tem is not accidentally contaminated by the use of the wrong refrigerant R 12 or refrigerant system ser vice...

Page 4193: ...rant system The high pressure service port 1 is located on the liquid line near the front of the engine compartment behind the front grille The low pressure service port 1 is located on the suction line on the left side of the engine compartment near the shock mounting 24 64 HEATING AIR CONDITIONING SERVICE INFORMATION ZH ...

Page 4194: ...penings clear of debris because leaf particles and other debris that is small enough to pass through the cowl plenum screen can accumulate within the HVAC housing This closed warm damp and dark environment created within the HVAC housing is ideal for the growth of certain molds mildews and other fungi Any accumulation of decaying plant matter provides an additional food source for fungal spores wh...

Page 4195: ...erant 4 evaporates in the evaporator 1 This evaporation process absorbs heat from the fresh air flowing across the system of tubes and honeycombs therefore cooling the air that is blown into the passen ger compartment The low pressure gas then returns to the A C compressor The moisture in the fresh air is condensed out and the condensation drained to the outside through a drain in the HVAC housing...

Page 4196: ... is transferred to the air in the passenger compartment The coolant flowing through the Heater Core 4 is controlled by a Coolant Circulation Valve 6 located in the coolant return The coolant can be controlled separately for the left and right sides The coolant returns to the Water Pump 7 via the coolant return hose A Coolant Circulation Pump 5 is installed between the Coolant Circulation Valve 6 a...

Page 4197: ... around the Heater Core 3 A temperature control knob on the A C Heater Control Panel determines the discharge air temperature by energizing the Blend Door Actuator which operates the Blend Door This allows an almost immediate control of the output air temperature of the system R E S T SYSTEM 24 68 HEATING AIR CONDITIONING SERVICE INFORMATION ZH ...

Page 4198: ... is active OPERATION REST SYSTEM The REST system is activated by a switch in the Heater A C Controls when the ignition is turned OFF This sys tem circulates residual heat from the engine to the Heater Core The coolant is recirculated by an auxiliary coolant pump mounted below the right front headlamp The temperature is automatically adjusted according to the temper ature setting in the Heater A C ...

Page 4199: ...t lower the tem perature of the moisture in the air that condenses on the evaporator fins Condensing the moisture in the air trans fers heat energy into the Evaporator fins and tubing This reduces the amount of heat the Evaporator can absorb from the air High humidity greatly reduces the ability of the Evaporator to lower the temperature of the air However Evaporator capacity used to reduce the am...

Page 4200: ...he discharge air temperature to the Performance Temperature and Pressure chart Performance Temperature and Pressure Ambient Air Temperature and Humidity 21 C 70 F 80 humidity 27 C 80 F 80 humidity 32 C 90 F 80 humidity 38 C 100 F 50 humidity 43 C 110 F 20 humidity Air Temperature at Center Panel Outlet 10 to 13 C 50 to 55 F 14 to 17 C 58 to 63 F 15 to 18 C 60 to 65 F 17 to 20 C 63 to 68 F 14 to 17...

Page 4201: ...properly 2 Inspect the blend door for proper operation and sealing and correct if required 3 Blend door actuator faulty or inoperative 3 Replace if faulty The low side pressure is normal or slightly low and the high side pressure is too low 1 Low refrigerant system charge 1 Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 2 Refrigerant flow throug...

Page 4202: ... kinks tight bends or improper routing Correct the routing or replace the refrigerant line if required 2 Restricted refrigerant flow through the A C Expansion Valve 2 Replace the Expansion Valve if restricted 3 Restricted refrigerant flow through the condenser 3 Replace the restricted condenser if required DIAGNOSIS AND TESTING HEATER PERFORMANCE Before performing the following tests refer to Cool...

Page 4203: ...oolant supply heater hose If the return hose is much cooler than the supply hose locate and repair the engine coolant flow obstruction in the cooling system Refer to the Cooling section for the procedures OBSTRUCTED COOLANT FLOW Possible locations or causes of obstructed coolant flow Pinched or kinked heater hoses Improper heater hose routing Plugged heater hoses or supply and return ports at the ...

Page 4204: ... switched back on in the cycled mode stage 1 A C PRESSURE TRANSDUCER Refrigerant pressure 2 bar A C compressor off Refrigerant pressure 28 bar A C compressor off CONTROL HEAD Manual type DRB IIIT MODE DOORS Vacuum BLEND DOOR Vacuum BLOWER MOTOR Resistor block CLUTCH Electromagnetic Coil DRAW DRB IIIT SPECIFICATIONS CHARGE CAPACITY The R 134a refrigerant system charge capacity for this vehicle is 0...

Page 4205: ...NSOR REMOVAL 87 INSTALLATION 88 HEATER CORE TEMPERATURE SENSOR REMOVAL 88 INSTALLATION 89 A C PRESSURE TRANSDUCER REMOVAL 89 INSTALLATION 90 RECIRC AIR SWITCHOVER VALVE REMOVAL 90 INSTALLATION 91 A C COMPRESSOR CLUTCH DESCRIPTION The pulley 1 on the A C compressor drive shaft 4 is driven by the poly V belt The clutch turns on the ball bearing 3 around the magnetic coil 5 fastened to the A C compre...

Page 4206: ...DIAGNOSIS AND TESTING COMPRESSOR CLUTCH COIL For circuit descriptions and diagrams refer to the appropriate wiring diagrams The battery must be fully charged before performing the following tests Refer to Battery for more information 1 Connect an ammeter 0 to 10 ampere scale in series with the clutch coil terminal Use a voltmeter 0 to 20 volt scale with clip type leads for measuring the voltage ac...

Page 4207: ...PROCEDURE COMPRESSOR CLUTCH BREAK IN After a new compressor clutch has been installed cycle the compressor clutch approximately twenty times five seconds on then five seconds off During this procedure set the A C Heater control in the Recirculation Mode the A C button in the on position the blower motor switch in the highest speed position and the engine speed at 1500 to 2000 rpm This procedure bu...

Page 4208: ...The electrical leads are a one way connec tion to the blower motor 5 Disconnect the electrical leads blue 2 and red 3 6 Remove the screws 1 attaching the blower motor regulator 4 to the blower motor assembly 7 Remove the electronic blower motor 4 regulator from the assembly ZH CONTROLS 24 79 ...

Page 4209: ... the screws 1 attaching the blower motor regulator to the blower motor assembly Note The electrical leads are a one way connec tion to the blower motor 3 Connect the electrical leads blue 2 and red 3 4 Swing the blower motor door up 5 Slide the motor door catch mounts 1 to the inside 24 80 CONTROLS ZH ...

Page 4210: ...6 Connect the blower motor electrical connector 1 7 Install the lower instrument panel cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION ZH CONTROLS 24 81 ...

Page 4211: ...s to exceed the needs of either front seat occupant The A C Heater Control Module panels are serviced only as complete units and cannot be repaired If faulty or damaged the entire A C Heater Control Module must be replaced The A C Heater Control Module makes it possible to make adjustments coming from the driver such as Temperature by setting the temperature thumb wheels 2 and 5 Air quantity by ad...

