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DaimlerChrysler Jeep Grand Cherokee 2002, Service Manual

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DaimlerChrysler Jeep Grand Cherokee 2002 Service Manual Download Page 228

Symptom:

*CHECKING THE EGR SYSTEM

POSSIBLE CAUSES

EGR VALVE

CHECKING VACUUM SUPPLY

EGR SOLENOID

TEST

ACTION

APPLICABILITY

1

Turn the ignition off.
Disconnect both vacuum lines at the EGR Solenoid.
Using a vacuum line connection tee, connect the vacuum supply line to the EGR
Solenoid Output line at the EGR Solenoid.
Disconnect the vacuum line at the EGR Valve.
Connect a vacuum gauge to the EGR Solenoid Output line at the EGR Valve.
Start the engine.
With the engine at idle, note the vacuum gauge reading.
Is the vacuum above 22 inches?

All

Yes

→

Go To

2

No

→

Inspect the vacuum hoses/tubes for damage, restriction and leaks.
If o.k. refer to the Service Information to check the Vacuum Pump
operation.
Perform ROAD TEST VERIFICATION - VER-2.

2

NOTE: The engine must be at operating temperature for this test to be valid.
Turn the ignition off.
Disconnect the vacuum line at the EGR Valve.
Connect a vacuum gauge to the EGR Solenoid Output line at the EGR Valve
Start the engine and observe the vacuum gauge reading for 1 minute.
NOTE: The vacuum reading should increase to above 18 inches approxi-
mately 5 seconds after the engine is started. The vacuum should decrease to
below 4 inches within 40 seconds of engine run time.
Did the vacuum reading increase to above 18 inches then decrease below 4 inches as
described?

All

Yes

→

Go To

3

No

→

Replace the EGR Solenoid.
Perform ROAD TEST VERIFICATION - VER-2.

3

Turn the ignition off.
Disconnect both vacuum lines at the EGR Solenoid.
Using a vacuum line connection tee, connect the vacuum supply line to the EGR
Solenoid Output line at the EGR Solenoid.
Test drive the vehicle and note the vehicles performance.
NOTE: With the connection tee in place the EGR valve will receive full
vacuum supply with the engine running. This should cause a severe
reduction in engine power.
Does the vehicle exhibit a severe loss of power?

All

Yes

→

Test Complete.

No

→

Replace the EGR Valve.
Perform ROAD TEST VERIFICATION - VER-2.

220

DRIVEABILITY - DIESEL

ProCarManuals.com

Summary of Contents for Jeep Grand Cherokee 2002

Page 1: ...1 DRBIIIT DOES NOT POWER UP 7 3 4 2 DISPLAY IS NOT VISIBLE 7 4 0 DISCLAIMERS SAFETY WARNINGS 7 4 1 DISCLAIMERS 7 4 2 SAFETY 7 4 2 1 TECHNICIAN SAFETY INFORMATION 7 4 2 2 VEHICLE PREPARATION FOR TESTIN...

Page 2: ...VIN CHECKSUM ERROR 26 P1680 EEPROM PLAUSIBILITY WRITE ERROR 26 P1685 SKIM SYSTEM INVALID SECRET KEY IN EEPROM 26 P1685 SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE 26 P0110 INTAKE AIR TEMP SENSOR CIRCUI...

Page 3: ...OLENOID CIRCUIT SHORT CIRCUIT 91 P0460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 93 P0460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 96 P0500 VEHICLE SPEED SENSOR FREQUENCY TOO HIGH 98 P...

Page 4: ...ONTROL IMPROPER GEAR 153 P0702 TRANS CONTROL IMPROPER RATIO OR TRANSMISSION SLIPPING 153 P0702 TRANS CONTROL INTERNAL SHIFTER FAILURE 153 P0702 TRANS CONTROL N2 OR N3 INPUT SENSOR CIRCUIT 153 P0702 TR...

Page 5: ...2 J1850 COMMUNICATION BUS UNAUTHORIZED RESET 199 P1685 SKIM SYSTEM INVALID KEY CODE RECEIVED 202 P1685 SKIM SYSTEM KEY COMMUNICATION TIMED OUT 203 P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY 20...

Page 6: ...CTOR PINOUTS 259 A C COMPRESSOR CLUTCH BLACK 2 WAY 259 A C PRESSURE TRANSDUCER BLACK 4 WAY 259 ACCELERATOR PEDAL POSITION SENSOR DIESEL BLACK 10 WAY 259 BATTERY TEMPERATURE SENSOR BLACK 2 WAY 259 BOOS...

Page 7: ...ARTER MOTOR RELAY DIESEL 269 GLOW PLUG RELAY NO 1 DIESEL 269 GLOW PLUG RELAY NO 2 DIESEL 269 VISCOUS CABIN HEATER RELAY DIESEL 269 SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY 270 SPEED CONTROL SWITCH NO...

Page 8: ...NOTES viii ProCarManuals com...

Page 9: ...M The ECM is located in the left side of the engine compartment attached to the left inner fender be hind the battery The sentry key immobilizer mod ule SKIM is located below the steering column behin...

Page 10: ...itored indirectly when the ECM conducts a rationality test to identify problems Although most subsystems of the engine control module are either directly or indirectly monitored there may be occasions...

Page 11: ...p to six times After the sixth attempt the ECM prevents the engine from crank ing until the fault is corrected 3 3 DIAGNOSTIC TROUBLE CODES Each diagnostic trouble code DTC is diagnosed by following a...

Page 12: ...TROL CIRCUIT SHUTS OFF TOO LATE BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW BATTERY SENSE LINE 1 VOLTAGE TOO HIGH BATTERY SENSE LINE 1 VOLTAG...

