Dodge 2004 Neon SRT4 Diagnostic Manual Download Page 659

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Symptom:

*ENGINE CRANKS DOES NOT START - 1.6L

POSSIBLE CAUSES

FUEL PUMP RELAY

NO START PRE-TEST

OTHER POSSIBLE CAUSES FOR NO START

POWERTRAIN FUSES OPEN

FUEL PRESSURE OUT OF SPECS

RESTRICTED FUEL SUPPLY LINE

FUEL PUMP INLET STRAINER PLUGGED

FUEL PUMP MODULE

FUEL PUMP RELAY FUSED B+ CIRCUIT

FUEL PUMP RELAY OUTPUT CIRCUIT OPEN

FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE

FUEL PUMP MODULE

5 VOLT SUPPLY CIRCUIT

CKP SENSOR SIGNAL CIRCUIT SHORTED GROUND

CKP SENSOR SIGNAL CIRCUIT OPEN

CKP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

CKP SENSOR SIGNAL SHORTED TO 5 VOLT SUPPLY CIRCUIT

SENSOR GROUND CIRCUIT OPEN

CRANKSHAFT POSITION SENSOR

PCM - CKP SENSOR SIGNAL

323

STARTING

Summary of Contents for 2004 Neon SRT4

Page 1: ...7 1 VEHICLE THEFT SECURITY SYSTEM 9 3 7 2 VEHICLE THEFT SECURITY SYSTEM EXPORT ONLY 10 3 7 3 POWER DOOR LOCKS 10 3 7 3 1 CENTRAL LOCKING W VTSS ONLY 10 3 7 3 2 ROLLING AUTOMATIC DOOR LOCKS 10 3 7 3 3...

Page 2: ...URED FOR SAB 47 NO CLUSTER MESSAGE 49 NO LEFT SIACM MESSAGE 51 NO PCI TRANSMISSION 53 NO RIGHT SIACM MESSAGE 56 PASSENGER SQUIB 1 CIRCUIT OPEN 58 PASSENGER SQUIB 1 CIRCUIT SHORT 61 PASSENGER SQUIB 1 S...

Page 3: ...RESPONSE FROM RADIO 113 NO RESPONSE FROM RIGHT SIACM 115 NO RESPONSE FROM RKE 117 NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE 119 NO RESPONSE FROM TRANSMISSION CONTROL MODULE NGC 121 PCI BUS COMMU...

Page 4: ...PERATIVE ALL LAMPS 175 COURTESY LAMPS ON AT ALL TIMES 176 ILLUMINATED ENTRY INOPERATIVE 179 POWER DOOR LOCKS RKE BODY STYLE MISMATCH 180 DRIVER DOOR SWITCH SHORTED OR STUCK 181 INCORRECT MODULE TYPE C...

Page 5: ...VERIFICATION TESTS VERIFICATION TESTS 235 8 0 COMPONENT LOCATIONS 239 8 1 AIRBAG SYSTEM 239 8 1 1 AIRBAG CONTROL MODULE ACM 239 8 1 2 AIRBAG MODULE DRIVER 239 8 1 3 AIRBAG MODULE PASSENGER 239 8 1 4...

Page 6: ...4 LEFT INSTRUMENT PANEL SPEAKER WHITE 2 WAY 254 LEFT REAR DOOR AJAR SWITCH BLACK 2 WAY 254 LEFT REAR DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY 255 LEFT REAR SPEAKER 3 WAY 255 LEFT SEAT AIRBAG SQUIB 2 WA...

Page 7: ...EM 265 10 2 AUDIO SYSTEM 266 10 2 1 CD CHANGER 267 10 3 COMPASS TEMPERATURE MIRROR 267 10 4 EXTERIOR LIGHTING 268 10 5 INSTRUMENT CLUSTER 269 10 6 INTERIOR LIGHTING 270 10 7 POWER DOOR LOCKS RKE 270 1...

Page 8: ...osis of the body system is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem isolation repair of isolated problem verification of proper o...

Page 9: ...ms of system malfunction Whenever the ignition key is turned to the run or start position the MIC performs a lamp check by turning the airbag warn ing lamp on for 6 8 seconds If the lamp turns off it...

Page 10: ...AG CONTAINS ARGON GAS PRESSURIZED TO OVER 2500 PSI DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR DO NOT PUNCTURE INCINERATE OR BRING INTO CONTACT WITH ELECTRICITY DO NOT STO...

Page 11: ...ce information for discon necting airbag system components Inspect the wir ing connector and terminals for damage or mis alignment Substitute the airbag load tool in place of a Driver or Passenger Air...

Page 12: ...r speakers on that output channel will also shut down until the circuit is repaired The radio will also set a trouble code which the DRBIIIt can display The in dash CD changer is designed to fit into...

Page 13: ...or C that was last selected CALIBRATION ZONE MODE Refer to the Zone Variance Map With the ignition in the ON position pressing and holding the Zone Cal button left reading lamp button for 5 10 seconds...

Page 14: ...the compass cali bration to adjust for gradual changes in the vehi cle s magnetic remnant field If the vehicle is sub jected to high magnetic influences the compass may appear to indicate false headin...

Page 15: ...temperature sensor sense circuit is open the temp display will be 45 C 49 F to indicate an OPEN circuit condition If there is an OPEN or SHORT circuit condition it must be repaired before the Compass...

Page 16: ...via the PCI bus circuit The front turn signals are wired through the cluster and then go to the front lamps For vehicles equipped with Daytime Running Lamps the DRL module is built into the cluster 3...

Page 17: ...NG W VTSS ONLY This feature allows the customer to lock unlock all vehicle doors with the key from the front door cylinder lock switch The customer can choose to program this feature to unlock all doo...

Page 18: ...ry Key Immobi lizer Symptoms of Individual module failure could include any one or more of the above The difference would be that at least one or more modules would respond to the DRBIIIt Diagnosis st...

Page 19: ...line 548 err 0x1 User Requested COLD Boot Press MORE to switch between this display and the application screen Press F4 when done noting information 3 9 2 DRBIIIT DOES NOT POWER UP If the LED s do no...

Page 20: ...pt ing to remove or repair certain system sub components may result in personal injury and or improper system operation Only those components with approved repair and installation procedures in the se...

Page 21: ...THE DRBIIIT OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIIIT OR OTHER TEST EQUIPMENT FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RE...

Page 22: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15...

Page 23: ...s continuously performs internal circuit tests Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 1 When Monitored With the ignition on the module on bo...

Page 24: ...sly performs internal circuit tests Set Condition This DTC will set if the ACM identifies an out of range internal circuit STORED ENERGY LOGIC When Monitored With the ignition on the ACM on board diag...

Page 25: ...ordance with Service Instructions Perform AIRBAG VERIFICATION TEST VER 1 LEFT SIACM ACTIVE or STORED DTC WARNING MAKE SURE THE BATTERY IS DISCONNECTED THEN WAIT TWO MINUTES BEFORE PROCEEDING Replace t...

Page 26: ...tored With ignition on the ACM monitors the PCI Bus for a message from the MIC containing the airbag warning indicator status The MIC transmits the message one time at ignition on upon lamp state chan...

Page 27: ...ST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe dis...

Page 28: ...DES CLUSTER MESSAGE MISMATCH STORED CODE OR INTERMITTENT CONDITION ACM CLUSTER MESSAGE MISMATCH ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged...

Page 29: ...l modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as y...

Page 30: ...T SIACM CONNECTOR LEFT SIDE IMPACT AIRBAG CONTROL MODULE LSIACM RIGHT SIDE IMPACT AIRBAG CONTROL MODULE LSIACM STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Tur...

Page 31: ...T VER 1 No Rewire the Right Side Impact Airbag Control Module connector Perform AIRBAG VERIFICATION TEST VER 1 4 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs fro...

Page 32: ...UIB CIRCUITS OPEN DRIVER SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM DRIVER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition o...

Page 33: ...DING Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH T...

Page 34: ...active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate air...

Page 35: ...SQUIB 1 CIRCUIT SHORT DRIVER SQUIB 1 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on...

Page 36: ...NUTES BE FORE PROCEEDING Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSON...

Page 37: ...active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate air...

Page 38: ...UIT SHORT TO BATTERY DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 1 CIRCUITS SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1...

Page 39: ...NING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag DTCs Does the DRBIIIt show DRIVER SQUIB 1 SHORT TO BATTERY All Yes Go To...

Page 40: ...ctive codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airba...

Page 41: ...CIRCUIT SHORT TO GROUND DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER SQUIB 1 CIRCUITS SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILI...

Page 42: ...he Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION...

Page 43: ...o stop NOTE Check connectors Clean and 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...

Page 44: ...ROGATE LEFT SIACM ACM NO ACTIVE LEFT SIACM DTCS STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Ensure the battery i...

Page 45: ...nger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airbag system and rotate the steering wheel from stop to stop NOTE Check co...

Page 46: ...ERROGATE RIGHT SIACM NO ACTIVE RIGHT SIACM DTCS STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Ensure the battery i...

Page 47: ...ger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airbag system and rotate the steering wheel from stop to stop NOTE Check con...

Page 48: ...ION OUTPUT RUN START CIRCUIT OPEN MODULE RUN START SHORTED TO GROUND RSIACM LOW IGNITION RUN START VOLTAGE LSIACM LOW IGNITION RUN START VOLTAGE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESE...

Page 49: ...the Fused Ignition Run Start circuit shorted to ground and replace Airbag Run Start Fuse Perform AIRBAG VERIFICATION TEST VER 1 4 Turn the ignition on Measure the voltage of the Ignition Switch Output...

Page 50: ...ndition 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...

Page 51: ...HORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTI...

Page 52: ...th Service Instructions and replace the Run Only Fuse Perform AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be dis...

Page 53: ...ODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH If there are no possible causes remai...

Page 54: ...N FAILURE MODULE NOT CONFIGURED ACM NOT CONFIGURED FOR SIDE AIRBAGS STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is ful...

Page 55: ...Perform AIRBAG VERIFICATION TEST VER 1 6 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any s...

Page 56: ...NDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM Turn the...

Page 57: ...s while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions...

Page 58: ...ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 2 With the DRBIIIt se...

Page 59: ...op to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist...

Page 60: ...de will set if the onboard diagnostic cannot detect the module transmitting information on the PCI BUS for 4 consecutive seconds NOTE Any PCI Bus Failure will may cause a stored code to set POSSIBLE C...

Page 61: ...Service Instructions Perform AIRBAG VERIFICATION TEST VER 1 ACM STORED Go To 2 LEFT SIACM ACTIVE WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Replace th...

Page 62: ...top to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist...

Page 63: ...INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules will be...

Page 64: ...as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airbag system and...

Page 65: ...AIRBAG OPEN PASSENGER SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACM PASSENGER SQUIB 1 CIRCUIT OPEN ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure the ba...

Page 66: ...accordance with the Service Information Perform AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PR...

Page 67: ...o stop NOTE Check connectors Clean and 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...

Page 68: ...IT SHORT PASSENGER SQUIB 1 LINE 1 SHORT TO LINE 2 ACM PASSENGER SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery...

Page 69: ...form AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Airbag Control Modu...

Page 70: ...stop NOTE Check connectors Clean and 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 i...

Page 71: ...ERY PASSENGER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PASSENGER SQUIB 1 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure...

Page 72: ...ce Passenger Airbag in accordance with the Service Infor mation Perform AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAI...

Page 73: ...stop NOTE Check connectors Clean and 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...

Page 74: ...CIRCUIT SHORT TO GROUND PASSENGER SQUIB 1 LINE 1 AND LINE 2 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACM PASSENGER SQUIB 1 CIRCUIT SHORT TO GROUND ACTIVE CODE PRESENT TEST ACTION APPLICAB...

Page 75: ...MINUTES BE FORE PROCEEDING Disconnect the Airbag Control Module connector NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool adaptor to the Airbag Control Module connect...

Page 76: ...stop NOTE Check connectors Clean and 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...

Page 77: ...NE 2 CIRCUIT OPEN SIACM SEAT SQUIB CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Ensure the battery is fully charged Turn the ignition on NOTE For...

Page 78: ...WARNING DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD DED SIDE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERIOUS OR FATAL INJURY Discon...

Page 79: ...p to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist y...

Page 80: ...T TO LINE 2 SIACM SEAT SQUIB CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Ensure the battery is fully charged Turn the ignition on NOTE For the p...

Page 81: ...NITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD DED SIDE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF...

Page 82: ...p to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist y...

Page 83: ...ORTED TO BATTERY SIACM SEAT SQUIB SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE F...

Page 84: ...FORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD DED SIDE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERIOUS OR FATA...

Page 85: ...to stop NOTE Check connectors Clean and 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...

Page 86: ...SHORTED TO GROUND SIACM SEAT SQUIB SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Ensure the battery is fully charged Turn the ignition on NOTE...

Page 87: ...WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD DED SIDE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESUL...

Page 88: ...to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist yo...

Page 89: ...ems related to Instrument Cluster Perform AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING...

Page 90: ...ED TO GROUND CIRCUIT SHORTED TO GROUND SPEAKER CIRCUITS SHORTED TOGETHER SPEAKER SECTION OF RADIO TEST ACTION APPLICABILITY 1 Turn the ignition on Turn the Radio on With the DRBIIIt erase the audio DT...

Page 91: ...ignition on Turn the radio on With the DRBIIIt erase the audio DTCs Cycle the ignition switch from off to on and wait 10 seconds With the DRBIIIt read DTC s Does the DRBIIIt display ALL OUTPUTS SHORT...

Page 92: ...tween ground and each speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignitio...

Page 93: ...PE EJECT SWITCH INOPERATIVE TIME SWITCH INOPERATIVE TUNE SWITCH INOPERATIVE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be CASSETTE PLAYER INOP...

Page 94: ...DTC is set erase the DTC and attempt to reset the DTC If DTC resets follow this test This is an internal radio failure View repair All Repair Replace the Radio Perform BODY VERIFICATION TEST VER 1 87...

Page 95: ...hanger turned on Set Condition The code will set if the CD Changer detects a mechanical failure POSSIBLE CAUSES INTERNAL FAILURE TEST ACTION APPLICABILITY 1 NOTE Erase DTC and attempt to reset If DTC...

Page 96: ...is not formatted as a music CD is installed in the CD Changer POSSIBLE CAUSES CD CHANGER READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn th...

Page 97: ...LICABILITY 1 With the DRBIIIt erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the veh...

Page 98: ...t is not formatted as a music CD or is scratched dirty so the radio can not play the CD POSSIBLE CAUSES CD PLAY FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched...

Page 99: ...f a CD that is not formatted as a music CD is installed in the radio CD player POSSIBLE CAUSES CD READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD...

Page 100: ...APPLICABILITY 1 With the DRBIIIt erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the...

Page 101: ...form BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio harness connector Start the engine Measure the voltage of each Fused B circuit and the Fused Ignition Switch Output circu...

Page 102: ...Go To 2 No Repair Antenna connection as needed Perform BODY VERIFICATION TEST VER 1 2 Refer to the Audio System in the service information and test the Antenna in accordance with the service procedure...

Page 103: ...TED TO GROUND CIRCUIT SHORTED TO GROUND SPEAKER CIRCUITS SHORTED TOGETHER SPEAKER SECTION OF RADIO TEST ACTION APPLICABILITY 1 Turn the ignition on Turn the Radio on With the DRBIIIt erase the audio D...

Page 104: ...ignition on Turn the radio on With the DRBIIIt erase the audio DTCs Cycle the ignition switch from off to on and wait 10 seconds With the DRBIIIt read DTC s Does the DRBIIIt display POWER AMP SHUTDOWN...

Page 105: ...ween ground and each speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition...

Page 106: ...cuits All Yes Go To 2 No Repair the Fused Ignition Switch Output Run and Fused Ignition Switch Output Run Start circuits for an open Perform AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting airba...

Page 107: ...input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts P...

Page 108: ...n the ignition off Disconnect the Compass Temperature Mirror harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 3 No...

Page 109: ...e Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Press F2 again when complete C...

Page 110: ...To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector Usi...

Page 111: ...lect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground...

Page 112: ...off Disconnect the Instrument Cluster harness connector Using a 12 volt test light connected to ground probe the Fused B circuit Is the test light illuminated All Yes Go To 3 No Repair the Fused B ci...

Page 113: ...select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete C...

Page 114: ...light connected to 12 volts probe the ground circuit NOTE Make sure test light is connected to the Battery positive terminal Is the test light illuminated All Yes Go To 3 No Repair the Ground circuit...

Page 115: ...e DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Pres...

Page 116: ...NESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH7058 Cable to Probe adapter CH...

Page 117: ...essary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIIIt from the DLC...

Page 118: ...gnition off Disconnect the PCM harness connector Disconnect the DRBIIIt from the DLC Measure the resistance between ground and the PCM SCI Receive circuit in the Data Link harness connector cav 12 Is...

Page 119: ...resistance of the PCM SCI Transmit circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the PC...

Page 120: ...ilure Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio C1 harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignitio...

Page 121: ...l one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 v...

Page 122: ...light connected to 12 volts probe the ground circuit NOTE Make sure test light is connected to the Battery positive terminal Is the test light illuminated All Yes Go To 3 No Repair the Ground circuit...

Page 123: ...DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Press...

Page 124: ...Module harness connector Using a 12 volt test light connected to ground probe each Fused B circuit Is the test light illuminated for each Fused B circuit All Yes Go To 3 No Check the fuses that feed...