Page 4212: ... AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNO SIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect the negative battery cable 2 Remove the radio Refer to 8 ELECTRICAL AU DIO RADIO REMOVAL 3 Remove the center console panel screws ...

Page 4213: ...AG SYSTEM BEFORE ATTEMPT ING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE CONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNO SIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN AC...

Page 4214: ...eater control module 2 by press ing in the catch lugs 1 at the sides 3 Install the center console panel screws 1 2 Refer to 23 BODY INTERIOR CENTER CON SOLE INSTALLATION 4 Install the radio Refer to 8 ELECTRICAL AUDIO RADIO INSTALLATION 5 Connect the negative battery cable ZH CONTROLS 24 85 ...

Page 4215: ... panel 3 Open the installation flap for left fog lamp located in the left inner fenderwell towards the front 4 Disconnect the ambient air temperature harness connector 2 located next to the front fascia mount 1 5 Unclip the ambient air temperature from the front bumper support 24 86 CONTROLS ZH ...

Page 4216: ...inner fenderwell 4 Install the engine compartment lower panel 5 Connect the negative battery cable EVAPORATOR TEMPERATURE SENSOR REMOVAL 1 Remove the center console Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 2 Remove the evaporator temperature sensor located on the left side of the heater A C case 3 Disconnect the evaporator temperature sensor har ness connector from the sensor ZH CONTROLS 2...

Page 4217: ...l the center console Refer to 23 BODY IN TERIOR CENTER CONSOLE INSTALLATION HEATER CORE TEMPERATURE SENSOR REMOVAL 1 Remove the center console Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 2 Remove the heater core temperature sensor 1 located on the front of the heater A C case 2 3 Disconnect the heater core temperature sensor harness connector from the sensor 24 88 CONTROLS ZH ...

Page 4218: ...ter A C case 2 3 Install the center console Refer to 23 BODY IN TERIOR CENTER CONSOLE INSTALLATION A C PRESSURE TRANSDUCER REMOVAL 1 Evacuate the A C system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE 2 Disconnect the A C pressure transducer harness connector 2 3 Remove the A C pressure transducer from the receiver dryer 1 ZH CONTROLS 24 89 ...

Page 4219: ...ING PLUMBING STANDARD PROCEDURE RECIRC AIR SWITCHOVER VALVE REMOVAL 1 Remove the glove compartment Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX REMOVAL 2 Disconnect the vacuum lines 1 from the recircula tion switchover valve 3 Disconnect the recirculation switchover valve har ness connector from the recirculation switchover valve 4 Remove the recirculation switchover valve 24 90 CONTROLS ZH ...

Page 4220: ...ct the recirculation switchover valve harness connector to the recirculation switchover valve 3 Connect the vacuum lines 1 to the recirculation switchover valve 4 Install the glove compartment Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX INSTALLATION ZH CONTROLS 24 91 ...

Page 4221: ...IDE AIR NOZZLE 122 REMOVAL CENTER AIR NOZZLE 122 INSTALLATION SIDE AIR NOZZLE 123 INSTALLATION CENTER AIR NOZZLE 123 DEFROSTER DUCTS REMOVAL 124 INSTALLATION 124 FLOOR DISTRIBUTION DUCTS REMOVAL FOOTWELL AIR OUTLET COVER 125 INSTALLATION FOOTWELL AIR OUTLET COVER 126 BLOWER MOTOR REMOVAL REMOVAL 1 Remove the lower instrument panel cover 2 from the instrument panel 1 Refer to 23 BODY IN STRUMENT PA...

Page 4222: ... in the blower motor door 3 Slide the blower motor door catch mounts 1 to the sides 4 Swing the blower motor door down 5 Remove the screws 1 attaching the blower motor to the heater housing 6 Remove the blower motor and squirrel cage as an assembly ZH DISTRIBUTION 24 93 ...

Page 4223: ...nect the negative battery cable 2 Remove the left lower instrument panel cover 2 from the instrument panel 1 3 Disconnect the blower motor harness connector 1 from the relief in the blower motor door 24 94 DISTRIBUTION ZH ...

Page 4224: ...tor door catch mounts 1 to the sides 5 Swing the blower motor door down 6 Remove the screws 1 attaching the blower motor to the heater housing 7 Remove the blower motor and squirrel cage as an assembly ZH DISTRIBUTION 24 95 ...

Page 4225: ...motor and squirrel cage as an assembly 2 Install the screws 1 attaching the blower motor to the heater housing 3 Swing the blower motor door up 4 Install the blower motor door catch mounts 1 by sliding them over to the detents 24 96 DISTRIBUTION ZH ...

Page 4226: ...5 Connect the blower motor electrical connector 1 6 Install the lower instrument panel cover 2 Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY INSTALLATION ZH DISTRIBUTION 24 97 ...

Page 4227: ...r and squirrel cage as an assembly 2 Install the screws 1 attaching the blower motor to the heater housing 3 Swing the blower motor door up 4 Install the blower motor door catch mounts 1 by sliding them over to the detents 24 98 DISTRIBUTION ZH ...

Page 4228: ...5 Connect the blower motor harness connector 1 6 Install the left lower instrument panel cover 2 7 Connect the negative battery cable ZH DISTRIBUTION 24 99 ...

Page 4229: ...S DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIR BAG FRONT IMPACT SENSOR SIDE IMPACT SENSOR SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVI...

Page 4230: ...talling a refrigerant line avoid sharp bends that may restrict refrigerant flow Position the refrig erant lines away from exhaust system components or any sharp edges which may damage the line Tighten refrigerant fittings only to the specified torque The aluminum fittings used in the refrigerant system will not tolerate overtightening When disconnecting a refrigerant fitting use a wrench on both h...

Page 4231: ...head then remove the two A C hoses from the expansion valve 7 Remove the instrument panel top section 1 Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY REMOVAL 8 Remove the lower instrument panel 2 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 24 102 DISTRIBUTION ZH ...

Page 4232: ...ICAL INSTRUMENT CLUSTER REMOVAL 13 Remove the Sentry Key Remote Entry Module SKREEM by Disconnect the 2 pin CAN harness connector from the SKREEM 1 Disconnect the 2 pin harness connector for the transponder coil 1 Disconnect the 18 pin harness connector 1 Press the retaining tabs apart 1 Remove the SKREEM control module from the base plate Note This is necessary to remove the instrument panel supp...

Page 4233: ... not necessary to fully remove the steer ing column from the vehicle 17 Relocate the steering column out of the working area WARNING BE SURE YOU HAVE TAKEN THE NEC ESSARY PRECAUTIONS TO DISABLE THE AIR BAG SYSTEM 18 Remove the electrical harness connector 1 on passenger airbag module 19 Remove the heater ducts on left and right side of the instrument panel support 24 104 DISTRIBUTION ZH ...