Page 13: ...NAL VOLTAGE TOO HIGH FUEL PRESS SENSOR CIRCUIT MALF SIG NAL VOLTAGE TOO LOW FUEL PRESS SENSOR CIRCUIT MALF SUP PLY VOLTAGE TOO HIGH OR LOW FUEL PRESSURE SOLENOID OPEN CIRCUIT FUEL PRESSURE SOLENOID P...

Page 14: ...KIM SYSTEM WRITE ACCESS TO EEPROM FAILURE STARTER RELAY CIRCUIT SHORT CIRCUIT SYSTEM VOLTAGE TOO HIGH SYSTEM VOLTAGE TOO LOW TRANSFER CASE POSITION SENSOR PLAU SIBILITY TRANSFER CASE POSITION SENSOR P...

Page 15: ...is fully charged an inoperative DRBIIIt may be the result of a faulty cable or vehicle wiring For a blank screen refer to the appropriate diagnostic manual 3 4 2 DISPLAY IS NOT VISIBLE Low temperature...

Page 16: ...r 25v AC The circuit being tested must be protected by a 10 amp fuse or circuit breaker Use the low current shunt to measure circuits up to 10 amps Use the high current shunt to mea sure circuits exce...

Page 17: ...even though it is able to crank at normal speed IAT intake air temperature sensor lack of power sluggish the engine power output has been reduced MAF mass air flow sensor MIL malfunction indicator lam...

Page 18: ...NOTES 10 ProCarManuals com...

Page 19: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 11 ProCarManuals com...

Page 20: ...tions follow the no start symptom in the powertrain diagnostic information Turn the ignition off Disconnect the ECM C1 harness connector Use Scope input cable CH7058 Cable to Probe adapter CH7062 and...

Page 21: ...sistance below 5 0 ohms All Yes Go To 3 No Go To 4 3 Turn the ignition off Disconnect the TCM C1 harness connector Measure the resistance between ground and the SCI Transmit circuit Is the resistance...

Page 22: ...the resistance below 5 0 ohms All Yes Go To 6 No Repair the SCI Transmit circuit for an open Perform ROAD TEST VERIFICATION VER 2 6 If there are no possible causes remaining view repair All Repair Re...

Page 23: ...Diagnostic Junction Port Using the DRB along with the Diagnostic Junction Port Tester 8339 select Junction Port Tool then PCI Bus Module Scan and follow the instructions on the DRB Was the DRB able t...

Page 24: ...o 5 No Go To 6 5 Measure the voltage of the PCI Bus circuit on the Diagnostic Junction Port tester that previously measured above 7 0 volts Note Turn the ignition off before disconnecting any module h...

Page 25: ...Yes Repair the PCI Bus circuit that measured below 100 0 ohms for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the module that when disconnected the short to ground was eliminate...

Page 26: ...tored With the ignition on Set Condition When the BCM detects low voltage on the Ambient Air Temperature Sensor Signal circuit a J1850 Bus message is sent to the ECM to set this DTC POSSIBLE CAUSES RE...

Page 27: ...eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bullet...

Page 28: ...he Mass Air Flow Sensor Signal voltage is below 1 6 volts for at least 3 seconds P0100 MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored With the ignition on Set Condition The Sensor...

Page 29: ...cle With the DRBIIIt read the ECM DTCs Does the DRB III display a Mass Air Flow Sensor DTC All Yes Go To 2 No Go To 18 2 Turn the ignition off Disconnect the MAF Sensor harness connector Turn the igni...

Page 30: ...of the MAF Sensor harness connector Is the resistance below 1000 ohms All Yes Repair the MAF Sensor Signal for a short to Sensor Ground Perform ROAD TEST VERIFICATION VER 2 No Go To 7 7 Turn the ignit...

Page 31: ...ect the MAF Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Reference Voltage A circuit Is the resistance below 10 0 ohms All Yes Go To 12 No Repair...

Page 32: ...rcuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Go To 15 15 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measu...

Page 33: ...FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at n...

Page 34: ...P1608 A D CONVERTER ERROR VOLTAGE FAILURE P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR P1680 EEPROM PLAUSIBIL...

Page 35: ...tion on Set Condition The ECM detects an internal failure P1601 CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH When Monitored With the engine running During every 180 of engine rotation Set Condition The ECM de...

Page 36: ...ftware programming P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY WRITE ERROR When Monitor...

Page 37: ...wing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Loo...

Page 38: ...ODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the...

Page 39: ...Cs Does the DRB display P0110 INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW All Yes Replace the Intake Air Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 No Go To 5 5 Turn the ignitio...

Page 40: ...eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulle...

Page 41: ...e DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the IAT Sensor harness connector Turn the ignition on Monitor the DRB for ECM DTCs Does the DRB...

Page 42: ...SE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperat...

Page 43: ...ILITY 1 NOTE If multiple DTCs are present the most likely cause is a 5 Volt Supply or Sensor Ground circuit shorted to voltage or ground Refer to the Service Information Wiring section for circuits th...

Page 44: ...the resistance below 10 0 ohms All Yes Go To 5 No Repair the ECT Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 5 Turn the ignition off Disconnect the ECM harness connectors Di...

Page 45: ...ter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulleti...

Page 46: ...ine Coolant Temperature ECT Sensor voltage Is the ECT Sensor voltage below 0 073 volt All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the ECT Sensor harness connector Turn the ignition o...

Page 47: ...ions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB paramet...

Page 48: ...OUND CIRCUIT OPEN INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE FUEL PRESSURE SENSOR ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 WARNING THE FUEL INJ...

Page 49: ...gine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Fuel Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICAT...

Page 50: ...or Ground circuit in the Fuel Pressure Sensor harness connector Turn the ignition on and monitor the DRB for DTCs Is DTC P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW present All Yes Rep...

Page 51: ...am eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bul...

Page 52: ...CTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING NOTE If DTC P0641 or P0651 is present...

Page 53: ...TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The condit...