Page 125: ...t Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set probe to x10 Press F2 again when...

Page 126: ...ess connector Measure the resistance between ground and the ground circuit Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the ground circuit for an open Perform SKIS VERIFICATION 3 Turn th...

Page 127: ...lect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground...

Page 128: ...m 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL...

Page 129: ...MISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TER...

Page 130: ...Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circui...

Page 131: ...ignition on Using the DRB attempt to communicate with the following control modules Airbag Control Module SKIM SENTRY KEY IMMOBILIZER MIC INSTRUMENT CLUSTER Was the DRBIIIt able to communicate with on...

Page 132: ...battery cable Turn the ignition on Measure the voltage of the PCI Bus circuit at the Data Link Connector DLC Is the voltage above 7 0 volts All Yes Go To 5 No Go To 6 5 Turn the ignition off Using a...

Page 133: ...resistance to ground thru all of the modules is typically between 350 to 1000 ohms The more modules on the bus the lower the total bus resistance will be Is the resistance below 150 0 ohms with all t...

Page 134: ...NE N NE E SE S SW W NW The numerals 0 through 9 C and F The Compass Temp Mirror will test the memory and the compass Press the left lamp button or cycle the ignition to exit the Self Check The Compass...

Page 135: ...dule will illuminate all of the VF segments and then display a P for Pass or an F for Fail Exit the self check by depressing the Zone Cal button or cycling the ignition Did the Compass Temp Mirror dis...

Page 136: ...ap in Overhead Console in the Service Manual To change the variance zone depress the STEP button to scroll through the zone numbers 1 15 until the desired zone is displayed After selecting the proper...

Page 137: ...ated fuse Turn the ignition on for approximately 1 minute Turn the ignition off Remove and inspect the 4 Fuse in the Fuse Block Is the 4 Fuse open All Yes Check the Fused B circuit for a short to grou...

Page 138: ...ut circuit and ground Is the voltage below 10 5 volts All Yes Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Discon...

Page 139: ...sor using the following values 10 C 50 F Sensor Resistance 17 99 21 81 Kilohms 20 C 68 F Sensor Resistance 11 37 13 61 Kilohms 25 C 77 F Sensor Resistance 9 12 10 88 Kilohms 30 C 86 F Sensor Resistanc...

Page 140: ...Check fuse 15 in the Fuse Block Is fuse 15 open All Yes Go To 3 No Go To 5 3 Remove fuse 15 from the Fuse Block Disconnect the Multifunction Switch connector Measure resistance of the Dimmer Switch L...

Page 141: ...the Dimmer Switch Low Beam Output Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 7 Disconnect the Multifunction Switch connector Turn the headlamps on Connect a jumper wire between...

Page 142: ...pair the Dimmer Switch High Beam Output Circuit for a short to voltage condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Instrument Cluster connector Disconnect the Multifunction Switch...

Page 143: ...isconnect the Instrument Cluster Turn the ignition on Measure voltage of the Dimmer Switch Low Beam Output Circuit Is the voltage below 1 0 volt All Yes Go To 3 No Repair the Dimmer Switch Low Beam Ou...

Page 144: ...it in the Circuit Breaker connector Is the voltage above 10 0 volts All Yes Go To 3 No Replace the Fuse Block Perform BODY VERIFICATION TEST VER 1 3 Remove Circuit Breaker 2 from the Fuse Block Measur...

Page 145: ...VER 1 6 Remove Circuit Breaker 2 from the Fuse Block Measure resistance of the Fused B circuit in the fuse connector to ground Is the resistance below 5 0 ohms All Yes Repair the Fused B Circuit for...

Page 146: ...PEN When Monitored With the ignition on and requested to turn on by the ACM Set Condition The Instrument Cluster detects an open during the internal test on the indicator POSSIBLE CAUSES INSTRUMENT CL...

Page 147: ...art position Set Condition The Instrument Cluster detects no PCI Bus message from the AECM for 5 five seconds EATX MESSAGE NOT RECEIVED When Monitored With the ignition on Set Condition The Instrument...

Page 148: ...ignition wait approximately 1 minute With the DRBIIIt read DTCs Did the DTC reset All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1...

Page 149: ...nspect the 13 Fuse in the PDC If the fuse is open replace with the proper rated fuse Turn the ignition on for approximately 1 minute Turn the ignition off Remove and inspect the 13 Fuse in the PDC Is...

Page 150: ...circuit to the Fuse Block 4 Fuse for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Instrument Cluster harness connector Check connectors Clean repair as necessar...

Page 151: ...loop back test on the PCI Bus NO PCI BUS TRANSMISSION When Monitored Continous Set Condition The Instrument Cluster microprocessor fails the loop back test on the PCI Bus POSSIBLE CAUSES INSTRUMENT CL...

Page 152: ...TEST ACTION APPLICABILITY 1 With the DRBIIIt read DTCs Does the DRBIIIt display 9EATX Bus Message Not Received9 All Yes Refer to Communication for the related symptom No Go To 2 2 With the DRBIIIt in...

Page 153: ...BIIIt read DTC s Does the DRBIIIt display 9Fuel Level Sensor Open9 All No Test complete DTC is intermittent Road test the vehicle and recheck for DTC s If the code returns rerun this test Refer to any...

Page 154: ...he resistance between ground and the Fuel Level Sensor Ground circuit Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Fuel Pump Module Ground circuit for an open Perform BODY VERIFICATI...

Page 155: ...n the ignition on wait for one minute With the DRBIIIt read DTC s Does the DRBIIIt display Fuel Level Sensor Short All No Test complete DTC is intermittent Road test the vehicle and recheck for DTC s...

Page 156: ...lean repair as necessary Measure the resistance of the Fuel Level Sensor Signal circuit to ground Is the resistance below 10 000 10 K ohms NOTE it should be infinite All Yes Repair the Fuel Level Sens...

Page 157: ...the Park Lamps on Wait 10 ten seconds Rotate the Panel Lamps Dimmer Switch through the full range of adjustment With the DRBIIIt read DTC s Does the DRBIIIt display Panel Dimmer Open All Yes Go To 2...

Page 158: ...resistance measure less than 5 0 ohms All Yes Go To 5 No Repair the open in the Multi Function Switch Ground circuit Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Instru...

Page 159: ...RBIIIt display MIC PRESENT on the BUS All Yes Go To 2 No Refer to the COMMUNICATION category and perform the appro priate symptom 2 Turn the ignition on With the DRBIIIt select Body MIC SYSTEM TESTS P...

Page 160: ...f Disconnect the Instrument Cluster harness connector Turn the ignition on Measure the voltage between the Fused Ignition Switch Output circuit pin 15 and ground For autostick equipped vehicles also m...

Page 161: ...off Remove the 4 Fuse from the Fuse Block Turn the ignition on then off Reinstall the 4 Fuse to the Fuse Block Procedure 2 Perform the Instrument Cluster self test Turn the ignition off Press and hold...

Page 162: ...any PCM ACM ABS RKE or SKIM DTCs before proceeding with this test Turn the ignition off Remove the Instrument Cluster Remove the inoperative LED from the Instrument Cluster Using a DVOM select 9Diode...

Page 163: ...on With the DRBIIIt in Inputs Outputs read the Parking Brake Switch state Does the DRBIIIt display 9Open9 All Yes Replace the Park Brake Switch in accordance with the Service Information Perform BODY...

Page 164: ...Level Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Disconnect the...

Page 165: ...ulb check or Instrument Cluster Self Test Did the indicator illuminate All Yes Go To 2 No Go To 8 2 NOTE The Brake Warning Indicator illuminates with the Park Brake engaged or with low Brake Fluid Is...

Page 166: ...state All Yes Replace the Brake Fluid Level Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Disconnect the Brake Fluid Level S...

Page 167: ...NOTE Ensure that the RED lead is on the of the LED Did the LED illuminate All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Rep...

Page 168: ...og Lamp Switch Output circuit and ground Is the voltage greater than 10 0 volts All Yes Go To 2 No Repair the open in the Front Fog Lamp Switch Output circuit Perform BODY VERIFICATION TEST VER 1 2 Tu...

Page 169: ...uel Level Sensor Short for the related symptom s No Go To 2 2 Perform the Instrument Cluster Self Test Turn the ignition off Press and hold the Trip Reset button Turn the ignition on Observe the Fuel...

Page 170: ...4 741 791 ohms Full 947 967 ohms NOTE The Fuel Level Sensor should read resistance through the full range of float arm motion Does the Fuel Level Sensor read the proper resistance values through the...

Page 171: ...nected to ground check the High Beam Indicator circuit Does the test light illuminate brightly All Yes Go To 2 No Repair the High Beam Indicator circuit for an open Perform BODY VERIFICATION TEST VER...

Page 172: ...he Instrument Cluster harness connector Turn the Park Lamps on Using a 12 volt test light connected to ground check the Headlamp Output circuit Does the test light illuminate brightly All Yes Go To 3...

Page 173: ...on off Disconnect the Engine Oil Pressure Switch harness connector With the DRBIIIt in Sensors read the Engine Oil Pressure Switch status Does the Engine Oil Pressure Switch status read 9Closed9 All Y...

Page 174: ...e Switch harness connector With the DRBIIIt in Sensors read the Oil Pressure Switch state Did the Engine Oil Pressure Switch change states All Yes Replace the Engine Oil Pressure Switch in accordance...

Page 175: ...NOTE Ensure that the RED lead is on the of the LED Did the LED illuminate All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repl...

Page 176: ...and perform the apropriate symptom No Go To 2 2 Perform the Instrument Cluster Self Test Turn the ignition off Press and hold the Trip Reset button Turn the ignition on Observe the gauge in question...

Page 177: ...ay any MIC PCM or TCM DTCs All Yes Refer to symptom list for problems related to DTC s No Go To 2 2 Perform the Instrument Cluster Self Test Turn the ignition off Press and hold the Trip Reset button...

Page 178: ...rcuit Does the test light illuminate brightly All Yes Go To 2 No Repair the Rear Fog Lamp Indicator circuit for an open Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove the Instrume...

Page 179: ...o 3 No Replace the Seat Belt Indicator LED in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Instrument Cluster harness connector D...

Page 180: ...circuit pin and the Ground circuit pin Is the resistance below 5 0 ohms All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repla...

Page 181: ...ent Cluster must be operational for the result of this test to be valid The Instrument Cluster Odometer vacuum fluorescent VF Display is not a repairable or replaceable item If there are no possible c...

Page 182: ...Lamp Does the test light illuminate brightly All Yes Replace the Instrument Cluster Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Remove the dome lamp bulb Disconnect the Instrument Cluster Connec...

Page 183: ...EST ACTION APPLICABILITY 1 Close all the doors Turn the Panel Lamps Dimmer Switch to the MID position With the DRBIIIt read the Electro Mech Cluster I O s Observe the Drv Door Ajar Sw Dome Lamp and th...

Page 184: ...osition Remove the Instrument Cluster Measure the resistance between ground and the Panel Lamps Dimmer Signal Circuit in the C2 connector Is the resistance below 100 0 ohms All Yes Go To 6 No Replace...

Page 185: ...ance of the Passenger Door Ajar Circuit in the Passenger Door Ajar Switch connector Is the resistance below 100 0 ohms All Yes Repair the Passenger Door Ajar RKE Sense Wire for a short to ground Perfo...

Page 186: ...ESY LAMPS INOPERATIVE Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt select THEFT ALARM VTSS MISCELLANEOUS ENABLE ILLUMINATED ENTRY With the DRBIIIt read the ILLUMINATED ENTRY status Does the...

Page 187: ...the RKE compares its configuration information with the PCI bus message transmitted by the Powertrain Control Module pertaining to body style A miscomparison will result in setting the trouble code PO...

Page 188: ...It erase DTCs Operate the door locks several times from the driver door lock switch and the cylinder lock switch if VTSS equipped With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER DOOR SWITCH...

Page 189: ...esistance below 8000 0 ohms All Yes Go To 4 No Replace the Cylinder Lock Switch Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the Door Lock Switch connector Disconnect the Re...

Page 190: ...h the part number Example Selecting BUX RKE when the module is a Domestic part number The RKE frequencies are not compatible POSSIBLE CAUSES INCORRECT MODULE TYPE CONFIGURATION FOR PART NUMBER TEST AC...

Page 191: ...DTCs Turn the ignition on Operate the decklid release from the interior switch With the DRBIIIt read DTCs Does the DRBIIIt display INTERIOR DECKLID RELEASE SWITCH SHORTED OR STUCK All Yes Go To 2 No...

Page 192: ...nd the Decklid Release Relay Control circuit Is the resistance below 1000 0 ohms All Yes Repair the Decklid Release Relay Control circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No...

Page 193: ...Condition When the operator attempts to program a transmitter and the RKE module is not configured for RKE POSSIBLE CAUSES MODULE NOT CONFIGURED FOR RKE TEST ACTION APPLICABILITY 1 The RKE transmitte...

Page 194: ...ON APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the ACM Was the DRB able to I D or communicate with the ACM All Yes Go To 2 No Refer to the Communication category for...

Page 195: ...DTCs If DTC resets replace the RKE Module Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRB attempt to communicate with the PCM Was the DRB able to communicate with t...

Page 196: ...APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the SKIM Was the DRB able to I D or communicate with the SKIM All Yes Go To 2 No Refer to the Communication category for t...

Page 197: ...IIt erase DTCs Operate the door locks several times from the passenger door lock switch and the cylinder lock switch if VTSS equipped With the DRBIIIt read DTCs Does the DRBIIIt display PASS DOOR SWIT...

Page 198: ...sistance below 8000 0 ohms All Yes Go To 4 No Replace the Cylinder Lock Switch Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the Door Lock Switch connector Disconnect the Rem...

Page 199: ...EASE SOLENOID SHORTED DOOR UNLOCK RELAY OUTPUT WIRE SHORT TO GROUND DEFECTIVE FUSE 14 RKE MODULE B SHORT TO GROUND RKE MODULE RELAYS OPEN RKE MODULE SHORTED TEST ACTION APPLICABILITY 1 Note Ensure the...

Page 200: ...te Keyless Entry module connector Measure the resistance of the Decklid Release Relay Output circuit to ground Is the resistance below 0 5 ohms All Yes Go To 6 No Go To 7 6 Disconnect the Remote Keyle...

Page 201: ...Unlock Relay Output circuit for a short to the Door Lock Relay Output circuit Perform BODY VERIFICATION TEST VER 1 No Go To 11 11 Disconnect the Remote Keyless Entry module connector Measure the resi...

Page 202: ...ry module connector Measure the resistance between the Driver Door Unlock Relay Output circuit and the Door Lock Relay Output circuit in the RKE module connector Is the resistance LESS than 17 0 ohms...

Page 203: ...nect the Passenger Door Lock Motor Ajar Switch connector Disconnect the Remote Keyless Entry Module connector Measure the resistance of the Door Unlock Relay Output circuit between the RKE module conn...

Page 204: ...ition off Disconnect the Remote Keyless Entry module connector Measure the resistance between ground and the Door Unlock Relay Output circuit Is the resistance below 1000 0 ohms All Yes Repair the Doo...

Page 205: ...ut terminal in the RKE Module connector Is the resistance below 100 0 ohms All Yes Repair the Decklid Release Relay Output wire for a short to the Door lock Relay Output wire Perform BODY VERIFICATION...

Page 206: ...PLICABILITY 5 If there are no possible causes remaining view repair All Repair Replace the Remote Keyless Entry Module Perform BODY VERIFICATION TEST VER 1 199 POWER DOOR LOCKS RKE ALL DOORS FAIL TO L...

Page 207: ...DOOR LOCKS Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt in Sensors read the appropriate DOOR LOCK SW voltage Select the reading found All Between 0 0 and 3 7 volts Replace the Re...

Page 208: ...no possible causes remaining view repair All Repair Replace the Door Lock Switch open resistor Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Remote Keyless Entry Module c...

Page 209: ...ST VER 1 2 Ensure all doors are closed With the DRBIII read all DOOR AJAR states Do any door ajar states show CLOSED All Yes Refer to symptom COURTESY LAMPS ON AT ALL TIMES in the INTERIOR LIGHTING ca...

Page 210: ...ecklid Solenoid connector Using a 12 volt test light connected to 12 volts check the Ground circuit in the Decklid Release connector Does the test light illuminate brightly All Yes Go To 3 No Repair t...

Page 211: ...Motor Ajar Switch connector Disconnect the Door Lock Motor Ajar Switch connector Left Front or Right Front Connect a jumper wire between Door Ajar Switch Sense circuit driver door and ground With the...

Page 212: ...ircuit between the ignition switch connector and the instrument cluster connector Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open Key In Ignition Switch Sense wire Perform BODY VER...

Page 213: ...connected before proceeding Remove the inner door trim panel to gain access to the Door Lock Motor connector Disconnect the Door Lock Motor connector Connect a test light between the Door Lock Relay O...

Page 214: ...eyless Entry module connector Measure the resistance of the Driver Door Unlock Relay Output wire between the RKE connector and the door lock motor connector Is the resistance below 5 0 ohms All Yes Te...

Page 215: ...Remote Keyless Entry module connector Measure the resistance of the Driver Door Unlock Relay Output circuit in the RKE module connector to body ground Is the resistance below 1000 0 ohms All Yes Repai...

Page 216: ...TEST VER 1 No Go To 2 2 Turn ignition off Remove the appropriate inner door trim panel to gain access to the Door Lock Motor connector Disconnect the Door Lock Motor connector Disconnect the Remote K...