Page 4234: ...ove the bolts from the instrument panel sup port attaching it to the body transmission tunnel 22 Remove the bolts 1 attaching the instrument panel support to the front of the vehicle bulkhead 23 Remove the bolts 1 attaching the instrument panel support to the A pillars ZH DISTRIBUTION 24 105 ...

Page 4235: ...cal harness connector from the fresh air recirculating air flap switchover valve 1 located on the right front of the heater housing where the vacuum lines for the reservoir where removed 28 Remove all the nylon ties on the heater housing attaching any wiring harnesses CAUTION To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support CAUTION B...

Page 4236: ... THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIR BAG FRONT IMPACT SENSOR SIDE IMPACT SENSOR SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS I...

Page 4237: ...he refrigerant system seal the open fittings with a cap or plug Before connecting an open refrigerant fitting always install a new seal or gasket Coat the fitting and seal with clean refrigerant oil before connecting Do not remove the sealing caps from a replacement component until it is to be installed When installing a refrigerant line avoid sharp bends that may restrict refrigerant flow Positio...

Page 4238: ...NDI TIONING PLUMBING A C EXPANSION VALVE REMOVAL 4 Drain the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 5 Disconnect the right side heater hoses 1 6 Disconnect the heater hose behind the battery on the left side of the engine compartment ZH DISTRIBUTION 24 109 ...

Page 4239: ...EMBLY REMOVAL 11 Remove the instrument cluster and bracket assembly Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 12 Disconnect the SKREEM harness connectors and remove SKREEM module and mounting bracket Refer to 8 ELECTRICAL VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE REMOVAL 13 Remove the glove box assembly Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX REMOVAL 14 Di...

Page 4240: ...17 Remove the center I P support to bulkhead bolts and nuts 2 18 Disconnect the heater core temperature sensor 1 19 Disconnect the evaporator temperature sensor 1 ZH DISTRIBUTION 24 111 ...

Page 4241: ... the HVAC unit from vehicle INSTALLATION INSTALLATION 1 Install the HVAC housing to the vehicle 2 Install any wiring harnesses associated with the HVAC housing with nylon ties in their respected routing positions 3 Connect the harness connector 1 to the fresh air recirculating air flap switchover valve located on the right side of the heater housing 24 112 DISTRIBUTION ZH ...

Page 4242: ... the HVAC case CAUTION To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support 5 Install the instrument panel support to the vehicle 6 Install the bolts 1 attaching the instrument panel support to the A pillars 7 Connect the connectors 1 to the vacuum reservoir switch over valve ZH DISTRIBUTION 24 113 ...

Page 4243: ...nstrument panel support attaching it to the body transmission tunnel 10 Install the nuts on the heater housing 1 attach ing it to the instrument panel support 11 Install the heater ducts on left and right side of the instrument panel support 12 Install the harness connector 1 on passenger airbag module 24 114 DISTRIBUTION ZH ...

Page 4244: ...g positions attaching them with nylon ties on the instrument panel support 17 Install the Sentry Key Remote Entry Module SKREM by Connecting the 2 pin CAN harness connector to the SKREM module Connecting the 2 pin harness connector for the transponder coil Connecting the 18 pin connector Installing the SKREM control module to the base plate 18 Install instrument cluster holder to the vehicle then ...

Page 4245: ...NT PANEL ASSEMBLY INSTALLATION 21 Install the left lower instrument panel 2 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 22 Install the lower right instrument panel 2 Refer to 23 BODY INSTRUMENT PANEL INSTRU MENT PANEL ASSEMBLY INSTALLATION 24 116 DISTRIBUTION ZH ...

Page 4246: ...er hose clamps to hot water hoses located on the right side of the bulkhead 25 Install the hot water hose 1 the install the hot water hose clamp located inboard to the brake booster on the bulkhead 26 Fill the coolant to the engine cooling system Re fer to 7 COOLING ENGINE COOLANT STAN DARD PROCEDURE 27 Connect the negative battery cable ZH DISTRIBUTION 24 117 ...

Page 4247: ...he HVAC unit drain tubes 3 Install the I P support bar into the vehicle 4 Install the I P support bar bolts 4 attaching the support bar to the A pillar on the right and left sides of the support bar 5 Connect the evaporator temperature sensor 1 24 118 DISTRIBUTION ZH ...

Page 4248: ...L ASSEMBLY INSTALLATION 12 Install the SKREEM module and mounting bracket Then connect the SKREEM harness con nectors Refer to 8 ELECTRICAL VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE INSTALLATION 13 Install the instrument cluster and bracket assem bly Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 14 Install the I P top cover Refer to 23 BODY IN STRUMENT PANEL ...

Page 4249: ...RUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 17 Install the right and left lower instrument panel covers 18 Install the steering column and wheel Refer to 19 STEERING COLUMN INSTALLATION 19 Connect the heater hose 1 behind the battery 24 120 DISTRIBUTION ZH ...

Page 4250: ...e two heater hoses 1 to the HVAC case 21 Connect the negative battery cable 1 22 Charge the A C system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE 23 Fill the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE ZH DISTRIBUTION 24 121 ...

Page 4251: ...air nozzle 2 tilt the deflector up to reveal the screw arrow 3 Pull the air nozzle out toward the rear REMOVAL CENTER AIR NOZZLE 1 Remove the cover on the center console Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 2 Remove the screws attaching the center air nozzle to the center console cover 2 3 Disconnect the air nozzle catch clips 3 4 Remove the air nozzle from the center console cover 4 2...

Page 4252: ...nozzle 2 tilt the deflector up to reveal the screw hole 3 Turn the plugs 1 90 to the right to install the fuse cover INSTALLATION CENTER AIR NOZZLE 1 Connect the air nozzles catch clips 3 2 Install the screws 2 attaching the center air noz zle 1 to the center console cover 4 3 Install the cover on the center console Refer to 23 BODY INTERIOR CENTER CONSOLE INSTALLATION ZH DISTRIBUTION 24 123 ...

Page 4253: ...l duct distribution These trim pieces can be removed by removing the screws 1 in the outside edge of the trim piece the inner edge is held into place by a tab slid under the top section of the instrument panel INSTALLATION 1 Install the defroster duct trim piece into the top sec tion of the instrument panel Then install the screw 1 24 124 DISTRIBUTION ZH ...

Page 4254: ...OTWELL AIR OUTLET COVER 1 Turn the screw 90 1 on the vent 4 to the left and remove the front cover 3 away from the rear portion 2 2 Remove the screw 1 attaching the footwell air outlet cover to the center console 2 ZH DISTRIBUTION 24 125 ...

Page 4255: ...3 Slide the panel 2 forward to release the hooks and then remove from the center console 1 INSTALLATION FOOTWELL AIR OUTLET COVER 1 Install the cover by sliding the panel rearward 24 126 DISTRIBUTION ZH ...

Page 4256: ...2 Install the screw attaching the footwell air outlet cover to the center console 3 Install the cover then turn the screw 90 to the right ZH DISTRIBUTION 24 127 ...