Page 54: ...NING THE FUEL INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY...

Page 55: ...SIDE P0204 CYLINDER 4 INJECTOR CIRCUIT CURRENT DECREASE P0204 CYLINDER 4 INJECTOR CIRCUIT LOAD DROP P0204 CYLINDER 4 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE P0204 CYLINDER 4 INJECTOR CIRCUIT OVERCURREN...

Page 56: ...ent current through the injector driver when on P0202 CYLINDER 2 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the co...

Page 57: ...RCURRENT LOW SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the injector driver circuit P0205 CYLINDER 5 INJECTOR CIRCUIT CURRENT DECREASE When Monitore...

Page 58: ...ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the appropriate Fuel Injector Control circuit Is the...

Page 59: ...ss connector Measure the resistance between the Fuel Injector Control circuit and the Common Driver circuit Is the resistance below 1000 ohms All Yes Repair the Fuel Injector Control circuit and Commo...

Page 60: ...he following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring har...

Page 61: ...ST ACTION APPLICABILITY 1 NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRB erase ECM DTCs Turn the ignitio...

Page 62: ...ROAD TEST VERIFICATION VER 2 No The repair is complete Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEA...

Page 63: ...ICABILITY 1 NOTE Ensure all turbocharger inlet and outlet tubes are connected prop erly without damage and restriction before continuing with this test Also ensure the wastegate actuator and actuator...

Page 64: ...To 6 5 Turn the ignition off Disconnect the Boost Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and...

Page 65: ...PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent c...

Page 66: ...d the Turbocharger Boost Pressure Sensor voltage Is the voltage below 0 3 volt All Yes Go To 2 No Go To 8 2 Turn the ignition off Disconnect the Boost Pressure Sensor harness connector Turn the igniti...

Page 67: ...the resistance above 100 kohms All Yes Go To 6 No Repair the Boost Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 6 Turn the ignition off...

Page 68: ...param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service...

Page 69: ...CABILITY 1 NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 30 s...

Page 70: ...ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the 5 volt Supply circuit at the APP Sensor harness connector...

Page 71: ...m eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bull...

Page 72: ...RGER WASTEGATE SOLENOID CONTROL CKT OPEN TURBOCHARGER WASTEGATE SOLENOID ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle Monit...

Page 73: ...ohms All Yes Go To 5 No Repair the Turbocharger Wastegate Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 5 Turn the ignition off Install a substitute Turbocharger Wastegate...

Page 74: ...eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulle...

Page 75: ...monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Turbocharger Wastegate Solenoid harness connector Turn the ignition on With the D...

Page 76: ...O NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal oper...

Page 77: ...ABILITY 1 NOTE This DTC indicates the Engine Speed Sensor has seen an engine speed above 5200 RPM This can occur if errant noise is picked up on the CKP Sensor Signal circuit Turn the ignition on With...

Page 78: ...TS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at...

Page 79: ...the acceleration or deceleration is greater than is physically possible POSSIBLE CAUSES CHECK CRANKSHAFT POSITION SENSOR SIGNAL ENGINE CONTROL MODULE OPEN SHIELD CIRCUIT INTERMITTENT CONDITION CRANKSH...

Page 80: ...sary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 3 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between grou...

Page 81: ...ts and Graphs to view a correct CKP Sensor signal Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRB Does the DRB display a steady clean CKP Si...

Page 82: ...MITTENT CONDITION TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase the ECM DTCs Attempt to start the engine With the DRBIIIt read the ECM DTCs Does the DRB III display this DTC...

Page 83: ...gnition off Using the DRB lab scope backprobe both of the CKP Sensor Signal circuits at the CKP Sensor harness connector NOTE Refer to Charts and Graphs to view a correct CKP Sensor signal Start the e...

Page 84: ...eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulle...

Page 85: ...M detects that engine speed is greater than 10 000 RPM P0340 CMP CKP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY When Monitored With the engine running Set Condition The ECM detects the Camshaft Senso...

Page 86: ...test light connected to ground check the ASD Relay Output circuit in CMP Sensor harness connector Does the test light illuminate brightly All Yes Go To 4 No Repair the ASD Relay Output circuit for an...

Page 87: ...Information Perform ROAD TEST VERIFICATION VER 2 8 Turn the ignition off Remove the CMP Sensor Inspect the camshaft for conditions such as loose mounting screws damage debris or cracked teeth Is there...

Page 88: ...ce Information Perform ROAD TEST VERIFICATION VER 2 13 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 L...

Page 89: ...1 Control circuit P0380 GLOW PLUG 1 CONTROL CIRCUIT SHORT CIRCUIT When Monitored With the ignition off Set Condition The ECM detects excessive current on the Glow Plug Relay 1 Control circuit POSSIBL...

Page 90: ...TION VER 2 No Test Complete 3 Turn the ignition off Remove Glow Plug Relay 1 from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does th...

Page 91: ...off Remove Glow Plug Relay 1 from the PDC Disconnect the ECM harness connectors Measure the resistance of the Glow Plug Relay 1 Control circuit Is the resistance below 10 0 ohms All Yes Go To 8 No Re...

Page 92: ...2 Control circuit P0382 GLOW PLUG 2 CONTROL CIRCUIT SHORT CIRCUIT When Monitored With the ignition off Set Condition The ECM detects excessive current on the Glow Plug Relay 2 Control circuit POSSIBL...

Page 93: ...CATION VER 2 No Test Complete 3 Turn the ignition off Remove Glow Plug Relay 2 from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does...

Page 94: ...off Remove Glow Plug Relay 2 from the PDC Disconnect the ECM harness connectors Measure the resistance of the Glow Plug Relay 2 Control circuit Is the resistance below 10 0 ohms All Yes Go To 8 No Re...

Page 95: ...id this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect both vacuum lines at the EGR Solenoid Using a vacuum line connection tee connect the vacuum supply line to the EGR S...