Page 217: ...ote Keyless Entry module connector Measure the resistance between the Door Unlock Relay Output circuit and the Door Lock Relay Output circuit Is the resistance below 1000 0 ohms All Yes Repair the Doo...

Page 218: ...test the transmitter several times Does the signal strength measure 9STRONG9 All Yes Go To 3 No Replace the transmitter Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition on Place transmission i...

Page 219: ...orm BODY VERIFICATION TEST VER 1 No Go To 5 5 Secure a known good Transmitter from another PL or PT vehicle Using the DRBIII select BODY Theft Alarm VTSS MISCELLANEOUS then RKE FOB Module Test Follow...

Page 220: ...HOOD AJAR SWITCH RKE MODULE HOOD AJAR TEST ACTION APPLICABILITY 1 Was the hood open during module configuration All Yes Go To 2 No Open the hood and attempt to reconfigure the RKE module 2 Open the ho...

Page 221: ...Go To 5 No Repair the Hood Ajar Switch Sense circuit for an open Perform VTSS VERIFICATION TEST 1A 5 Disconnect the Hood Ajar Switch connector Connect a jumper wire between the Hood Ajar Switch Sense...

Page 222: ...ould only appear if attempting to re configure a used RKE module POSSIBLE CAUSES REMOTE KEYLESS ENTRY MODULE TEST ACTION APPLICABILITY 1 The RKE module attempting to be configured to non VTSS has orig...

Page 223: ...S to arm Lightly tap on hood near ajar switch to simulate wind and noise vibration Did the VTSS trip to the alarming state All Yes Replace the hood ajar switch Perform VTSS VERIFICATION TEST 1A No Go...

Page 224: ...LAMPS WILL NOT TURN ON in the EXTERIOR LIGHTING category Disconnect the Remote Keyless Entry module connector Connect a test light from the Dimmer Switch Low Beam Output circuit to ground Turn the Low...

Page 225: ...n and repair the Horn circuit as necessary Disconnect the Remote Keyless Entry module connector Connect one end of a jumper wire to the Horn Relay Control circuit in the RKE connector Momentarily touc...

Page 226: ...ome Lamp Intrusion Sensor connector Measure the voltage between the Intrusion Sensor Signal circuit and ground Is the voltage above 10 0 volts All Yes Replace the Intrusion Sensor Perform VTSS VERIFIC...

Page 227: ...ION DETECTED All Yes Verify the system has not been armed with the intrusion sensor disabled Replace the Intrusion Sensor if the problem remains intermittent Perform VTSS VERIFICATION TEST 1A No Go To...

Page 228: ...ound Is the resistance below 1000 0 ohms All Yes Repair the Intrusion Sensor Signal circuit for a short to ground Perform VTSS VERIFICATION TEST 1A No Go To 6 6 Disconnect the Dome Lamp Intrusion Sens...

Page 229: ...trusion sensor causing the false triggering Disconnect the Dome Lamp Intrusion Sensor connector Close all the doors and arm the VTSS Does the alarm inadvertently trigger due to intrusion sense even th...

Page 230: ...jumper wire between the Door Ajar Switch Sense circuit and ground With the DRBIIIt select THEFT ALARM VTSS INPUT OUTPUT With the DRBIIIt read the DRV DOOR AJAR SW state Does the DRBIIIt show CLOSED A...

Page 231: ...ith the DRBIIIt select THEFT ALARM VTSS INPUT OUTPUT Read the PASS DOOR AJAR SW state and open and close each passenger door Select the door s that did not show CLOSED when that door was opened All Pa...

Page 232: ...eft Rear Door Ajar Switch Ground circuit for an open Perform VTSS VERIFICATION TEST 1A 5 Open the Left Rear Door Disconnect the Left Rear Door Ajar Switch connector Close all the other Passenger Doors...

Page 233: ...jar Switch Sense circuit for an open between the door ajar switch and the splice Perform VTSS VERIFICATION TEST 1A 8 Turn the ignition off Disconnect the Passenger Door Ajar Switch connector Disconnec...

Page 234: ...te Service Information and repair the Park Lamp circuit as necessary Disconnect the Remote Keyless Entry Module connector Connect a test light to the Park Lamp Switch Output circuit cav 2 to ground Tu...

Page 235: ...d the door locks operate properly All Yes Go To 2 No Refer to symptom ALL LOCKS INOPERATIVE FROM DRIVER DOOR LOCK SWITCH in the POWER DOOR LOCKS RKE category 2 Disconnect the Cylinder Lock Switch conn...

Page 236: ...ITCH in the POWER DOOR LOCKS RKE category 2 Disconnect the Cylinder Lock Switch connector Measure the resistance of the ground circuit to body ground Is the resistance below 5 0 ohms All Yes Go To 3 N...

Page 237: ...Entry Module Perform VTSS VERIFICATION TEST 1A No Go To 2 2 Disconnect the Remote Keyless Entry Module connector Disconnect the Instrument Cluster connector Measure the resistance of the VTSS Indicat...

Page 238: ...s Does the DRBIIIt show OPEN All Yes Go To 4 No Go To 3 3 Disconnect the Hood Ajar switch connector Disconnect the Remote Keyless Entry Module connector Measure the resistance of the Hood Ajar Switch...

Page 239: ...Decklid Security Switch Ground circuit for an open Perform VTSS VERIFICATION TEST 1A 8 Turn the ignition off Disconnect the Remote Keyless Entry Module connector Disconnect the Decklid Security Switch...

Page 240: ...rently not present Inspect the related wiring harness for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform VTSS VERIFICATION TEST 1A No Go To 2 2...

Page 241: ...the Siren in accordance with the Service Information Perform VTSS VERIFICATION TEST 1A No Go To 5 5 Turn the ignition off Disconnect the Siren connector Disconnect the Remote Keyless Entry Module con...

Page 242: ...or 9 Road test the vehicle With the DRBIIIt monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25...

Page 243: ...he customer s concern can no longer be duplicated the repair is complete Are any DTC s present or is the original concern still present All Yes Repair is not complete refer to appropriate symptom No R...

Page 244: ...been replace and the vehicle is equipped with a 2 4L Turbo Manual Transmission the Pinion Factor MUST be programmed into the PCM Failure to do so will cause the speedometer to become inoperative or i...

Page 245: ...o the new SKIM 7 NOTE Prior to returning vehicle to the costumer perform a module scan to be sure that all DTC s are erased Erase any DTC s that are found 8 With the DRB III erase all DTC s Perform 5...

Page 246: ...8 0 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM 8 1 1 AIRBAG CONTROL MODULE ACM 8 1 2 AIRBAG MODULE DRIVER 8 1 3 AIRBAG MODULE PASSENGER C O M P O N E N T L O C A T I O N S 239 COMPONENT LOCATIONS...

Page 247: ...8 1 4 CLOCKSPRING 8 1 5 SIDE IMPACT AIRBAG CONTROL MODULE SIACM 8 2 DATA LINK CONNECTOR C O M P O N E N T L O C A T I O N S 240 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM Continued...

Page 248: ...8 3 FUSE BLOCK 8 4 INSTRUMENT CLUSTER 8 4 1 BASE CLUSTER 8 4 2 PREMIUM CLUSTER C O M P O N E N T L O C A T I O N S 241 COMPONENT LOCATIONS...

Page 249: ...8 5 POWER DOOR LOCKS 8 5 1 REMOTE KEYLESS ENTRY MODULE 8 5 2 DECKLID RELEASE SOLENOID C O M P O N E N T L O C A T I O N S 242 COMPONENT LOCATIONS...

Page 250: ...8 5 3 DOOR LOCK MOTOR 8 6 VEHICLE COMMUNICATION 8 6 1 CONTROLLER ANTILOCK BRAKE MODULE 8 6 2 SENTRY KEY IMMOBILIZER MODULE SKIM C O M P O N E N T L O C A T I O N S 243 COMPONENT LOCATIONS...

Page 251: ...8 7 VEHICLE THEFT SECURITY 8 7 1 REMOTE KEYLESS ENTRY MODULE 8 7 2 HOOD AJAR SWITCH EXPORT 8 7 3 DOOR CYLINDER LOCK SWITCH IF EQUIPPED C O M P O N E N T L O C A T I O N S 244 COMPONENT LOCATIONS...

Page 252: ...8 7 4 DECKLID SECURITY SWITCH C O M P O N E N T L O C A T I O N S 245 COMPONENT LOCATIONS...

Page 253: ...R SQUIB 1 LINE 2 9 10 11 12 13 14 F15 20DG WT FUSED IGNITION SWITCH OUTPUT RUN START 15 F25 20TN LG FUSED IGNITION SWITCH OUTPUT RUN 16 17 18 19 20 21 D25 20VT YL PCI BUS 22 23 C208 YELLOW SEAT SIDE C...

Page 254: ...COMPACT DISC CHANGER BLACK 8 WAY CAV CIRCUIT FUNCTION 1 24GY WT AUDIO OUT RIGHT 2 24OR YL PANEL LAMPS DIMMER SIGNAL 3 24VT YL PCI BUS 4 24RD FUSED IGNITION SWITCH OUTPUT 5 24DG WT AUDIO OUT LEFT 6 24...

Page 255: ...11 12 13 14 15 16 Z1 12BK GROUND 17 18 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 19 B3 18LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 22 B8 18RD DB L...

Page 256: ...Z1 20BK GROUND 2 G71 20VT YL DECKLID SECURITY SWITCH SENSE DECKLID SOLENOID BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q2 14LG BK DECKLID RELEASE RELAY OUTPUT 2 Z1 14BK GROUND DOME LAMP INTRUSION SENSOR EXPO...

Page 257: ...TOR AJAR SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20TN LHD LEFT FRONT DOOR AJAR SWITCH SENSE 1 G74 20TN RD RHD RIGHT FRONT DOOR AJAR SWITCH SENSE 2 Z14 20BK YL GROUND 3 P34 18PK BK DRIVER DOOR UN...

Page 258: ...BK IGNITION SWITCH OUTPUT RUN ACC 4 F1 16DB BK FUSED B 5 G26 22LB KEY IN IGNITION SWITCH SENSE 6 A41 14YL IGNITION SWITCH OUTPUT START 7 A31 14BK WT IGNITION SWITCH OUTPUT RUN ACC 8 A22 12BK OR IGNIT...

Page 259: ...UTPUT 15 F11 20RD WT AUTO STICK IGNITION SWITCH OUTPUT OFF RUN START 15 G5 20DB WT EXCEPT AU TOSTICK FUSED IGNITION SWITCH OUTPUT RUN START 16 L161 18LG OR EXCEPT EXPORT LEFT TURN SIGNAL 17 L160 18TN...

Page 260: ...KER 3 WAY CAV CIRCUIT FUNCTION 1 X55 20BR RD LEFT FRONT SPEAKER 2 3 X53 20DG LEFT FRONT SPEAKER LEFT INSTRUMENT PANEL SPEAKER WHITE 2 WAY CAV CIRCUIT FUNCTION 1 X53 20DG LEFT FRONT SPEAKER 2 X55 20BR...

Page 261: ...LEFT REAR SPEAKER 2 3 X57 20BR LB LEFT REAR SPEAKER LEFT SEAT AIRBAG SQUIB 2 WAY CAV CIRCUIT FUNCTION 1 R31 18OR LEFT SEAT SQUIB LINE 2 2 R33 18WT LEFT SEAT SQUIB LINE 1 LEFT SIDE IMPACT AIRBAG CONTR...

Page 262: ...CH OUTPUT 10 11 A15 18WT FUSED B 12 L38 16BR WT EXPORT REAR FOG LAMP FEED 12 L38 16BR WT EXPORT REAR FOG LAMP FEED 13 L4 14VT WT EXCEPT EX PORT DIMMER SWITCH LOW BEAM OUTPUT 13 F61 16WT OR EXPORT FUSE...

Page 263: ...D PASSENGER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20TN RD LHD RIGHT FRONT DOOR AJAR SWITCH SENSE 1 G75 20TN RHD LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z14 20BK YL GROUND 3 P3...

Page 264: ...39 F62 18RD 2 4L TURBO FUSED B 40 F62 20RD 2 0L FUSED B 40 F62 18RD 2 4L TURBO FUSED B 41 X2 20DG RD 2 0L HORN RELAY OUTPUT 41 X2 18DG RD 2 4L TURBO HORN RELAY OUTPUT 42 43 X3 20BK RD HORN RELAY CONTR...

Page 265: ...SWITCH SENSE 15 K55 18LB 2 4L TURBO TIP SOL CONTROL 16 17 K150 18DB YL 2 4L TURBO SURGE SOL CONTROL 18 Z12 18BK TN GROUND 19 20 G6 20GY OIL PRESSURE SIGNAL 21 22 K145 20BR OR AAT SIGNAL 23 K153 18LB 2...

Page 266: ...13 14 D25 20VT YL PCI BUS 15 16 17 18 X51 20BR YL LEFT REAR SPEAKER 19 X57 20BR LB LEFT REAR SPEAKER 20 X58 20DB OR RIGHT REAR SPEAKER 21 X52 20DB WT RIGHT REAR SPEAKER 22 RADIO C2 COMPACT DISC CHANGE...

Page 267: ...IGHT DOOR SWITCH MUX 11 P97 20LG RHD LEFT DOOR SWITCH MUX 12 Z1 20BK GROUND 13 14 Q33 20BR LB DECKLID RELEASE RELAY CONTROL 15 X5 22WT RD EXPORT SIREN CONTROL 16 Q2 16LG BK DECKLID RELEASE RELAY OUTPU...

Page 268: ...14 18BK ALARM GROUND 3 Z14 20BK YL EXCEPT ALARM GROUND RIGHT FRONT DOOR SPEAKER 3 WAY CAV CIRCUIT FUNCTION 1 X56 20DB RD RIGHT FRONT SPEAKER 2 3 X54 20VT RIGHT FRONT SPEAKER RIGHT INSTRUMENT PANEL SPE...

Page 269: ...IGHT REAR SPEAKER 3 WAY CAV CIRCUIT FUNCTION 1 X52 20DB WT RIGHT REAR SPEAKER 2 3 X58 20DB OR RIGHT REAR SPEAKER RIGHT SEAT AIRBAG SQUIB 2 WAY CAV CIRCUIT FUNCTION 1 R32 18OR RIGHT SEAT SQUIB LINE 2 2...

Page 270: ...ACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 22VT YL PCI BUS 3 4 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 5 Z2 20BK LG GROUND 6 M1 20PK FUSED B SIREN EXPORT BLACK 4 WAY CAV CIRCUIT FUNCTION 1 X5 20...

Page 271: ...10 0 SCHEMATIC DIAGRAMS 10 1 AIRBAG SYSTEM S C H E M A T I C D I A G R A M S 265 SCHEMATIC DIAGRAMS...

Page 272: ...10 2 AUDIO SYSTEM S C H E M A T I C D I A G R A M S 266 SCHEMATIC DIAGRAMS...

Page 273: ...10 2 1 CD CHANGER 10 3 COMPASS TEMPERATURE MIRROR S C H E M A T I C D I A G R A M S 267 SCHEMATIC DIAGRAMS...

Page 274: ...10 4 EXTERIOR LIGHTING S C H E M A T I C D I A G R A M S 268 SCHEMATIC DIAGRAMS...

Page 275: ...10 5 INSTRUMENT CLUSTER S C H E M A T I C D I A G R A M S 269 SCHEMATIC DIAGRAMS...

Page 276: ...10 6 INTERIOR LIGHTING 10 7 POWER DOOR LOCKS RKE S C H E M A T I C D I A G R A M S 270 SCHEMATIC DIAGRAMS...

Page 277: ...10 8 VEHICLE COMMUNICATION S C H E M A T I C D I A G R A M S 271 SCHEMATIC DIAGRAMS...

Page 278: ...10 9 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 272 SCHEMATIC DIAGRAMS...

Page 279: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Page 280: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 281: ...BIIIT ERROR MESSAGES 4 3 5 1 DRBIIIT DOES NOT POWER UP BLANK SCREEN 5 3 5 2 DISPLAY IS NOT VISIBLE 5 4 0 DISCLAIMERS SAFETY WARNINGS 5 4 1 DISCLAIMERS 5 4 2 SAFETY 5 4 2 1 TECHNICIAN SAFETY INFORMATIO...

Page 282: ...K BRAKE 39 8 2 DATA LINK CONNECTOR 39 8 3 FUSES 39 8 4 HYDRAULIC CONTROL UNIT 40 8 5 PUMP MOTOR 40 8 6 TONE WHEELS 40 8 7 WHEEL SPEED SENSORS 41 8 8 WHEEL SPEED SENSOR CONNECTORS 42 9 0 CONNECTOR PINO...

Page 283: ...lysis problem isolation repair of isolated problem verification of proper operation 2 0 IDENTIFICATION OF SYSTEM Vehicles equipped with the Teves Mark 20e an tilock brake system can be identified by t...

Page 284: ...tendencies due to wheel hop and cycle the ABS In that event the brake pedal may pulsate with a perceived loss of deceleration ABS braking may also be activated at times while on dry pavement with sand...

Page 285: ...ks the inlet valve is closed to prevent any further pressure increase Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping Once the wheel i...

Page 286: ...n present If vehicle speed is not below 10 km h 6 mph a no response message could be displayed by the DRBIIIt The following are characteristics of diagnostic mode The amber ABS and red brake warning i...