Page 4257: ...OVAL 137 INSTALLATION 138 A C CONDENSER DESCRIPTION 139 OPERATION 139 REMOVAL 139 INSTALLATION 141 A C EVAPORATOR DESCRIPTION 143 OPERATION 143 REMOVAL 143 INSTALLATION 145 LIQUID LINE REMOVAL 147 INSTALLATION 147 SUCTION LINE REMOVAL 148 INSTALLATION 149 A C EXPANSION VALVE DESCRIPTION 151 OPERATION 151 DIAGNOSIS AND TESTING A C EXPANSION VALVE 151 REMOVAL 152 INSTALLATION 152 HEATER CORE DESCRIP...

Page 4258: ...he proper tools when making a refrigerant plumbing connection is very important Improper tools or improper use of the tools can damage the refrigerant fittings Always use two wrenches when loosening or tightening tube fittings Use one wrench to hold one side of the connection stationary while loosening or tightening the other side of the connection with a second wrench The refrigerant must be reco...

Page 4259: ...on the R 134a system Damage to the system will result Do not overcharge the refrigerant system This will cause excessive compressor head pressure and can cause noise and system failure Recover the refrigerant before opening any fitting or connection Open the fittings with caution even after the system has been discharged Never open or loosen a connection before recovering the refrigerant The refri...

Page 4260: ...onnector fittings and components 5 To inspect the evaporator coil for leaks insert the electronic leak detector probe into the center instrument panel outlet Set the blower motor switch to the lowest speed position the A C button in the On position and select the Recirculation Mode SYSTEM LOW 1 Position the vehicle in a wind free work area This will aid in detecting small leaks 2 Bring the refrige...

Page 4261: ...an R 134a refrigerant system Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE WARNING REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PER FORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARN ING If the refrigerant system has been ...

Page 4262: ...ube If dual thermocouple probes are used attach probe 1 to the evaporator inlet tube and probe 2 to the evap orator outlet tube Attach both probes to the evaporator tubes just before the collar of the refrigerant line con nector fittings The probes must make contact with the bottom surfaces of the evaporator inlet and outlet tubes 3 Open all of the windows or doors of the passenger compartment 4 S...

Page 4263: ... F With a 2 C 4 F temperature differential at 21 C 70 F ambient temperature the system is fully charged 12 Add enough refrigerant to bring the refrigerant system up to a full charge 13 Remove the jumper wire from the low pressure cycling clutch switch wire harness connector and plug the con nector back into the switch A C COMPRESSOR DESCRIPTION A C COMPRESSOR The Air Conditioning System uses a Nip...

Page 4264: ...h as possible Switch the compressor on and off several times to clearly identify the compressor noise Listen to the compressor while the clutch is engaged and disengaged Probe the compressor with an engine stethoscope or a long screwdriver with the han dle held to your ear to better localize the source of the noise 2 Loosen all of the compressor mounting hardware and retighten Tighten the compress...

Page 4265: ... harness connector from the compressor INSTALLATION 1 Connect the A C harness connector to the com pressor 2 Install the bolts on the high side and the low side pressure lines Tighten to 23 N m 17 ft lbs 3 Install the A C compressor then install the three bolts 1 Tighten to 23 N m 17 ft lbs 4 Install the lower engine compartment panel 5 Install the accessory drive belt Refer to 7 COOLING ACCESSORY...

Page 4266: ...is controlled by the A C heater control module in the same manner as when the ignition is ON The A C heater control module switches the electric motor for the coolant circulation pump which drives the impeller via a magnetic clutch REMOVAL 1 Drain the coolant system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 2 Remove the headlamp assembly 4 from the right side of the vehicle Refer to 8 E...

Page 4267: ...all the coolant circulation pump harness connector to the coolant circulation pump 3 4 Install the two hoses 2 the coolant circulation pump 3 5 Install the headlamp assembly to the vehicle Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT INSTALLATION 6 Fill the coolant system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 24 138 PLUMBING ZH ...

Page 4268: ...here are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the Condenser fins 6 that might obstruct proper air flow Also any factory installed air seals or shrouds must be properly reinstalled following radiator or condenser service The Condenser 6 cannot be repaired and if faulty or damaged it must be replaced Refer to 24 HEATING AIR CON...

Page 4269: ...ES PROTEC TIVE CLOTHING AND PROTECTIVE GOGGLES 3 Relieve pressure in cooling system by turning the radiator cap on the reservoir to catch 1 4 Remove the radiator fan Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove the coolant reservoir 1 Refer to 7 COOLING ENGINE COOLANT RECOVERY PRESS CONTAINER REMOVAL 6 Remove the refrigerant lines 1 from the condenser 7 Loosen the mount for the condense...

Page 4270: ...INSTALLATION 1 Install the condenser 2 Tighten the mount for the condenser connection fit tings 1 2 3 Install the refrigerant lines 1 to the condenser Tighten to 24 N m 18 ft lbs ZH PLUMBING 24 141 ...

Page 4271: ...OLING EN GINE RADIATOR INSTALLATION 5 Install the lower radiator hose to the radiator 6 Install the upper radiator hose 1 to the radiator 7 Install the radiator fan 1 Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 24 142 PLUMBING ZH ...

Page 4272: ...tor from the orifice tube as a low temperature low pressure liquid As air flows over the fins of the evaporator the humidity in the air condenses on the fins and the heat from the air is absorbed by the refrigerant Heat absorption causes the refrigerant to boil and vaporize The refrigerant becomes a low pressure gas before it leaves the evaporator The Evaporator Coil cannot be repaired and if faul...

Page 4273: ...ve the valve strip on the top of the HVAC housing by removing the four screws and removing the aluminum lines from the housing 4 Disconnect the vacuum lines from the vacuum ele ment 2 5 Separate the blower housing from air distribution housing unclip the two sliding clips 1 6 Remove the four spring clips 7 Remove the screw 1 behind the expansion valve 8 Remove the foam gasket 24 144 PLUMBING ZH ...

Page 4274: ...upper section by removing the spring clips 10 Remove the evaporator from the housing INSTALLATION 1 Install the evaporator to the housing 2 Install the air distribution housing upper section by installing the spring clips ZH PLUMBING 24 145 ...

Page 4275: ...wo sliding clips 1 6 Install the four spring clips 7 Connect the vacuum lines to the vacuum element 8 Install the valve strip 9 Install the heater core Refer to 24 HEATING AIR CONDITIONING PLUMBING HEATER CORE INSTALLATION 10 Install the HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION 24 146 PLUMBING ZH ...

Page 4276: ... PER FORMING THE FOLLOWING OPERATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system Kinks and sharp bends reduce the flow of refrigerant in the system 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 In addition the flexible hose refrigerant lines s...

Page 4277: ...ft lbs 2 Install the liquid line 1 to the receiver dryer Tighten to 17 N m 12 ft lbs 3 Install the front inner wheel well panel 4 Install the left front wheel and tire assembly 5 Charge the A C system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE SUCTION LINE REMOVAL WARNING REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PER FORMING THE FOLLOWING OPERATION ...

