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Dodge 2006 Sprinter, Manual

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INDEX

ABS INDICATOR . . . . . . . . . . . . . . . . . . . . . . . 8J-9

ACCELERATOR PEDAL POSITION SENSOR . . . 14-32
ACCESSORY SWITCH BEZEL . . . . . . . . . . . . 23-56

ADR INDICATOR

. . . . . . . . . . . . . . . . . . . . . 8J-10

AIR CLEANER ELEMENT

. . . . . . . . . . . . . . . . 9-21

AIR CLEANER HOUSING . . . . . . . . . . . . . . . . 9-21

AIR FILTER . . . . . . . . . . . . . . . . . . . . 24-45, 24-58
AIR OUTLET TEMPERATURE SENSOR

. . . . 24-16

AIR OUTLETS

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

AIRBAG CONTROL MODULE . . . . . . . . . . . . . 8O-8
AIRBAG INDICATOR . . . . . . . . . . . . . . . . . . . 8J-11

ALB CONTROLLER

. . . . . . . . . . . . . . . . . . . . 5-16

ALB LEVER

. . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

AMBIENT TEMPERATURE INDICATOR . . . . . 8J-11
AMBIENT TEMPERATURE SENSOR . . . . . . . 24-17

ANTENNA BODY & CABLE

. . . . . . . . . . . . . . 8A-1

ARMREST

. . . . . . . . . . . . . . . . . . . . . . . . . . 23-79

ASH RECEIVER

. . . . . . . . . . . . . . . . . . . . . . 23-57

ASH RECEIVER / CIGAR LIGHTER LAMP

UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-30

ASSIST HANDLE

. . . . . . . . . . . . . . . . . . . . . 23-71

AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1

AUTOMATIC TRANSMISSION NAG1 -

SERVICE INFORMATION . . . . . . . . . . . . . . . . 21-3

A - PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . 23-70
A / C CLUTCH RELAY

. . . . . . . . . . . . . . . . . 24-24

A / C COMPRESSOR CLUTCH COIL . . . . . . . 24-12
A / C COMPRESSOR CLUTCH

. . . . . . . . . . . . 24-8

A / C COMPRESSOR

. . . . . . . . . . . . . . . . . . 24-66

A / C CONDENSER COVER

. . . . . . . . . . . . . 24-52

A / C CONDENSER FAN RELAY

. . . . . . . . . . 24-26

A / C CONDENSER HOUSING

. . . . . . . . . . . 24-52

A / C CONDENSER . . . . . . . . . . . . . . . . . . . . 24-69
A / C CONTROL MODULE

. . . . . . . . . . . . . . 24-28

A / C DISCHARGE LINE . . . . . . . . . . . . . . . . 24-71
A / C EVAPORATOR COVER . . . . . . . . . . . . . 24-55
A / C EVAPORATOR HOUSING . . . . . . . . . . . 24-55
A / C EVAPORATOR . . . . . . . . . . . . . . . . . . . 24-72
A / C EXPANSION VALVE . . . . . . . . . . . . . . . 24-73
A / C HEATER CONTROL

. . . . . . . . . . . . . . . 24-12

A / C HIGH PRESSURE SWITCH

. . . . . . . . . 24-30

A / C LOW PRESSURE SWITCH

. . . . . . . . . 24-32

A / C PRESSURE TRANSDUCER

. . . . . . . . . 24-14

BACKLITE- BULKHEAD TRIM PANEL

. . . . . 23-84

BACKUP LAMP BULB

. . . . . . . . . . . . . . . . . . 8L-5

BASECOAT / CLEARCOAT FINISH

. . . . . . . . 23-77

BATTERY CABLES

. . . . . . . . . . . . . . . . . . . . 8F-14

BATTERY HOLDDOWN . . . . . . . . . . . . . . . . . 8F-13
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . 8F-1
BATTERY TRAY

. . . . . . . . . . . . . . . . . . . . . . 8F-16

BATTERY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-6

BEARINGS - DIFFERENTIAL CASE . . . . . . . . . 3-38
BEARING/ SEAL - AXLE HUB

. . . . . . . . . . . . 3-28

BEARING/ SEAL - AXLE

. . . . . . . . . . . . . . . . 3-24

BELT TENSIONERS

. . . . . . . . . . . . . . . . . . . . . 7-5

BLOWER MOTOR RELAY . . . . . . . . . . . . . . . 24-33
BLOWER MOTOR RESISTOR . . . . . . . . . . . . 24-17
BLOWER MOTOR SWITCH . . . . . . . . 24-19, 24-35
BLOWER MOTOR . . . . . . . . . . . . . . . 24-47, 24-58
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
BOOST PRESSURE SENSOR . . . . . . . . . . . . 14-33
BRAKE INDICATOR

. . . . . . . . . . . . . . . . . . . 8J-12

BRAKE LAMP SWITCH

. . . . . . . . . . . . . . . . . 8L-6

BRAKE LINES

. . . . . . . . . . . . . . . . . . . . . . . . . 5-8

BRAKE PADS / SHOES . . . . . . . . . . . . . . . . . . . 5-8
BRAKE WEAR INDICATOR . . . . . . . . . . . . . . 8J-13
BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . 5-30
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-2
BRAKE/ PARK LAMP BULB

. . . . . . . . . . . . . 8L-7

BULKHEAD TRIM PANEL . . . . . . . . . . . . . . . 23-72
BUMPERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
B - PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . 23-71
CABIN HEATER

. . . . . . . . . . . . . . . . . . . . . 24-104

CABLE TENSIONER

. . . . . . . . . . . . . . . . . . . . 5-24

CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
CAMSHAFT POSITION SENSOR . . . . . . . . . . 14-33
CAMSHAFT(S)

. . . . . . . . . . . . . . . . . . . . . . . . 9-28

CARGO LAMP SWITCH

. . . . . . . . . . . . . . . . 8L-31

CARGO/ DOME LAMP BULB . . . . . . . . . . . . 8L-30

CARGO/ DOME LAMP UNIT

. . . . . . . . . . . . 8L-31

CARPETS AND FLOOR MATS

. . . . . . . . . . . 23-72

CATALYTIC CONVERTER

. . . . . . . . . . . . . . . . 11-3

CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . 3-9
CENTER HIGH MOUNTED STOP LAMP BULB . . . 8L-8
CENTER HIGH MOUNTED STOP LAMP UN

. . . . . 8L-8

CENTER ROLLER ARM

. . . . . . . . . . . . . . . . 23-36

CENTER TRACK . . . . . . . . . . . . . . . . . . . . . . 23-37
CENTRAL TIMER MODULE

. . . . . . . . . . . . . . 8E-1

CHARGE AIR COOLER AND PLUMBING

. . . . 11-4

CHARGING INDICATOR

. . . . . . . . . . . . . . . . 8J-14

CHARGING SYSTEM

. . . . . . . . . . . . . . . . . . 8F-17

CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . 8R-11

CHECK

. . . . . . . . . . . . . . . . . . . . . . . 23-13, 23-23

CHIME/ BUZZER . . . . . . . . . . . . . . . . . . . . . . 8B-1
CIGAR LIGHTER OUTLET

. . . . . . . . . . . . 8W-97-1

CIRCUIT BREAKER

. . . . . . . . . . . . . . . . . 8W-97-2

CLEARANCE LAMP BULB

. . . . . . . . . . . . . . . 8L-9

CLEARANCE LAMP UNIT . . . . . . . . . . . . . . . . 8L-9

CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-14
CLOCKSPRING

. . . . . . . . . . . . . . . . . . . . . . 8O-12

CLUSTER BEZEL

. . . . . . . . . . . . . . . . . . . . . 23-55

COLUMN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4

CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . Intro.-9

CONNECTOR/GROUND/SPLICE

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1

CONTROLLER ANTILOCK BRAKE

. . . . . . . . . 8E-3

COOLANT LEVEL SENSOR . . . . . . . . . . . . . . . 7-13
COOLANT LOW INDICATOR . . . . . . . . . . . . . 8J-15

COOLANT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

COWL TRIM

. . . . . . . . . . . . . . . . . . . . . . . . 23-73

CRANKCASE VENTILATION BREATHER . . . . . . 25-2

CRANKCASE VENTILATION HEATER

. . . . . . . 25-1

CRANKSHAFT OIL SEAL - FRONT

. . . . . . . . . 9-42

CRANKSHAFT OIL SEAL - REAR

. . . . . . . . . . 9-41

CRANKSHAFT POSITION SENSOR . . . . . . . . 14-35
CRANKSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 9-39

CUP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . 23-57

CYLINDER HEAD COVER(S)

. . . . . . . . . . . . . 9-33

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 9-22
DAYTIME RUNNING LAMP RELAY

. . . . . . . 8L-10

DEFROSTER DUCTS

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

DIFFERENTIAL

. . . . . . . . . . . . . . . . . . . . . . . . 3-31

DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-9

DISC BRAKE CALIPER ADAPTER

. . . . . . . . . 5-14

DISC BRAKE CALIPERS . . . . . . . . . . . . . . . . . 5-11
DOME LAMP / INTRUSION SENSOR

BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33

DOME LAMP / INTRUSION SENSOR . . . . . . 8L-33
DOME/ READING LAMP BULB

. . . . . . . . . . 8L-32

DOME/ READING LAMP UNIT

. . . . . . . . . . 8L-32

DOOR GLASS

. . . . . . . . . . . . 23-15, 23-30, 23-46

DOOR JAMB SWITCH

. . . . . . . . . . . . . . . . . 8L-34

DOOR LOCK MOTOR . . . . . . . . . . . . . . . . . . . 8N-1
DOOR OPENING SEALS . . . . . . . . . . . . . . . . 23-90
DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-14, 23-23
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DRIVER AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-16
DRIVER HEATED SEAT SWITCH

. . . . . . . . . 8G-11

D - PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . 23-73
ELECTRIC COOLANT PUMP . . . . . . . . . . . . . 24-75
ELECTRICAL

. . . . . . . . . . . . . . . . . . . . . . . . . 5-30

ELECTROHYDRAULIC UNIT . . . . . . . . . . . . 21-105
ENGINE BLOCK HEATER

. . . . . . . . . . . . . . . . 7-14

ENGINE BLOCK

. . . . . . . . . . . . . . . . . . . . . . . 9-37

ENGINE CONTROL MODULE . . . . . . . . . . . . . 8E-3
ENGINE COOLANT TEMP SENSOR

. . . . . . . . 7-15

ENGINE COOLANT THERMOSTAT

. . . . . . . . . 7-16

ENGINE CRADLE CROSSMEMBER

. . . . . . . . 13-8

ENGINE TEMPERATURE GAUGE

. . . . . . . . . 8J-15

ENGINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

ENTRY / EXIT LAMP BULB

. . . . . . . . . . . . . 8L-34

ENTRY / EXIT LAMP UNIT . . . . . . . . . . . . . . 8L-35
ESP INDICATOR . . . . . . . . . . . . . . . . . . . . . . 8J-16
EVAPORATOR TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . . . . 24-19, 24-37

EXHAUST GAS RECIRCULATION . . . . . . . . . . 25-4
EXHAUST MANIFOLD

. . . . . . . . . . . . . . . . . . 9-68

EXHAUST PIPE

. . . . . . . . . . . . . . . . . . . . . . . 11-3

EXHAUST SYSTEM

. . . . . . . . . . . . . . . . . . . . 11-1

EXHAUST TUBE . . . . . . . . . . . . . . . . . . . . . 24-105
EXTERIOR HANDLE

. . . . . . . 23-16, 23-31, 23-35

FAN DRIVE VISCOUS CLUTCH

. . . . . . . . . . . 7-17

FASTENER IDENTIFICATION

. . . . . . . . . . . Intro.-3

FASTENER USAGE . . . . . . . . . . . . . . . . . . . Intro.-6
FINESSE SANDING/ BUFFING & POLISH

. . 23-78

FLOOR DISTRIBUTION DUCTS

. . . . . . . . . . 24-47

FLUID AND FILTER

. . . . . . . . . . . . . . . . . . 21-131

FLUID CAPACITIES

. . . . . . . . . . . . . . . . . . . . . 0-5

FLUID COOLER TUBE

. . . . . . . . . . . . . . . . . 19-13

FLUID FILL / CHECK LOCATIONS

. . . . . . . . . . 0-5

FLUID RESERVOIR

. . . . . . . . . . . . . . . . . . . . 5-15

FLUID TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43

FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . 8L-10

FOG LAMP RELAY . . . . . . . . . . . . . . . . . . . . 8L-11

FOG LAMP SWITCH . . . . . . . . . . . . . . . . . . . 8L-12

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
FREEWHEELING CLUTCH

. . . . . . . . . . . . . 21-135

FRONT BUMPER - STEPS

. . . . . . . . . . . . . . . 13-2

FRONT DOOR INNER BELT

WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-90

FRONT DOOR OUTER BELT

WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-90

FRONT FASCIA

. . . . . . . . . . . . . . . . . . . . . . . 13-2

FRONT LAMP UNIT

. . . . . . . . . . . . . . . . . . . 8L-13

FRONT POSITION LAMP BULB

. . . . . . . . . . 8L-14

FRONT SEAT BELT & RETRACTOR

. . . . . . . 8O-20

FRONT SEAT BELT BUCKLE

. . . . . . . . . . . . 8O-23

FRONT TURN / PARK / SIDE MARKER

LAMP BULB. . . . . . . . . . . . . . . . . . . . . . . . . 8L-15

FRONT WHEEL SPEED SENSOR

. . . . . . . . . . 5-31

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . 14-6
FUEL DOSING PUMP . . . . . . . . . . . . . . . . . 24-106

FUEL DRAIN TUBES

. . . . . . . . . . . . . . . . . . 14-10

FUEL FILL DOOR . . . . . . . . . . . . . . . . . . . . . 23-48
FUEL FILTER CLOGGED INDICATOR

. . . . . . 8J-17

FUEL FILTER

. . . . . . . . . . . . . . . . . . . . . . . . 14-10

FUEL GAUGE

. . . . . . . . . . . . . . . . . . . . . . . . 8J-17

FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . 14-35
FUEL LEVEL SENDING UNIT / SENSOR . . . . 14-28

FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . 24-107
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
FUEL PRESSURE SENSOR

. . . . . . . . . . . . . 14-39

FUEL PRESSURE SOLENOID . . . . . . . . . . . . 14-40

FUEL PUMP MODULE . . . . . . . . . . . . . . . . . 14-18
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
FUEL QUANTITY CONTROL VALVE

. . . . . . . 14-21

FUEL RAIL PRESSURE SENSOR

. . . . . . . . . 14-12

FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
FUEL SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . 14-1