Page 96: ...e loss of power All Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Replace the EGR Valve Perform ROAD TEST VERIFIC...

Page 97: ...s between each ignition cycle Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on...

Page 98: ...E ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at...

Page 99: ...for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB f...

Page 100: ...OTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature m...

Page 101: ...Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 7 2 Turn th...

Page 102: ...el Sensor harness connector Turn the ignition on With the DRB read and record the Fuel Level Sensor voltage NOTE The Fuel Level Sensor voltage should be 5 0 0 3 volts with the sensor harness connector...

Page 103: ...am eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bul...

Page 104: ...nition on With the DRB read ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read...

Page 105: ...NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor...

Page 106: ...than 2400 RPM while vehicle speed is below 20 km h 12 MPH Set Condition The ECM compares the amount of fuel the fuel injectors are delivering to the vehicle speed from the VSS The VSS indicates a veh...

Page 107: ...t Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wir...

Page 108: ...e Controller Antilock Brake Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Infor...

Page 109: ...TEMPERATURE SENSOR BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB monitor the Battery Temperature Sensor voltage Is...

Page 110: ...in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Battery Temperature Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN...

Page 111: ...y Temperature Sensor voltage below 0 151 volt All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Battery Temperature Sensor harness connector Turn the ignition on With the DRB read the...

Page 112: ...set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters relate...

Page 113: ...OPEN INTERMITTENT CONDITION TEST ACTION APPLICABILITY 1 NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRBII...

Page 114: ...ectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance of the Sensor Ground circuit Is the resistance below 5 0 ohms All Yes Replace the Engine Oil Pressure Sensor Perform...

Page 115: ...aram eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service B...

Page 116: ...on and off several times leaving the key on for at least 10 seconds at a time With the DRBIIIt read ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the O...

Page 117: ...t present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC w...

Page 118: ...is DTC diagnose DTCs P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then start and idle the engine With the DRB read...

Page 119: ...WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not pres...

Page 120: ...on on Set Condition The A C Pressure Sensor Signal voltage is below 0 15 volt P0530 A C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored With the ignition on Set Condition The Sen...

Page 121: ...sure Sensor harness connector Is the resistance above 100 kohms All Yes Go To 3 No Repair the A C Pressure Sensor Signal circuit for a short to the 5 volt Supply circuit Perform ROAD TEST VERIFICATION...

Page 122: ...IFICATION VER 2 No Go To 6 6 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Disconnect the ECM harness connector Measure the resistance of the A C Pressure Sensor Signal ci...

Page 123: ...the above conditions present All Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 10 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Turn the ig...

Page 124: ...trol Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 15 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Disconnect the ECM harness con...

Page 125: ...on off Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check all of the ECM Ground circuits including the Battery Sense circuit Does the test light illuminate br...

Page 126: ...ARGING VERIFICATION VER 3 4 Turn the ignition off Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Control terminal on the back of the Gen...

Page 127: ...ine running Set Condition The ECM detects the current on the Generator Field above 10 7 amps POSSIBLE CAUSES INTERMITTENT CONDITION GENERATOR BELT CONDITION OR TENSION GENERATOR FIELD HIGH RESISTANCE...

Page 128: ...post 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 Start the engine Is the voltage on...

Page 129: ...connect the Generator Field harness connector Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltag...

Page 130: ...tance Perform CHARGING VERIFICATION VER 3 14 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 CLOTH...

Page 131: ...Go To 2 No Go To 5 2 Turn the ignition off Disconnect the S C Switch harness connectors Disconnect the ECM harness connectors Measure the resistance of the S C Switch Signal circuit Is the resistance...

Page 132: ...e not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC w...

Page 133: ...C ON OFF SET Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the S C Switch Signal circuit Is the resistance below 10 0 ohms All Yes Replace and program the E...

Page 134: ...orm SPEED CONTROL VERIFICATION VER 4 5 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of th...

Page 135: ...ch Perform SPEED CONTROL VERIFICATION VER 4 No Go To 3 3 Turn the ignition on With the DRBIIIt monitor the S C Switch voltage Disconnect the S C Resume Accel Switch harness connector Did the volt chan...

Page 136: ...OTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature m...

Page 137: ...Turn the ignition on With the DRB erase ECM DTCs Attempt to start the engine several times pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this D...

Page 138: ...NG NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monit...

Page 139: ...ION TOO HIGH When Monitored and Set Condition P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO HIGH When Monitored With the engine running Set Condition The ECM detects the battery vol...

Page 140: ...ERMITTENT CONDITION GENERATOR BELT CONDITION OR TENSION GENERATOR FIELD GENERATOR FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND GENERATOR FIELD CONTROL CIR...

Page 141: ...ASD Relay connector Turn the ignition on Measure the voltage of the Generator Field Control circuit Is the voltage below 1 0 volt All Yes Go To 5 No Repair the Generator Field Control circuit for a s...

Page 142: ...T PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent...

Page 143: ...PPLICABILITY 1 Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the MAF and APP Sensor...

Page 144: ...FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the int...

Page 145: ...OLTAGE A CIRCUIT SHORTED TO GROUND SENSOR REFERENCE VOLTAGE A CIRCUIT SHORTED TO SENSOR GROUND FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT S...

Page 146: ...sistance between ground and the Sensor Reference Voltage A circuit Is the resistance above 100 kohms All Yes Go To 6 No Repair the Sensor Reference Voltage A circuit for a short to ground Perform ROAD...

Page 147: ...tion Perform ROAD TEST VERIFICATION VER 2 10 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 CLOTH...

Page 148: ...N DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal o...

Page 149: ...nition off Remove the A C Clutch Relay from the PDC Disconnect the ECM harness connector Measure the resistance of the A C Clutch Relay Control circuit Is the resistance below 5 0 ohms All Yes Go To 6...