Page 4278: ... line assembly from the vehicle INSTALLATION WARNING REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PER FORMING THE FOLLOWING OPERATION WARNING ANY KINKS OR SHARP BENDS IN THE REFRIGERANT PLUMBING WILL REDUCE THE CAPACITY OF THE ENTIRE AIR CONDITIONING SYSTEM KINKS AND SHARP BENDS REDUCE THE FLOW OF REFRIGERANT IN THE SYSTEM A GOOD RULE FOR THE FLEXIBLE HOSE REFRIGERANT LINES...

Page 4279: ...RLY ROUTED 1 Install the suction line to the compressor Tighten the mounting bolt to 23 N m 18 ft lbs 2 Install the A C compressor bolts 1 Refer to 24 HEATING AIR CONDITIONING PLUMBING A C COMPRESSOR INSTALLATION 3 Slide the suction line and the liquid line over the expansion valve stud Tighten the nut 1 to 10 N m 88 in lbs 4 Connect the negative battery cable 5 Evacuate the refrigerant system Ref...

Page 4280: ...refrigerant which can be evaporated optimally is injected DIAGNOSIS AND TESTING A C EXPANSION VALVE The Expansion Valve is located on the engine side of the dash panel near the shock tower The Expansion Valve can fail in three different positions open closed or restricted Open Position this will result in a noisy compressor or no cooling The cause can be a broken spring broken ball or excessive mo...

Page 4281: ...ff 4 Remove the screws 2 5 Remove the expansion valve 3 off of the pressure lines INSTALLATION 1 Install the expansion valve 3 to the pressure lines Note Tighten the screws evenly to avoid canting 2 Install the bolts 2 Tighten to 8 N m 71 in lb 3 Replace the O rings Install the pressure lines 4 Install the nut 1 Tighten to 10 N m 88 in lb 5 Charge the air conditioning check for any leakage Refer t...

Page 4282: ...he blower motor 2 speed controls the volume of air flowing through the HVAC hous ing The heater core cannot be repaired and if faulty or damaged it must be replaced Refer to 24 HEATING AIR CONDITIONING PLUMBING HEATER CORE REMOVAL Refer to Cooling for more information on the engine cooling system REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT ING ANY STE...

Page 4283: ...ousing Refer to 24 HEAT ING AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Remove the bolts on the cover 1 3 Unclip the spring clamps 4 Remove the cover 5 Remove the guide for the heating water flow pipe 2 6 Remove the heating water return line 1 7 Remove the heater core together with the heating water pipes 24 154 PLUMBING ZH ...

Page 4284: ...from the heater core INSTALLATION 1 Install the heating water pipes on the heater core then install the clip 1 2 Install the heat exchanger together with the heating water pipes 3 Connect the socket yoke for heating water flow pipe ZH PLUMBING 24 155 ...

Page 4285: ...stall the guide 2 for the heating water flow pipe 6 Install the cover 1 7 Clip the spring clamps 8 Install the bolts on the cover 9 Install HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION 24 156 PLUMBING ZH ...

Page 4286: ...action to prevent foreign material in the refrigerant from con taminating the Expansion Valve 3 A desiccant bag is mounted inside the Receiver Drier canister 5 to absorb any moisture which may have entered and become trapped within the refrigerant system In addi tion during periods of high demand A C operation the Receiver Drier 5 acts as a reservoir to store surplus refrigerant Refrigerant enters...

Page 4287: ...e line 1 4 Remove the refrigerant pressure sensor 2 5 Raise and support the vehicle 6 Remove the wheel and tire assembly 7 Remove left inner fender front section by remov ing the plastic nuts and the screws attaching the panel to the inner fender liner 8 Remove the pressure line 1 9 Remove the mounting nuts 2 10 Remove the receiver drier from the vehicle 24 158 PLUMBING ZH ...

Page 4288: ...e R 12 which is a ChloroFluoroCarbon CFC R 134a refrigerant does not contain ozone depleting chlorine R 134a refrig erant is a non toxic non flammable clear and colorless liquefied gas Even though R 134a does not contain chlorine it must be reclaimed and recycled just like CFC type refrigerants This is because R 134a is a greenhouse gas and can contribute to global warming OPERATION R 134a refrige...

Page 4289: ...tainer immediately to prevent moisture contamination STANDARD PROCEDURE REFRIGERANT OIL LEVEL When an Air Conditioning System is assembled at the factory all components except the Compressor are refriger ant oil free After the refrigerant system has been charged and operated the refrigerant oil in the Compressor is dispersed throughout the refrigerant system The Accumulator Evaporator Condenser an...

Page 4290: ...ter Control module switches the Coolant Circulation Valve 3 Solenoid to ground the solenoid pulls in and blocks the coolant flow through the Heater Core 2 separately on the left and right sides If the temperature dial is set to 9MAX9 the A C Heater Control module interrupts the ground connection current does not flow through the solenoid and the maximum quantity of coolant flows through the Heater...

Page 4291: ...en the cooling system only when the coolant temperature is below 90 C Open the cap slowly and reduce the pressure Wear protective gloves protective clothing and protective goggles 1 Relieve the pressure in the cooling system by turn ing the radiator cap on the reservoir to catch 1 2 Loosen the top screw for the heat shield Then remove the heat shield 3 Clamp off the hot water hoses 4 Loosen the ho...

Page 4292: ... Connect the electrical connector 1 on the coolant circulation valve 4 Install the heater water hose 2 5 Tighten the hose clamps on heater water hose 6 Unclamp the hot water hose 7 Tighten the top screw for the heat shield 8 Top off the cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE ZH PLUMBING 24 163 ...

Page 4293: ......

Page 4294: ... DEFINITION 10 DESCRIPTION VEHICLE EMISSION CONTROL INFORMATION LABEL 10 OPERATION OPERATION SYSTEM 11 OPERATION SYSTEM 11 EVAPORATIVE EMISSIONS 13 EXHAUST GAS RECIRCULATION 23 AIR INJECTION 29 ON BOARD DIAGNOSTICS 40 EMISSIONS CONTROL DESCRIPTION DESCRIPTION MONITORED COMPONENTS There are several components that will affect vehicle emissions if they malfunction If one of these components malfunct...

Page 4295: ...the diagnostic system monitor any component that could affect emissions levels In many cases these components were being tested under OBD I The OBD I requirements focused mainly on testing emissions related components for electrical opens and shorts However OBD II also requires that inputs from powertrain components to the PCM be tested for rationality and that outputs to powertrain components fro...

Page 4296: ...lyst works best to remove hydrocarbons HC carbon monoxide CO and nitrous oxide NOx from the exhaust The O2S is also the main sensing element for the EGR Purge System and Catalyst and Fuel Monitors The O2S may fail in any or all of the following manners Slow response rate Big Slope Reduced output voltage Half Cycle Heater Performance Dynamic shift Shorted or open circuits Slow Response Rate Big Slo...