FUEL TANK

. . . . . . . . . . . . . . . . . . . . . . . . . 14-23

FUEL TEMPERATURE SENSOR

. . . . . . . . . . 14-42

FUSE BLOCK #1

. . . . . . . . . . . . . . . . . . . 8W-97-2

FUSE BLOCK #2

. . . . . . . . . . . . . . . . . . . 8W-97-3

GAP AND FLUSH . . . . . . . . . . . . . . . . . . . . . 23-91
GEAR SELECTOR INDICATOR

. . . . . . . . . . . 8J-18

GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
GEARSHIFT CABLE

. . . . . . . . . . . . . . . . . . 21-138

GEAR - PINION / RING

. . . . . . . . . . . . . . . . . 3-41

GENERATOR DECOUPLER PULLEY

. . . . . . . 8F-19

GENERATOR

. . . . . . . . . . . . . . . . . . . . . . . . 8F-18

GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 23-58
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . 8I-1
GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-1
GRILLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-48

HCU (HYDRAULIC CONTROL UNIT)

. . . . . . . 5-36

HEADLAMP LEVELING MOTOR . . . . . . . . . . 8L-16
HEADLAMP LEVELING SWITCH

. . . . . . . . . 8L-17

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-73
HEADREST . . . . . . . . . . . . . . . . . . . . . . . . . . 23-79
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . 8G-1
HEATED MIRRORS

. . . . . . . . . . . . . . . . . . . . 8G-9

HEATED SEAT ELEMENT . . . . . . . . . . . . . . . 8G-12
HEATED SEAT RELAY

. . . . . . . . . . . . . . . . . 8G-12

HEATED SEAT SENSOR . . . . . . . . . . . . . . . . 8G-13
HEATED SEATS

. . . . . . . . . . . . . . . . . . . . . . 8G-10

HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-76
HEATER UNIT

. . . . . . . . . . . . . . . . . . . . . . 24-110

HEATING & AIR CONDITIONING

. . . . . . . . . . 24-1

HIGH BEAM HEADLAMP BULB

. . . . . . . . . . 8L-18

HIGH BEAM INDICATOR

. . . . . . . . . . . . . . . 8J-19

HINGE . . . . . . . . . . . . . . . . . . 23-17, 23-32, 23-51
HOISTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5

HOLDING CLUTCH B1

. . . . . . . . . . . . . . . . 21-143

HOLDING CLUTCH B2

. . . . . . . . . . . . . . . . 21-148

HOLDING CLUTCHES . . . . . . . . . . . . . . . . . 21-141
HOOD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-51

HORN SWITCH

. . . . . . . . . . . . . . . . . . . . . . . 8H-1

HORN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-1

HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-14
HUB / BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2-4
HVAC HOUSING . . . . . . . . . . . . . . . . . . . . . . 24-48

HYDRAULIC/ MECHANICAL

. . . . . . . . . . . . . . 5-5

IGNITION CONTROL

. . . . . . . . . . . . . . . . . . . . 8I-1

INLET HOSE . . . . . . . . . . . . . . . . . . . . . . . . 24-111
INPUT CLUTCH K1

. . . . . . . . . . . . . . . . . . . 21-92

INPUT CLUTCH K2

. . . . . . . . . . . . . . . . . . . 21-97

INPUT CLUTCH K3

. . . . . . . . . . . . . . . . . . 21-102

INPUT CLUTCHES

. . . . . . . . . . . . . . . . . . . . 21-90

INPUT SPEED SENSORS . . . . . . . . . . . . . . 21-153

VA

INDEX

1

Description

Group-Page

Description

Group-Page

Description

Group-Page

Summary of Contents for 2006 Sprinter

Page 1: ...CABIN HEATER MODULE CHM HEATER BOOSTER MODULE HBM 7 3 3 2 1 SYSTEM DESCRIPTION 7 3 3 2 2 VENTING THE HEATER S EXHAUST 8 3 3 2 3 SYSTEM DIAGNOSTICS 8 3 4 INSTRUMENT CLUSTER 9 3 5 POWER DOOR LOCKS RKE...

Page 2: ...PEN 33 DRIVER SQUIB 1 CIRCUIT SHORT 36 DRIVER SQUIB 1 SHORT TO BATTERY 39 DRIVER SQUIB 1 SHORT TO GROUND 42 LOSS OF IGNITION RUN START 45 PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN 47 PASSENGER SEAT B...

Page 3: ...26 HEATING A C A C COMPRESSOR CONTROL HIGH OR OPEN ACTIVE 128 A C COMPRESSOR CONTROL HIGH OR OPEN STORED 130 A C COMPRESSOR CONTROL SHORTED LOW STORED 130 AIR OUTLET TEMP SENSOR HIGH OR OPEN STORED 13...

Page 4: ...EN ACTIVE 171 REFRIG PRESS SENSOR SHORTED LOW ACTIVE 173 WATER CYCLE VALVE CONTROL HIGH OR OPEN ACTIVE 175 WATER CYCLE VALVE CONTROL SHORTED LOW ACTIVE 177 INSTRUMENT CLUSTER AMBIENT TEMP SENSOR OPEN...

Page 5: ...SECURITY SYSTEM INTERFACE FAILURE SSM 233 SIREN CIRCUIT OPEN SHORTED TO GROUND 235 SIREN INTERNAL FAILURE 237 SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND 238 WINDSHIELD WIPER WASHER CHECKING THE RAIN...

Page 6: ...NTILOCK BRAKE 262 CYLINDER LOCK SWITCH DRIVER 263 DATA LINK CONNECTOR BLACK 263 DOOR LOCK MOTOR AJAR SWITCH ASSEMBLY DRIVER C1 263 DOOR LOCK MOTOR AJAR SWITCH ASSEMBLY DRIVER C2 263 DOOR LOCK MOTOR AJ...

Page 7: ...TIONAL EQUIPMENT RELAY RELAY BLOCK 284 REMOTE KEYLESS ENTRY ANTENNA 284 SEAT BELT SWITCH 284 SEAT BELT TENSIONER DRIVER YELLOW 285 SEAT BELT TENSIONER PASSENGER YELLOW 285 SECURITY SYSTEM MODULE C1 BR...

Page 8: ...TCH AND MISCELLANEOUS CIRCUITS 298 10 6 VEHICLE THEFT SECURITY SYSTEM 299 10 7 RAIN SENSOR SYSTEM 300 11 0 CHARTS AND GRAPHS 301 11 1 EVAP TEMP SENSOR RESISTANCE TO TEMPERATURE SPECIFICATIONS 301 11 2...

Page 9: ...please fill out the form in the back of this book and mail it back to us 1 1 SYSTEM COVERAGE This diagnostic procedures manual covers all Sprinter vehicles 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagn...

Page 10: ...ion As part of the system test the ACM illuminates the Warning Indicator on for 4 0 second bulb test After the lamp check if the indicator turns off it means that the ACM has checked the system and fo...

Page 11: ...proper electrical signal the passenger airbag inflator discharges the gas di rectly into the cushion The airbag module cannot be repaired and must be replaced if deployed or in any way damaged WARNING...

Page 12: ...uble code indicates an on going malfunction This means that the defect is currently there every time the airbag control mod ule checks that circuit or component Some DTCs Internal Module and squib DTC...

Page 13: ...odule communication only and is no way connected to the K Lines The following modules that use the CAN Bus on this vehicle are Automatic Temperature Control ATC Controller Antilock Brake CAB Engine Co...

Page 14: ...o 104 F An implausible tem perature value indicates that the Interior Temper ature Sensor is bad The repair in this case would be to replace the ATC Module since the sensor is integral to the module E...

Page 15: ...UST WHEN OPERATING THE HEATER REFER TO VENTING THE HEATER S EXHAUST BELOW FOR PROPER EXHAUST VENTING INSTRUCTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH WARNING AL...

Page 16: ...ater s exhaust pipe 3 3 2 3 SYSTEM DIAGNOSTICS CAUTION Always Perform The Heater Pre Test In The Diagnostic Procedures Prior To Performing Any Other Test For The Test Result To Be Valid Fault detectio...

Page 17: ...uses yellow LED s and can be adjusted electronically to daylight and darkness The instrument cluster includes a warning buzzer which sounds in addition to a warning light in some cases when The headli...

Page 18: ...it is possible that the DTC could be set and therefore the door locks would be inop erable Whenever the door locks are not opera tional use the DRBIII and check DTC s If the code ACM has unlocked the...

Page 19: ...y be the result or a faulty cable or vehicle wiring 3 10 DISPLA Y IS NOT VISIBLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition 4 0 DIS...

Page 20: ...ency Generated 0 10 kHz Temperature 58 1100 F 50 600 C Ohms cannot be measured if voltage is present Ohms can be measured only on a non powered circuit Voltage between any terminal and ground must not...

Page 21: ...ake system ACM airbag control module ACT actuator AECM airbag electronic control module ACM ASDM airbag system diagnostic module ACM ATC automatic temperature control CAB controller antilock bake CAN...

Page 22: ...NOTES 14...

Page 23: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15...

Page 24: ...AG WARNING LAMP DRIVER CIRCUIT SHORTED TO BATTERY CLUSTER SRS INDICATOR SHORTED TO BATTERY CLUSTER SRS INDICATOR SHORTED TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTIO...

Page 25: ...l Yes Go To 3 No Go To 4 3 Turn the ignition off Disconnect the Instrument Cluster connectors NOTE Check connectors Clean and repair as necessary Measure the voltage of the Airbag Warning Indicator Dr...

Page 26: ...a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII m...

Page 27: ...OPEN ACM AIRBAG WARNING LAMP DRIVER CIRCUIT OPEN OPEN AIRBAG WARNING INDICATOR DRIVER ACM WARNING INDICATOR CIRCUIT LOW AIRBAG WARNING INDICATOR DRIVER SHORT TO GROUND STORED CODE OR INTERMITTENT CON...

Page 28: ...nition on Does the SRS indicator illuminate All Yes Go To 4 No Replace the Instrument Cluster in accordance with Service In structions Perform AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONA...

Page 29: ...TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors...

Page 30: ...s Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 2 When Monitored With the ignition on the module on board diagnostics continuously performs interna...

Page 31: ...TH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING TO AVOID PERSONAL INJURY OR DEATH IF THE MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED Select the a...

Page 32: ...w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the ba...

Page 33: ...Off switch read the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION...

Page 34: ...ll be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Batter...

Page 35: ...d with Passenger Airbag On Off switch read the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY O...

Page 36: ...ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Batte...

Page 37: ...Line 2 circuits between the Driver SBT connector and ground Is there any voltage present All Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuit short to battery Perform AIRBAG VERIFICATION...

Page 38: ...ossible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII moni...

Page 39: ...w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Ba...

Page 40: ...read the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONN...

Page 41: ...SPRING SQUIB 1 CIRCUIT OPEN DRIVER SQUIB 1 LINE 1 OR LINE 2 CIRCUITS OPEN ACM DRIVER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the...

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

Page 43: ...Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possibl...

Page 44: ...SQUIB 1 CIRCUITS SHORT DRIVER AIRBAG SQUIB 1 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB LINE 1 SHORT TO LINE 2 STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn t...

Page 45: ...bag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL IN...

Page 46: ...Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possibl...

Page 47: ...QUIB 1 SHORT TO BATTERY DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 1 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn...

Page 48: ...B 1 SHORT TO BATTERY All Yes Go To 3 No Replace the Driver Airbag in accordance with the Service Infor mation Perform AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN TH...

Page 49: ...ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE P...

Page 50: ...IVER SQUIB 1 SHORT TO GROUND DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1...

Page 51: ...g connector s Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY O...

Page 52: ...Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible...

Page 53: ...s fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM DETERMINE ACTIVE OR STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC...

Page 54: ...Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work...

Page 55: ...AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be t...

Page 56: ...bag On Off switch read the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGN...

Page 57: ...ules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and th...

Page 58: ...the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT T...

Page 59: ...modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and...

Page 60: ...he Passenger SBT Line 1 and Line 2 circuits between the Passenger Seat Belt Tensioner connector and ground Is there any voltage on either circuit All Yes Repair the Passenger Seat Belt Tensioner Line...

Page 61: ...sible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monito...

Page 62: ...d ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned o...

Page 63: ...ff switch read the DTC s in all switch positions If any ACTIVE codes are present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION O...

Page 64: ...IB 1 CIRCUIT OPEN PAB SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PAB SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE...

Page 65: ...E IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control module connector s NOTE Chec...

Page 66: ...ng a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBII...

Page 67: ...CIRCUIT SHORT PAB SQUIB 1 LINE 1 SHORT TO LINE 2 ACM PAB SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure t...

Page 68: ...NJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module...

Page 69: ...ng a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBII...

Page 70: ...TTERY PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PAB SQUIB 1 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on...

Page 71: ...SCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean...

Page 72: ...a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII...

Page 73: ...SHORT TO GROUND PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO GROUND ACM PAB SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on...

Page 74: ...OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module conne...

Page 75: ...g a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII...

Page 76: ...TY 1 Erase all DTCs Cycle the ignition switch OFF then to ON With the DRBIII read the active and stored DTCs Are all DTC s erased All Yes With the DRBIII perform Airbag Control Module initialization t...

Page 77: ...st ventilation system do not attach the exhaust ventilation hose directly to the heater s exhaust pipe Too much suction can prevent heater operation When using a powered exhaust ventilation system aff...

Page 78: ...Cabin Heater or Heater Booster is switched off Set the blend control to the max heat position and the mode control to the floor position With the DRBIII record and erase the Cabin Heater or Heater Bo...

Page 79: ...E INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH Turn the ignition on With the DRBIII read Automatic Temperature Control DTCs Are any DTCs present All Yes Refer to Heating A C information for the...

Page 80: ...EMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH CAUTION DO NOT PERFORM THIS TEST UNLESS DIRECTED...

Page 81: ...NSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH Turn the ignition off Reconnect the Cabin Heater harness connector Install a substitute relay in place of the Circulation Pump Relay Turn the ignitio...

Page 82: ...nition on Verify that the Cabin Heater is switched off Set the blend control to the max heat position and the mode control to the floor position With the DRBIII erase the Cabin Heater Module s DTCs St...

Page 83: ...N TEST VER 1 No Go To 3 3 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE TO FOLLOW THE...

Page 84: ...E TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH WARNING ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE IN...

Page 85: ...UST WHEN OPERATING THE HEATER FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH WARNING ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REP...

Page 86: ...THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH WARNING ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS C...

Page 87: ...as specified All Yes Replace the Dosing Pump in accordance with the Service Infor mation Perform HEATER VERIFICATION TEST VER 1 No Go To 3 3 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT D...

Page 88: ...f NOTE Check connectors Clean repair as necessary Disconnect the Cabin Heater or Heater Booster harness connector NOTE Check connectors Clean repair as necessary Disconnect the Dosing Pump harness con...