Page 287: ...CHNICIAN SAFETY INFORMATION WARNING ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS CAUSES SLOWER REACTION TIME AND CAN LEAD TO SERIOUS INJURY WHEN THE ENGINE IS OPERATING KEEP SERVICE AREAS WELL VEN...

Page 288: ...ule When testing voltage or continuity at any control module use the terminal side not the wire end of the connector Do not probe a wire through the insulation this will damage it and eventually cause...

Page 289: ...stop Slight brake pedal drop and pop noise when ignition is initially turned on Brake pedal ratcheting down at the end of an ABS stop 8 If the complaint is ABS cycling at the end of a stop at low spee...

Page 290: ...NOTES 8...

Page 291: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...

Page 292: ...LURE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt read Freeze Frame information With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on W...

Page 293: ...in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Bus circuit for an open Perform ABS VERIFICATION TEST VER 1 4 Turn the ignition off Visually inspect the re...

Page 294: ...OUND CIRCUIT OPEN ABS VALVE FUSED B CIRCUIT OPEN ABS PUMP FUSED B CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTC...

Page 295: ...nnect the CAB harness connector Using a 12 volt test light connected to ground probe the ABS Pump Fused B circuit at the CAB harness connector Did the test light illuminate All Yes Replace the Control...

Page 296: ...LT SIGNAL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs Are there any Instrument Cluster or ABS DTCs present All Yes Refer to the appropriate category for the related sym...

Page 297: ...R 1 4 NOTE The following steps will initiate the Instrument Cluster self test Turn the ignition off Press and hold the odometer reset button Turn the ignition to RUN Observe the Instrument Cluster ind...

Page 298: ...detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set RIGHT FRONT SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit c...

Page 299: ...or Is the affected Wheel Speed Sensor or any of the connectors damaged All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the affected Wheel...

Page 300: ...el Speed Sensor Signal circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Se...

Page 301: ...1 11 Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors Disconnect the affected Wheel Speed Sensor connector Turn the ignition on Measure the voltage of the affected Wh...

Page 302: ...wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were any pro...

Page 303: ...reafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is...

Page 304: ...ptom s Perform ABS VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt in Sensors monitor ALL the Wheel Speed Sensor Signals while an assistant drives the vehicle Slowly acceler...

Page 305: ...o Repair as necessary Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Inspect the wheel bearings for excessive runout or clearance NOTE Refer to the appropriate service information if nece...

Page 306: ...RUNNING CONTINUOUSLY ABS PUMP FUSE ABS PUMP MOTOR INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR ABS PUMP FUSED B CIRCUIT INTERMITTENT SHORT TO GROUND ABS PUMP FUSED B CIRCUIT SHORT TO GROUND CAB...

Page 307: ...Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 4 Turn the ignition off Remove and inspect the ABS Pump fuse Is the ABS Pump fuse open All Yes Go To 5 No Go To 8 5 Turn the ig...

Page 308: ...ecessary Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Fused B terminal in the CAB harness connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wir...

Page 309: ...ess connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground Did the ABS Pump Motor operate All...

Page 310: ...IGNITION SWITCH OUTPUT RUN CIRCUIT HIGH DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s With...

Page 311: ...oken bent pushed out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the CAB connector Note Check connector C...

Page 312: ...roded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Ensure the battery is fully charged Inspect the vehicle for aftermarket accessories that may exceed the Gener...

Page 313: ...NITION SWITCH OUTPUT RUN CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s With the DRBIIIt erase DTC s Turn the ignition off Turn the igniti...

Page 314: ...Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Fused Ignition Switch Output RUN circuit for an open Perform ABS...

Page 315: ...OPEN ABS VALVE FUSED B CIRCUIT INTERMITTENT SHORT TO GROUND ABS VALVE FUSED B CIRCUIT SHORT TO GROUND DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABI...

Page 316: ...ults of this test to be valid Using a test light connected to 12 volts probe the ABS Valve Fused B circuit fuse terminal Did the test light illuminate All Yes Replace the Controller Antilock Brake in...

Page 317: ...t illuminate All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAB Ground circuit for an open Perform ABS VERIF...

Page 318: ...o To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector Us...

Page 319: ...elect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground...

Page 320: ...to Symptom list and troubleshoot new or recurring symptom 7 NOTE For Sensor Signal and Pump Motor faults the CAB must sense all 4 wheels at 25 km h 15 mph before it will extinguish the ABS Indicator 8...

Page 321: ...8 0 COMPONENT LOCATIONS 8 1 CONTROLLER ANTILOCK BRAKE 8 2 DATA LINK CONNECTOR 8 3 FUSES C O M P O N E N T L O C A T I O N S 39 COMPONENT LOCATIONS...

Page 322: ...8 4 HYDRAULIC CONTROL UNIT 8 5 PUMP MOTOR 8 6 TONE WHEELS FRONT C O M P O N E N T L O C A T I O N S 40 COMPONENT LOCATIONS...

Page 323: ...REAR 8 7 WHEEL SPEED SENSORS FRONT REAR C O M P O N E N T L O C A T I O N S 41 COMPONENT LOCATIONS...

Page 324: ...8 8 WHEEL SPEED SENSOR CONNECTORS FRONT REAR C O M P O N E N T L O C A T I O N S 42 COMPONENT LOCATIONS...

Page 325: ...1 18YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 3 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 4 5 D25 18VT YL PCI BUS 6 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 7 B7 18WT RIGHT FRONT W...

Page 326: ...ACK 2 WAY CAV CIRCUIT FUNCTION 1 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B8 18RD DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1...

Page 327: ...WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL C O N N E C T O R P I N O U T S 45 CONNECT...

Page 328: ...10 0 SCHEMATIC DIAGRAMS 10 1 TEVES MARK 20e CONTROLLER ANTILOCK BRAKE ABS S C H E M A T I C D I A G R A M S 47 SCHEMATIC DIAGRAMS...

Page 329: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Page 330: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 331: ...IMMOBILIZER MODULE 12 3 3 DIAGNOSTIC TROUBLE CODES 12 3 3 1 HARD CODE 12 3 3 2 INTERMITTENT CODE 13 3 3 3 STARTS SINCE SET COUNTER 13 3 3 4 DISTANCE SINCE MI SET 13 3 4 USING THE DRBIIIT 13 3 5 DRBII...

Page 332: ...MPERATURE SENSOR LOW 71 P0118 ENGINE COOLANT TEMPERATURE SENSOR HIGH 73 P0122 THROTTLE POSITION SENSOR 1 LOW 75 P0123 THROTTLE POSITION SENSOR 1 HIGH 78 P0125 INSUFFICIENT COOLANT TEMP FOR CLOSED LOOP...

Page 333: ...NCE AUTO TRANS 187 P0501 VEHICLE SPEED SENSOR 1 PERFORMANCE MANUAL TRANS 188 P0506 IDLE SPEED LOW PERFORMANCE 190 P0507 IDLE SPEED HIGH PERFORMANCE 190 P0519 IDLE SPEED PERFORMANCE 190 P0508 IAC VALVE...

Page 334: ...M 1 2 RICH 276 P2302 IGNITION COIL 1 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 279 P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 279 P2503 CHARGING SYSTEM VOLTAGE LOW 282 U0101 NO TR...

Page 335: ...LAMP SWITCH BLACK 6 WAY 352 CAMSHAFT POSITION SENSOR BLACK 3 WAY 353 CLOCKSPRING GREEN 7 WAY 353 CLUTCH INTERLOCK UPSTOP SWITCH MTX BLACK 3 WAY 353 CRANKSHAFT POSITION SENSOR BLACK 3 WAY 353 DATA LINK...

Page 336: ...68 POWERTRAIN CONTROL MODULE C2 2 0L ORANGE 38 WAY 369 POWERTRAIN CONTROL MODULE C3 WHITE 38 WAY 370 RADIATOR FAN MOTOR 2 0L BLACK 2 WAY 371 RADIATOR FAN MOTOR 2 4L TURBO BLACK 4 WAY 371 SENTRY KEY IM...

Page 337: ...All connector pinouts are in Section 9 0 All system schematics are in Section 10 0 An placed before the symptom description indi cates a customer complaint When repairs are required refer to the appro...

Page 338: ...then a trouble code will be stored in the PCM It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred This may happen b...

Page 339: ...l Control Short To Ground Oxygen Sensor Heater System For Short To Voltage Oxygen Sensor Response Fuel System Lean Fuel System Rich Inputs Checked For Requires 3 Consecutive Rationality Catalytic Conv...

Page 340: ...informa tion refer to the Chrysler Corporation Technical Training Workbook title On Board Diagnostics part number 81 699 97094 The most efficient order to run the monitors has been outlined below inc...

Page 341: ...vacuum allow ing throttle position to decrease A special vacuum dump solenoid allows immediate release of the throttle during speed control operation Speed control may be cancelled by braking driver i...

Page 342: ...The solenoid actuates the valve to unseal the canister vent while the engine is running It also will be used to close the vent during the medium and large leak tests and during the purge flow check T...

Page 343: ...ge Flow The above rationality check is considered suffi cient to confirm purge solenoid function and con formance with the purge flow test requirement The Purge Flow Monitor is passed based on switch...

Page 344: ...FIGURE 1 8 GENERAL INFORMATION...

Page 345: ...FIGURE 2 9 GENERAL INFORMATION...

Page 346: ...pinched fuel supply Fuel Injectors The PCM cannot detect if a fuel injector is clogged the pintle is sticking or the wrong injectors are installed Fuel Requirements Poor quality gasoline can cause pro...

Page 347: ...code is stored The SKIS incorporates a VTSS LED located on the instrument panel upper cover The LED re ceives switched ignition voltage and is hardwired to the body control module The LED is actuated...

Page 348: ...to each SKIM AT ONE TIME Once a key is learned to a SKIM it the key cannot be transferred to another vehicle If ignition key programming is unsuccessful the DRBIIIt will display one of the following...

Page 349: ...traveled by the vehicle while the MI is activated must be available at any instant through the serial port on the standard data link connector This feature works as follows 1 If the MI is illuminated...

Page 350: ...the vehicle It is especially important to block the wheels on front wheel drive vehicles the parking brake does not hold the drive wheels When servicing a vehicle always wear eye pro tection and remov...

Page 351: ...drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition CAUTION Before road testing a vehicle be sure that all...

Page 352: ...sluggish The engine has less than expected power with little or no increase in vehicle speed when the throttle is opened LDP leak detection pump MAP manifold absolute pressure sensor MIL malfunction i...

Page 353: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 17...

Page 354: ...RNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Use Scope input cable CH7058 Cable to Probe adapter C...

Page 355: ...essary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIIIt from the DLC...

Page 356: ...ignition off Disconnect the PCM harness connector Disconnect the DRBIIIt from the DLC Measure the resistance between ground and the PCM SCI Receive circuit in the Data Link harness connector cav 12 Is...

Page 357: ...resistance of the PCM SCI Transmit circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the P...

Page 358: ...ness connector Measure the resistance between ground and the ground circuit Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the ground circuit for an open Perform SKIS VERIFICATION 3 Turn t...

Page 359: ...elect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground...

Page 360: ...rm 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WIL...

Page 361: ...SMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TE...

Page 362: ...Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circui...

Page 363: ...ignition on Using the DRB attempt to communicate with the following control modules Airbag Control Module SKIM SENTRY KEY IMMOBILIZER MIC INSTRUMENT CLUSTER Was the DRBIIIt able to communicate with o...

Page 364: ...battery cable Turn the ignition on Measure the voltage of the PCI Bus circuit at the Data Link Connector DLC Is the voltage above 7 0 volts All Yes Go To 5 No Go To 6 5 Turn the ignition off Using a...

Page 365: ...s resistance to ground thru all of the modules is typically between 350 to 1000 ohms The more modules on the bus the lower the total bus resistance will be Is the resistance below 150 0 ohms with all...

Page 366: ...pinched partially broken wires and broken bent pushed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULT...

Page 367: ...CTION INTERMITTENT CKP SIGNAL CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR TEST ACTION APPLICABILITY 1 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT...

Page 368: ...gnition off Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found All Yes Repair or replace the Tone Wheel Pul...

Page 369: ...ed out or corroded terminals Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s tight Refer to any TSBs that may apply Were any of th...

Page 370: ...the Crank Position Sensor and wiggle the CKP Sensor Turn the ignition off Inspect the Sensor harness connector PCM harness connector Sensor connector and PCM connector for loose bent corroded or push...

Page 371: ...Set Condition Desired state does not match Actual state P0037 O2 SENSOR 1 2 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition Desir...

Page 372: ...orm POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBIIIt actuate the O2 Heater Test Using a 12 volt...

Page 373: ...s out of range high One trip fault P0038 O2 SENSOR 1 2 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition The O2 heater voltage is...

Page 374: ...and 2 1 3 0 to 4 0 ohms or 1 2 and 2 2 4 0 to 5 0 ohms Is the O2 Sensor Heater element within specification All Yes Go To 4 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 T...

Page 375: ...ING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the O2 Heater...

Page 376: ...ABILITY 1 Ignition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTE...

Page 377: ...ONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K150 Surge Sol Control circuit...

Page 378: ...in a predetermined time an error will be detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO HIGH RESISTANCE IN MAP K7 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K7 5 VOLT SUPPLY CI...

Page 379: ...wly depressing the throttle pedal from the idle position to the wide open throttle position Does the voltage start approximately at 0 8 volts and go above 3 5 volts with a smooth transition All Yes Re...

Page 380: ...ignition off Disconnect the TP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERM...

Page 381: ...on Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECT...

Page 382: ...pecial tool 8815 Is the resistance below 5 0 ohms All Yes Go To 15 No Repair the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 15 Turn the ignition off Disconnect the MAP Sensor...

Page 383: ...nal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform...

Page 384: ...TTERY VOLTAGE AMBIENT AIR TEMPERATURE SENSOR VOLTAGE BELOW 0 1 VOLT K145 AAT SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN K145 AAT SIGNAL CIRCUIT SHORTED TO GROUND K145 AAT SIGNAL CIRCUIT SHORTED...

Page 385: ...Sensor harness connector Using a jumper wire jumper across the Ambient Air Temperature Sensor harness connector Ignition on engine not running With the DRBIIIt read the Ambient Air Temperature voltag...

Page 386: ...5 NGC 7 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K145 AAT Signal circui...

Page 387: ...either the ignition is OFF for more than 5 hours or the vehicle has been driven at a speed greater than 20 MPH for more than 2 minutes Ignition on engine not running With the DRBIIIt read the Ambient...

Page 388: ...e PCM harness connector Measure the resistance between the K145 AAT Signal circuit and the K167 Sensor ground circuit in the Ambient Air Temperature Sensor harness connector Is the resistance below 10...

Page 389: ...OFF for more than 5 hours or the vehicle has been driven at a speed greater than 20 MPH for more than 2 minutes Ignition on engine not running With the DRBIIIt read the Ambient Air Temperature Sensor...

Page 390: ...Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K145 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Ambient Air Te...

Page 391: ...GROUND K1 MAP SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT PCM K7 5 VOLT SUPPLY CIRCUIT PCM K1 MAP SENSOR SIGNAL CIRCUIT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read th...

Page 392: ...K1 MAP Signal circuit and the K4 Sensor ground circuit in the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the K4 Sensor ground shorted to the K1 MAP Signal circuit Pe...

Page 393: ...AP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open in the K7 5 volt Supply circuit Perform POWERTRAIN VERI...

Page 394: ...PEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read the MAP Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTER...

Page 395: ...E PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K1 MAP Signal c...

Page 396: ...damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Info...

Page 397: ...SIGNAL SHORTED TO GROUND K21 IAT SIGNAL CIRCUIT SHORTED TO K167 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the rela...

Page 398: ...ss connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER...

Page 399: ...the PCM harness connector Measure the resistance between the K4 Sensor ground circuit and the K21 IAT Sensor Signal circuit at the IAT Sensor harness connector Is the resistance below 5 0 ohms All Yes...

Page 400: ...2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the IAT harness connector Ignition on e...

Page 401: ...167 Sensor ground shorted to the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damag...

Page 402: ...T OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read the IAT Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION...

Page 403: ...ir the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the PCM harness connector CAUTIO...

Page 404: ...OLT K2 ECT SIGNAL CIRCUIT OPEN K167 SENSOR GROUND CIRCUIT OPEN K2 ECT SIGNAL CIRCUIT SHORTED TO GROUND K2 ECT SIGNAL SHORTED TO K167 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 NOTE The...

Page 405: ...nsor harness connector Using a jumper wire jumper across the ECT Sensor harness connector Ignition on engine not running With the DRBIIIt read the ECT Sensor voltage Is the voltage below 0 1 volt All...

Page 406: ...t the ECT Sensor harness connector Turn the ignition off Disconnect the PCM harness connector Measure the resistance between ground and the K2 ECT Signal circuit in the ECT Sensor harness connector Is...

Page 407: ...lt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Disconnect the ECT harness connect...

Page 408: ...ensor ground shorted to the K2 ECT Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion dama...

Page 409: ...CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read the ECT Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CON...

Page 410: ...ir the open in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the ECT Sensor harness connector Disconnect the PCM harness connector CAUTION...

Page 411: ...TP SENSOR INTERNAL FAILURE K22 TP SIGNAL CIRCUIT SHORTED TO GROUND K22 TP SIGNAL CIRCUIT SHORTED TO K167 SENSOR GROUND CIRCUIT PCM K6 5 VOLT SUPPLY CIRCUIT PCM K22 TP SENSOR SIGNAL TEST ACTION APPLIC...