Page 4297: ...with clean air regulations vehicles are equipped with catalytic converters These con verters reduce the emission of hydrocarbons oxides of nitrogen and carbon monoxide Normal vehicle miles or engine misfire can cause a catalyst to decay A meltdown of the ceramic core can cause a restriction of the exhaust This can increase vehicle emissions and deteriorate engine performance driveability and fuel ...

Page 4298: ...e Malfunction Indicator Lamp MIL will be illuminated These monitors generate Diagnostic Trouble Codes that can be displayed with the a DRB IIIT scan tool The following is a list of the system monitors EGR Monitor Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor Oxygen Sensor Heater Monitor Catalyst Monitor Evaporative Vacuum Leak Detection System Monitor Following is a description of each...

Page 4299: ...sted to ensure that it is heating the sensor properly The heater resistance is checked by the PCM almost immediately after the engine is started The same O2S heater return pin used to read the heater resistance is capa ble of detecting an open shorted high or shorted low circuit OPERATION The Oxygen Sensor Heater Monitor begins after the ignition has been turned OFF and the O2 sen sors have cooled...

Page 4300: ...r absorbs the oxygen there will be a lack of oxygen downstream of the converter The output of the downstream O2S will indicate limited activity in this condition As the converter loses the ability to store oxygen the condition can be detected from the behavior of the down stream O2S When the efficiency drops no chemical reaction takes place This means the concentration of oxygen will be the same d...

Page 4301: ... vacuum to detect a leak in the purge system The PCM seals the Charcoal Canister Shutoff Valve and opens the EVAP Purge Solenoid to perform the 3 stage leak test after the following conditions have been met Battery voltage 11 volts Engine running for approximately 16 minutes Engine idling Vehicle at rest Emission controls in closed loop Intake air temperature less than 45 C 113 F Engine coolant te...

Page 4302: ...s that could have malfunctions causing driveability problems However malfunctions in these systems may cause the PCM to store diagnostic trouble codes for other systems or components For example a fuel pressure problem will not register a fault directly but could cause a rich lean condition or misfire This could cause the PCM to store an oxygen sensor or misfire diagnostic trouble code The major n...

Page 4303: ...TION TRIP DEFINITION A Trip means vehicle operation following an engine off period of duration and driving mode such that all com ponents and systems are monitored at least once by the diagnostic system The monitors must successfully pass before the PCM can verify that a previously malfunctioning component is meeting the normal operating conditions of that component For misfire or fuel system malf...

Page 4304: ...nitored Circuits in this section Note Various diagnostic procedures may actually cause a diagnostic monitor to set a DTC For instance pulling a spark plug wire to perform a spark test may set the misfire code When a repair is completed and verified use the DRB IIIT scan tool to erase all DTCs and extinguish the MIL Technicians can retrieve stored DTCs For obtaining the DTC information use the Data...

Page 4305: ...ed Circuits in this section Note Various diagnostic procedures may actually cause a diagnostic monitor to set a DTC For instance pulling a spark plug wire to perform a spark test may set the misfire code When a repair is completed and verified use the DRB IIIT scan tool to erase all DTCs and extinguish the MIL Technicians can retrieve stored DTCs For obtaining the DTC information use the Data Link...

Page 4306: ...ASE VENT HOSE DESCRIPTION DESCRIPTION 15 OPERATION 16 DIAGNOSIS AND TESTING CRANKCASE VENTILATION SYSTEM 16 EVAP PURGE SOLENOID DESCRIPTION 17 OPERATION 17 REMOVAL REMOVAL 17 REMOVAL 18 INSTALLATION INSTALLATION 18 INSTALLATION 19 FUEL FILLER CAP DESCRIPTION 19 OPERATION 19 ORVR DESCRIPTION 19 OPERATION 20 VAPOR CANISTER DESCRIPTION 20 OPERATION 20 REMOVAL 21 INSTALLATION 22 ZH EVAPORATIVE EMISSIO...

Page 4307: ... EVAP Purge Solenoid in this section Note The evaporative system uses specially manufactured hoses If they need replacement only use fuel resistant hose Also the hoses must be able to pass an Ozone compliance test Note For more information on Onboard Refueling Vapor Recovery ORVR refer to the Fuel Delivery section CHARCOAL CANISTER SHUTOFF VALVE DESCRIPTION The Charcoal Canister Shutoff Valve is p...

Page 4308: ...Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS VAPOR CANISTER INSTALLATION CRANKCASE VENT HOSE DESCRIPTION DESCRIPTION The Positive Crankcase Ventilation PCV System consists of a draft tube style throttle body insert 2 and hoses 1 and 3 connected between the cylinder head covers and the throttle body insert 2 ZH EVAPORATIVE EMISSIONS 25 15 ...

Page 4309: ...tes a vacuum in the Crankcase Vent Hoses 1 and 3 DIAGNOSIS AND TESTING CRANKCASE VENTILATION SYSTEM TESTING CLEANING The Crankcase Ventilation CCV system performs the same function as a conventional PCV system but does not use a vacuum controlled valve 1 Check each CCV system tube line 1 and 3 and the draft tube style insert 2 for leaks cracks kinks or bends Replace as necessary 2 Disconnect each ...

Page 4310: ...d The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body The PCM controls the frequency at which the solenoid operates in order to customize the vapor volume for each cylinder OPERATION The PCM will only energize the EVAP solenoid when the engine is at operating temperature but will de energize it during periods of deceleration When de energized no vapors are pur...

Page 4311: ... 2 Disconnect vapor hoses 1 and 4 from solenoid 3 3 Remove solenoid 3 from bracket 5 INSTALLATION INSTALLATION 1 Install solenoid 3 on bracket 5 2 Connect vapor hoses 1 and 4 to solenoid 3 3 Connect connector 2 to solenoid 3 25 18 EVAPORATIVE EMISSIONS ZH ...

Page 4312: ... valve that is closed to atmosphere during normal operating con ditions The relief valve is calibrated to open when a pressure of 172 mbar 2 5 psi or vacuum of 20 mbar 8 inH2O occurs in the fuel tank When the pressure or vacuum is relieved the valve returns to the normally closed position WARNING REMOVE THE FUEL FILLER CAP IN ORDER TO RELEASE FUEL TANK PRESSURE BEFORE DIS CONNECTING ANY FUEL SYSTE...

Page 4313: ...r is absorbed in the canister 7 until vapor flow in the lines stops either following refueling shut off or by having the fuel level in the tank rise high enough to close the check valves in the tank vent rollover valves 1 The fuel filler tube 3 also incorporates a fuel tank overfill check valve 5 As fuel level rises the fuel tank overfill check valve 5 seals the in tank end of the fuel filler tube...

Page 4314: ...from splash shield 4 Remove the splash shield 5 Carefully disconnect the vapor vacuum vent hoses 2 6 Slide the EVAP canister 4 to the left off of mounting bracket 7 Disconnect the charcoal canister shutoff valve harness connector 1 8 Depress the locking tab 2 to release charcoal canister shutoff valve 1 9 While holding the lock tab 2 in release position turn charcoal canister shutoff valve 1 clock...