Page 89: ...as necessary Disconnect the Dosing Pump harness connector Turn the ignition on Verify that the Cabin Heater or Heater Booster is switched off Set the blend control to the max heat position and the mo...

Page 90: ...it Perform HEATER VERIFICATION TEST VER 1 No Go To 3 3 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE...

Page 91: ...TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH CAUTION DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE...

Page 92: ...CAN RESULT IN PERSONAL INJURY OR DEATH Turn the ignition off Reconnect the Cabin Heater harness connector Install a substitute relay in place of the Fan Stage 1 Relay Turn the ignition on Verify that...

Page 93: ...ion on Verify that the Cabin Heater is switched off Set the blend control to the max heat position and the mode control to the floor position With the DRBIII erase the Cabin Heater Module s DTCs Start...

Page 94: ...ST VER 1 No Go To 3 3 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE TO FOLLOW THESE I...

Page 95: ...SEMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH CAUTION DO NOT PERFORM THIS TEST UNLESS DIRECTE...

Page 96: ...ion This DTC will set if the Flame Sensor s resistance is not within the expected parameters NO START When Monitored After heater activation Set Condition This DTC will set if the Flame Sensor s resis...

Page 97: ...EATER VERIFICATION TEST VER 1 2 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE TO FOLL...

Page 98: ...wise proceed to the next step of this procedure With the DRBIII in System Tests select Dosing Pump OUTPUT Allow the Dosing Pump Output test to run the full 90 seconds When the Dosing Pump Output test...

Page 99: ...in the expected parameters FLAME SENSOR SHORTED When Monitored During heater activation and operation Set Condition This DTC will set if the Flame Sensor s resistance is not within the expected parame...

Page 100: ...OMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH CAUTION DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY THE HEATER PRE TEST ALWAYS...

Page 101: ...system is in a steady state of operation Set Condition This DTC will set if the Temperature Sensor s resistance or Overheating Sensor s resistance is not within the expected parameters coolant tempera...

Page 102: ...VER 1 No Go To 2 2 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE TO FOLLOW THESE INST...

Page 103: ...If the heater s control unit detects a reoccurrence of a stored fault it w ill overw rite that fault s DTC w ith the most recent occurrence Turn the ignition on Verify that the Cabin Heater or Heater...

Page 104: ...THE HEATER ASSEMBLY TO COOL BEFORE PER FORMING A COMPONENT INSPECTION REPAIR REPLACEMENT FAIL URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH CAUTION DO NOT PERFORM THIS TEST...

Page 105: ...ING SENSOR TEST ACTION APPLICABILITY 1 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE...

Page 106: ...CTION APPLICABILITY 1 WARNING NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES ALWAYS VENT THE EXHAUST WHEN OPERATING THE HEATER FAILURE TO FOLLOW THESE I...

Page 107: ...spect the vehicle s battery terminals cable terminals and cables for corrosion and damage in accordance with the Service Information Test the vehicle s battery in accordance with the Service Informati...

Page 108: ...IN PERSONAL INJURY OR DEATH Turn the ignition on With the DRBIII in Sensors record the Cabin Heater s or Heater Booster s Operating Voltage NOTE Check connectors Clean repair as necessary Disconnect...

Page 109: ...ne to idle NOTE Do not disconnect the vehicle s battery or the heater s main pow er supply w hile the heater is in operation or in run dow n mode Failure to follow these instructions can result in exc...

Page 110: ...TTERY AND WAIT TWO MINUTES BEFORE PROCEEDING FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH Disconnect the ACM harness connector Disconnect the DRBIII from the DLC Measure the resistance betw...

Page 111: ...nnect the DRBIII from the DLC Measure the resistance of the K ACM circuit between the ACM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace the Airbag Control Module in accordance...

Page 112: ...Go To 2 2 Turn the ignition off Disconnect the Automatic Temperature Control harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K IC ATC HBM CHM circu...

Page 113: ...est light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly with all the above modules disconnected All Yes Repair t...

Page 114: ...2 Turn the ignition off Disconnect the Cabin Heater Module harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the K IC ATC HBM CHM circuit Is the resistance...

Page 115: ...he test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly with all the above modules disconnected All Yes Repa...

Page 116: ...isolate an open or shorted condition Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the CTM harness connectors Disconnect the DRBIII from the D...

Page 117: ...ightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K CTM SSM circuit for a short to voltage Perform BODY VERIFICATIO...

Page 118: ...tion to help isolate an open or shorted condition Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the CAB harness connector Disconnect the DRBIII...

Page 119: ...pare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K ABS Shifter Assembly circuit for a short to voltage Perform ABS VERIFICAT...

Page 120: ...R 2 No Go To 2 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K ECM circuit Is the resistance below 5 0...

Page 121: ...circuit between the ECM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIF...

Page 122: ...2 2 Turn the ignition off Disconnect the Heater Booster Module harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the K IC ATC HBM CHM circuit Is the resist...

Page 123: ...e test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly with all the above modules disconnected All Yes Repai...

Page 124: ...Turn the ignition off Disconnect the Instrument Cluster harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K IC ATC HBM CHM circuit Is the resistance b...

Page 125: ...t light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly with all the above modules disconnected All Yes Repair the...

Page 126: ...shorted condition Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Radio harness connectors Disconnect the DRBIII from the DLC Measure the re...

Page 127: ...rightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K TCM RADIO circuit for a short to voltage Perform BODY VERIFICA...

Page 128: ...help isolate an open or shorted condition Repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the SSM harness connectors Disconnect the DRBIII from t...

Page 129: ...htly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K CTM SSM circuit for a short to voltage Perform BODY VERIFICATION...

Page 130: ...VER 1 No Go To 2 2 Turn the ignition off Disconnect the SKREEM harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the K SKREEM circuit Is the resistance bel...

Page 131: ...between the SKREEM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace and program the Sentry Key Remote Entry Module in accordance with the Service Information Perform BODY VERIFIC...

Page 132: ...rted condition Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Shifter Assembly harness connector Disconnect the DRBIII from the...

Page 133: ...at of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K ABS Shifter Assembly circuit for a short to voltage Perform NAG1 TRANSMISSION VERIFICATION TEST VE...

Page 134: ...ate an open or shorted condition Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the TCM harness connectors Disconnect the DRBIII fr...

Page 135: ...hat of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K TCM RADIO circuit for a short to voltage Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Rep...

Page 136: ...ompressor Clutch harness connector Turn the ignition on Measure the voltage of the A C Compressor Clutch Control circuit Is the voltage above 0 2 volts All Yes Repair the A C Compressor Clutch Control...

Page 137: ...ch Control circuit between the Automatic Temperature Control ATC C1 harness connector and the A C Compres sor Clutch harness connector Is the resistance below 5 0 ohms All Yes Replace the Automatic Te...

Page 138: ...ION WITH IC STORED RECIRC AIR SOLENOID CONTROL HIGH OR OPEN STORED RECIRC AIR SOLENOID CONTROL SHORTED LOW STORED REFRIG PRESS SENSOR HIGH OR OPEN STORED REFRIG PRESS SENSOR SHORTED LOW STORED WATER C...

Page 139: ...ng switch On With the DRBIII verify that the ambient temperature is above 59 F 15 C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature is above 36 5 F 2 5 C and...

Page 140: ...Clutch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the A C Compressor Clutch harness connector Disconnect the Automat...

Page 141: ...d the Sensor Ground circuit in the Automatic Temperature Control C1 harness connector Is the resistance below 10k ohms All Yes Repair the A C Compressor Clutch Control circuit for a short to the Senso...

Page 142: ...ess connector Disconnect the Automatic Temperature Control ATC C1 harness connector Turn the ignition on Measure the voltage of the Air Outlet Temperature Sensor Signal circuit Is the voltage above 0...

Page 143: ...an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Check connectors Clean repair as necessary Disconnect the Automatic Temperature Control ATC C1 harness connector Disconnect th...

Page 144: ...SENSOR HIGH OR OPEN All Yes Replace the Air Outlet Temperature Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the...

Page 145: ...perature Sensor Signal circuit and the Sensor Ground circuit Is the resistance below 10k ohms All Yes Repair the Air Outlet Temperature Sensor Signal circuit for a short to the Sensor Ground circuit P...

Page 146: ...g to run the ATC Function Test ATC FUNCTION TEST FAILURE When Monitored With the engine running Set Condition This DTC will set if specific operating criteria are not met when attempting to run the AT...

Page 147: ...eria are met If the criteria cannot be met proceed to Test 2 of this procedure Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIII read Automatic Temperature Control DTCs Does...

Page 148: ...ion off NOTE Check connectors Clean repair as necessary Remove the A C Auxiliary Fan Relay from the relay center Measure the resistance between ground and the Ground circuit in the relay center A C Au...

Page 149: ...wait 5 seconds then turn the ignition on With the DRBIII read Automatic Temperature Control DTCs Does the DRBIII display AUX FAN RELAY CONTROL HIGH OR OPEN All Yes Replace the Automatic Temperature C...

Page 150: ...C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature is above 36 5 F 2 5 C and the coolant temperature is above 158 F 70 C With the DRBIII in Automatic Temperat...

Page 151: ...1 No Go To 4 4 Turn the ignition off Remove the A C Auxiliary Fan Relay from the relay center Disconnect the Automatic Temperature Control ATC C1 harness connector Measure the resistance between the...

Page 152: ...connector Turn the ignition on Measure the voltage of each of the Blower Motor Driver circuits Low M1 M2 High Is the voltage above 0 2 volts on any of the circuits All Yes Repair each circuit with vol...

Page 153: ...and cavity 3 The approximate resistance should be 0 8 ohms Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 4 The approximate resistance should be 1 6 ohms Is the resist...

Page 154: ...2 and 24 bar the evaporator temperature is above 36 5 F 2 5 C and the coolant temperature is above 158 F 70 C With the DRBIII in Automatic Temperature Control ATC select System Tests and select ATC F...

Page 155: ...the Blower Motor Fuse and replace it if necessary Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Blower Motor Resistor Block harness connector Measure the resi...

Page 156: ...Heater or Heater Booster switch on The test light should illuminate brightly Does the test light function as specified All Yes Light Only Illuminates w Switch On Replace the Cabin Heater Assembly or t...

Page 157: ...ntrol circuit between the Automatic Temperature Control ATC C1 harness connector and the Cabin Heater or Heater Booster harness connector as applicable Is the resistance below 5 0 ohms All Yes Replace...

Page 158: ...is above 59 F 15 C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature is above 36 5 F 2 5 C and the coolant temperature is above 158 F 70 C With the DRBIII in A...

Page 159: ...1 No Go To 4 4 Turn the ignition off Disconnect the Cabin Heater or Heater Booster harness connector Disconnect the Automatic Temperature Control ATC C1 harness connector Measure the resistance betwe...

Page 160: ...e Press the Residual Engine Heat Utilization REST switch on The test light should illuminate brightly Does the test light function as specified All Yes Light Only Illuminates With REST On Replace the...

Page 161: ...5 0 ohms All Yes Go To 4 No Repair the Circulation Pump Control circuit for an open Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off NOTE Check connectors Clean repair as necessary Discon...

Page 162: ...nnect the Circulation Pump harness connector Disconnect the Automatic Temperature Control ATC C1 harness connector Measure the resistance between the Circulation Pump Control circuit and the Ground ci...

Page 163: ...er wire between ground and Circulation Pump cavity 1 Does the Circulation Pump run All Yes Replace the Automatic Temperature Control ATC in accordance with the Service Information Perform BODY VERIFIC...

Page 164: ...s connector Disconnect the Automatic Temperature Control ATC C1 harness connector Turn the ignition on Measure the voltage of the Evaporator Temperature Sensor Signal circuit Is the voltage above 0 2...

Page 165: ...or an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off NOTE Check connectors Clean repair as necessary Disconnect the Automatic Temperature Control ATC C1 harness connector Disconnect...

Page 166: ...Yes Replace the Evaporator Temperature Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Automatic Temperature Co...

Page 167: ...Temperature Sensor Signal circuit and the Sensor Ground circuit Is the resistance below 10k ohms All Yes Repair the Evaporator Temperature Sensor Signal circuit for a short to the Sensor Ground circui...

Page 168: ...MODULE SHORT TO VOLTAGE CAN CIRCUITS SHORTED TO GROUND MODULE SHORT TO GROUND CAN CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE SENTRY KEY REMOTE ENTRY MODULE TEST ACTION APPLICABILITY 1 Turn the ig...

Page 169: ...t Cluster harness connectors Disconnect the negative battery cable Measure the resistance between ground and the CAN C Bus circuit Measure the resistance between ground and the CAN C Bus circuit Is th...

Page 170: ...air the CAN C Bus circuit for a short to the CAN C Bus circuit Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Reconnect the Engine Control Module harness connectors While back...

Page 171: ...TIC TEMPERATURE CONTROL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read Automatic Temperature Control DTCs Does the DRBIII display NO COMMUNICATION BUS All Yes Refer to the Commu...

Page 172: ...tor Is the resistance 57 to 63 ohms All Yes Replace the Engine Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the CAN C Bus CAN C Bus circuit...

Page 173: ...TO AUTOMATIC TEMPERATURE CONTROL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read Automatic Temperature Control DTCs Does the DRBIII display NO COMMUNICATION BUS All Yes Refer to...

Page 174: ...s the resistance 57 to 63 ohms All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the CAN C Bus CAN C Bus circuit s for an...

Page 175: ...st light should not illuminate Press the Air Recirculation switch on The test light should illuminate brightly Does the test light function as specified All Yes Light Only Illuminates w Recirc On Repl...

Page 176: ...low 5 0 ohms All Yes Go To 4 No Repair the Recirculated Air Solenoid Valve Control circuit for an open Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off NOTE Check connectors Clean repair a...

Page 177: ...ion off Disconnect the Recirculated Air Solenoid Valve harness connector Disconnect the Automatic Temperature Control ATC C1 harness connector Measure the resistance between the Recirculated Air Solen...

Page 178: ...circulated Air Solenoid harness connector Turn the ignition on The test light should operate as follows With the Air Recirculation switch off the test light should not illuminate Press the Air Recircu...

Page 179: ...VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off NOTE Check connectors Clean repair as necessary Disconnect the Automatic Temperature Control ATC C1 harness connector Turn the ignition on Me...

Page 180: ...FICATION TEST VER 1 6 Turn the ignition off NOTE Check connectors Clean repair as necessary Disconnect the Refrigerant Pressure Sensor harness connector Disconnect the Automatic Temperature Control AT...

Page 181: ...erating temperature Set the blower to high speed Press the Air Conditioning switch On With the DRBIII verify that the ambient temperature is above 59 F 15 C the refrigerant pressure is between 29 and...