Page 412: ...nal circuit and the K167 Sensor ground circuit in the TPS harness connector Is the resistance below 100 ohms All Yes Repair the short to K4 Sensor ground in the K22 TP Signal circuit Perform POWERTRAI...

Page 413: ...the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Co...

Page 414: ...R GROUND CIRCUIT OPEN K22 TP SIGNAL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the throttle is fully closed and free from binding or carbon build up Start the engine With the DRBIIIt rea...

Page 415: ...THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K167 Sensor g...

Page 416: ...ER 5 NGC 8 Ignition on engine not running With the DRBIIIt monitor the TP Sensor voltage Slowly open the throttle from the idle position to the wide open throttle position Does voltage start at approx...

Page 417: ...CT DTC is set along with this code diagnose the ECT DTC first NOTE Inspect the ECT terminals and related PCM terminals Ensure the terminals are free from corrosion and damage NOTE The best way to diag...

Page 418: ...per temperature All Yes Go To 3 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 3 Ignition on engine not running With the DRBIIIt read the ECT Sensor temperature value If the...

Page 419: ...E COOLANT TEMPERATURE TEMPERATURE SENSOR VOLTAGE BELOW 0 1 VOLT SIGNAL CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH...

Page 420: ...h the DRBIIIt monitor the Engine Coolant temperature If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temper...

Page 421: ...l operating temperature monitor the Temperature sensor parameters while wiggling the wire harness Look for parameter values to change Visually inspect the related wire harness Look for any chafed pier...

Page 422: ...nal circuit from the Temperature Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 11 No Repair the open in the Signal circuit Pe...

Page 423: ...e Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the Signal circuit and the Sensor ground circuit in the Temperature Sensor harness connector Is the resis...

Page 424: ...ITION K7 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K7 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K7 5 VOLT SUPPLY CIRCUIT OPEN MAP SENSOR INTERNAL FAILURE K1 MAP SIGNAL CIRCUIT OPEN K1 MAP SIGNAL CIRCUIT...

Page 425: ...GNOSIS Measure the resistance of the K1 MAP Signal circuit from the MAP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Re...

Page 426: ...ECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K7 5 Volt Supply circuit from the...

Page 427: ...h the DRBIIIt read the IAC Current Is the IAC Current above 999 mA All Yes Refer to P0509 IAC Valve Sense Circuit High Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Refer to the INTERMITTENT CONDI...

Page 428: ...on The oxygen sensor signal voltage is below 2 402 volts for 9 seconds Two trip Fault P0137 O2 SENSOR 1 2 VOLTAGE LOW When Monitored Engine Running Set Condition The oxygen sensor signal voltage is be...

Page 429: ...engine not running With the DRBIIIt monitor the O2 Sensor voltage Is the O2 Sensor voltage above 4 8 volts All Yes Go To 3 No Go To 5 3 Turn the ignition off Disconnect the O2 Sensor harness connector...

Page 430: ...rted to the O2 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 7 7 Turn the ignition off Disconnect the O2 Sensor harness connector Disconnect the PCM harness connector Measure...

Page 431: ...ltage greater than 10 99 volts Set Condition The Oxygen Sensor voltage is above 3 9902 volts Two trip fault P0138 O2 SENSOR 1 2 VOLTAGE HIGH When Monitored The engine running for 119 seconds O2 Sensor...

Page 432: ...e to idle Measure the voltage on the O2 Sensor Signal circuit in the O2 Sensor harness connector NOTE Measure the voltage in reference to ground not the O2 Sensor Return circuit Is the voltage above 5...

Page 433: ...r harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO...

Page 434: ...tion The PCM monitors the state of change of the front O2 sensor and the rear 02 sensor The PCM will then compare the differences between both readings if the differences are greater than a calibrated...

Page 435: ...the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 3 3 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Meas...

Page 436: ...in 90 second during monitoring conditions Two Trip Fault P0141 O2 SENSOR 1 2 HEATER PERFORMANCE When Monitored Engine Running and Heater duty cycle greater than 0 Set Condition O2 Heater Temperature d...

Page 437: ...nsor Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignition off Disconnect the O2 Sensor harness connector Measure the resistance between an engine ground and the O2 Heater Ground circuit...

Page 438: ...terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Per...

Page 439: ...GED FUEL PUMP MODULE O2 SENSOR O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT O2 SENSOR HEATER OPERATION THROTTLE POSITION SENSOR SWEEP MAP SENSOR OPERATION ECT SENSOR OPERATION ENGINE MECHANICAL PROBLEM FUEL CO...

Page 440: ...ned to normal follow the diagnostic procedure for the remaining O2 Sensors Start the engine Allow the engine to reach normal operating temperature With the DRBIIIt read the O2 Sensor voltage Is the vo...

Page 441: ...onitor the ECT Sensor value The temperature value change should be a smooth transition from start up to normal operating temperature 82 C 180 F The value should reach at least 82 C 180 F Did the ECT v...

Page 442: ...No Check the O2 Signal circuit for a short to ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in...

Page 443: ...ion is 400 KPa 34 KPa 58 psi 5 psi Is the fuel pressure within specification All Yes Repair or replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 13 Caution...

Page 444: ...E CAUSES GOOD TRIP EQUAL TO ZERO O2 SENSOR HEATER OPERATION O2 SENSOR EVAP PURGE SOLENOID OPERATION O2 SIGNAL CIRCUIT O2 RETURN CIRCUIT MAP SENSOR OPERATION ECT SENSOR OPERATION ENGINE MECHANICAL PROB...

Page 445: ...eadings have not returned to normal follow the diagnostic procedure for the remaining O2 Sensors Start the engine Allow the engine to reach normal operating temperature With the DRBIIIt read the O2 Se...

Page 446: ...Coolant Temperature value The temp value change should be a smooth transition from start up to normal operating temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Coolant Temper...

Page 447: ...round open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN V...

Page 448: ...Shutdown Relay energized Engine speed less than 3000 rpm Set Condition No inductive spike is detected after injector turn off One Trip Fault P0203 FUEL INJECTOR 3 When Monitored With battery voltage g...

Page 449: ...the Fuel Injector harness connector Ignition on engine not running Using a 12 volt test light connected to 12 volts backprobe the Injector Control circuit With the DRBIIIt actuate the Fuel Injector D...

Page 450: ...e short to ground in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or t...

Page 451: ...ondition The PCM does not detect sufficient difference between TIP Sensor signal and BARO Pressure signal during turbocharger boost mode P1188 TIP SENSOR PERFORMANCE When Monitored During the engine t...

Page 452: ...harger TIP Solenoid Surge Solenoid and Wastegate Solenoid for loose connection damage or restriction NOTE Solenoid design and hose connections are identical for all three solenoids It is possible to c...

Page 453: ...id 8 Turn the ignition off Disconnect the hoses from the appropriate Solenoid Install a plug on Solenoid hose C connection point Connect a vacuum pump to the Solenoid hose B connection point NOTE For...

Page 454: ...10 Did all the solenoids function correctly All Yes Replace the Turbocharger assembly in accordance with the Ser vice Information No Replace Solenoid s as necessary 118 DRIVEABILITY NGC P0234 OVERBOO...

Page 455: ...ST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer t...

Page 456: ...To 5 5 Turn the ignition off Disconnect the Wastegate Solenoid harness connector Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTO...

Page 457: ...e or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informatio...

Page 458: ...t has been successfully updated Set Condition When more than a 1 0 misfire rate is measured during two trips P0302 CYLINDER 2 MISFIRE When Monitored Any time the engine is running and the Target Learn...

Page 459: ...PCM IGNITION SYSTEM PCM TEST ACTION APPLICABILITY 1 Read and record the FREEZE FRAME DATA Select OBD II MONITORS Read and record the MIS FIRE SIMILAR CONDITIONS WINDOW DATA With these screens attempt...

Page 460: ...the Ignition wire from the spark plug NOTE Before continuing inspect the ignition wire for damage or carbon tracking Replace as necessary Install a spark tester to the ignition wire While cranking th...

Page 461: ...m to reach maximum pressure Turn the ignition off NOTE Fuel specification is 400 KPa 34 KPa 58 psi 5 psi Using special tool C4390 Hose Clamp Pliers slowly clamp off the rubber hose on the Fuel Pressur...

Page 462: ...VER 5 NGC 10 Turn the ignition off Disconnect the Fuel Injector harness connector Ignition on engine not running Using a 12 volt test light connected to 12 volts probe the Injector Control circuit Wit...

Page 463: ...r line the fuel system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet Strainer Perform...

Page 464: ...PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Ch...

Page 465: ...ed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLE...

Page 466: ...battery disconnect to reset the PCM Start the engine If the MIL has not yet illuminated test drive the vehicle to try to get the code to reset Does the code reset while cranking or during the test dr...

Page 467: ...movement Were any problems found All Yes Repair or replace the Tone Wheel Flex Plate as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 If there are no possible causes remaining...

Page 468: ...CIRCUIT SHORTED TO K45 KS RETURN CIRCUIT K45 KS RETURN CIRCUIT OPEN KNOCK SENSOR TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Fr...

Page 469: ...5 No Repair the open in the K42 KS Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Knock Sensor harness connector Measure the resistance between t...

Page 470: ...It read DTC s Does the DRBIIIt display the DTC that was previously erased All Yes NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as n...

Page 471: ...KP SIGNAL K7 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K7 5 VOLT SUPPLY CIRCUIT OPEN K7 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL CIRCUIT SHORTED GROUND K24 CKP SIGNAL CIRCUIT OPEN K24 CKP...

Page 472: ...WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Ignition on engine not running Wiggle the related...

Page 473: ...ON TEST VER 5 NGC 8 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K24 CKP Signal circuit in the C...

Page 474: ...and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 13 Turn the ignition off Disconnect the CKP Sensor harness connecto...

Page 475: ...e K7 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repa...

Page 476: ...CTION CHECKING CAMSHAFT POSITION SENSOR SIGNAL WITH THE DRBIIIt LAB CRANKSHAFT POSITION SENSOR K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORT TO GROUND K24 CKP SIGNAL CIRCUIT SHORTED TO B K2...

Page 477: ...s Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are tight Refer to any TSBs that may apply Were any of the above conditions pres...

Page 478: ...isconnect the CKP Sensor connector Disconnect the PCM connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERM...

Page 479: ...7 5 Volt Supply circuit and the K24 CKP signal circuit at the CKP Sensor harness connector Wiggle the related wire harness while taking this measurement Is the resistance below 5 0 ohms All Yes Repair...

Page 480: ...N SENSOR SIGNAL INTERMITTENT CAMSHAFT POSITION SENSOR SIGNAL K7 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K7 5 VOLT SUPPLY CIRCUIT OPEN K7 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL CIRCUIT...

Page 481: ...IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Ignition on engine not running Wiggle the related wire harness a...

Page 482: ...IN VERIFICATION TEST VER 5 NGC 8 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K44 CMP Signal cir...

Page 483: ...the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 13 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect...

Page 484: ...he K7 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Rep...

Page 485: ...PLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the IN...

Page 486: ...IFICATION TEST VER 5 NGC 5 Turn the ignition off Carefully disconnect the Battery Ground cable Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or exce...

Page 487: ...cuit in the CMP Sensor harness connector Wiggle the related wire harness while monitoring the resistance value Does the resistance stay below 100 ohms All Yes Repair the short to ground in the K44 CMP...

Page 488: ...terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Per...

Page 489: ...Vehicle speed greater than 20 MPH and less than 55 MPH Engine Speed greater than 1216 RPM and less than 1952 RPM Set Condition As catalyst efficiency deteriorates the switch rate of the downstream O2...

Page 490: ...OD TRIP EQUAL TO ZERO VISUAL AND PHYSICAL INSPECTION EVAP PURGE SOLENOID VACUUM SUPPLY INSPECTION EVAP PURGE SOLENOID STUCK CLOSED NVLD SWITCH OPERATION Z1 GROUND CIRCUIT OPEN NVLD ASSEMBLY K107 NVLD...

Page 491: ...TION TEST VER 5 NGC No Go To 4 4 Disconnect the vacuum supply hoses form the EVAP Purge Solenoid Using a hand vacuum pump apply 10 in Hg to the 9CAN9 side of the EVAP Purge Solenoid Ignition on engine...

Page 492: ...tester s control panel Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote...

Page 493: ...smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that are left behind by the smoke The exiting smoke deposits a...

Page 494: ...ULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K107 NVLD Switch Signal circuit from the NVLD electrical harness connector...

Page 495: ...P0498 or P0499 diagnose them first before continuing with P0441 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed an...

Page 496: ...e Solenoid Inspect the vacuum port at the throttle body for any damage or plugging Were any problems found All Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST...

Page 497: ...EVAP system If the NVLD switch reopens before the calibrated amount of time for a Medium leak an error is detected Two Trip Fault P0455 EVAP SYSTEM LARGE LEAK When Monitored Engine Running Cold start...

Page 498: ...rd the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 7 2 Perform a visual and physical inspection of the entire Evaporative Emission system Ch...

Page 499: ...el 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 remo...

Page 500: ...leak is concealed from view i e top of fuel tank release the remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces o...

Page 501: ...ELTS OR FAN DO NOT WEAR LOOSE CLOTHING Review the DRBIIIt Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB...

Page 502: ...ORTED TO GROUND POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displa...

Page 503: ...Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the Evap Purge Solenoid harness connector Disconnect the PCM harness connectors CA...

Page 504: ...or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information...

Page 505: ...ND EVAP PURGE SOLENOID LEAKS STUCK OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter disp...

Page 506: ...RTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition on Using the DRBIIIt monitor the NVLD Switch State Disconnect the NVLD electrical connector Does the Switch change from CLOSED to OPEN...

Page 507: ...resistance below 5 0 ohms All Yes Repair the short to ground in the K52 EVAP Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No NOTE Before continuing check the PCM harness co...

Page 508: ...the DRBIIIt perform the NVLD FORCED MONITOR TEST Monitor the NVLD Switch state NOTE As the test runs the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the te...

Page 509: ...Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the Z1 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the NVLD electrical harne...

Page 510: ...APPLICABILITY 1 NOTE The difference in ambient temperature outside temp VS shop temp may conceal a leak it is best to perform this test after the vehicle s temperature has stabilized in the work area...

Page 511: ...ht 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...

Page 512: ...ORTED TO GROUND G4 FUEL LEVEL SIGNAL CIRCUIT OPEN Z2 GROUND CIRCUIT OPEN INTERNAL INSPECTION OF THE FUEL TANK FUEL LEVEL SENSOR TEST ACTION APPLICABILITY 1 NOTE Diagnose P0462 or P0463 first if set al...

Page 513: ...Module harness connector Measure the resistance of the Z2 Ground circuit from the Fuel Pump Module harness connector to ground Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in th...

Page 514: ...R 1 HIGH When Monitored Ignition on and battery voltage above 10 4 volts Set Condition The fuel level sensor signal voltage at the PCM goes above 4 7 volts for more than 5 seconds One Trip Fault POSSI...

Page 515: ...PEN LOW SPEED RAD FAN RELAY CONTROL CIRCUIT SHORT TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt actuate the Radiator Fan Relay Is the Radiator Fan Relay ope...

Page 516: ...o the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C24 Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5...

Page 517: ...TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt actuate the High Speed Radiator Fan Relay Are both Radiator Fan operating at high speed All Yes Refer to the INTERMITTENT CONDITION sy...

Page 518: ...the Radiator Fan Relay 3 Control circuit between the PDC and the splice Perform POWERTRAIN VERIFICATION TEST VER 5 NGC Does NOT flash for both 2 and 3 Relays Go To 4 Flashes at both Relays Install a s...

Page 519: ...stance of the Radiator Fan Relay 3 Control circuit from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes NOTE Before continuing check the PCM harness c...

Page 520: ...tion off Disconnect the NVLD electrical harness connector Measure the resistance of the NVLD Solenoid coil Is the resistance between 7 5 to 8 5 ohms All Yes Go To 3 No Replace the NVLD Assembly Perfor...

Page 521: ...1 GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to...

Page 522: ...he K106 NVLD Sol Control circuit from the NVLD Assembly harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K1...

Page 523: ...nition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION...

Page 524: ...LICABILITY 1 Raise the drive wheels off the ground WARNING BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Start the engine With the DRBIIIt monitor the Vehicle Speed Sensor Place the transmis...

Page 525: ...0 ohms All Yes Repair the G7 VSS Signal circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 6 6 Turn the ignition off Disconnect the Vehicle Speed Sensor harness conn...

Page 526: ...P0507 IDLE SPEED HIGH PERFORMANCE When Monitored Engine Running During an idle condition Set Condition If the engine RPM does not come within a calibratable high limit of the target idle speed a failu...

Page 527: ...form POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 4 4 Start the engine Inspect the vehicle for external vacuum leaks Inspect the engine for internal vacuum leaks Were any vacuum leaks found All Yes...

Page 528: ...ngine will not idle maintain an engine speed between 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIIIt read the IAC Current Is the IAC Current below 146 mA All Yes Go To 2 No...

Page 529: ...circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connector Disconnect the PCM harness connectors Measure the resistance betwee...

Page 530: ...or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information...

Page 531: ...CUIT PCM TEST ACTION APPLICABILITY 1 NOTE If the engine will not idle maintain an engine speed between 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIIIt read the IAC Current...