Page 4315: ... ring 3 2 Connect the charcoal canister shutoff valve har ness connector 1 3 Connect the hoses 2 4 Slide the EVAP canister to the right on to mounting bracket 5 Install the splash shield and retaining nuts 6 Lower the vehicle 7 Connect the negative battery cable 25 22 EVAPORATIVE EMISSIONS ZH ...

Page 4316: ...AUST GAS RECIRCULATION SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs EGR VALVE TO CYLINDER HEAD 31 23 275 EGR TUBE TO EGR VALVE 11 95 EGR TUBE TO INTAKE MANIFOLD 11 95 EGR SOLENOID TO EGR VALVE 11 95 SOLENOID REMOVAL 1 Disconnect the negative battery cable 2 Remove the air cleaner housing 3 Disconnect the solenoid harness connector 1 4 Disconnect the solenoid vacuum lin...

Page 4317: ...ATION 1 Position the solenoid to valve and loosely install solenoid to valve bolt 2 2 Install the valve bolt 1 to cylinder head Tighten to 31 N m 23 ft lbs 3 Tighten the solenoid to valve bolt 2 to 11 N m 95 in lbs 4 Connect the vacuum hoses 2 5 Connect the EGR solenoid harness connector 1 6 Install the air cleaner housing 7 Connect the negative battery cable 25 24 EXHAUST GAS RECIRCULATION ZH ...

Page 4318: ...e Any loose dirt can lodge between the tube and manifold and cause vacuum leakage that will give a rough idle and reduced manifold vacuum INSTALLATION 1 Loosely install the EGR tube flange nut 2 to the EGR valve 2 Position the new gasket between tube and intake manifold 3 Install the tube bolts 1 to intake manifold Tighten to 31 N m 23 ft lbs 4 Tighten the EGR tube flange nut 2 to 11 N m 95 in lbs...

Page 4319: ...haust Gas Recirculation flow is determined by the Powertrain Control Module PCM For a given set of conditions the PCM calculates the ideal exhaust gas recirculation flow to minimize NOx emissions and maximize fuel economy by adjusting the pintle position Pintle position is controlled by the EGR Solenoid The PCM adjusts the duty cycle of the power supplied to the solenoid coil to obtain the correct...

Page 4320: ...lin der head 2 Loosely install valve front bolt 1 to cylinder head do not tighten bolt 3 Position solenoid to valve and loosely install sole noid 3 to valve bolt 4 Loosely install valve rear bolt 2 to cylinder head do not tighten bolt 5 Loosely install the EGR tube flange nut 2 to valve 6 Tighten the valve to cylinder head bolts 1 to 31 N m 23 ft lbs 7 Tighten the flange nut 2 to 11 N m 95 in lbs ...

Page 4321: ...9 Connect the solenoid harness connector 1 10 Connect the vacuum hose 2 11 Install the air cleaner housing 12 Connect the negative battery cable 25 28 EXHAUST GAS RECIRCULATION ZH ...

Page 4322: ...njected into the exhaust will cause the catalytic converters to heat up more quickly This will improve the emission levels during a cold start The Air Pump Switchover System incorporates an Air Pump 4 with two Air Pump Switchover Valves 1 and 6 an Air Pump Switchover Solenoid 3 an Air Pump Relay a Vacuum Check Valve 5 and the PCM The Air Pump Relay is located in the Relay Control Module and can be...

Page 4323: ...r through a maintenance free filter and pumps it to the Air Pump Switchover Valves 3 and 6 The Air Pump Switchover Valves 3 and 6 prevent exhaust gases from flowing back into the Air Pump 1 The Air Pump Switchover Solenoid 4 is supplied with vacuum from the intake manifold through a check valve 5 When the Air Pump Switchover Solenoid 4 is activated it passes engine vacuum to the Air Pump Switchove...

Page 4324: ...ery cable 2 Remove the air cleaner housing 3 Disconnect the air pump switchover tube 1 4 Disconnect the air pump harness connector 2 5 Remove the air pump retaining bolt 2 6 Remove the air pump 1 from the air pump retain ing bracket 3 ZH AIR INJECTION 25 31 ...

Page 4325: ...tive battery cable 2 Disconnect the air pump tube assembly 1 from the air pump 3 Disconnect the air pump harness connector 2 4 Remove the air pump retaining nuts 1 5 Remove air pump from air pump mounting bracket 25 32 AIR INJECTION ZH ...

Page 4326: ...retain ing bracket 3 2 Install the air pump retaining bolt 2 Tighten bolt to 20 N m 177 in lbs 3 Connect the air pump harness connector 2 4 Connect the air pump switchover tube 1 5 Install the air cleaner housing 6 Connect the negative battery cable ZH AIR INJECTION 25 33 ...

Page 4327: ...ump mounting bracket 2 Install the air pump retaining nuts 1 Tighten nuts to 7 N m 62 in lbs 3 Connect the air pump harness connector 2 4 Connect the air pump tube assembly 1 to the air pump 5 Connect the negative battery cable 25 34 AIR INJECTION ZH ...

Page 4328: ...onnect the air pump switchover solenoid har ness connector 2 4 Disconnect the vacuum lines 1 5 Pull the air pump switchover solenoid locking tab 1 away from air pump switchover solenoid 2 6 Remove the air pump switchover solenoid 2 from air pump switchover solenoid retaining bracket 3 ZH AIR INJECTION 25 35 ...

Page 4329: ...olenoid mounting bracket 3 and lower until air pump switchover solenoid locking tab 1 snaps into place 2 Connect the vacuum lines 1 3 Connect the air pump switchover solenoid harness connector 2 4 Install the air cleaner housing 5 Connect the negative battery cable 25 36 AIR INJECTION ZH ...

Page 4330: ...alve retaining bolt 4 6 Remove the air pump switchover valve 1 discard the old gasket INSTALLATION 1 Position the new gasket between intake manifold and air pump switchover valve 1 2 Install the retaining bolt 4 Tighten bolt to 20 N m 177 in lbs 3 Connect the vacuum line 3 4 Connect the air pump switchover tube 2 5 Install the air cleaner housing 6 Connect the negative battery cable ZH AIR INJECTI...

Page 4331: ...both of the cor ners of the front engine cover and pull up firmly 2 Remove the air pump tube assembly retaining bolts 2 3 Disconnect the air pump tubes 1 from the air pump and solenoids 4 Remove the air pump tube assembly from the engine 25 38 AIR INJECTION ZH ...

Page 4332: ...pump and the switchover valves 3 Install the air pump tube assembly retaining bolts 2 Tighten the bolts to 10 N m 89 in lbs 4 Install the engine cover Realign the engine cover retaining clips to the mounting brackets and push down firmly to connect the engine cover to the mounting brackets ZH AIR INJECTION 25 39 ...

Page 4333: ...iven monitor Many of the diagnostic tests must be performed under certain operating conditions However there are times when tests cannot be run because another test is in progress Conflict another test has failed Pending or the Task Manager has set a fault that may cause a failure of the test Suspend Pending Under some situations the Task Manager will not run a monitor if the MIL is illuminated an...