Page 182: ...ce below 10k ohms All Yes Repair the Refrigerant Pressure Sensor Feedback circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Disconnect the Automatic...

Page 183: ...ight should operate as follows With the Residual Engine Heat Utilization REST switch off the test light should not illuminate Press the Residual Engine Heat Utilization REST switch on With the Blend c...

Page 184: ...onnect the Water Cycle Valve harness connector Measure the resistance of the Water Cycle Valve Control circuit between the Automatic Temperature Control ATC C1 harness connector and the Water Cycle Va...

Page 185: ...Disconnect the Water Cycle Valve harness connector Disconnect the Automatic Temperature Control ATC C1 harness connector Measure the resistance between the Water Cycle Valve Control circuit and the Gr...

Page 186: ...s the Residual Engine Heat Utilization REST switch on With the Blend control set to Full Cold the test light should illuminate brightly and continuously With the Blend control set to one position belo...

Page 187: ...onnect the Ambient Temperature Sensor harness connector Connect a jumper wire between the Ambient Temperature Sensor Signal and Ambient Temperature Sensor Signal Return circuit Turn the ignition on wi...

Page 188: ...between the Instrument Cluster C1 harness connector and the Ambient Temperature Sensor harness connector Is the resistance above 10 ohms All Yes Repair the Ambient Temperature Sensor Signal circuit f...

Page 189: ...mperature Sensor harness connector Measure the resistance between ground and the Ambient Temperature Sensor Signal circuit Is the resistance below 1000 ohms All Yes Repair the Ambient Temperature Sens...

Page 190: ...ster C1 harness connector Disconnect the Fuel Pump Module harness connector Connect a jumper wire between the Fuel Level Sensor Signal and the Fuel Level Sensor Signal Return circuit Turn the ignition...

Page 191: ...it between the Fuel Pump Module harness connector and the Instrument Cluster harness connector Is the resistance above 10 ohms All Yes Repair the Fuel Level Sensor Signal circuit for an open Perform B...

Page 192: ...uel Pump Module harness connector Measure the resistance between ground and the Fuel Level Sensor Signal circuit Is the resistance below 1000 ohms All Yes Repair the Fuel Level Sensor Signal circuit f...

Page 193: ...lts present All Yes Refer to the symptom list for repair information relating to CAN Bus failures Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIII erase DTCs Turn the ignition off wai...

Page 194: ...lts present All Yes Refer to the symptom list for repair information relating to CAN Bus failures Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIII erase DTCs Turn the ignition off wai...

Page 195: ...oper operation in accordance with the Service Information Is the Charging system operating properly All Yes Replace the Instrument Cluster in accordance with the service information Perform BODY VERIF...

Page 196: ...ror DTC Is the same or similar DTC set in the other modules All Yes Go To 3 No Go To 5 3 Turn the ignition off Disconnect the Controller Antilock Brake harness connector Check each power and ground ci...

Page 197: ...the CAN C Bus circuit in the Instrument Cluster harness connector Is the resistance 60 ohms 3 0 ohms All Yes Replace the Instrument Cluster in accordance with the service information Perform BODY VER...

Page 198: ...ilar ECM message error DTC Is the same or similar DTC set in the other modules All Yes Go To 3 No Go To 5 3 Turn the ignition off Disconnect the ECM harness connector Check each power and ground circu...

Page 199: ...C Bus circuit and the CAN C Bus circuit in the Instrument Cluster harness connector Is the resistance 60 ohms 3 0 ohms All Yes Replace the Instrument Cluster in accordance with the service informatio...

Page 200: ...TCM message error DTC Is the same or similar DTC set in the ECM All Yes Go To 3 No Go To 5 3 Turn the ignition off Disconnect the TCM harness connector Check each power and ground circuit to the modu...

Page 201: ...the CAN C Bus circuit in the Instrument Cluster harness connector Is the resistance 60 ohms 3 0 ohms All Yes Replace the Instrument Cluster in accordance with the service information Perform BODY VER...

Page 202: ...dicators during each ignition cycle With the DRBIII erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIII read DTCs Does the DRBIII read Preglow Indicator Lamp Fai...

Page 203: ...ment Cluster performs internal tests on the indicators during each ignition cycle With the DRBIII erase DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIII read DTCs D...

Page 204: ...C s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s Operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display DRIVER DOOR AJ AR...

Page 205: ...the Driver Door Ajar Indicator Driver circuit Is the resistance below 20000 0 ohms All Yes Repair the Driver Door Ajar Indicator Driver wire for a short to ground Perform BODY VERIFICATION TEST VER 1...

Page 206: ...DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s Operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display PASSENGER DOOR...

Page 207: ...Passenger Door Ajar Indicator Driver circuit Is the resistance below 20000 0 ohms All Yes Repair the Passenger Door Ajar Indicator Driver wire for a short to ground Perform BODY VERIFICATION TEST VER...

Page 208: ...volts and the module is connected Set Condition The SKREEM has detected an internal failure and must be replaced POSSIBLE CAUSES CTM INTERNAL FAILURE TEST ACTION APPLICABILITY 1 View repair All Repair...

Page 209: ...the DRBIII read DTC s Using the RKE transmitter operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display RKE INTERFACE CIRCUIT SHORT TO GROUND All Yes Go...

Page 210: ...en ground and the RKE Interface circuit Is the resistance below 20000 0 ohms All Yes Repair the RKE Interface circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Sentry K...

Page 211: ...OFF to ON With the DRBIII read DTC s Using the RKE transmitter operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display RKE INTERFACE CIRCUIT OPEN OR SH...

Page 212: ...ICATION TEST VER 1 No Go To 4 4 Disconnect the Central Timer Module C1 connector Disconnect the SKREEM connector Measure the resistance of the RKE Interface circuit between the SKREEM connector and th...

Page 213: ...1 Turn the ignition off Disconnect the Central Timer Module C1 connector Measure the voltage between ground and the RKE Interface circuit Is there any voltage present All Yes Go To 2 No Replace the Ce...

Page 214: ...N With the DRBIII read DTC s Turn the ignition off and remove the key Using the RKE transmitter operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display...

Page 215: ...he voltage between ground and the RKE Interface circuit Is there any voltage present All Yes Repair the RKE Interface circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the...

Page 216: ...ES DTC PRESENT POWERTRAIN DTC TEST ACTION APPLICABILITY 1 With the DRBIII record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s Operate the Door Locks severa...

Page 217: ...TC s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s Turn the ignition off and remove the key Using the RKE transmitter operate the Door Locks several times while observing t...

Page 218: ...mitter pass the rest All Yes Go To 3 No Replace and program the RKE Transmitter Perform BODY VERIFICATION TEST VER 1 3 NOTE If only one of the transmitters used w ith this vehicle is inoperative follo...

Page 219: ...All Yes Refer to symptom list for problems related to POWER DOOR LOCKS RKE Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Gain access to and disconnect the SKREEM module connector Measure the resi...

Page 220: ...to OFF to ON With the DRBIII read DTC s Remove the ignition key Lock and unlock the doors from the Driver Cylinder Lock Switch several times while observing the DRBIII Wait 10 seconds Does the DRBIII...

Page 221: ...ween ground and the Driver Cylinder Lock Sense circuit Is the resistance below 400 0 ohms All Yes Repair the Driver Cylinder Lock Sense circuit for a short to ground Perform BODY VERIFICATION TEST VER...

Page 222: ...switch from ON to OFF to ON With the DRBIII read DTC s Lock and unlock the doors from the Driver Cylinder Lock Switch several times while observing the DRBIII Wait 10 seconds Does the DRBIII display D...

Page 223: ...n ground and the Driver Cylinder Unlock Sense circuit Is the resistance below 400 0 ohms All Yes Repair the Driver Cylinder Unlock Sense circuit for a short to ground Perform BODY VERIFICATION TEST VE...

Page 224: ...this code is active the front courtesy lamps w ill remain on w ith all the doors closed With the DRBIII record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s...

Page 225: ...rn the ignition off Disconnect the Security System Module C1 connector Ensure the driver and passenger doors are closed or the switches are disconnected Observe the courtesy lamps Did the courtesy lam...

Page 226: ...ATION SENSOR BEYOND LIMITS When Monitored Whenever the battery voltage is above 10 0 volts and the Security System Module is connected Set Condition If the internal module test fails this DTC will set...

Page 227: ...RBIII read DTC s Does the DRBIII display the same DTC All Yes Replace the Security System Module Perform BODY VERIFICATION TEST VER 1 No Using the wiring diagram schematic as a guide inspect the wirin...

Page 228: ...INTRUSION SENSOR INTERFACE WIRE SHORTED INTRUSION SENSOR INTERFACE WIRE OPEN INTRUSION SENSOR TEST ACTION APPLICABILITY 1 With the DRBIII record and erase DTC s Remove the ignition key Close and lock...

Page 229: ...onnector Measure the resistance of the Intrusion Sensor 1 Signal circuit between the SSM C2 connector and the Intrusion Sensor No 1 connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair...

Page 230: ...y Close and lock all doors and set the Vehicle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same DTC All Yes Go To 2 No Us...

Page 231: ...INTRUSION SENSOR INTERFACE WIRE SHORTED INTRUSION SENSOR INTERFACE WIRE OPEN INTRUSION SENSOR TEST ACTION APPLICABILITY 1 With the DRBIII record and erase DTC s Remove the ignition key Close and lock...

Page 232: ...onnector Measure the resistance of the Intrusion Sensor 2 Signal circuit between the SSM C2 connector and the Intrusion Sensor No 2 connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair...

Page 233: ...y Close and lock all doors and set the Vehicle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same DTC All Yes Go To 2 No Us...

Page 234: ...INTRUSION SENSOR INTERFACE WIRE SHORTED INTRUSION SENSOR INTERFACE WIRE OPEN INTRUSION SENSOR TEST ACTION APPLICABILITY 1 With the DRBIII record and erase DTC s Remove the ignition key Close and lock...

Page 235: ...onnector Measure the resistance of the Intrusion Sensor 3 Signal circuit between the SSM C2 connector and the Intrusion Sensor No 3 connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair...

Page 236: ...y Close and lock all doors and set the Vehicle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same DTC All Yes Go To 2 No Us...

Page 237: ...ar courtesy lamps w ill remain on w ith all the doors closed With the DRBIII record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIII read DTC s Open and close the sliding...

Page 238: ...he ignition off Disconnect the Security System Module C1 connector Ensure the sliding and rear doors are closed or the switches are disconnected Observe the courtesy lamps Did the courtesy lamps go of...

Page 239: ...ON With the DRBIII read DTC s Remove the ignition key Using the RKE transmitter operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display RKE INTERFACE CI...

Page 240: ...VERIFICATION TEST VER 1 No Go To 4 4 Disconnect the Central Timer Module C1 connector Disconnect the Security System Module C2 connector Measure the resistance of the RKE Interface circuit between the...

Page 241: ...h from ON to OFF to ON With the DRBIII read DTC s Using the RKE transmitter operate the Door Locks several times while observing the DRBIII Wait 10 seconds Does the DRBIII display SECURITY SYSTEM INTE...

Page 242: ...BODY VERIFICATION TEST VER 1 No Go To 4 4 Disconnect the Sentry Key Remoter Entry connector Disconnect the Security System Module C2 connector Measure the resistance of the Security System circuit bet...

Page 243: ...C s Remove the ignition key Close and lock all doors and set the Vehicle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same...

Page 244: ...t Is the resistance below 5 0 ohms All Yes Repair the Siren Signal Control circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Disconnect the Siren connector Disconnect the...

Page 245: ...cle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same DTC All Yes Go To 2 No Using the wiring diagram schematic as a guide...

Page 246: ...k all doors and set the Vehicle Theft Security System Wait 1 minute Disarm the Vehicle Theft System With the DRBIII read DTC s Does the DRBIII display the same DTC All Yes Go To 2 No Using the wiring...

Page 247: ...R WIPER MOTOR TEST ACTION APPLICABILITY 1 Turn the ignition on Monitor the windshield wipers while turning the wiper switch to each of the 4 switch positions OFF INTERMITTENT LOW and HIGH Did the wipe...

Page 248: ...10 0 ohms for each measurement All Yes Go To 6 No Repair the circuit s that measured above 10 0 ohms for an open 6 Turn the ignition off Disconnect the Rain Sensor harness connector Disconnect the Rai...

Page 249: ...off Disconnect the Rain Sensor Module harness connector Turn the ignition on Refer to the Wiper Washer Switch Voltage Chart in Charts and Graphs to verify correct wiper switch voltage signals to the R...

Page 250: ...erving the voltmeter move the wiper switch from the OFF position to the INTERMITTENT position only Does the voltmeter display above 10 0 volts for both of the wiper switch positions All Yes Go To 14 N...

Page 251: ...Sensor Module 16 Turn the ignition off Disconnect the wiper motor harness connector Connect a voltmeter between ground and the wiper motor harness connector cavity 6 harness side Move the wiper switch...

Page 252: ...I read DTC s If any DTC s are present return to Symptom list 13 If there are no Diagnostic Trouble Codes DTC s present and the customer s concern can no longer be duplicated the repair is complete Are...

Page 253: ...ress the Air Conditioning switch On 11 With the DRBIII verify that the ambient temperature is above 59 F 15 C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature...

Page 254: ...nectors 10 If a heater installation cooling system service was performed purge the coolant circuit of air in accordance with the Service Information 11 Turn the ignition on 12 Verify that the Cabin He...

Page 255: ...ial symptom still exists If there are no trouble codes and the symptom no longer exists the repair was successful and testing is now complete 4 If the initial or another symptom exists the repair is n...

Page 256: ...NOTES 248...

Page 257: ...8 0 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM 8 2 AIRBAG CONTROL MODULE 8 3 DRIVER AIRBAG SQUIB C O M P O N E N T L O C A T I O N S 249 COMPONENT LOCATIONS...

Page 258: ...8 4 CLOCKSPRING 8 5 SEA T BELT TENSIONER 8 6 HEA TING A C 8 6 1 AUTOMA TIC TEMPERA TURE CONTROL A TC SYSTEM COMPONENTS C O M P O N E N T L O C A T I O N S 250 COMPONENT LOCATIONS...

Page 259: ...A TER HEA TER BOOSTER SYSTEM COMPONENTS 8 6 3 AUTO TEMP CONTROL CABIN HEA TER HEA TER BOOSTER FUSES RELA YS 8 6 4 EVAP TEMP SENSOR AIR OUTLET TEMP SENSOR C O M P O N E N T L O C A T I O N S 251 COMPON...

Page 260: ...8 7 INSTRUMENT CLUSTER 8 7 1 AMBIENT TEMPERA TURE SENSOR 8 8 POWER DOOR LOCKS RKE 8 8 1 CENTRAL TIMER MODULE C O M P O N E N T L O C A T I O N S 252 COMPONENT LOCATIONS...