Page 150: ...TE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor th...

Page 151: ...ECM harness connector Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the A C Clutch Rel...

Page 152: ...the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the Boost Pressure Sensor harness connector Disconnect the Engi...

Page 153: ...IRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in...

Page 154: ...NTERMITTENT CONDITION A C PRESS OIL PRESS BOOST PRESS OR APP SENSOR SHORTED TO GROUND SENSOR REFERENCE VOLTAGE B CIRCUIT SHORTED TO GROUND SENSOR REFERENCE VOLTAGE B CIRCUIT SHORTED TO SENSOR GROUND A...

Page 155: ...s connectors Disconnect the Boost Pressure A C Pressure and Engine Oil Pressure Sensors harness connectors Measure the resistance between ground and the Sensor Reference Voltage B circuit Is the resis...

Page 156: ...ntrol Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 8 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEA...

Page 157: ...Cs Are other DTCs present All Yes Refer to the Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 Turn the ignition on With the DRB erase...

Page 158: ...TE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor th...

Page 159: ...CUIT SHORTED TO GROUND INTERMITTENTLY ASD RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB check for additional DTCs Are othe...

Page 160: ...rm ROAD TEST VERIFICATION VER 2 No Repair the ASD Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE...

Page 161: ...ptoms listed above are diagnosed using the same tests The title for the tests will be P0700 TRANS CONTROL 1 2 4 5 SOLENOID CIRCUIT POSSIBLE CAUSES VERIFY CURRENT DTC TEST ACTION APPLICABILITY 1 NOTE I...

Page 162: ...not agree P0703 BRAKE SWITCH SIGNAL CKTS PLAUS W REDUNDANT CONTACT AF TER INITIALIZATION When Monitored With the ignition on Set Condition The ECM detects the Primary Brake Switch Signal circuit and S...

Page 163: ...unning at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Moni...

Page 164: ...th the Service Information Perform ROAD TEST VERIFICATION VER 2 8 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance...

Page 165: ...s connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the vo...

Page 166: ...BILITY 2 When Monitored With the ignition on Set Condition The ECM detects a voltage signal from the transfer case switch that does not fall into a valid switch position voltage range P0836 TRANSFER C...

Page 167: ...ignal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Go To 3 3 Turn the ignition off to the lock position Disconnect the ECM harness connectors Disconnect the Transfer Case Pos...

Page 168: ...n shifting the transfer case selector to each position the Sensor voltage should result in the following voltages 4WD Low 0 16 0 40 Neutral 0 68 0 97 4WD Full Time 1 24 1 55 Does each position provide...

Page 169: ...cord and erase DTCs Test drive the vehicle With the DRBIIIt read the ECM DTCs Does the DRBIIIt display this DTC All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the TCM harness connector...

Page 170: ...the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the P N Switch Sense circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATING DO...

Page 171: ...ine speed above 730 rpm Set Condition The fuel rail pressure sensor indicates fuel pressure above what the ECM commanded P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED When Monitored With the e...

Page 172: ...G THE FUEL INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOG...

Page 173: ...e of the Common Injector Driver circuit between the ECM harness connector and each Fuel Injector harness connector Is the resistance below 10 0 ohms for each measurement All Yes Go To 6 No Repair the...

Page 174: ...aram eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service B...

Page 175: ...ol circuit P1131 FUEL PRESSURE SOLENOID POWERSTAGE ERROR When Monitored When the ignition is turned off Set Condition The ECM detects engine speed does not fall below 650 RPM within 1 5 second after i...

Page 176: ...3 Turn the ignition off Disconnect the Fuel Pressure Solenoid harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavi...

Page 177: ...E The DRB should display P1131 FUEL PRESSURE SOLENOID OPEN CIRCUIT Turn the ignition off Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Pressure Solenoid harness connector Turn the ig...

Page 178: ...for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Serv...

Page 179: ...N APPLICABILITY 1 Turn the ignition on With the DRBIIIt check for the correct classification of all of the Fuel Injectors Are all of the injectors classified correctly All Yes Replace and program the...

Page 180: ...This DTC indicates a communication problem between the TCM and the ECM Turn the ignition on With the DRB erase ECM DTCs Perform several engine run cycles turning the ignition off for at least 20 seco...

Page 181: ...for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Ser...

Page 182: ...n expected CAN Bus message from the TCM POSSIBLE CAUSES CAN C BUS CIRCUITS OPEN CAN C BUS CIRCUITS SHORTED TO GROUND CAN C BUS CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE TRANSMISSION CONTROL MODU...

Page 183: ...it at the TCM harness connector Is the resistance above 1000 ohms for each measurement All Yes Go To 4 No Repair the CAN C Bus circuit s for a short to ground Perform ROAD TEST VERIFICATION VER 2 4 Tu...

Page 184: ...lace the Transmission Control Module Perform ROAD TEST VERIFICATION VER 2 8 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...

Page 185: ...the ECM harness connectors Measure the resistance of the CAN C Bus circuit between the ECM and the TCM harness connectors Measure the resistance of the CAN C Bus circuit between the ECM and the TCM h...

Page 186: ...rness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Tec...

Page 187: ...e ignition on With the DRB erase ECM DTCs With the DRBIIIt actuate the Swirl Solenoid With the DRBIIIt read the ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 4 2 Turn the ignition off Disco...

Page 188: ...following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harnes...

Page 189: ...hen Monitored With the ignition on Set Condition The ECM detects an internal fault with the Intake Port Swirl Actuator POSSIBLE CAUSES INTAKE PORT SWIRL ACTUATOR Repair Instructions INTAKE PORT SWIRL...

Page 190: ...tor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the Swirl Solenoid harness connector Turn the ignition on Using a 12 volt test light conne...

Page 191: ...OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time Th...