Page 4334: ...uel system rich lean and misfire or one trip catalyst dam aging misfire Non emissions related failures have no priority One trip failures of two trip faults have low priority Two trip failures or matured faults have higher priority One and two trip failures of fuel system and misfire monitor take precedence over non fuel system and non misfire failures DTC Self Erasure With one trip components or ...

Page 4335: ...n threshold Less than threshold for a predetermined time If all of the previous criteria are met the PCM will count a good trip three required and turn off the MIL Misfire Good Trip If the following conditions are met the PCM will count one good trip three required in order to turn off the MIL Operating in Similar Condition Window 1000 engine revolutions with no misfire Warm up Cycles Once the MIL...

Page 4336: ...od Trip Counter A Trip Counter used to turn OFF the MIL for Fuel System DTCs To increment a Fuel System Good Trip the engine must be in the Similar Conditions Window Adaptive Memory Factor must be less than the calibrated threshold and the Adaptive Memory Factor must stay below that threshold for a calibrated amount of time Test Done This Trip Indicates that the monitor has already been run and co...

Page 4337: ......

Page 4338: ... 98 DRIVER DOOR LOCK SWITCH 8N 40 DRIVING CLUTCH K1 21 270 DRIVING CLUTCH K2 21 274 DRIVING CLUTCH K3 21 279 DRIVING CLUTCHES 21 268 ELECTROHYDRAULIC UNIT 21 281 ELECTRONIC CONTROL MODULES ELECTRICAL DIAGNOSTICS 8E 1 EMERGENCY TOW HOOKS 0 12 EMISSIONS CONTROL 25 1 ENGINE 3 2L SERVICE INFORMATION 9 712 ENGINE 3 2L SRT SERVICE INFORMATION 9 838 ENGINE ELECTRICAL DIAGNOSTICS 9 4 ENGINE BLOCK 9 761 9 ...

Page 4339: ...L MODULE 7 37 RADIATOR FAN 7 33 RADIATOR PRESSURE CAP 7 55 RADIATOR 7 48 RADIO 8A 35 REAR AXLE CARRIER 2 81 REAR BOW WEATHERSTRIPS 23 565 REAR DIFFERENTIAL HOUSING 3 45 REAR DIFFERENTIAL 3 40 REAR FASCIA 13 6 REAR MOUNT 9 789 9 922 REAR RISER MOTOR 8N 99 REAR SECTION HOUSING 21 376 REAR SPOILER 23 309 REAR SUPPORT BRACKET 13 9 REAR SUSPENSION 2 44 REAR WHEEL SPEED SENSOR 5 335 REAR WINDOW ANTENNA ...

Page 4340: ...P MOTOR 8R 44 WASHER RESERVOIR 8R 45 WATER PUMP 7 56 WELD LOCATIONS 23 264 WET SANDING BUFFING POLISHING 23 425 WHEEL ALIGNMENT 2 3 WHEELS 22 60 WINDOW MOTOR 8N 122 WINDOW REGULATOR 23 292 WINDSHIELD 23 449 WIPER ARMS 8R 46 WIPER BLADES 8R 49 WIPER LINKAGE 8R 55 WIPER MODULE 8R 56 WIPER MOTOR 8R 61 WIPERS WASHERS ELECTRICAL DIAGNOSTICS 8R 1 WIPERS WASHERS SERVICE INFORMATION 8R 31 WIRING DIAGRAM I...

Page 4341: ......

Page 4342: ...CYLINDER TRAVEL SENSOR BASE SIDE INOPERATIVE 23 157 9904 MAIN CYLINDER TRAVEL SENSOR BASE SIDE STUCK 23 159 9905 REAR BOW CYLINDER TRAVEL SENSOR ROD SIDE INOPERATIVE 23 161 9906 REAR BOW CYLINDER TRAVEL SENSOR ROD SIDE STUCK 23 163 9907 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE INOPERATIVE 23 165 9908 REAR BOW CYLINDER TRAVEL SENSOR BASE SIDE STUCK 23 167 9909 REAR BOW SWITCH SENSE CIRCUIT OPEN 23...

Page 4343: ...ANSMITTER 22 28 RIGHT HEATER CORE TEMPERATURE SENSOR CIRCUIT 24 15 RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER SIGNAL JAMMED 22 17 RIGHT REAR TIRE PRESSURE SENSOR TRANSMITTER 22 30 RIGHT SIDE AIRBAG SQUIB CIRCUIT 8O 35 RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT 8O 65 SENTRY KEY ANTENNA CIRCUIT 8Q 40 SENTRY KEY REMOTE ENTRY MODULE INTERNAL FAILURE 8Q 36 SENTRY KEY VERIFICATION TEST 8Q 45 SIGNAL JAMMED...

Page 4344: ...ON SENSOR 5 140 1040 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 5 144 1042 NO CAN COMMUNICATIONS WITH YAW RATE ACCELERATION SENSOR 5 148 1100 LEFT FRONT WHEEL SPEED SENSOR CIRCUIT 5 152 1101 LEFT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL 5 160 1102 LEFT FRONT WHEEL SPEED SENSOR LOW SIGNAL 5 162 1103 LEFT FRONT WHEEL SPEED SENSOR LONG GAP 5 164 1104 LEFT FRONT WHEEL SPEED SENSOR TONE WHE...

Page 4345: ... HIGH 9 219 P0161 O2 SENSOR 2 2 HEATER CIRCUIT LOW 9 215 P0161 O2 SENSOR 2 2 HEATER CIRCUIT OPEN 9 217 P0161 O2 SENSOR 2 2 HEATER PERFORMANCE 9 213 P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT IDLE 9 225 P0171 FUEL SYSTEM 1 1 RICH CONTROL OVER LIMIT AT LOAD 9 229 P0171 FUEL SYSTEM 1 1 UNDERCORRECTION OF FUEL MIXTURE OFF IDLE 9 221 P0172 FUEL SYSTEM 1 1 LEAN CONTROL BELOW LIMIT AT IDLE 9 249 P0...

Page 4346: ... 671 P2561 HVAC CONTROL MODULE REQUESTED MIL ILLUMINATION 9 678 POWERTRAIN VERIFICATION TEST VER 1 9 696 POWERTRAIN VERIFICATION TEST VER 2 9 697 POWERTRAIN VERIFICATION TEST VER 3 7 10 POWERTRAIN VERIFICATION TEST VER 3 9 698 POWERTRAIN VERIFICATION TEST VER 4 9 699 POWERTRAIN VERIFICATION TEST VER 5 9 700 CHARGE AIR COOLER CIRCULATION PUMP INOPERATIVE 9 691 CHECKING FUEL DELIVERY 9 680 CHECKING ...

Page 4347: ...____________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Dealership Technician Dealer Code Retail Customer Manual Title Year Number and Page _________________________________________________ _______________________________________...

Page 4348: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757 ...

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