Page 261: ...8 8 2 SENTRY KEY REMOTE ENTRY MODULE 8 8 3 DOOR LOCK MOTOR AJAR SWITCH 8 8 4 CONTACT PLA TES C O M P O N E N T L O C A T I O N S 253 COMPONENT LOCATIONS...

Page 262: ...CK MOTOR AJAR SWITCH CONNECTORS 8 9 VEHICLE THEFT SECURITY SYSTEM 8 9 1 SECURITY SYSTEM MODULE 8 9 2 INTRUSION SENSORS C O M P O N E N T L O C A T I O N S 254 COMPONENT LOCATIONS 8 8 POWER DOOR LOCKS...

Page 263: ...8 9 3 SWITCHES 8 9 4 SIREN C O M P O N E N T L O C A T I O N S 255 COMPONENT LOCATIONS...

Page 264: ...NOTES 256...

Page 265: ...20BR YL DRIVER SEAT BELT TENSIONER LINE 1 3 20BL PASSENGER SEAT BELT TENSIONER LINE 2 4 20BR PASSENGER SEAT BELT TENSIONER LINE 1 5 20BK FUSED IGNITION SWITCH OUTPUT RUN START 6 20BR GROUND 7 20YL AIR...

Page 266: ...SQUIB PASSENGER YELLOW CAV CIRCUIT FUNCTION 1 20BL DG PASSENGER AIRBAG SQUIB 1 LINE 2 2 20BR DG PASSENGER AIRBAG SQUIB 1 LINE 1 AMBIENT TEMPERA TURE SENSOR CAV CIRCUIT FUNCTION 1 20BL DG AMBIENT TEMP...

Page 267: ...EMPERATURE SENSOR SIGNAL 17 20DG WT CAN C BUS 18 18BR BL SENSOR GROUND 19 20BR RD REFRIGERANT PRESSURE SENSOR FEEDBACK 20 20DG CAN C BUS 21 16BK BL DG FUSED IGNITION SWITCH OUTPUT AUTOMA TIC TEMPERA T...

Page 268: ...OCK DRIVER 4 16YL BK DRIVER DOOR LOCK SENSE 5 16DG BL WT PASSENGER FRONT DOOR UNLOCK SENSE 6 16YL BL PASSENGER FRONT DOOR LOCK SENSE 7 16WT YL MASTER DOOR LOCK SWITCH SENSE ALL DOORS 8 16RD BK FUSED D...

Page 269: ...DOOR UNLOCK SENSE 15 16 17 16BK RD PASSENGER DOORS UNLOCK DRIVER 18 16BL RD PASSENGER DOORS LOCK DRIVER CIRCULA TION PUMP CABIN HEA TER MODULE CAV CIRCUIT FUNCTION 1 18DG RD CIRCULATION PUMP RELAY OUT...

Page 270: ...T WHEEL SPEED SENSOR 16 18BK RIGHT FRONT WHEEL SPEED SENSOR 17 18 19 20 20WT BRAKE SWITCH OUTPUT 21 20BR GROUND 22 23 18BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR...

Page 271: ...IO 12 20GY DG RD K CTM SSM 13 20BK RD K ACM 14 15 20WT GY K IC ATC HBM CHM 16 20RD YL FUSED B DOOR LOCK MOTOR AJAR SWITCH ASSEMBL Y DRIVER C1 CAV CIRCUIT FUNCTION 1 16YL BK DRIVER DOOR LOCK SENSE 2 16...

Page 272: ...PASSENGER C2 CAV CIRCUIT FUNCTION 1 16BK RD PASSENGER DOORS UNLOCK DRIVER 2 16BL RD PASSENGER DOORS LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH ASSEMBL Y REAR C1 CAV CIRCUIT FUNCTION 1 16BK RD PASSENGER D...

Page 273: ...IGHT SLIDING DOOR LOCK SENSE 4 16DG YL RIGHT SLIDING DOOR UNLOCK SENSE DOSING PUMP CAV CIRCUIT FUNCTION 1 16DG DOSING PUMP CONTROL 2 16BR GROUND ENGINE CONTROL MODULE C1 EXCEPT OBD BLACK CAV CIRCUIT F...

Page 274: ...ROUND 10 11 20DG WT CAN C BUS 12 20DG CAN C BUS 13 18BK FUSED IGNITION SWITCH OUTPUT RUN START 14 18DG ACCEL SET SIGNAL 15 16 18YL DECEL SET SIGNAL 17 20DG ENHANCED ACCIDENT REPORT DRIVER 18 19 18RD S...

Page 275: ...M 19 18BK FUSED IGNITION SWITCH OUTPUT RUN START 24 18BL RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY 25 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 26 18BR BL ACCEL PEDAL POSITION SENSOR GROUND N...

Page 276: ...SENSOR 5 VOLT SUPPLY 18 20YL DG MASS AIR FLOW SENSOR SIGNAL 19 20BR BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY 20 18VT IGNITION SWITCH OUTPUT START 21 22 18BR WT BOOST PRESSURE SENSOR GROUND 23 18BR BL ACC...

Page 277: ...UNCTION 1 18BR DG EVAPORATOR TEMPERATURE SENSOR SIGNAL 2 18BR BL SENSOR GROUND FUEL LEVEL SENSOR CAV CIRCUIT FUNCTION 2 20BL BK FUEL LEVEL SENSOR SIGNAL 3 20BR FUEL LEVEL SENSOR SIGNAL RETURN C O N N...

Page 278: ...C O N N E C T O R P I N O U T S 270 CONNECTOR PINOUTS...

Page 279: ...14BK FUSED IGNITION SWITCH OUTPUT RUN START 19 15A 14RD BK OBD FUSED B 20 15A 16RD BL FUSED B 21 30A 12RD FUSED B FUSE BLOCK NO 1 C1 CAV CIRCUIT FUNCTION 1 INTERNAL FOG LAMP SWITCH OUTPUT 3 INTERNAL...

Page 280: ...11 16RD YL FUSED IGNITION SWITCH OUTPUT RUN START 12 16BR BK WIPER MOTOR CONTROL 13 14 16WT BL RD FUSED IGNITION SWITCH OUTPUT RUN START 15 FUSE BLOCK NO 1 C5 BLACK CAV CIRCUIT FUNCTION 1 16BK BL WT...

Page 281: ...C O N N E C T O R P I N O U T S 273 CONNECTOR PINOUTS...

Page 282: ...25A 16BK YL OPTIONAL EQUIPMENT RELAY OUTPUT 8 10A 16BK RD OPTIONAL EQUIPMENT RELAY OUTPUT 9 15A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 10 7 5A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 11 7 5A 16RD YL WT FU...

Page 283: ...C O N N E C T O R P I N O U T S 275 CONNECTOR PINOUTS...

Page 284: ...B 9 16RD BK WT FUSED B 10 16RD GY FUSED B 11 14RD FUSED B 12 16BK RD OPTIONAL EQUIPMENT RELAY OUTPUT 13 18BK BL OPTIONAL EQUIPMENT RELAY OUTPUT 14 16BK GY OPTIONAL EQUIPMENT RELAY OUTPUT 15 16VT YL OP...

Page 285: ...C O N N E C T O R P I N O U T S 277 CONNECTOR PINOUTS...

Page 286: ...9 40A 12RD FUSED B 10 30A 12RD GY FUSED B HOOD AJAR SWITCH BLACK CAV CIRCUIT FUNCTION 1 16BK BL HOOD AJAR SWITCH SENSE 2 3 16BR GROUND HORN VTSS CAV CIRCUIT FUNCTION 1 16BK BR HORN RELAY OUTPUT 2 16B...

Page 287: ...BR GROUND 7 20GY DG RD LAMP DRIVER 8 20BL WT FUSED HIGH BEAM SWITCH OUTPUT 9 20BL RD WT VEHICLE SPEED SENSOR OUTPUT 10 20BK FUSED IGNITION SWITCH OUTPUT RUN START 11 20BL BK KEY IN IGNITION SWITCH SIG...

Page 288: ...DRIVER 2 16WT DG PASSENGER DOOR AJAR INDICATOR DRIVER 3 16WT YL MASTER DOOR LOCK SWITCH SENSE ALL DOORS 4 5 6 7 8 16WT RD MASTER DOOR LOCK SWITCH SENSE PASSENGER DOORS 9 16WT BK DRIVER DOOR AJAR INDIC...

Page 289: ...PDC FUSE NO AMPS FUSED CIRCUIT FUNCTION 1 200A 4RD FUSED B 2 70A 10RD FUSED B 3 125A 8RD FUSED B 4 80A 8RD FUSED B 5 125A 8RD FUSED B 6 100A 8RD FUSED B C O N N E C T O R P I N O U T S 281 CONNECTOR P...

Page 290: ...GHT FRONT B4 18BK SPEAKER RIGHT FRONT B5 18BR DG SPEAKER LEFT FRONT B6 18BR SPEAKER LEFT FRONT B7 16BR BL SPEAKER LEFT REAR B8 16WT BL SPEAKER LEFT REAR RADIO C2 CAV CIRCUIT FUNCTION 1 16BK RADIO ANTE...

Page 291: ...C O N N E C T O R P I N O U T S 283 CONNECTOR PINOUTS...

Page 292: ...RD FUSED B 85 16RD BK FUSED D RELAY NO 1 OUTPUT 86 16BR GROUND 87 14BL YL D RELAY NO 2 OUTPUT 87A FAN STAGE 1 RELA Y RELA Y BLOCK CAV CIRCUIT FUNCTION 30 14BK VT F AN STAGE 1 RELAY OUTPUT 85 16BR GROU...

Page 293: ...T TURN SIGNAL 5 16BK VT F AN STAGE 1 RELAY 6 16WT RD WARM AIR AUXILIARY HEATER CONTROL 7 16RD GY FUSED B 8 16BK GY FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 9 18VT DG TOWING INTRUSION SENSOR INDICATOR DRI...

Page 294: ...AL 5 20DG WT CAN C BUS 6 20DG CAN C BUS 7 16BK YL FUSED IGNITION SWITCH OUTPUT RUN START 8 20WT DG K SKREEM 9 16WT BL RD EXCEPT VTSS RKE INTERF ACE 9 16WT BL RD VTSS SECURITY SYSTEM INTERF ACE 10 18DG...

Page 295: ...18GY DG RD LAMP DRIVER 2 3 18GY YL INTRUSION SENSOR SWITCH SENSE 4 18BR GROUND 5 6 7 8 18GY BR TOWING SENSOR SWITCH SENSE 9 18VT DG TOWING INTRUSION SENSOR INDICATOR DRIVER 10 18BR GROUND TRANSMISSION...

Page 296: ...ESSURE SOLENOID CONTROL 38 16BK SOLENOID SUPPLY VOLTAGE H 20DG WT CAN C BUS L 20DG CAN C BUS WA TER CYCLE VALVE CAV CIRCUIT FUNCTION 1 18BR VT WATER CYCLE VALVE CONTROL 2 18BR GROUND WINDOW DEFOGGER L...

Page 297: ...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 289 SCHEMATIC DIAGRAMS...

Page 298: ...10 2 COMMUNICA TION 10 2 1 COMMUNICA TION K LINES S C H E M A T I C D I A G R A M S 290 SCHEMATIC DIAGRAMS...

Page 299: ...10 2 2 CAN BUS NETWORK S C H E M A T I C D I A G R A M S 291 SCHEMATIC DIAGRAMS...

Page 300: ...10 3 HEA TING A C 10 3 1 AUTOMA TIC TEMPERA TURE CONTROL A TC S C H E M A T I C D I A G R A M S 292 SCHEMATIC DIAGRAMS...

Page 301: ...10 3 2 CABIN HEA TER MODULE CHM S C H E M A T I C D I A G R A M S 293 SCHEMATIC DIAGRAMS...

Page 302: ...10 3 3 HEA TER BOOSTER MODULE HBM S C H E M A T I C D I A G R A M S 294 SCHEMATIC DIAGRAMS 10 3 HEA TING A C Continued...

Page 303: ...10 4 INSTRUMENT CLUSTER S C H E M A T I C D I A G R A M S 295 SCHEMATIC DIAGRAMS...

Page 304: ...10 5 POWER DOOR LOCKS RKE 10 5 1 FRONT DOORS S C H E M A T I C D I A G R A M S 296 SCHEMATIC DIAGRAMS...

Page 305: ...10 5 2 SLIDING AND REAR DOORS S C H E M A T I C D I A G R A M S 297 SCHEMATIC DIAGRAMS...

Page 306: ...10 5 3 SWITCH AND MISCELLANEOUS CIRCUITS S C H E M A T I C D I A G R A M S 298 SCHEMATIC DIAGRAMS 10 5 POWER DOOR LOCKS RKE Continued...

Page 307: ...10 6 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 299 SCHEMATIC DIAGRAMS...

Page 308: ...10 7 RAIN SENSOR SYSTEM S C H E M A T I C D I A G R A M S 300 SCHEMATIC DIAGRAMS...

Page 309: ...CHARTS AND GRAPHS 11 1 EVAP TEMP SENSOR RESISTANCE TO TEMPERA TURE SPECIFICA TIONS 11 2 AIR OUTLET TEMP SENSOR RESISTANCE TO TEMPERA TURE SPECIFICA TIONS C H A R T S A N D G R A P H S 301 CHARTS AND G...

Page 310: ...11 3 WIPER SWITCH WASHER SWITCH VOLTAGE SIGNALS C H A R T S A N D G R A P H S 302 CHARTS AND GRAPHS...

Page 311: ...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 312: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 313: ...DRBIII ERROR MESSAGES 4 3 9 1 DRBIII DOES NOT POWER UP BLANK SCREEN 5 3 9 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 INFORMATI...

Page 314: ...EED SENSOR CIRCUIT 43 RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT 43 RIGHT REAR WHEEL SPEED SENSOR CIRCUIT 43 LEFT FRONT WHEEL SPEED SENSOR SIGNAL 46 LEFT REAR WHEEL SPEED SENSOR SIGNAL 46 RIGHT FRONT WHEE...

Page 315: ...EXCEPT ESP BLACK 83 CONTROLLER ANTILOCK BRAKE 84 INSTRUMENT CLUSTER C2 WHITE 85 STEERING ANGLE SENSOR 85 TCS SWITCH ASR BLACK 85 WHEEL SPEED SENSOR LEFT FRONT 85 WHEEL SPEED SENSOR LEFT REAR 86 WHEEL...

Page 316: ...NOTES iv...

Page 317: ...iagnosis of the Antilock Brake Systems is done in six basic steps Verification of complaint Verification of any related symptoms Symptom analysis Problem isolation Repair of isolated problem Verificat...

Page 318: ...toring the brake pressure and wheel speed and negative slip when the driver applies the brakes The system will then produce a more accu rate calculation of payload depending on brake retardation The a...