Page 192: ...NTROL CKT OPEN HYDRAULIC COOLING FAN SOLENOID ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB erase ECM DTCs With the DRBIIIt actuate the Hydraulic Cooling Fan Sole...

Page 193: ...ll Yes Go To 5 No Repair the Hydraulic Cooling Fan Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 5 Turn the ignition off Install a substitute Hydraulic Cooling Fan Solenoid...

Page 194: ...m eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bull...

Page 195: ...e ignition on With the DRB erase ECM DTCs With the DRBIIIt actuate the Hydraulic Cooling Fan Solenoid With the DRBIIIt read the ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 4 2 Turn the ig...

Page 196: ...at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling...

Page 197: ...AGE TOO LOW When Monitored With the ignition on or the engine running Set Condition The ECM detects Battery Sense circuit voltage below 6 0 volts P1512 BATTERY SENSE LINE 2 VOLTAGE TOO HIGH When Monit...

Page 198: ...s for an open Perform ROAD TEST VERIFICATION VER 2 4 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87...

Page 199: ...T STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following lis...

Page 200: ...milliseconds during ECM initialization at Key On Look for an intermittent open or short to ground on the Ignition Switch Sense circuit Turn the ignition on With the DRB erase ECM DTCs Cycle the igniti...

Page 201: ...TH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying t...

Page 202: ...ISCOUS HEATER RELAY SHORT CIRCUIT When Monitored With the ignition on Set Condition The ECM detects excessive current on the Viscous Heater Relay Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION...

Page 203: ...the ignition off Disconnect the Viscous Heater Relay from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit at the Viscous Heater Relay co...

Page 204: ...T VERIFICATION VER 2 7 Turn the ignition off Remove the Viscous Heater Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the Viscous Heater Relay Control circuit Is th...

Page 205: ...eive a response from the instrument cluster when a J1850 message to actuate the MIL is transmitted P1651 MIL DIAG LAMP VIA J1850 BUS STATUS ERROR When Monitored With the ignition on Set Condition The...

Page 206: ...ions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB paramet...

Page 207: ...d while the ECM was sending a message P1652 J1850 COMMUNICATION BUS RECEIVE TIMEOUT When Monitored With the ignition on Set Condition The ECM has not received a J1850 Bus massage for 2 0 seconds P1652...

Page 208: ...ment Cluster communicating with the DRB All Yes Go To 2 No Refer to the appropriate symptom in the Body Diagnostic Infor mation Perform ROAD TEST VERIFICATION VER 2 2 Turn the ignition on With the DRB...

Page 209: ...param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service...

Page 210: ...ndition The ECM receives a message from the SKIM indicating an incorrect message was received from the ignition key POSSIBLE CAUSES SKIM IGNITION KEY FAULT TEST ACTION APPLICABILITY 1 This fault indic...

Page 211: ...s before continuing Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 Turn the ignition on With the DRBIIIt erase ECM DTCs Turn the ignition on and off several times pausing 10 seconds between each ke...

Page 212: ...r param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Servic...

Page 213: ...n P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY When Monitored With the ignition on Set Condition The Accelerator Pedal Position Sensor Signal is below 1 6 or above 17 6 and the idle switch is no...

Page 214: ...O HIGH When Monitored With the ignition on Set Condition The ECM detects voltage on the Accelerator Pedal Position Sensor Signal circuit above 3 3 volts P2125 ACC PEDAL POSITION SENSOR 2 CKT SUPPLY VO...

Page 215: ...ith the accelerator pedal in the at rest position Does the DRB display between 0 50 and 0 90 volt for sensor 1 and 1 2 the 1 voltage for 2 All Yes Go To 2 No Go To 5 2 Turn the ignition on Fully depre...

Page 216: ...omplete 5 NOTE Perform the rest of this diagnostic procedure on the individual APP Sensor Potentiometer 1 or 2 that did not display the correct voltages in the previous test Turn the ignition off Disc...

Page 217: ...isconnect the ECM harness connectors Measure the resistance of the APP Sensor Signal circuit Is the resistance below 10 0 ohms All Yes Go To 11 No Repair the APP Sensor Signal circuit for an open Perf...

Page 218: ...or Reference Voltage A on Sensor 2 circuit for an open Perform ROAD TEST VERIFICATION VER 2 15 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors M...

Page 219: ...e 5 volt Supply Sensor Reference Voltage A on Sensor 2 circuit in the ECM harness connector Is the voltage above 1 0 volt All Yes Repair the 5 volt Supply Sensor Reference Voltage A on Sensor 2 circui...

Page 220: ...hoose the symptom s Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 Turn the ignition on Position the Mode switch on the AZC Module or the A C Heater Control Module to the Panel position Turn the A...

Page 221: ...lutch Relay from the PDC Disconnect the A C Clutch harness connector Measure the resistance between ground and the A C Clutch Relay Output circuit Is the resistance above 100 kohms All Yes Go To 7 No...

Page 222: ...ss connector Does the A C Select Switch state change from Off to On when the jumper wire is connected All Yes Replace the AZC Module or the A C Heater Control Module in accordance with the Service Inf...

Page 223: ...ion Turn the A C Select switch off With the DRBIIIt in BCM select Inputs Outputs Monitor the A C Select Switch state while turning the A C Select switch from off to on and then back to off Does the sw...

Page 224: ...l circuit between the AZC Module C2 harness connector or the A C Heater Control C1 harness connector and ground Is the resistance below 100K ohms All Yes Repair the A C Switch Signal Circuit for a sho...

Page 225: ...s Go To 2 No Replace the Accelerator Pedal Position Sensor Perform ROAD TEST VERIFICATION VER 2 2 Turn the ignition on Fully depress the accelerator pedal With the DRB read the voltage for APP Sensor...