Page 532: ...olt All Yes Repair the short to voltage in the K610 IAC Motor Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connect...

Page 533: ...Yes Go To 2 No Go To 7 2 With the DRBIIIt attempt to communicate with the SKIM Turn the ignition on Can the DRBIIIt communicate with the SKIM All Yes Go To 3 No Refer to the No Communication category...

Page 534: ...cessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform SKIS VERIFICATION No Test Complete 7 NOTE You must obtain the SKIM pin number NOTE This DTC...

Page 535: ...shed until either the ignition is OFF for more than 3 hours or the vehicle is driven above 10 MPH for more than 10 minutes Ignition on engine not running With the DRBIIIt read the Battery Temp Sensor...

Page 536: ...ctor Measure the resistance between the K118 Battery Temp Signal circuit and the K167 Sensor ground circuit in the Battery Temp Sensor harness connector Is the resistance below 100 ohms All Yes Repair...

Page 537: ...ition is OFF for more than 3 hours or the vehicle is driven above 10 MPH for more than 10 minutes Ignition on engine not running With the DRBIIIt read the Battery Temp Sensor voltage Is the voltage ab...

Page 538: ...hms All Yes Go To 5 No Repair the open in the K118 Battery Temp Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Battery Sensor harness connector Di...

Page 539: ...econds With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in th...

Page 540: ...ccor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connector...

Page 541: ...K10 PSP SWITCH SIGNAL CIRCUIT OPEN POWER STEERING PRESSURE SWITCH PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is...

Page 542: ...8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K10 PSP Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 5 Turn the ignition off Disconnect the Pow...

Page 543: ...GEN FIELD CONTROL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the Battery is in good condition Using the Midtronics Battery Tester test the Battery before continuing NOTE Inspect the vehi...

Page 544: ...tage between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN...

Page 545: ...AMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K20 Gen Field Control circuit from the Generat...

Page 546: ...rator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse is found to be open use the wiring diagram schematic as a guide inspect the wiring and connectors for damage...

Page 547: ...ltage in the K20 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal...

Page 548: ...mptom in the Diagnostic category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 2 Turn the ignition off Remove the Brake Lamp Switch and disconnect the harness connector Measure the resistance between...

Page 549: ...s a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program the Pow...

Page 550: ...lated Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION in the symptom Diagnostic category Perform POWERTRAIN VERIFICATION T...

Page 551: ...ATION TEST VER 5 NGC 4 Measure the resistance between the Z2 Ground circuit and ground at the Brake Lamp Switch harness connector Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in...

Page 552: ...h the DRBIIIt read the Speed Control voltage Is the Speed Control voltage above 4 8 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN...

Page 553: ...harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO P...

Page 554: ...DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt actuate the Speed Control Vacuum Solenoid and note operation Does the Speed Control Vacuum Solenoid actuate properly All Ye...

Page 555: ...N VERIFICATION TEST VER 4 NGC 4 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V36 S C Vacuum Solen...

Page 556: ...ated Freeze Frame data With the DRBIIIt actuate the Speed Control Vent Solenoid and note operation Does the Speed Control Vent Solenoid acutate properly All Yes Refer to the INTERMITTENT CONDITION sym...

Page 557: ...RIFICATION TEST VER 4 NGC 4 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V35 S C Vent Sol Control...

Page 558: ...EDTO GROUND V40 S C BRAKE SWITCH OUTPUT CIRCUIT OPEN BRAKE LAMP SWITCH PCM S C SOURCE CIRCUIT TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the Speed Control Servo harness connector Ign...

Page 559: ...tch harness connector Is the resistance below 100 ohms All Yes Go To 4 No Repair the short to ground in the V32 S C Power Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 4 Turn the ignit...

Page 560: ...ing Does the test light illuminate brightly All Yes Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 7 7 NOTE Before continuing check the PCM harness connector ter...

Page 561: ...s communication failure between the Engine and Transmis sion processors P0601 INTERNAL MEMORY CHECKSUM INVALID When Monitored With the ignition on Set Condition Internal checksum for software failed d...

Page 562: ...ION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Refer to the INTERMI...

Page 563: ...resistance below 100 ohms All Yes Repair the K20 Gen Field Control circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 6 6 Turn the ignition off Disconnect the Genera...

Page 564: ...the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the Fuel Pump Relay from the PDC Ignition on en...

Page 565: ...cuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the Fuel Pump Relay from the PDC Measure the resistance between ground and the K31 Fuel Pump Relay Control circuit in...

Page 566: ...g temperature With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No The VIN has been successfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE...

Page 567: ...To 2 No The mileage has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition switch must be left in the off position for a minimum...

Page 568: ...the engine to reach normal operating temperature With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No The SKIM KEY information has been succcessfully programmed into the PCM Test is comple...

Page 569: ...GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt actuate the A C Clutch Relay Is the A C Clutch Relay operating All Yes Refer to the INTERMITTENT CONDITION sympt...

Page 570: ...from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C28 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFIC...

Page 571: ...UND MTV RELAY MTV RELAY CONTROL CIRCUIT OPEN MANIFOLD TUNING VALVE SLOENOID PCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s Is the Good Trip displayed and equal to zer...

Page 572: ...to ground probe the ASD Relay Output circuit in the PDC Turn the ignition on With the DRBIIIt actuate the MTV Relay Does the test light illuminate brightly All Yes Go To 6 No Repair the ASD Relay Outp...

Page 573: ...no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information 10 Turn the ignition off Disconnect the MTV Solenoid...

Page 574: ...Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 NGC No Go To 2 2 Turn the ignition off Remove the ASD Relay from the PDC Ignitio...

Page 575: ...Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 5 Turn the ignition off Remove the ASD Relay from the PDC Measure the resistance between ground and the K51 ASD Relay Control circuit in the PDC Is the...

Page 576: ...PUT CIRCUIT OPEN PCM NO START PCM START TEST ACTION APPLICABILITY 1 NOTE Diagnose P0685 Auto Shutdown Relay Control Circuit first if set along with this DTC With the DRBIIIt erase the DTC Attempt to s...

Page 577: ...inal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform...

Page 578: ...to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the A142 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC...

Page 579: ...ow that a DTC s is stored in the Transmission Control Module Erase this DTC from the PCM after all Transmission DTC s have been repaired Using the DRBIIIt read the Transmission Controller DTC and refe...

Page 580: ...Z12 GROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 With the DRBIIIt monitor the Clutch Upstop Switch Depress the Clutch Pedal completely to the floor and release all the way up several times Did the...

Page 581: ...IS Measure the resistance of the Clutch Upstop Signal circuit between the Clutch Pedal Position Switch harness connector and the appropriate terminal of special tool 8815 Is the resistance below 5 0 o...

Page 582: ...icate with the TCM refer to the Communication Category and preform the appropriate symptom With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal...

Page 583: ...D TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes...

Page 584: ...SULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K55 TIP Sol Control circuit from the TIP Solenoid harness connector to th...

Page 585: ...D CIRCUIT OPEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 NOTE The PCM compares IAT AAT and ECT to determine if they are with...

Page 586: ...es Go To 5 No Go To 6 5 Inspect the Temperature sensors for any physical damage Inspect the engine coolant Ensure the coolant is at the proper level Refer to the Service Information COOLING Ensure the...

Page 587: ...le Temperature Sensor harness connector Using a jumper wire jumper across the Temperature Sensor harness connector Ignition on engine not running With the DRBIIIt read the Temperature voltage Is the v...

Page 588: ...T VER 5 NGC 11 Turn the ignition off Disconnect the applicable Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the Signal circuit in...

Page 589: ...PEN TIP SENSOR INTERNAL FAILURE A23 TIP SIGNAL CIRCUIT SHORTED TO GROUND A23 TIP SIGNAL CIRCUIT SHORTED TO K167 SENSOR GROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt...

Page 590: ...or Measure the resistance between the A23 TIP Sensor signal circuit and the K167 Sensor ground circuit in the TIP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the A23 TIP S...

Page 591: ...between the K6 5 Volt Supply circuit and the K167 Sensor Ground circuit in the TIP Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the K6 5 Volt Supply circuit for a short to...

Page 592: ...SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt read the TIP Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CON...

Page 593: ...HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K153 TIP Signal circ...

Page 594: ...ge or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informati...

Page 595: ...UIT SHORTED TO BATTERY VOLTAGE V37 S C SIGNAL CIRCUIT OPEN K4 SENSOR GROUND OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIIIt monitor each switch function for the Speed Control Sw...

Page 596: ...PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V37...

Page 597: ...hematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and progr...

Page 598: ...The PCM has been successfully programmed Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition switch must be left in the off position for a minimum of 10 seconds Cycle the...

Page 599: ...ctor CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO...

Page 600: ...Monitored With the ignition on continuous Set Condition An attempt to program write to the internal EEPROM failed Also checks at power down POSSIBLE CAUSES DRB DISPLAYS WRITE FAILURE DRB DISPLAYS WRIT...

Page 601: ...Complete 4 With the DRBIIIt perform the SRI Memory Test Does the DRBIIIt display SRI Mileage Invalid All Yes Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER 1 No...

Page 602: ...K167 SENSOR GROUND CIRCUIT OPEN TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal...

Page 603: ...PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the...

Page 604: ...d hose A connection point NOTE Vacuum should escape through the Solenoid hose B connection point Does vacuum escape through the Solenoid hose B connection point All Yes Go To 8 No Replace the TIP Sole...

Page 605: ...Ground to the appropriate solenoid terminals to turn the solenoid on Attempt to apply 20 inches of vacuum to the TIP Solenoid hose B connection point NOTE Vacuum should escape through the Solenoid hos...

Page 606: ...AL TO ZERO VACUUM LEAK HIGH RESISTANCE IN MAP K7 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K7 5 VOLT SUPPLY CIRCUIT MAP SENSOR HIGH RESISTANCE IN K1 MAP SIGNAL CIRCUIT RESISTANCE TO GROUND IN...

Page 607: ...spect the Intake Manifold for leaks and cracks Inspect the Power Brake Booster for any vacuum leaks Inspect the PCV system for proper operation or any vacuum leaks Were any vacuum leaks found All Yes...

Page 608: ...VERIFICATION TEST VER 5 NGC 7 Turn the ignition off Disconnect the TP Sensor harness connector With the DRBIIIt monitor the TP Sensor voltage Ignition on engine not running Connect a jumper wire betw...

Page 609: ...Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 11 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If ther...

Page 610: ...TION TEST VER 5 NGC No Go To 15 15 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PC...

Page 611: ...ctor to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 18 No Repair the K4 Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 18 NOTE Be...

Page 612: ...erm compensation to long term adaptive and a certain percentage is exceeded for two trips a freeze frame is stored the MIL illuminates and a trouble code is stored P2097 DOWN STREAM FUEL SYSTEM 1 2 RI...

Page 613: ...SYSTEM must be free from leaks ENGINE VACUUM must be at least 13 inches in neutral ENGINE VALVE TIMING must be within specifications ENGINE COMPRESSION must be within specifications ENGINE EXHAUST SY...

Page 614: ...FICATION TEST VER 5 NGC 6 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the voltage on the O2 Return circuit in the O2 Sensor harness connecto...

Page 615: ...t or not present an error is detected One Trip Fault P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION When Monitored Engine Running Set Condition If PCM detects that the secondary ignit...

Page 616: ...Measure the resistance of the ignition wire Is the resistance below 10K ohms All Yes Go To 4 No Replace the Ignition Wire Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 4 Turn the ignition off Disconn...

Page 617: ...NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace...

Page 618: ...ON Z1 GEN FIELD GROUND CIRCUIT OPEN K20 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K20 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND K20 GEN FIELD CONTROL CIRCUIT OPEN PCM TEST ACTION APPLICAB...

Page 619: ...ge between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VE...

Page 620: ...RIFICATION TEST VER 3 NGC No Go To 8 8 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBI...

Page 621: ...ABILITY 1 NOTE If P1603 or P1604 are set along with this DTC diagnose them first before continuing with U0101 NOTE Before continuing inspect all fuses and ensure that all power and ground circuits are...

Page 622: ...r the F12 Fused Ignition Switch Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 3 Note Determine which modules this vehicle is equipped with before begin ning Note When attemptin...

Page 623: ...eability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIIIt attempt to communicate with the Instrument cluster Can communication be established with...

Page 624: ...te if the Bus is operational from the DLC to the SKIM Was the DRB III able to communicate with the SKIM All Yes Go To 3 No Refer to symptom BUS SIGNAL OPEN FROM SKIM in the COMMUNICATION category Perf...

Page 625: ...DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related t...

Page 626: ...second each time With the DRBIIIt read DTCs Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 1 2...

Page 627: ...L TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit from the Instrument Cluster harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5...

Page 628: ...THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the...

Page 629: ...With the DRBIIIt actuate the Low Speed Rad Fan Relay 1 NOTE Both Fans should be operating at high speed Is the Rad Fan 2 operation at high speed All Yes The High Speed Fans are operating normal at th...

Page 630: ...the PDC Does the test light illuminate brightly All Yes Go To 6 No Repair the Fused B circuit Inspect fuses and replace as neces sary Perform POWERTRAIN VERIFICATION TEST VER 5 NGC 6 Turn the ignitio...

Page 631: ...APPLICABILITY 1 Turn the ignition on With the DRBIIIt actuate the Low Speed Rad Relay Observe the Radiator Fans Choose a conclusion that best match the Radiator Fans operation All Both Fans operation...

Page 632: ...the DRBIIIt actuate the Low Speed Rad Relay WARNING Keep hands away from the Rad Fan when it is operating Disconnect the Rad Fan 1 harness connector Is the Fan 2 still operating All Yes Repair the Low...

Page 633: ...IIIt actuate the Low Speed Rad Fan Relay 1 Using a fused jumper wire connected to ground probe the Low Speed Rad Relay Output in the Rad Fan Control Relay 3 Does the Rad Fan 2 operate All Yes Check fo...

Page 634: ...resistance below 5 0 ohms All Yes Go To 3 No Repair the Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 3 Disconnect the Radiator Fan harness connector Turn the ignition on W...

Page 635: ...or Fan Relay Output circuit between the PDC and the Radiator Fan harness connector Is the resistance below 5 0 ohms All Yes Replace the Radiator Fan Relay Perform POWERTRAIN VERIFICATION TEST VER 2 NG...

Page 636: ...rness connector to ground Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Z1 Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 3 Disconnect the A C Clutch harnes...

Page 637: ...A C Clutch Relay Output circuit between the PDC and the A C Clutch harness connector Is the resistance below 5 0 ohms All Yes Replace the A C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 N...

Page 638: ...reset by the micro controller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after...

Page 639: ...erase the SKIM DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIIIt read the SKIM DTCs Did the same SKIM DTC return All Yes Replace and...

Page 640: ...that occurs with the PCM due to a SKIM reset or during SECRET KEY transfers to the PCM Set Condition When the SKIM does not receive an expected PCI BUS message trans mission acknowledgement from the P...

Page 641: ...M and 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 th...

Page 642: ...d by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the PCM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the PCM does not m...

Page 643: ...all PCM 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 Replace an...

Page 644: ...REDUNDANCY 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 mess...

Page 645: ...gnition on 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...

Page 646: ...the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded termin...

Page 647: ...No Go To 5 Caution Stop All Actuations 2 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting o...

Page 648: ...el system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet Strainer Perform POWERTRAIN V...

Page 649: ...Perform POWERTRAIN VERIFICATION TEST VER 1 9 Turn the ignition off Remove the Fuel Pump Relay from the PDC Disconnect the Fuel Pump Module harness connector NOTE Check connectors It is critical that t...

Page 650: ...sting or servicing any fuel system hose fitting or line the fuel system pressure must be released Install special 5 16 fuel line adapter tool 6539 Attach a fuel pressure test gauge to the T fitting on...

Page 651: ...OUND CIRCUIT OPEN HIGH RESISTANCE FUEL PUMP MODULE 5 VOLT SUPPLY CIRCUIT CKP SENSOR SIGNAL CIRCUIT OPEN CKP SENSOR SIGNAL CIRCUIT SHORTED GROUND CKP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE CKP SENSOR...

Page 652: ...lish communicate refer to the Communication category for the proper symptoms The Sentry Key Immobilizer System must be operating properly Check for proper communication with the DRBIIIt and check for...

Page 653: ...fuel pressure reading All Below Specification Go To 6 Within Specification Go To 8 Above Specification Replace the fuel filter fuel pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 1 Cautio...

Page 654: ...from vacuum leaks Were any of the above conditions found All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 No Test Complete 9 Turn the ignition on With the DRBIIIt in Sensors sele...

Page 655: ...Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 15 Turn the ignition off Disconnect the CKP Sensor harness con...

Page 656: ...t at the CKP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the CKP Sensor Signal circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 21 21 Turn...

Page 657: ...l that the connector is free from any signs of corrosion or deformities Clean repair as necessary Using a test light connected to battery voltage probe the Fuel Pump ground circuit at the Fuel Pump Mo...

Page 658: ...y signs of corrosion or deformities Measure the resistance of the Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector Is the resistance below 5 0 ohms All Yes Rep...

Page 659: ...GGED FUEL PUMP MODULE FUEL PUMP RELAY FUSED B CIRCUIT FUEL PUMP RELAY OUTPUT CIRCUIT OPEN FUEL PUMP GROUND CIRCUIT OPEN HIGH RESISTANCE FUEL PUMP MODULE 5 VOLT SUPPLY CIRCUIT CKP SENSOR SIGNAL CIRCUIT...