Page 319: ...king Wheel Speed Sensors are monitored to determine when a wheel is tending to lock up The CAB will operate the valves in the HCU to control braking pressure during ABS braking Detect ABS system relat...

Page 320: ...on is dependent on Tone Wheel speed signal from the WSS The vehicle wheels and tires should all be the same size and type to get accurate signals In addition all tires should be at recommended tire pr...

Page 321: ...IS ODORLESS CAUSES SLOWER REACTION TIME AND CAN LEAD TO SERIOUS INJURY WHEN THE ENGINE IS OPERATING KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL...

Page 322: ...on is off Failure to do so could damage the module When testing voltage or continuity at any control module use the terminal side not the wire end of the connector Do not probe a wire through the insu...

Page 323: ...al ratcheting down at the end of an ABS stop 8 If the complaint is ABS cycling at the end of a stop at low speeds it may be caused by a marginal wheel speed sensor signal The sensor air gap tone wheel...

Page 324: ...NOTES 8...

Page 325: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...

Page 326: ...f check CAB INTERNAL When Monitored Ignition On Continuously Set Condition When there is a deviation from the expected result of a CAB internal self check POSSIBLE CAUSES INTERMITTENT CAB INTERNAL DTC...

Page 327: ...the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to ground check both Fused B circuits at the CAB harness connector NOTE The test light must illuminate bright...

Page 328: ...harness Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found All Yes Repair as necessary Perform ABS VERIFICATIO...

Page 329: ...fluid is at the proper level in accordance w ith the Service Information Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Measure the resistance between the terminals o...

Page 330: ...nspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found All Yes Repair as necessar...

Page 331: ...neuvers With the DRBIII read DTCs Does this DTC reset All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the Brake Pressure Sensor harness connector Disconnect the CAB harness connector Tur...

Page 332: ...are found repair as necessary If no problems are found replace the Brake Pressure Sensor in accordance with the Service Information With the DRBIII clear DTCs Road test the vehicle and perform severa...

Page 333: ...SWITCH OUTPUT CIRCUIT BRAKE LAMP SWITCH BRAKE SWITCH ANTI LOCK BRAKE CONTROLLER TEST ACTION APPLICABILITY 1 NOTE This DTC w ill set if the Brake Sw itch the Brake Lamp Sw itch or both sw itches are in...

Page 334: ...VER 1 No Test Complete 4 Turn the ignition off Disconnect the C1 Brake Switch harness connector Turn the ignition on With the DRBIII in Inputs Outputs monitor the Brake Switch state Connect a jumper...

Page 335: ...affected circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off Disconnect the CAB harness connector Disconnect the appropriate brake switch harness conn...

Page 336: ...utput circuit and Brake Lamp Switch Output circuit in the C1 and C2 connectors Is the resistance below 5 0 ohms All Yes Repair the Brake Switch Output circuit for a short to the Brake Lamp Switch Outp...

Page 337: ...OUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the D...

Page 338: ...he battery Does the test light illuminate brightly All Yes Go To 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the CAB harness conn...

Page 339: ...OUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the D...

Page 340: ...the battery Does the test light illuminate brightly All Yes Go To 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the CAB harness co...

Page 341: ...l Module and Instrument Cluster Are there any CAN communication DTCs present in any of these modules All Yes Refer to the diagnostic procedures for any CAN DTCs in ECM TCM and Cluster before proceedin...

Page 342: ...nce below 5 0 ohms between the circuits All Yes Repair the shorted CAN circuit s Perform ABS VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the Engine Control Module harness con...

Page 343: ...olts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate br...

Page 344: ...indicating that a fault free road test procedure has been completed Turn the ignition on With the DRBIII clear DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Are any other D...

Page 345: ...s With the DRBIII perform the road test procedure in accordance with the Service Information With the DRBIII read DTCs NOTE Failure to perform the road test procedure properly can cause this DTC to se...

Page 346: ...between ground and the Lateral Acceleration Sensor supply circuit Is the resistance below 5 0 ohms for any of the circuits All Yes Repair the Lateral Acceleration Sensor circuit s for a short to groun...

Page 347: ...nd connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken...

Page 348: ...RECT TIRES ON VEHICLE TIRE CIRCUMFERENCES NOT MATCHING WHEEL SPEED SENSOR CIRCUIT SHORT TO VOLTAGE INCORRECT TONE WHEEL WHEEL SPEED SENSOR CIRCUIT SHORT TO GROUND DAMAGED WHEEL BEARING WHEEL SPEED SEN...

Page 349: ...learance NOTE Refer to the service information if necessary for procedures or specifications Is the wheel bearing clearance within specifications All Yes Go To 6 No Repair as necessary Perform ABS VER...

Page 350: ...e the resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector Is the resistance over 1 800 ohms All Yes Repair the affected Wheel Speed Sensor circuit for an open Perf...

Page 351: ...elated wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Were any...

Page 352: ...m voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication betw een the sensor and the CAB With the DRBIII erase DTCs Road t...

Page 353: ...tween ground and the Lateral Acceleration Sensor supply circuit Is the resistance below 5 0 ohms for any of the circuits All Yes Repair the Lateral Acceleration Sensor circuit s for a short to ground...

Page 354: ...tors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pus...

Page 355: ...the DRBIII erase DTCs Road test the vehicle and perform several steering and braking maneuvers With the DRBIII perform the road test procedure With the DRBIII read DTCs Does this DTC reset All Yes Rep...

Page 356: ...sed using the same tests The title for the tests w ill be LEFT FRONT INLET SOLE NOID When Monitored and Set Condition LEFT FRONT INLET SOLENOID When Monitored Ignition On Continuousy Set Condition Whe...

Page 357: ...ff Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE Th...

Page 358: ...ll Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Ground circuit for an open Perform ABS VERIFICATION TEST VER 1...

Page 359: ...en or shorted POSSIBLE CAUSES INTERMITTENT WHEEL SPEED SENSOR CIRCUIT DTC DAMAGED CAB CAB HARNESS CONNECTOR WHEEL SPEED SENSOR CIRCUIT SHORT TO VOLTAGE WHEEL SPEED SENSOR CIRCUIT SHORT TO GROUND WHEEL...

Page 360: ...rcuits in the CAB harness connector Is the resistance below 5 0 ohms All Yes Repair the affected Wheel Speed Sensor circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn...

Page 361: ...rness Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found All Yes Repair as necessary Perform ABS VERIFICATION T...

Page 362: ...ter a wheel speed sensor signal has been lost POSSIBLE CAUSES INTERMITTENT WHEEL SPEED SENSOR SIGNAL DTC DAMAGED SENSOR CAB HARNESS CONNECTOR DAMAGED WHEEL SPEED SENSOR TONE WHEEL EXCESSIVE WHEEL SPEE...

Page 363: ...nition off Inspect the affected Wheel Speed Sensor air gap NOTE Refer to the appropriate Service information if necessary for procedures or specifications Is the affected air gap OK All Yes Go To 5 No...

Page 364: ...Wheel Speed Sensor in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 8 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinche...

Page 365: ...E CAN CIRCUITS SHORTED TO GROUND MODULE SHORT TO GROUND CAN CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE SENTRY KEY REMOTE ENTRY MODULE TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect...

Page 366: ...ent Cluster harness connectors Disconnect the negative battery cable Measure the resistance between ground and the CAN C Bus circuit Measure the resistance between ground and the CAN C Bus circuit Is...

Page 367: ...epair the CAN C Bus circuit for a short to the CAN C Bus circuit Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Reconnect the Engine Control Module harness connectors While ba...

Page 368: ...ION APPLICABILITY 1 Turn the ignition on With the DRBIII read CAB DTCs Does the DRBIII display NO COMMUNICATION WITH BUS All Yes Refer to the symptom list for the appropriate diagnostic proce dure Per...

Page 369: ...Is the resistance 57 to 63 ohms All Yes Replace the Engine Control Module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAN C Bus CAN C Bus circuit s for...

Page 370: ...ROLLER TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read CAB DTCs Does the DRBIII display NO COMMUNICATION WITH BUS All Yes Refer to the symptom list for the appropriate diagnostic...

Page 371: ...Is the resistance 57 to 63 ohms All Yes Replace the Instrument Cluster in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAN C Bus CAN C Bus circuit s for an...

Page 372: ...aced refer to cluster reprogramming to ensure correct config uration before proceeding Using the DRBIII view the vehicle parameters entered into this module and the Instrument Cluster If possible corr...

Page 373: ...CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN PUMP MOTOR TEST ACTION APPLICABILITY 1 NOTE If a system undervoltage or overvoltage DTC is set alo...

Page 374: ...5 Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harn...

Page 375: ...its NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Replace the Pump Motor in accordan...

Page 376: ...PLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on Start the engine Drive the vehicle above 6 km h 4 mph for at least 30...

Page 377: ...4 volts Go To 7 Voltage between 9 4 and 17 4 volts Go To 8 5 Turn the ignition off Disconnect the CAB harness connector Start the engine Allow the engine to idle WARNING WHEN THE ENGINE IS OPERATING D...

Page 378: ...Fused B circuit and both Ground circuits in the CAB harness connector Is the voltage above 9 4 volts All Yes Repair any charging system related DTCs before continuing If no charging system or system...

Page 379: ...CUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition o...

Page 380: ...he battery Does the test light illuminate brightly All Yes Go To 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the CAB harness conn...

Page 381: ...t been Calibrated Turn the ignition on With the DRBIII clear DTCs With the DRBIII perform the Steering Angle Calibration under Miscellaneous functions Turn the ignition off Turn the ignition on Test d...

Page 382: ...rees Turn the ignition on With the DRBIII erase DTCs Move the Steering Wheel from stop to stop several times With the DRBIII read DTCs Does this DTC reset All Yes Go To 2 No Go To 3 2 NOTE When the ve...

Page 383: ...pinched or partially broken wires Look for broken bent pushed out or corroded terminals Inspect the tires and wheels to make sure that they are the correct size All tires must be the same size Inspec...

Page 384: ...ecalculated using the DRBIII if alignment has been changed by more than 5 degrees Turn the ignition on With the DRBIII erase DTCs Test drive the vehicle Using the DRBIII perform the road test procedur...

Page 385: ...RBIII read DTCs Does this DTC reset All Yes Replace the CAB in accordance with the Service Information No Test Complete 4 The condition that set this DTC is not present at this time Monitor the DRBIII...

Page 386: ...heel from stop to stop several times With the DRBIII perform the road test procedure With the DRBIII read DTCs Does this DTC reset All Yes Go To 2 No Go To 3 2 NOTE When the vehicle is in a turn the E...

Page 387: ...rced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Inspect the tires and wheels to make sure that they are the correct size All tires must be the same size In...

Page 388: ...ead DTCs NOTE If the ESP lamp remains illuminated after the test has completed a fault code w ill be set indicating the cause of the failure Does this DTC reset All Yes Go To 2 No Go To 3 2 NOTE When...

Page 389: ...Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed o...

Page 390: ...s Does this DTC reset All Yes Inspect the Steering Angle Sensor for proper installation Inspect the wiring and connectors Repair as necessary If no other problems are found replace the Steering Angle...

Page 391: ...t the CAB CAB harness connector for damage Is there any broken bent pushed out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 3 Turn the igniti...

Page 392: ...wiring harness Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found All Yes Repair as necessary Perform ABS VERIF...

Page 393: ...o To 2 No Go To 6 2 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB CAB harness connector for damage Is there any broken bent pushed out corroded or spread terminals All Yes...

Page 394: ...volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate b...

Page 395: ...sure the CAB has been initialized 8 NOTE If the SKREEM or ECM w as replaced refer to the service information for proper programming procedures 9 NOTE For Sensor Circuit Signal and Pump Motor faults th...

Page 396: ...ress the Air Conditioning switch On 11 With the DRBIII verify that the ambient temperature is above 59 F 15 C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature...

Page 397: ...8 0 COMPONENT LOCATIONS 8 1 DLC INDICA TORS C O M P O N E N T L O C A T I O N S 81 COMPONENT LOCATIONS...

Page 398: ...8 2 CAB WSS C O M P O N E N T L O C A T I O N S 82 COMPONENT LOCATIONS...

Page 399: ...C1 EXCEPT ESP CAV CIRCUIT FUNCTION 1 20WT BRAKE SWITCH OUTPUT 2 16RD BK FUSED IGNITION SWITCH OUTPUT RUN START 3 20BK BL RD BRAKE LAMP SWITCH 4 BRAKE LAMP SWITCH C2 EXCEPT ESP BLACK CAV CIRCUIT FUNCTI...

Page 400: ...OR 17 18 19 20 20WT BRAKE SWITCH OUTPUT 21 20BR GROUND 22 23 18BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR GROUND 26 20WT GY BRAKE PRESSURE SENSOR SIGNAL 27 18BK BL...

Page 401: ...FIELD DRIVER 16 20YL AIRBAG WARNING INDICATOR DRIVER 17 18 20BL VT D RELAY NO 1 CONTROL 18 20BL VT D RELAY NO 1 CONTROL STEERING ANGLE SENSOR CAV CIRCUIT FUNCTION 1 20DG WT CAN C BUS 2 3 20DG CAN C BU...

Page 402: ...SENSOR WHEEL SPEED SENSOR RIGHT FRONT CAV CIRCUIT FUNCTION 1 18BK RIGHT FRONT WHEEL SPEED SENSOR 2 18BR RIGHT FRONT WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT REAR CAV CIRCUIT FUNCTION 1 18BK RIGHT...

Page 403: ...10 0 SCHEMATIC DIAGRAMS 10 1 BOSCH 5 7 ANTILOCK BRAKE SYSTEM ABS S C H E M A T I C D I A G R A M S 87 SCHEMATIC DIAGRAMS...

Page 404: ...NOTES 88...

Page 405: ...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 406: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 407: ...T POWER UP 8 3 4 2 DISPLAY IS NOT VISIBLE 8 4 0 DISCLAIMERS SAFETY WARNINGS 8 4 1 DISCLAIMERS 8 4 2 SAFETY 8 4 2 1 TECHNICIAN SAFETY INFORMATION 8 4 2 2 VEHICLE PREPARATION FOR TESTING 9 4 2 3 SERVICI...

Page 408: ...1 ECM INTERNAL ERROR 5 16 P2323 ECM INTERNAL ERROR 16 P2324 ECM INJECTOR MONITORING 1 16 P2324 ECM INJECTOR MONITORING 2 16 P2324 ECM INJECTOR MONITORING 3 16 P2324 ECM INJECTOR MONITORING 4 16 P2324...

Page 409: ...SENSOR 42 P0115 ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 44 P2054 ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 44 P2054 ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAG...