Page 226: ...N APPLICABILITY 1 Allow the engine to idle With the DRBIIIt select Engine then Sensors Read the Boost Pressure Voltage Is the Boost Pressure Voltage between 1 50 and 2 00 volts All Yes Test Complete N...

Page 227: ...C1 cavity 22 Is the test light on All Yes Go To 3 No Repair the Fused Ignition Switch Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 3 Turn the ignition off Remove the ASD Relay from...

Page 228: ...cuum gauge to the EGR Solenoid Output line at the EGR Valve Start the engine and observe the vacuum gauge reading for 1 minute NOTE The vacuum reading should increase to above 18 inches approxi mately...

Page 229: ...No Replace the Engine Coolant Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 2 NOTE The thermostat must be operating correctly for this test to be valid Start the engine and bring the engine...

Page 230: ...shaft tone wheel for debris and deterioration Engine Exhaust System must be free of any restriction Engine Drive Chain and Sprockets must be properly positioned Vacuum System must operate properly and...

Page 231: ...tuator test Does the test light cycle on and off at each Glow Plug harness connector during actuation All Yes Go To 2 No Go To 3 2 Refer to the Service Information and perform the Glow Plug Test Are a...

Page 232: ...epair the Glow Plug Relay Output circuit for a short to ground Inspect the fuse or fuselink and replace as necessary Perform ROAD TEST VERIFICATION VER 2 6 Turn the ignition off Disconnect the Glow Pl...

Page 233: ...ad the P N Switch state Connect one end of a fused jumper wire to the P N Switch Sense circuit at the TCM harness connector Connect the other end of the jumper to ground for 10 seconds then disconnect...

Page 234: ...5 Turn the ignition off Disconnect the TCM harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the P N Switch Sense circuit Is the resistance above 1000 0...

Page 235: ...NCEL 1 2 2 05v COAST 2 2 2 95v No Button Pressed 4 4 4 7v Does each switch provide the correct voltage All Yes Go To 3 No Refer to symptom list for problems related to S C Switches Perform SPEED CONTR...

Page 236: ...THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for...

Page 237: ...shifting the transfer case selector to each position the Sensor voltage should result in the following voltages 4WD Full Time 1 24 1 55 4WD Low 0 16 0 40 Neutral 0 68 0 97 Does each position provide t...

Page 238: ...us Heater Relay connector Does the test light illuminate brightly All Yes Go To 3 No Repair the Fused B Fuse Fuselink circuit for an open Perform ROAD TEST VERIFICATION VER 2 3 Turn the ignition off D...

Page 239: ...he Viscous Heater Relay Output circuit in the Viscous Heater harness connector Does the test light illuminate brightly All Yes Go To 6 No Repair the Viscous Heater Relay Output circuit for an open Per...

Page 240: ...ay Output circuit at the WIF Sensor harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 3...

Page 241: ...n the ignition off Disconnect the Water In Fuel Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Water In Fuel Sensor Signal circuit Is the...

Page 242: ...MECHANICAL FUEL SYSTEM RESTRICTION SENSOR GROUND OPEN TEST ACTION APPLICABILITY 1 NOTE The ECM must have proper power and ground connections for the following tests to be valid Refer to Checking the E...

Page 243: ...etween Ground and each Fuel Injector Driver circuit at it s respective Fuel Injector harness connector Is the resistance below 1000 ohms for any of the measurements All Yes Repair the Fuel Injector Dr...

Page 244: ...d compare the two readings Are the two readings within 3450 kPa 500 PSI of each other All Yes Go To 11 No Go To 13 11 Refer to the Service Information to ensure the Engine Drive Gears Sprocket are ins...

Page 245: ...pen Perform NO START VERIFICATION VER 1 15 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground...

Page 246: ...he battery cables for corrosion looseness or other problems Is there evidence of problems All Yes Repair as necessary Perform NO START VERIFICATION VER 1 No Go To 2 2 Turn the ignition on With the DRB...

Page 247: ...the ignition switch to the START position Does the test light illuminate with the ignition switch in the START position All Yes Go To 7 No Repair the Ignition Switch Start circuit for an open Perform...

Page 248: ...1 Turn the ignition off Remove the Starter Relay from the PDC Disconnect the Starter Relay Output wire from the Starter Solenoid Connect the Starter Relay Output wire at the Starter to ground Using a...

Page 249: ...the micro controller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the writ...

Page 250: ...SKIM DTCs Perform 10 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the SKIM DTCs Did the same SKIM DTC return All Yes Replace and program...

Page 251: ...rs with the ECM due to a SKIM reset or during SECRET KEY transfers to the ECM Set Condition When the SKIM does not receive an expected PCI BUS message trans mission acknowledgement from the ECM after...

Page 252: ...SKIM DTC s Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the SKIM DTCs Does the code appear All Yes Replace and program the Engi...

Page 253: ...SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the ECM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the ECM does not match the...

Page 254: ...y and clear all ECM and SKIM DTC s Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle With the DRBIIIt check for SKIM DTCs Does the DRBIIIt display the same DTC All Yes...

Page 255: ...CY CHECK CRC FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When 5 consecutive transponder signal transmissions are sent to the SKIM with the correct message forma...

Page 256: ...n With the DRBIIIt read the SKIM DTCs Is the DTC present for all ignition keys All Yes Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VER...

Page 257: ...ted wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note...

Page 258: ...Access Mode using an incorrect PIN Secured Access Mode will be locked out for 1 hour which causes the DRB to display 9Bus Signals Open9 To exit this mode turn ignition to Run for 1 hour 12 Ensure all...

Page 259: ...itial or another symptom exists the repair is not complete Check all pertinent Technical Service Bulletins TSBs and return to the Symptom List if necessary 5 For previously read DTCs that have not bee...

Page 260: ...MPH 4 Turn the speed control ON OFF switch on 5 Depress and release the SET switch If the speed control does not engage the repair is not complete continue with step 12 6 Quickly depress and release t...