Page 660: ...mmunicate refer to the Communication category for the proper symptoms The Sentry Key Immobilizer System must be operating properly Check for proper communication with the DRBIIIt and check for DTC s t...

Page 661: ...t and disconnect the fuel pressure line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pressure test...

Page 662: ...WERTRAIN VERIFICATION TEST VER 1 1 6L No Test Complete 9 Turn the ignition off Disconnect the CKP Sensor harness connector Turn the ignition on Measure the voltage of the 5 Volt Supply circuit in the...

Page 663: ...ess connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 15 No Repair the CKP Sensor Signal circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 1 6L 15 Turn...

Page 664: ...the connector is free from any signs of corrosion or deformities Clean repair as necessary Using a test light connected to battery voltage probe the Fuel Pump ground circuit at the Fuel Pump Module ha...

Page 665: ...of corrosion or deformities Measure the resistance of the Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector Is the resistance below 5 0 ohms All Yes Replace the...

Page 666: ...seized Is the engine able to turn over All Yes Go To 2 No Repair the mechanical condition preventing the starter motor from cranking Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off...

Page 667: ...neutral Warning The engine may be cranked in the next step Keep away from moving engine parts Briefly connect a jumper wire between Starter Relay B circuit and the Starter Relay Output Circuits Did t...

Page 668: ...e of the Starter Relay Output circuit between the Relay and the Solenoid harness connector Is the resistance below 5 0 ohms All Yes Go To 10 No Repair Starter Relay Output circuit for an open Perform...

Page 669: ...tion off Disconnect the PCM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the PCM Fused Ignition Switch Output circuit in the PCM harness connector Does t...

Page 670: ...rn the ignition on With the DRBIIIt read DTC s Are any DTCs present All Yes Refer to the Driveability Category and perform the appropriate symptom Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 2...

Page 671: ...le on hoist and disconnect the fuel pressure line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pre...

Page 672: ...is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the engine During engine warm up monitor the Engine Coolant Temperature value The temperature value change should be a s...

Page 673: ...nd downshift several times using the AutoStickt feature during the road test 13 NOTE Use the EATX OBDII task manager to run Good Trip time in each gear this will confirm the repair and to ensure that...

Page 674: ...RIFICATION TEST VER 2 NGC APPLICABILITY 1 NOTE After completing the Powertrain Verification Test the Transmission Verifi cation Test must be performed 2 NOTE If the PCM has been replace and the vehicl...

Page 675: ...r to the Service Information for the PCM SKIM and the Transponder ignition key for programming information 5 Inspect the vehicle to ensure that all components related to the repair are connected prope...

Page 676: ...and then if necessary return to Symptom List 11 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...

Page 677: ...nk has at least a quarter tank of fuel Turn off all accessories 10 If a Comprehensive Component DTC was repaired perform steps 5 8 If a Major OBDII Monitor DTC was repaired skip those steps and contin...

Page 678: ...verification test when the repair is complete Did the indicator ball indicate the a leak is present All Yes Repeat the DTC test to identify the leak and repair No Repair is complete POWERTRAIN VERIFIC...

Page 679: ...n continually for 1 hour Turn off all accessories and connect a battery charger if necessary 5 With the DRB III select Theft Alarm SKIM and Miscellaneous Then select desired procedure and follow the s...

Page 680: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES AND PDC 2 0L SRT 4 8 2 CONTROLS AND SOLENOIDS 2 0L C O M P O N E N T L O C A T I O N S 345 COMPONENT LOCATIONS...

Page 681: ...2 0L SRT 4 SRT 4 2 0L SRT 4 C O M P O N E N T L O C A T I O N S 346 COMPONENT LOCATIONS 8 2 CONTROLS AND SOLENOIDS Continued...

Page 682: ...8 3 DATA LINK CONNECTOR 8 4 SENSORS SRT 4 C O M P O N E N T L O C A T I O N S 347 COMPONENT LOCATIONS...

Page 683: ...2 0L SRT 4 2 0L SRT 4 C O M P O N E N T L O C A T I O N S 348 COMPONENT LOCATIONS 8 4 SENSORS Continued...

Page 684: ...2 0L SRT 4 8 5 FUEL SYSTEM 8 6 SWITCHES GAUGES C O M P O N E N T L O C A T I O N S 349 COMPONENT LOCATIONS...

Page 685: ...SRT 4 C O M P O N E N T L O C A T I O N S 350 COMPONENT LOCATIONS 8 6 SWITCHES GAUGES Continued...

Page 686: ...TCH SENSE 1 C20 20BR 2 4L TURBO A C SWITCH SENSE 2 C22 20DB WT PRESSURE SWITCH OUTPUT A C LOW PRESSURE SWITCH 2 0L LHD DK GREEN 2 WAY CAV CIRCUIT FUNCTION 1 C22 20DB WT PRESSURE SWITCH OUTPUT 2 C21 20...

Page 687: ...TURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K118 20PK YL BATTERY TEMP SIGNAL 2 K167 20BR YL 2 0L SENSOR GROUND 2 2 K167 20BR YL 2 4L TURBO SENSOR GROUND 2 BRAKE LAMP SWITCH BLACK 6 WAY CAV CIRCUIT...

Page 688: ...K LB DRIVER SQUIB 1 LINE 1 3 4 5 X3 22BK RD HORN RELAY CONTROL 6 V37 20RD LG 2 0L SPEED CONTROL S C SWITCH SIGNAL 7 K914 20BR WT 2 0L SPEED CONTROL GROUND CLUTCH INTERLOCK UPSTOP SWITCH MTX BLACK 3 WA...

Page 689: ...20WT DG 2 0L SCI TRANSMIT TCM 16 A14 18RD WT FUSED B ENGINE COOLANT TEMP SENSOR 2 0L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 K2 20VT LG ECT SIGNAL ENGINE COOLANT TEMP SENSOR 2 4L...

Page 690: ...EL INJECTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K12 18TN INJECTOR CONTROL NO 2 2 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 3 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K13 18YL WT INJ...

Page 691: ...P MODULE LT GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 Z2 20BK LG GROUND 3 G4 20DB FUEL LEVEL SENSOR SIGNAL 4 A141 18DG WT FUEL PUMP RELAY OUTPUT C O N N E C T O R P I N O U T S 356 CONNECTOR...

Page 692: ...C O N N E C T O R P I N O U T S 357 CONNECTOR PINOUTS...

Page 693: ...10A F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 7 10A F20 20WT DAYTIME RUNNING LAMPS FUSED IGNITION SWITCH OUTPUT RUN 8 15A L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 9 10A F15 20DG WT FUSED IGNITION SW...

Page 694: ...C O N N E C T O R P I N O U T S 359 CONNECTOR PINOUTS...

Page 695: ...RUN 9 10A A81 20DG RD AUTOSTICK FUSED B 10 10A G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 11 15A F12 18DB PK FUSED IGNITION SWITCH OUTPUT RUN START 12 10A F15 20DG WT FUSED IGNITION SWITCH OUTP...

Page 696: ...R VT 2 4L TURBO IAC RETURN IGNITION COIL BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K17 18DB TN 2 0L COIL CONTROL NO 2 1 K17 16DB TN 2 4L TURBO COIL CONTROL NO 2 2 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPU...

Page 697: ...MP SWITCH OUTPUT 15 F11 20RD WT AUTO STICK IGNITION SWITCH OUTPUT OFF RUN START 15 G5 20DB WT EXCEPT AU TOSTICK FUSED IGNITION SWITCH OUTPUT RUN START 16 L161 18LG OR EXCEPT EXPORT LEFT TURN SIGNAL 17...

Page 698: ...UNCTION 1 K1 20DG RD MAP SIGNAL 2 K4 20BK LB SENSOR GROUND 3 K7 20OR 5 VOLT SUPPLY MANIFOLD TUNING VALVE SOLENOID RT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K201 20BR YL MTV RELAY OUTPUT 2 Z1 18BK GROUND O...

Page 699: ...20BK 2 4L TURBO GROUND 2 K199 18BR VT O2 1 2 HEATER CONTROL 3 K904 20DB DG O2 RETURN 4 K141 20TN WT O2 1 2 SIGNAL OXYGEN SENSOR CONNECTOR COMPONENT SIDE 4 WAY CAV CIRCUIT FUNCTION 1 GROUND 2 O2 HEATE...

Page 700: ...C O N N E C T O R P I N O U T S 365 CONNECTOR PINOUTS...

Page 701: ...O FUSED B 19 20 25A F61 16WT OR EXPORT FUSED B 21 20A A14 16RD WT FUSED B 22 10A A17 20RD BK FUSED B 23 15A F32 18PK DB FUSED B A C COMPRESSOR CLUTCH RELAY CAV CIRCUIT FUNCTION 29 C28 20DB OR 2 0L A C...

Page 702: ...N START 76 C116 12LG WT RAD FAN HIGH LOW FEED 77 C23 12DG RAD FAN CONTROL HIGH RELAY OUTPUT 78 Z1 12BK GROUND RADIATOR FAN HIGH RELAY 2 4L TURBO CAV CIRCUIT FUNCTION 69 C27 18DB PK HIGH SPEED RAD FAN...

Page 703: ...SWITCH SENSE 15 K55 18LB 2 4L TURBO TIP SOL CONTROL 16 17 K150 18DB YL 2 4L TURBO SURGE SOL CONTROL 18 Z12 18BK TN GROUND 19 20 G6 20GY OIL PRESSURE SIGNAL 21 22 K145 20BR OR AAT SIGNAL 23 K153 18LB 2...

Page 704: ...HEATER CONTROL 18 K99 18BR OR O2 1 1 HEATER CONTROL 19 K20 20DG GEN FIELD CONTROL 20 K2 20VT LG ECT SIGNAL 21 K22 20OR DB TP SIGNAL 22 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG...

Page 705: ...URBO SENSOR GROUND 2 18 19 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20PK BK EVAP PURGE CONTROL 21 T141 20YL RD CLUTCH INTERLOCK SWITCH SIGNAL 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 C20 2...

Page 706: ...LOW FEED 4 C25 12YL RAD FAN LOW RELAY OUTPUT SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 22VT YL PCI BUS 3 4 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 5 Z2 20BK LG G...

Page 707: ...B TIP SIGNAL 2 K167 20BR YL SENSOR GROUND 2 3 K6 18VT WT 5 VOLT SUPPLY THROTTLE INLET PRESSURE SOLENOID 2 4L TURBO BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K55 18LB TIP SOL CONTROL 2 F12 20DB RD FUSED IGNIT...

Page 708: ...2 WAY CAV CIRCUIT FUNCTION 1 E2 20OR PANEL LAMPS DRIVER 2 Z3 20BK OR GROUND VEHICLE SPEED SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K7 20OR 5 VOLT SUPPLY 2 K4 20BK LB SENSOR GROUND 3 G7 20WT OR VEHIC...

Page 709: ...10 0 SCHEMATIC DIAGRAMS 10 1 2004 PL 2 0L ENGINE S C H E M A T I C D I A G R A M S 375 SCHEMATIC DIAGRAMS...

Page 710: ...S C H E M A T I C D I A G R A M S 376 SCHEMATIC DIAGRAMS 10 1 2004 PL 2 0L ENGINE Continued...

Page 711: ...10 2 2004 SRT 4 2 4L ENGINE S C H E M A T I C D I A G R A M S 377 SCHEMATIC DIAGRAMS...

Page 712: ...S C H E M A T I C D I A G R A M S 378 SCHEMATIC DIAGRAMS 10 2 2004 SRT 4 2 4L ENGINE Continued...

Page 713: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 379 CHARTS AND GRAPHS...

Page 714: ...C H A R T S A N D G R A P H S 380 CHARTS AND GRAPHS...

Page 715: ...C H A R T S A N D G R A P H S 381 CHARTS AND GRAPHS...

Page 716: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Page 717: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 718: ...DTC DESCRIPTIONS 6 3 3 9 QUICK LEARN 18 3 3 10 CLUTCH VOLUMES 19 3 3 11 ELECTRONIC PINION FACTOR IF APPLICABLE 19 3 4 USING THE DRBIIIT 19 3 5 DRBIIIT ERROR MESSAGES 19 3 5 1 DRBIIIT DOES NOT POWER U...

Page 719: ...5 ENGINE SPEED SENSOR CIRCUIT 70 P0731 GEAR RATIO ERROR IN 1ST 72 P0732 GEAR RATIO ERROR IN 2ND 74 P0733 GEAR RATIO ERROR IN 3RD 77 P0734 GEAR RATIO ERROR IN 4TH 80 P0736 GEAR RATIO ERROR IN REVERSE 8...

Page 720: ...CATIONS 181 8 1 AUTOSTICK IF EQUIPPED 181 8 2 POWERTRAIN CONTROL MODULE 181 8 3 PRESSURE PORT 181 8 4 TRANSMISSION COMPONENT LOCATIONS 182 9 0 CONNECTOR PINOUTS 183 AUTOSTICK SWITCH NATURAL 4 WAY 183...

Page 721: ...tinued 11 0 CHARTS AND GRAPHS 199 11 1 TRANSMISSION RANGE SENSOR STATES 199 11 2 PRESSURE SWITCH STATES 199 11 3 SOLENOID APPLICATION CHART 200 11 4 SHIFT LEVER ERROR CODES 200 11 5 TRANSMISSION TEMPE...

Page 722: ...04 PL vehicles equipped with a 40 41TE tran saxle 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the 40 41TE electronic transaxle is done in six basic steps verification of complaint verification...

Page 723: ...te during normal operation However if a transmission is overfilled a transmis sion oil cooler becomes restricted or if a customer drives aggressively in low gear the calculated oil temperature will be...

Page 724: ...ing is a possible list of causes for a bus problem open or short to ground battery in PCI bus circuit internal failure of any module or component on the bus Each diagnostic trouble code is diagnosed b...

Page 725: ...t has not reset for 40 warm up cycles A warm up cycle is defined as sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a mi...

Page 726: ...after shift No No 37 P1775 Solenoid switch valve latched in TCC position No Yes 38 P0740 Torque converter clutch control circuit No Yes 41 P0750 LR Solenoid circuit Yes Yes 42 P0755 2 4 Solenoid circ...

Page 727: ...d values When the battery B is discon nected the memory is lost When the B is restored this memory loss is detected by the PCM The code is set and the learned values are initial ized to known constant...

Page 728: ...Name of code P1694 19 Bus Communication with Engine Module When monitored Continuously with key on Set condition If no PCI bus messages are re ceived from the Powertrain Control Module PCM for 10 sec...

Page 729: ...mode If the 2 4 pressure switch is identified as being closed in 1st or 3rd gear and was not identified as being closed in P or N then 2nd gear or 4th gear will be substituted for 1st or 3rd gear depe...

Page 730: ...condition 3 occurrences in one key start of an invalid PRNDL code which lasts for more than 0 1 second Theory of operation The C1 through C4 T1 T3 T41 and T42 sense circuits communicate the shift leve...

Page 731: ...ecked for out of range as well as intermittency excessive signal changes The engine controller transmits the throttle value via the Dual Port RAM Most engine controllers can synthesize the throttle va...

Page 732: ...s pump prime will return and normal operation will continue The pump should be replaced only after all other possible causes above have been checked and verified Name of code P1790 36 Fault Immediatel...

Page 733: ...switch error DTC is detected Set condition All four solenoids are tested for continuity continuously immediately upon start up and during vehicle operation For solenoids that are currently energized...

Page 734: ...h the following checks 1 When in gear if the gear ratio does not compare to a known gear ratio the corresponding in gear trouble code is set codes 50 through 54 2 An excessive change in input or outpu...

Page 735: ...rain failures which should be obvious upon disassembly If code P0944 35 is also set follow diagnostic procedure for code P0944 35 first Failed or slipping 2 4 clutch may also set code P0734 54 2 4 sea...

Page 736: ...applications is substituted while operating in the AutoStick gear selector position No Limp in mode occurs Possible causes Engine overheat refer to service manual for diagnosis and repair Transmission...

Page 737: ...ers up Set condition If the PCM powers up while in the Drive position and the vehicle is going above 32 Km h 20 MPH the code is set Theory of operation If a vehicle loses power to the PCM the vehicle...

Page 738: ...When monitored Every 7 milliseconds with the engine running and no loss of prime DTC set Set condition A temperature reading of 80 F is not reached in the specified period of time Theory of operation...

Page 739: ...d as a repair procedure unless directed by a repair or diagnostic procedure If the transmission system is exhibiting a problem that you think is caused by an invalid CVI you should try to relearn the...

Page 740: ...clutch volume should be between 24 and 70 Transmission effects These codes usually set with other DTC s which indicates an internal transmission problem Possible causes Clutch pack clearance out of sp...

Page 741: ...failed mechanical component but it can tell you that the control module and wiring are working properly and that the problem is internal The ignition switch should be in the lock position before atte...

Page 742: ...not use the test leads if the insulation is damaged or if metal is exposed To avoid electrical shock do not touch the test leads tips or the circuit being tested Choose the proper range and function f...

Page 743: ...he PCM monitors the Shift Lever Position SLP Sensor continuously If the shifter is incor rectly adjusted the PCM will sense a shift lever position that is not correct for the gear chosen by the driver...

Page 744: ...Generation Controller OBDII On Board Diagnostics OD Overdrive Clutch or Pressure Switch OSS Output Speed Sensor PCM Powertrain Control Module PEMCC Partial Electronically Modulated Converter Clutch P...