Page 410: ...P2567 MISFIRE CYLINDER 1 66 P2568 LEAKAGE CYLINDER 2 66 P2568 MISFIRE CYLINDER 2 66 P2569 LEAKAGE CYLINDER 3 66 P2569 MISFIRE CYLINDER 3 66 P2570 LEAKAGE CYLINDER 4 66 P2570 MISFIRE CYLINDER 4 66 P257...

Page 411: ...CURRENT 82 P2137 GLOW PLUG 5 CIRCUIT OPEN CIRCUIT 82 P2137 GLOW PLUG 5 CIRCUIT SHORT TO GROUND 82 P2137 GLOW PLUG 5 CIRCUIT SHORT TO VOLTAGE 82 P1482 GLOW PLUG MODULE INCORRECT TIMER 85 P1482 GLOW PLU...

Page 412: ...UNCTION MAXIMUM FUEL PRESSURE EXCEEDED 117 P2019 FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS TOO LOW 117 P2020 FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS TOO LOW 117 P2020 FUEL RAIL PRESSURE...

Page 413: ...AIR FLOW SENSOR PLAUSIBILITY 150 P2355 EGR FLOW RATE IS TOO HIGH 150 P2355 EGR FLOW RATE IS TOO LOW 150 P2066 MASS AIR FLOW SENSOR PLAUSIBILITY AIR MASS TOO HIGH 153 P2066 MASS AIR FLOW SENSOR PLAUSI...

Page 414: ...E MISSING OR INCORRECT 184 P2234 ABS DTC EXTERNAL QUANTITY CONTROL FAULT PRESENT 184 P2252 LATERAL ACCELERATOR SENSOR PLAUSIBILTY 184 P2211 ETC CAN MESSAGE MISSING OR INCORRECT 186 P2258 TCM MESSAGE E...

Page 415: ...N CIRCUIT 218 P2527 EGR VALVE SIGNAL CIRCUIT SHORTED TO GROUND 218 P2514 CRANKCASE VENT HEATER OPEN CIRCUIT 221 P2514 CRANKCASE VENT HEATER SHORTED TO GROUND 221 P2514 CRANKCASE VENT HEATER SHORTED TO...

Page 416: ...BLACK 257 CRANKSHAFT POSITION SENSOR BLACK 258 DATA LINK CONNECTOR BLACK 258 EGR VALVE BLACK 258 ENGINE CONTROL MODULE C1 OBD 259 ENGINE CONTROL MODULE C2 OBD 260 ENGINE COOLANT TEMPERATURE SENSOR BLA...

Page 417: ...SENSOR BLACK 271 OXYGEN SENSOR OBD 271 FUSED IGNITION SWITCH RUN START RELAY RELAY BLOCK 273 SPEED CONTROL SWITCH 273 WATER IN FUEL SENSOR BLACK 273 10 0 SCHEMATIC DIAGRAMS 275 10 1 ENGINE CONTROL MOD...

Page 418: ...NOTES xii...

Page 419: ...FICATION OF SYSTEM The ECM is located to the left of the steering column behind the steering column opening cover The sentry remote entry module SKREEM is attached to the rear of the instrument cluste...

Page 420: ...fault will result in a fixed idle speed of approximately 680 rpm regardless of actual pedal position Other less critical faults will result in power reduction throughout the full range of driv ing con...

Page 421: ...he specific test s that must be performed 3 3 1 HARD CODE A DTC that comes back within one cycle of the ignition key is a hard code This means that the problem is current every time the ECM SKREEM che...

Page 422: ...tion error crankcase vent heater excessive current crankcase vent heater open circuit crankcase vent heater shorted to ground crankcase vent heater shorted to voltage crankshaft position sensor circui...

Page 423: ...all fuel injector 2 read too large fuel injector 2 read too large fuel injector 2 read too small fuel injector 2 read too small fuel injector 3 read too large fuel injector 3 read too large fuel injec...

Page 424: ...me below limit injector 3 injection time above limit injector 3 injection time below limit injector 4 injection time above limit injector 4 injection time below limit injector 5 injection time above l...

Page 425: ...or supply 2 voltage is too low sensor supply 3 voltage is too high sensor supply 3 voltage is too low starter relay circuit ecm thermal overload starter relay circuit open or shorted to voltage starte...

Page 426: ...SAFETY WARNINGS 4 1 DISCLAIMERS All information illustrations and specifications contained in this manual are based on the latest information available at the time of publication The right is reserve...

Page 427: ...nal and ground must not exceed 500v DC or 500v peak AC Use caution when measuring voltage above 25v DC or 25v AC The circuit being tested must be protected by a 10 amp fuse or circuit breaker Use the...

Page 428: ...dule DLC data link connector ECM engine control module ECT engine coolant temperature sensor EGR exhaust gas recirculation solenoid valve EOS engine oil sensor IAT intake air temperature sensor IP int...

Page 429: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 11...

Page 430: ...ER 2 No Go To 2 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K ECM circuit Is the resistance below 5 0...

Page 431: ...M circuit between the ECM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERI...

Page 432: ...VER 1 No Go To 2 2 Turn the ignition off Disconnect the SKREEM harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the K SKREEM circuit Is the resistance be...

Page 433: ...between the SKREEM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace and program the Sentry Key Remote Entry Module in accordance with the Service Information Perform BODY VERIFIC...

Page 434: ...P2140 ECM INJECTOR OUTPUT STAGE 2 SHORT CIRCUIT P2149 ECM A D CONVERTER HIGH P2149 ECM A D CONVERTER LOW P2149 ECM A D CONVERTER PLAUSIBILITY P2153 STARTER RELAY CIRCUIT ECM THERMAL OVERLOAD P2197 FU...

Page 435: ...ll be P 1105 ATMOSPHERIC PRES SURE SENSOR PLAUSIBILITY WITH BOOST PRESSURE SENSOR When Monitored and Set Condition P1105 ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH When Monitored With the ign...

Page 436: ...th the DRBIII read the ECM DTCs Did this DTC set again All Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Go To 2...

Page 437: ...SIBILITY SIGNAL RATIO ERROR P2633 MAF SENSOR SIGNAL PLAUSIBILITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests w ill be P0100 MASS AIR FLOW SENSOR SIGN...

Page 438: ...R When Monitored With the ignition on Set Condition The ECM detects a rationality problem with the MAF Sensor POSSIBLE CAUSES 12 VOLT SUPPLY CIRCUIT OPEN CHECKING THE ENGINE CONTROL RELAY SYSTEM ECM 5...

Page 439: ...d to ground or low voltage problems Does the DRB also display these type of DTC s All Yes Go To 3 No Go To 4 3 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect...

Page 440: ...nnect the ECM harness connectors Measure the resistance between ground and the MAF Sensor Signal circuit Is the resistance below 1000 ohms All Yes Repair the MAF Sensor Signal circuit for a short to g...

Page 441: ...harness connectors Measure the resistance of the 5 Volt Supply circuit Is the resistance below 10 0 ohms All Yes Go To 13 No Repair the MAF Sensor 5 Volt Supply circuit for an open Perform ROAD TEST V...

Page 442: ...FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running and at...

Page 443: ...diagnose DTCs P1611 P2306 or P2332 before diagnosing this DTC NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some o...

Page 444: ...Check connectors Clean repair as necessary Measure the resistance of both the CAN C Bus circuit and the CAN C Bus circuit between the Shifter Module harness connector and ECM harness connector Is the...

Page 445: ...DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to t...

Page 446: ...as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE If DTC P1611 P2306 or P2332 is present w ith this DTC diagnose DTCs P1611 P2306 or P2332 before dia...

Page 447: ...ignition off Disconnect the Intake Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the Engine Control Relay Connect a jumper wire between cavity 30 and cavity 87 of the...

Page 448: ...WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifyin...

Page 449: ...RE SENSOR SIGNAL CIRCUIT OPEN TEST ACTION APPLICABILITY 1 NOTE If DTC P1611 P2306 or P2332 is present w ith this DTC diagnose DTCs P1611 P2306 or P2332 before diagnosing this DTC Turn the ignition on...

Page 450: ...5 Turn the ignition off Disconnect the Intake Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Intake Pressure Sensor Signal circuit and Sens...

Page 451: ...Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical...

Page 452: ...age is above 4 83 volts POSSIBLE CAUSES CHECK FOR ACTIVE DTC INTERMITTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE INTAKE AIR TEMP SENSOR GROUND CIRCUIT OPEN INTAKE AIR TEMP...

Page 453: ...or Measure the resistance of the Intake Air Temperature Sensor Signal circuit Is the resistance below 10 0 ohms All Yes Go To 4 No Repair the Intake Air Temperature Sensor Signal circuit for an open P...

Page 454: ...ook for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical...

Page 455: ...r Temperature Sensor Signal voltage is below 0 073 volt for more than 60 seconds POSSIBLE CAUSES INTERMITTENT CONDITION IAT SENSOR INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND INTAKE AIR TE...

Page 456: ...the Intake Air Temperature Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 4 Turn the ignition off Disconnect the ECM harness connectors Disconnect the IAT Sensor harn...

Page 457: ...Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical...

Page 458: ...With the DRBIII set the engine RPM to 1500 and allow the engine to warm up for 10 15 minutes With the DRBIII monitor the Engine Coolant Temperature value during the warm up cycle Make sure the transi...

Page 459: ...t Complete No Go To 4 4 Disconnect the ECT harness connector Disconnect the ECM harness connectors Measure the resistance of the ECT Sensor Signal circuit between the ECM harness connector and the ECT...

Page 460: ...DRBIII erase ECM DTCs With the DRBIII set the engine RPM to 1500 and allow the engine to warm up for 10 15 minutes With the DRBIII monitor the Engine Coolant Temperature value during the warm up cycl...

Page 461: ...Sensor With the DRBIII select Engine then Sensors and read the engine coolant temperature Are the readings within 7 C 13 F of each other All Yes Replace the Engine Oil Sensor Perform ROAD TEST VERIFIC...

Page 462: ...hen Monitored With the ignition on Set Condition The Engine Coolant Temperature Sensor Signal voltage is above 4 98 volts for more than 3 seconds P2054 ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAG...

Page 463: ...ir the ECT Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Go To 3 3 Turn the ignition off Disconnect the ECT Sensor harness connector Connect a jumper wire betwee...

Page 464: ...mperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If p...

Page 465: ...ores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs recor...

Page 466: ...RNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are no...

Page 467: ...r circuits that w ould affect multiple DTCs NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions...

Page 468: ...the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Fuel Temperature Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATIN...

Page 469: ...al voltage is above 4 8 volts POSSIBLE CAUSES INTERMITTENT CONDITION FUEL TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL TEMPERATURE SENSOR SIGNAL AND GROUND CIRCUITS...

Page 470: ...Perform ROAD TEST VERIFICATION VER 2 No Repair the Fuel Temperature Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 5 WARNING WHEN THE ENGINE IS OPERATING D...

Page 471: ...UIT MALF SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Fuel Rail Pressure Sensor Signal voltage is above 4 8 volts POSSIBLE CAUSES ECM FUEL PRESSURE SENSOR SIGNAL CIRCU...

Page 472: ...a time With the DRB read ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Turn the ignition on Measure the volt...

Page 473: ...tion on Measure the voltage of the Sensor Ground circuit at the Fuel Pressure Sensor and ECM harness connectors Is the voltage above 1 0 volt at either connector All Yes Repair the Sensor Ground circu...

Page 474: ...this time The follow ing list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggli...

Page 475: ...FUEL INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOGGLES...

Page 476: ...e Fuel Pressure Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 4 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harnes...

Page 477: ...ok for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical S...

Page 478: ...YLINDER 4 INJECTOR CIRCUIT SHORTED TO GROUND P0204 CYLINDER 4 INJECTOR CIRCUIT SHORTED TO VOLTAGE P0205 CYLINDER 5 INJECTOR CIRCUIT EXCESSIVE CURRENT P0205 CYLINDER 5 INJECTOR CIRCUIT OPEN OR SHORTED...

Page 479: ...XCESSIVE CURRENT When Monitored With the engine running Set Condition The ECM detects excessive current through the Cylinder 2 Injector driver when on P0202 CYLINDER 2 INJECTOR CIRCUIT OPEN OR SHORTED...

Page 480: ...OR SHORTED TO GROUND When Monitored With the engine running Set Condition The ECM detects an open or short to ground on the Cylinder 4 Injector circuit P0204 CYLINDER 4 INJECTOR CIRCUIT SHORTED TO GR...

Page 481: ...TO GROUND FUEL INJ ECTOR CIRCUITS SHORTED TOGETHER FUEL INJ ECTOR CONTROL CIRCUIT OPEN FUEL INJ ECTOR TEST ACTION APPLICABILITY 1 NOTE If the ECM detects and stores a DTC the ECM also stores the engi...

Page 482: ...Block No 1 Turn the ignition on Measure the voltage of all of the Fuel Injector Control circuit Is the voltage above 1 0 volt for any of the measurements All Yes Repair the appropriate Fuel Injector C...

Page 483: ...FICATION VER 2 8 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that...

Page 484: ...R 2 INJECTION TIME ABOVE LIMIT P2575 INJECTOR 2 INJECTION TIME BELOW LIMIT P2576 INJECTOR 3 INJECTION TIME ABOVE LIMIT P2576 INJECTOR 3 INJECTION TIME BELOW LIMIT P2577 INJECTOR 4 INJECTION TIME ABOVE...

Page 485: ...fuel pressure solenoid and all fuel injectors for evidence of fuel leakage Is there fuel leakage near any of the injectors or the fuel rail All Yes Refer to the Service Information to repair fuel leak...

Page 486: ...Informa tion Were any problems found All Yes Repair or replace as necessary in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Test Complete 8 WARNING WHEN THE ENGINE...

Page 487: ...TC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing...

Page 488: ...et the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters relate...

Page 489: ...e these conditions may assist w hen checking for an active DTC Turn the ignition on With the DRBIII erase the ECM DTCs Test drive the vehicle With the DRBIII read the ECM DTCs Did this DTC set again A...

Page 490: ...DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal o...

Page 491: ...PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY POSSIBLE CAUSES ACCELERATOR PEDAL POSITION SENSOR ECM APP SENSOR 1 5 VOLT SUPPLY CIRCUIT SENSOR GROUND OPEN APP SENSOR INTERMITTENT CONDITION APP SENSOR 5 VOL...

Page 492: ...28 and 0 37 volt for sensor 1 and 0 10 and 0 19 volt for sensor 2 All Yes Go To 2 No Go To 5 2 Turn the ignition on Fully depress the accelerator pedal Using a voltmeter backprobe the APP Sensor harn...

Page 493: ...ICATION VER 2 No Test Complete 5 NOTE Perform the rest of this diagnostic procedure on the individual APP Sensor Potentiometer 1 or 2 that did not display the correct voltages in the previous test Tur...