Page 261: ...ll void this procedure 16 From a stop moderately accelerate the vehicle and obtain all forward gear ranges while keeping the Engine RPM below 1800 RPM Repeat this procedure 4 to 5 times 17 Obtaining 5...

Page 262: ...NOTES 254 ProCarManuals com...

Page 263: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES 8 2 CONTROLS AND SOLENOIDS C O M P O N E N T L O C A T I O N S 255 COMPONENT LOCATIONS ProCarManuals com...

Page 264: ...8 3 DATA LINK CONNECTOR 8 4 FUEL SYSTEM 8 5 SENSORS C O M P O N E N T L O C A T I O N S 256 COMPONENT LOCATIONS ProCarManuals com...

Page 265: ...C O M P O N E N T L O C A T I O N S 257 COMPONENT LOCATIONS ProCarManuals com...

Page 266: ...8 6 SWITCHES C O M P O N E N T L O C A T I O N S 258 COMPONENT LOCATIONS 8 5 SENSORS Continued ProCarManuals com...

Page 267: ...FUNCTION 1 2 F855 18BR YL SENSOR REFERENCE VOLTAGE A 3 K22 14RD DB ACCELERATOR PEDAL POSITION SENSOR 2 SIGNAL 4 5 6 K225 18BK ACCELERATOR PEDAL POSITION SENSOR 2 GROUND 7 K81 20DB DG ACCELERATOR PEDAL...

Page 268: ...CONTROL BRAKE SWITCH OUTPUT 5 L50 20VT TN LHD PRIMARY BRAKE SWITCH SIGNAL 5 L50 20WT TN RHD PRIMARY BRAKE SWITCH SIGNAL 6 F32 20PK DB FUSED B CAMSHAFT POSITION SENSOR DIESEL BLACK 3 WAY CAV CIRCUIT FU...

Page 269: ...IVE 7 D21 20PK SCI TRANSMIT 8 9 D19 20VT OR BODY CONTROL MODULE FLASH ENABLE 10 11 12 13 14 D20 20LG SCI RECEIVE 15 16 F33 20PK RD FUSED B EGR SOLENOID DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F15 18...

Page 270: ...RATOR PEDAL POSITION SENSOR 1 5 VOLT SUPPLY 36 C18 20DB A C PRESSURE SENSOR SIGNAL 37 38 V37 20RD DG SPEED CONTROL SWITCH SIGNAL 39 K226 20DB WT FUEL LEVEL SENSOR SIGNAL 40 K2 20DG RD ENGINE COOLANT T...

Page 271: ...CH SENSE 113 114 115 K14 14BK YL FUEL INJECTOR NO 4 CONTROL 116 K63 14BK COMMON INJECTOR DRIVER 117 118 K11 14BK DB FUEL INJECTOR NO 1 CONTROL 119 K38 14BK DG FUEL INJECTOR NO 5 CONTROL 120 K12 14BK V...

Page 272: ...MMON INJECTOR DRIVER FUEL INJECTOR NO 2 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K12 14BK VT FUEL INJECTOR NO 2 CONTROL 2 K63 14BK COMMON INJECTOR DRIVER FUEL INJECTOR NO 3 DIESEL BLACK 2 WAY CAV CIR...

Page 273: ...20DG VT FUEL PRESSURE SENSOR SIGNAL 3 K7 20RD WT FUEL PRESSURE SENSOR 5 VOLT SUPPLY FUEL PRESSURE SOLENOID DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K46 20DB BK FUEL PRESSURE SOLENOID CONTROL 2 F142 1...

Page 274: ...R SIGNAL INTAKE PORT SWIRL ACTUATOR DIESEL BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z18 18BK GROUND 2 F15 18RD DG FUSED AUTO SHUT DOWN RELAY OUTPUT 3 K900 18GY INTAKE PORT SWIRL ACTUATOR SIGNAL MASS AIR FLO...

Page 275: ...C O N N E C T O R P I N O U T S 267 CONNECTOR PINOUTS ProCarManuals com...

Page 276: ...10A F300 18RD BK FUSED B 23 15A A80 18RD LG FUSED B 24 25 20A A20 12RD DB FUSED B 26 20A F142 14OR DG FUSED AUTO SHUT DOWN RELAY OUTPUT 27 20A A148 16LG RD FUSED B 28 A C COMPRESSOR CLUTCH RELAY DIESE...

Page 277: ...GY GLOW PLUG RELAY NO 1 OUTPUT 87A GLOW PLUG RELAY NO 2 DIESEL CAV CIRCUIT FUNCTION 30 A110 VT RD FUSED B 85 K236 18GY PK GLOW PLUG RELAY NO 2 CONTROL 86 F15 20DB WT FUSED AUTO SHUT DOWN RELAY OUTPUT...

Page 278: ...RD LG SPEED CONTROL SWITCH SIGNAL 4 SPEED CONTROL SWITCH NO 2 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 K4 20BK LB SENSOR GROUND 3 V37 20RD LG SPEED CONTROL SWITCH SIGNAL 4 TRANSFER CASE POSITION SENSOR BL...

Page 279: ...D IGNITION SWITCH OUTPUT RUN START 30 Z234 20WT GROUND VISCOUS CABIN HEATER DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 A82 16PK LG VISCOUS CABIN HEATER RELAY OUTPUT 2 Z18 16BK GROUND WASTEGATE SOLENOID...

Page 280: ...NOTES 272 ProCarManuals com...

Page 281: ...10 0 SCHEMATIC DIAGRAMS 10 1 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 273 SCHEMATIC DIAGRAMS ProCarManuals com...

Page 282: ...NOTES 274 ProCarManuals com...

Page 283: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 275 CHARTS AND GRAPHS ProCarManuals com...

Page 284: ...NOTES 276 ProCarManuals com...

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