Page 745: ...NOTES 24...

Page 746: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 25...

Page 747: ...ymptom Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNE...

Page 748: ...ANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM...

Page 749: ...Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Rep...

Page 750: ...he DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connec...

Page 751: ...the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repa...

Page 752: ...the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and conne...

Page 753: ...e schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair...

Page 754: ...rforming any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagra...

Page 755: ...tion Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 NOTE Due to the integration of the Powertrain and Transmission Control Modules communication between the modules is internal Using the sche...

Page 756: ...symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide ins...

Page 757: ...aid the Technician in diagnosing shift quality complaints This DTC indicates that the transmission has been operating in the 9Overheat9 shift schedule which may generate a customer complaint The custo...

Page 758: ...se of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully cha...

Page 759: ...SINCE SET counter set at 0 All Yes Go To 4 No Go To 9 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT P...

Page 760: ...open or high resistance Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Remove the Transmission Control Relay No...

Page 761: ...articular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII...

Page 762: ...ERROR TEST ACTION APPLICABILITY 1 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possib...

Page 763: ...ng in park or neutral if a problem exists POSSIBLE CAUSES SHIFTER OUT OF ADJUSTMENT TRS T1 SENSE CIRCUIT OPEN TRS T3 SENSE CIRCUIT OPEN TRS T41 SENSE CIRCUIT OPEN TRS T42 SENSE CIRCUIT OPEN TRS T1 SEN...

Page 764: ...y flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine software NOTE Check for applicable TSB s related to the problem Perform this...

Page 765: ...ver Position Test pass All Yes Go To 5 No Go To 6 NOTE After completion of this procedure make sure to disconnect the Transmission Simulator Miller tool 8333 and FWD adaptor cable kit Miller tool 8333...

Page 766: ...ECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T1 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T1 Sense circuit...

Page 767: ...NG IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T3 Sense circuit Is the resistance below 5 0 ohms All Yes...

Page 768: ...NG IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T41 Sense circuit Is the resistance below 5 0 ohms All Yes...

Page 769: ...G IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T42 Sense circuit Is the resistance below 5 0 ohms All Yes...

Page 770: ...Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 21 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connect...

Page 771: ...evel per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to perf...

Page 772: ...the Transmission Simulator turn the Input Output switch to OFF With the DRBIIIt monitor the TRANS TEMP VOLTS while turning the Thermistor Voltage switch to all three positions on the Transmission Sim...

Page 773: ...circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found...

Page 774: ...s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the...

Page 775: ...r Do the readings on the Transmission Simulator match the DRBIIIt readings 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission...

Page 776: ...ANSMISSION VERIFICATION TEST VER 1 8 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wi...

Page 777: ...s perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics...

Page 778: ...smission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Note Check connectors Clean repair as necessary Ignition on engine not running With the Transmission Simulator...

Page 779: ...epair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL...

Page 780: ...this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems f...

Page 781: ...mission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a g...

Page 782: ...IIt reading 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission Solenoid TRS assembly per the Service Information Perform 41TE...

Page 783: ...NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom...

Page 784: ...s Go To 4 No Go To 5 4 If there are no possible causes remaining view repair All Repair Replace the Input Speed Sensor per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1...

Page 785: ...PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Input Speed Sensor Signal circuit Is the resistance Below 5 0 ohms All Yes Repair th...

Page 786: ...rm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground c...

Page 787: ...ion NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission sympt...

Page 788: ...ion With the DRBIIIt read the Input and Output RPM Does the Input RPM read 3000 and the Output RPM read 1250 within 50 RPM All Yes Go To 4 No Go To 5 4 If there are no possible causes remaining view r...

Page 789: ...POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Output Speed Sensor Signal circuit Is the resistance below 5 0 ohms...

Page 790: ...TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If...

Page 791: ...DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perf...

Page 792: ...ule per the Service Informa tion WITH THE DRBIIIt PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set the DTC are no...

Page 793: ...It read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagn...

Page 794: ...still sets Gear Ratio DTC check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the...

Page 795: ...symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 T...

Page 796: ...h Test and still sets Gear Ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and...

Page 797: ...internal transmission per the Service Information Check all of the components related to the UD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NG...

Page 798: ...symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 T...

Page 799: ...e vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission...

Page 800: ...r internal transmission per the Service Information Check all of the components related to the UD and OD clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NG...

Page 801: ...symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 T...

Page 802: ...cuits If the vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a T...

Page 803: ...internal transmission per the Service Information Check all of the components related to the OD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 41TE NG...

Page 804: ...RBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE D...

Page 805: ...h test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC...

Page 806: ...s low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt...

Page 807: ...essary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorte...

Page 808: ...then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repa...

Page 809: ...d the L R Solenoid LED on the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmi...

Page 810: ...CTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the LR...

Page 811: ...OR Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors speci...

Page 812: ...adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine...

Page 813: ...n the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure...

Page 814: ...HE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure t...

Page 815: ...rm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to t...

Page 816: ...e fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prio...

Page 817: ...ransmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch...

Page 818: ...HE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure t...

Page 819: ...rm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to t...

Page 820: ...Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmissi...

Page 821: ...the Transmission Simulator blink on and off All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly pe...

Page 822: ...Connect a jumper wire between the Fused B circuit and Transmission Control Relay Output circuit in the Transmission Control Relay connector Ignition on engine not running CAUTION DO NOT PROBE THE PCM...

Page 823: ...Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmissi...

Page 824: ...tion off to the lock position Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Install the Transmission Simulato...

Page 825: ...NNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Sw...

Page 826: ...ke sure to check for a short to ground Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular att...

Page 827: ...ily turns on element pressure to the clutch circuits that don t have pressure to identify the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES...

Page 828: ...iving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engine softwa...

Page 829: ...e and inspect the Valve Body per the Service Informa tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly Perfo...

Page 830: ...ONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Pressure Switch Sense circuit...

Page 831: ...rm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to t...

Page 832: ...OTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom di...

Page 833: ...the Transmission Simulator Did the state of the 2 4 Pressure Switch change while pressing the Pressure Switch Test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view re...

Page 834: ...CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of...

Page 835: ...erform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific...

Page 836: ...on element pressure to the clutch circuits that don t have pressure to identify the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES LOSS OF P...

Page 837: ...et by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Powertrain Control Module Some problems are corrected by software upgrades to the Transmission and Engin...

Page 838: ...Informa tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 41TE NGC TRAN...

Page 839: ...NG THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Pressure S...

Page 840: ...rm 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to t...

Page 841: ...ays perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnosti...

Page 842: ...e Switch test button Did the OD Pressure Switch state change while pressing the Pressure Switch test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repai...

Page 843: ...CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERF...

Page 844: ...NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this cir...

Page 845: ...ss of power to the Transmission portion of the PCM CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN C...

Page 846: ...of the Powertrain and Transmission Control Modules the transmission part of the PCM has its own specific power and ground circuits POSSIBLE CAUSES FUSED B CIRCUIT OPEN TRANSMISSION CONTROL RELAY OUTP...

Page 847: ...s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIIIt Check the STARTS SINCE SET counter for P0888 Note This counter only applies to the la...

Page 848: ...HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Transmission Control...

Page 849: ...GE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Connect a jumper wire between the Fused B circuit and the Transmission Control...

Page 850: ...is circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there...

Page 851: ...el is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRB...

Page 852: ...Is the voltage above 0 5 volt All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off to th...

Page 853: ...r a short to voltage Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 6 6 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention t...

Page 854: ...ssion problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to av...

Page 855: ...engine not running CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL...

Page 856: ...41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this...

Page 857: ...DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Fail...

Page 858: ...and adjust the fluid per the Service Information With the DRBIIIt perform a Battery Disconnect NOTE The Battery Disconnect must be done to re enable EMCC during an A C Clutch engagement NOTE The vehi...

Page 859: ...ce Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmi...

Page 860: ...ing and connectors specific to this circuit Wiggle the wiring while checking for shorted and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC w...

Page 861: ...there are no possible causes remaining view repair All Repair Replace the Transmission Oil Pump per the Service Information Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 140 TRANSMISSION NGC...

Page 862: ...INTERMITTENT WIRING AND CONNECTORS TEST ACTION APPLICABILITY 1 With the DRBIIIt Check the STARTS SINCE SET counter for P0951 Note This counter only applies to the last DTC set Is the Starts Since Set...

Page 863: ...NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSI...

Page 864: ...to this circuit Wiggle the wires while checking for shorts and open circuits With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problem...

Page 865: ...form diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With...

Page 866: ...diagnostics for both P0870 and P0845 to determine which switch is failing With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the DTC was set If there are no possible c...

Page 867: ...ny Engine Communication DTC s present All Yes Refer to the Powertrain category and perform the appropriate symptom Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt e...

Page 868: ...trollers on the bus on this vehicle If there is a bus problem refer to the Communication Category for diagnosis With the DRBIIIt check the EATX EVENT DATA to help identify the conditions in which the...

Page 869: ...and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Eng...

Page 870: ...5 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNE...

Page 871: ...rightness to that of a direct connection to the battery Does the test light illuminate brightly for all the ground circuits All Yes Go To 7 No Repair the Ground circuits for an open Perform 41TE NGC T...

Page 872: ...m diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect t...

Page 873: ...the Communications category and perform test for 9MIC MESSAGES NOT RECEIVED9 Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Ignition on engine not running With the DRBIIIt erase Tr...

Page 874: ...To 3 2 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view re...

Page 875: ...rvice Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any tran...

Page 876: ...iller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Ignition on engine not running With the Transmission Simulator turn the Pressure Switch selector switch to L R With the DRBIIIt mon...

Page 877: ...TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is the re...

Page 878: ...ntrol Relay Output circuit for an open Perform 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay pa...

Page 879: ...and adjust the fluid level per the Service Information NOTE Always perform diagnostics with a fully charged battery to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engi...

Page 880: ...possible causes remaining view repair All Repair Repair Internal Transmission as necessary Inspect the Solenoid Switch Valve per the Service Information and repair or replace as necessary If no probl...

Page 881: ...THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is...

Page 882: ...set this DTC are not present at this time Test Drive and verify if the transmission is launching in 2nd gear and or no TCC engagement With the DRBIIIt check the EATX EVENT DATA to help identify the c...

Page 883: ...lly matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom tes...

Page 884: ...quent torque reduction messages to the Powertrain Control Module PCM and does not receive a confirmation from the PCM Note Due to the integration of the Powertrain and Transmission Control Modules bus...

Page 885: ...ith the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record all DTC s and 1 Trip Failur...

Page 886: ...RIFICATION TEST VER 1 No Test Complete 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Input and Output Speed Sensor harness connectors Note Check conn...

Page 887: ...to avoid false symptoms With the DRBIIIt read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIIIt read Transmission DTC s Record a...

Page 888: ...the Service Information Make sure it is not overfilled NOTE Aggressive driving or driving in low for extended periods of time in AutoStick mode will set this DTC If there are no possible causes remai...

Page 889: ...ased before returning the vehicle to the customer Did the Backup Lamps go out when the TRS harness connector was disconnected All Yes Go To 3 No Go To 4 3 If there are no possible causes remaining vie...

Page 890: ...for shorted and open circuits View repair options All Repair Repair as necessary 3 Turn the ignition off to the lock position Remove the Starter Relay CAUTION Removal of the Starter Relay is to preve...

Page 891: ...ure to check for a short to ground 6 Turn the ignition off to the lock position Install the Transmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Remove the Back...

Page 892: ...ERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the P N Position Switch Sense circuit from the appropriate termin...

Page 893: ...NECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Did the resistance change from above 10 0 ohms to below 10 0 o...

Page 894: ...harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the AutoStickt Ground circuit at the AutoStickt harness connector Is the resistance above 5...

Page 895: ...witch harness connector Is the resistance above 5 0 ohms All Yes Repair the AutoStickt Downshift Sense circuit for an open No Go To 5 5 Ignition on engine not running With the DRBIIIt monitor the Auto...

Page 896: ...least three times pausing momentarily in each gear NOTE If all the PRNDL lights box individually then the error was cleared Shift into park and turn the ignition off to the lock position Ignition on...

Page 897: ...engine speed and listen to the noise NOTE THE RADIO MUST BE TURNED OFF Alternator noise can come through the speakers and be misinterpreted as Transmission Pump Whine This can happen even with the vo...

Page 898: ...ry to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorts and open circuits A...

Page 899: ...on Control Relay can cause the Trans mission Simulator to not Power up NOTE If the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapter kit 8333 1A will not power up make su...

Page 900: ...9 Road test the vehicle With the DRBIIIt monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 de...

Page 901: ...8 0 COMPONENT LOCATIONS 8 1 AUTOSTICK IF EQUIPPED 8 2 POWERTRAIN CONTROL MODULE 8 3 PRESSURE PORT C O M P O N E N T L O C A T I O N S 181 COMPONENT LOCATIONS...

Page 902: ...8 4 TRANSMISSION COMPONENT LOCATIONS C O M P O N E N T L O C A T I O N S 182 COMPONENT LOCATIONS...

Page 903: ...20RD WT IGNITION SWITCH OUTPUT OFF RUN START DATA LINK CONNECTOR WHITE 16 WAY CAV CIRCUIT FUNCTION 1 2 D25 20VT YL PCI BUS PCM 3 4 Z12 20BK TN GROUND 5 Z12 20BK TN GROUND 6 7 D21 20PK SCI TRANSMIT PCM...

Page 904: ...C O N N E C T O R P I N O U T S 184 CONNECTOR PINOUTS...

Page 905: ...10A F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 7 10A F20 20WT DAYTIME RUNNING LAMPS FUSED IGNITION SWITCH OUTPUT RUN 8 15A L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 9 10A F15 20DG WT FUSED IGNITION SW...

Page 906: ...C O N N E C T O R P I N O U T S 186 CONNECTOR PINOUTS...

Page 907: ...RUN 7 20A C1 14DG FUSED IGNITION SWITCH OUTPUT RUN 8 10A F25 20TN LG FUSED IGNITION SWITCH OUTPUT RUN 9 10A A81 20DG RD AUTOSTICK FUSED B 10 10A G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 11 15...

Page 908: ...PUT SPEED SENSOR SIGNAL LEFT BACKUP LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 L1 20VT BK BACKUP LAMP FEED OUTPUT SPEED SENSOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 20DB BK SPEED SENSOR...

Page 909: ...C O N N E C T O R P I N O U T S 189 CONNECTOR PINOUTS...

Page 910: ...B 15 15A A15 18RD PK 2 4L TURBO FUSED B 16 15A A200 18RD BR 2 0L RT FUSED B 17 20A A30 16RD WT 2 0L EATX FUSED B 18 10A F62 20RD 2 0L FUSED B 18 10A F62 20RD 2 0L FUSED B 18 15A F62 18RD 2 4L TURBO FU...

Page 911: ...SWITCH SENSE 15 K55 18LB 2 4L TURBO TIP SOL CONTROL 16 17 K150 18DB YL 2 4L TURBO SURGE SOL CONTROL 18 Z12 18BK TN GROUND 19 20 G6 20GY OIL PRESSURE SIGNAL 21 22 K145 20BR OR AAT SIGNAL 23 K153 18LB 2...

Page 912: ...HEATER CONTROL 18 K99 18BR OR O2 1 1 HEATER CONTROL 19 K20 20DG GEN FIELD CONTROL 20 K2 20VT LG ECT SIGNAL 21 K22 20OR DB TP SIGNAL 22 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG...

Page 913: ...ROL 18 K99 18BR OR O2 1 1 HEATER CONTROL 19 K20 18DG GEN FIELD CONTROL 20 K2 20TN BK ECT SIGNAL 21 K22 20OR DB TP SIGNAL 22 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG KS SIGNAL 2...

Page 914: ...URBO SENSOR GROUND 2 18 19 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20PK BK EVAP PURGE CONTROL 21 T141 20YL RD CLUTCH INTERLOCK SWITCH SIGNAL 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 C20 2...

Page 915: ...NTROL RELAY OUTPUT 20 21 22 T9 18OR BK OVERDRIVE PRESSURE SWITCH SENSE 23 24 25 26 27 T41 20BK WT TRS T41 SENSE 28 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 29 T50 18DG LOW REVERSE PRESSURE SWITCH SE...

Page 916: ...T PK TRANSMISSION TEMPERATURE SENSOR SIGNAL 5 6 L1 20VT BK BACKUP LAMP FEED 7 T1 20LG BK TRS T1 SENSE 8 T3 20VT TRS T3 SENSE 9 T42 20VT WT TRS T42 SENSE 10 T41 20BK WT TRS T41 SENSE TRANSMISSION SOLEN...

Page 917: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 197 SCHEMATIC DIAGRAMS...

Page 918: ...11 0 CHARTS AND GRAPHS 11 1 TRANSMISSION RANGE SENSOR STATES 11 2 PRESSURE SWITCH STATES C H A R T S A N D G R A P H S 199 CHARTS AND GRAPHS...

Page 919: ...11 3 SOLENOID APPLICATION CHART 11 4 SHIFT LEVER ERROR CODES C H A R T S A N D G R A P H S 200 CHARTS AND GRAPHS...

Page 920: ...11 5 TRANSMISSION TEMPERATURE SENSOR C H A R T S A N D G R A P H S 201 CHARTS AND GRAPHS...

Page 921: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Page 922: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

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Dodge 2004 Neon SRT4, Diagnostic Manual

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