Page 494: ...connector Disconnect the ECM harness connectors Measure the resistance of the APP Sensor Signal circuit Is the resistance below 10 0 ohms All Yes Go To 11 No Repair the APP Sensor Signal circuit for a...

Page 495: ...o To 15 No Repair the Accelerator Pedal Position Sensor 5 Volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 15 Turn the ignition off Disconnect the APP Sensor harness connector Disc...

Page 496: ...e the voltage of the Accelerator Pedal Position Sensor 5 Volt Supply circuit in the ECM harness connector Is the voltage above 1 0 volt All Yes Repair the Accelerator Pedal Position Sensor 5 Volt Supp...

Page 497: ...the CAN Bus POSSIBLE CAUSES VERIFY CURRENT DTC TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII erase the ECM DTCs Perform several ignition key cycles leaving the ignition on for 10 se...

Page 498: ...hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these cond...

Page 499: ...the DRBIII read the ECM DTCs Did this DTC set again All Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Test Compl...

Page 500: ...W PLUG 3 CIRCUIT SHORT TO VOLTAGE P2136 GLOW PLUG 4 CIRCUIT EXCESSIVE CURRENT P2136 GLOW PLUG 4 CIRCUIT OPEN CIRCUIT P2136 GLOW PLUG 4 CIRCUIT SHORT TO GROUND P2136 GLOW PLUG 4 CIRCUIT SHORT TO VOLTAG...

Page 501: ...rcuit Is the resistance below 10 0 ohms for each circuit All Yes Go To 3 No Repair the appropriate Glow Plug Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 3 Turn the ignition off Di...

Page 502: ...may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for para...

Page 503: ...e DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions...

Page 504: ...rness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Tec...

Page 505: ...DTCs present All Yes Refer to the Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 NOTE If the ECM detects and stores a DTC the ECM als...

Page 506: ...R THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the...

Page 507: ...Are other DTCs present All Yes Refer to the Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 NOTE If the ECM detects and stores a DTC t...

Page 508: ...Service Information Perform ROAD TEST VERIFICATION VER 2 5 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WE...

Page 509: ...n on With the DRB check for additional DTCs Are other DTCs present All Yes Refer to the Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2...

Page 510: ...it while wiggling the wiring harness and connectors Was the resistance below 1000 0 ohms at any time while wiggling the wiring harness and connectors All Yes Repair the Engine Control Relay Control ci...

Page 511: ...ss Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Techni...

Page 512: ...ns under w hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate...

Page 513: ...YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condi...

Page 514: ...e ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is d...

Page 515: ...e Camshaft Position Sensor 5 volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 5 Turn the ignition off Disconnect the APP Sensor harness connector Disco...

Page 516: ...t present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC whil...

Page 517: ...AN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the inte...

Page 518: ...S CHECKING ECM POWER AND GROUNDS ECM INTERMITTENT CONDITION TEST ACTION APPLICABILITY 1 NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hic...

Page 519: ...entifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values...

Page 520: ...ditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an...

Page 521: ...TE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor t...

Page 522: ...nditions Attempting to duplicate these conditions may assist w hen checking for an active DTC With the DRB check the Airbag Module for proper communication and DTCs If there are any ACM DTCs repair th...

Page 523: ...R THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the...

Page 524: ...ILITY 1 NOTE If DTC P1611 P2306 or P2332 is present w ith this DTC diagnose DTCs P1611 P2306 or P2332 before diagnosing this DTC NOTE If the ECM detects and stores a DTC the ECM also stores the engine...

Page 525: ...orm ROAD TEST VERIFICATION VER 2 3 Turn the ignition off Disconnect the Water In Fuel Sensor harness connector Turn the ignition on Measure the voltage of the Water In Fuel Sensor Signal circuit Selec...

Page 526: ...Turn the ignition off Disconnect the ECM harness connectors Disconnect the Water In Fuel Sensor harness connector Measure the resistance of the Sensor Ground circuit Is the resistance below 10 0 ohms...

Page 527: ...that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parame...

Page 528: ...d With the ignition on Set Condition The ECM detects a rationality problem with the MAF Sensor P2010 MASS AIR FLOW SENSOR POSITIVE DEVIATION When Monitored With the ignition on Set Condition The ECM d...

Page 529: ...DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow...

Page 530: ...VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Ambient Air Temperature Sensor signal is above 4 82 volts P2013 AMBIENT AIR TEMPERATURE SIGNAL VOLTAGE TOO LOW When Monitored Wi...

Page 531: ...61 ENGINE OIL SENSOR OPEN CIRCUIT P2062 ENGINE OIL SENSOR SIGNAL ERROR P2062 ENGINE OIL SENSOR SYNCHRONIZATION ERROR Test Note All symptoms listed above are diagnosed using the same tests The title fo...

Page 532: ...l Yes Go To 2 No Go To 10 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Refer to any...

Page 533: ...n Perform ROAD TEST VERIFICATION VER 2 6 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Engine Oil Sensor harness connector Measure the resistance of the Sensor Ground circ...

Page 534: ...he DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters relate...

Page 535: ...RE TOO HIGH P2021 FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE TOO LOW P2023 FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE TOO HIGH P2047 FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL PRESSURE EXCEEDED P...

Page 536: ...EME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS WARNING FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE TRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHE...

Page 537: ...Go To 4 4 NOTE Mixing any other fuels such as gasoline or kerosine can cause this DTC to set Turn the ignition off WARNING HIGH PRESSURE FUEL LINES DELIVER DIESEL FUEL UN DER EXTREME PRESSURE FROM TH...

Page 538: ...the ECM DTCs Does the DRBIII display this DTC All Yes Go To 6 No Go To 16 6 Start the engine With the DRBIII in Sensors compare the Fuel Pressure Setpoint with the Actual Fuel Pressure readings NOTE...

Page 539: ...All Yes Using the Service Information remove and inspect the Fuel Injectors for signs of damage or debris that may cause the injector to stick Sticking injectors may cause the combustion chamber to be...

Page 540: ...uel Quantity Solenoid in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Replace Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFI...

Page 541: ...EST VERIFICATION VER 2 No Go To 19 19 NOTE An injector that sticks open can cause this DTC A sticking injector w ill cause the engine to misfire and emit excessive black smoke from the exhaust system...

Page 542: ...he DRBIII erase the ECM DTCs Attempt to start and test drive the vehicle With the DRBIII read the ECM DTCs Did this DTC set again All Yes Replace the Fuel Pump in accordance with the Service Informa t...

Page 543: ...306 or P2332 before diagnosing this DTC NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are...

Page 544: ...TEST VERIFICATION VER 2 5 Turn the ignition off Disconnect the Intake Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit Is the...

Page 545: ...ess Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Techn...

Page 546: ...ION APPLICABILITY 1 NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are displayed on the DRB...

Page 547: ...orm ROAD TEST VERIFICATION VER 2 4 Turn the ignition off Disconnect the Intake Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the Engine Control Relay Connect a jumper...

Page 548: ...this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling t...

Page 549: ...is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an active DTC NOTE Ensure all turbocharger inlet and outlet...

Page 550: ...2 5 Turn the ignition off Disconnect the Intake Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Intake Pressure Sensor Signal circ...

Page 551: ...ook for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical...

Page 552: ...SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH P2059 O2 SENSOR SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH P2090 O2 SENSOR PLAUSIBILITY P2090 O2 SENSOR SIGNAL FAULT P2091 O2 SENSOR LOW O2 CONCENTRATION P2091 O2 SE...

Page 553: ...orm ROAD TEST VERIFICATION VER 2 No Go To 3 3 Turn the ignition off Disconnect the O2 Sensor harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Power Suppl...

Page 554: ...All Yes Repair the circuits that measured below 1000 ohms for a short together Perform ROAD TEST VERIFICATION VER 2 No Go To 7 7 Turn the ignition off Disconnect the O2 Sensor harness connector Disco...

Page 555: ...g harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any...

Page 556: ...ng and connectors between the ECM and the O2 sensor for damage corrosion poor terminal contact or other problems Were any problems found All Yes Clean repair or replace as necessary Perform ROAD TEST...

Page 557: ...Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical...

Page 558: ...SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE CHECKING 5 VOLT SUPPLY CIRCUIT DAMAGED CMP SENSOR OR CAMSHAFT ECM ECM ECM CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND CIRCUIT OPE...

Page 559: ...s may assist w hen checking for an active DTC Turn the ignition on With the DRBIII erase the ECM DTCs Attempt to start the engine cranking the engine for at least 7 seconds With the DRBIII read the EC...

Page 560: ...ROAD TEST VERIFICATION VER 2 Voltage is between 4 7 and 5 4 volts Go To 6 Voltage is below 4 7 volts Go To 10 6 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the ECM har...

Page 561: ...ne Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Replace the Camshaft Position Sensor in accordance with the Service Information Perform ROAD TEST V...

Page 562: ...Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 14 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance betwee...

Page 563: ...aram eter values to change and or a DTC to set Remove the CMP Sensor and the CKP Sensor checking for loose mounting screws and debris on the sensor magnets that can corrupt the sensor signal Refer to...

Page 564: ...CONDITION CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT S SHORTED TO GROUND CKP SENSOR CIRCUITS SHORTED TOGETHER CKP SENSOR SIGNAL CIRCUITS OPEN CKP SENSOR SIGNAL CIRCUIT S SHORTED TO VOLTAGE TEST ACTION...

Page 565: ...efer to the Service Information to ensure the Engine Drive Gears Sprocket are installed correctly and the camshaft and crankshaft gears are timed correctly Turn the ignition off Disconnect the CKP Sen...

Page 566: ...gine for several seconds while monitoring the DRB Does the DRB display a steady clean CKP Signal pattern for both circuits All Yes Go To 8 No Replace the Crankshaft Position Sensor Perform ROAD TEST V...

Page 567: ...ine oil level Add or remove as necessary to obtain proper engine oil level Start the engine and allow it to reach operating temperature Test drive the vehicle With the DRBIII read the ECM DTCs Did thi...

Page 568: ...ION CHECKING FOR AIR LEAKS EGR ACTUATION 1200 RPM EGR VALVE MAF SENSOR MAF SENSOR READING 3OOO RPM INTERMITTENT CONDITION EGR RESTRICTION TEST ACTION APPLICABILITY 1 NOTE If the ECM detects and stores...

Page 569: ...The EGR Positioner w ill actuate from 5 to 95 With the engine idling at approximately 680 RPM the MAF reading should sw itch a mini mum of 200 mg strk betw een 5 and 95 of EGR actuation Note the MAF...

Page 570: ...Is there evidence of smoke leakage All Yes Repair or replace as necessary Perform ROAD TEST VERIFICATION VER 2 No Replace the MAF Sensor Perform ROAD TEST VERIFICATION VER 2 10 WARNING WHEN THE ENGINE...

Page 571: ...When Monitored and Set Condition P2066 MASS AIR FLOW SENSOR PLAUSIBILITY AIR MASS TOO HIGH When Monitored With the engine running Set Condition The ECM detects excessive air flow from the MAF Sensor P...

Page 572: ...w restriction Were any of these problems found All Yes Replace the Air Filter element Perform ROAD TEST VERIFICATION VER 2 No Go To 3 3 NOTE Inspect all air intake and turbocharger related tubes for d...

Page 573: ...for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Ser...

Page 574: ...a rationality problem with the MAF Sensor POSSIBLE CAUSES RESTRICTED INTAKE SYSTEM Repair Instructions RESTRICTED INTAKE SYSTEM This DTC indicates a restriction in the intake system Check for clogged...

Page 575: ...hich the DTC w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these cond...

Page 576: ...Repair the Fuel Lift Pump Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HAND...

Page 577: ...cycle on and off All Yes Go To 2 No Go To 3 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOT...

Page 578: ...ay Remove the Engine Control Relay Connect a jumper wire between cavity 30 and cavity 87 of the Engine Control Relay connector Turn the ignition on Measure the voltage of the Fuel Lift Pump Relay Cont...

Page 579: ...ELAY STARTER RELAY CONTROL CIRCUIT SHORTED TO GROUND STARTER RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE STARTER RELAY CONTROL CIRCUIT OPEN TEST ACTION APPLICABILITY 1 NOTE If the E...

Page 580: ...N VER 2 4 Turn the ignition off Install a substitute relay in place of the Starter Relay Turn the ignition on With the DRBIII erase DTCs Attempt to start the engine several times pausing for at least...

Page 581: ...CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperatu...

Page 582: ...TOR BOOST PRESSURE SERVO MOTOR CONTROL SHORT TO VOLTAGE ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE INTERNAL SHORT TO VOLTAGE TEST ACTION APPLICABILITY 1 NOTE If DTC P1611 P2306 or P2332 is p...

Page 583: ...le in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Go To 4 4 Turn the ignition off Disconnect the Boost Pressure Servo Motor harness connector Disconnect the ECM har...

Page 584: ...ok for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical S...

Page 585: ...BOOST PRESSURE SERVO MOTOR CIRCUIT SHORT TO GROUND When Monitored With the ignition on Set Condition The ECM detects a short to battery on the Boost Pressure Servo Motor Control circuit P2112 BOOST PR...

Page 586: ...Yes Go To 3 No Go To 4 3 Turn the ignition off Disconnect the ECM harness connectors Connect a jumper wire between ground and the Engine Control Relay Signal circuit in ECM C2 harness connector cavity...

Page 587: ...he Boost Pressure Servo Motor Control circuit Is the resistance below 10 0 ohms All Yes Go To 7 No Repair the Boost Pressure Servo Motor Control circuit for an open Perform ROAD TEST VERIFICATION VER...

Page 588: ...k for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Se...

Page 589: ...w as set Some of these conditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may as...

Page 590: ...t at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggli...

Page 591: ...ondition The ECM detects an open or short to ground on the Fuel Pressure Solenoid Control circuit P2501 FUEL PRESSURE SOLENOID CIRCUIT SHORTED TO GROUND OR B When Monitored With the ignition on and th...

Page 592: ...L SYSTEM Turn the ignition on With the DRB erase ECM DTCs Start the engine several times turning the ignition off for at least 30 seconds between each run cycle Monitor the DRB for ECM DTCs Did this D...

Page 593: ...istance between ground and the Fuel Pressure Solenoid Control circuit Measure the resistance between ground and the Fuel Pressure Solenoid 12 volt Supply Is the resistance above 1000 ohms for both mea...

Page 594: ...OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time Th...

Page 595: ...DS CHECKING THE ENGINE CONTROL RELAY SYSTEM FUEL QUANTITY SOLENOID FUEL QUANTITY SOLENOID CIRCUIT S SHORTED TO GROUND FUEL QUANTITY SOLENOID CIRCUIT S SHORTED TO VOLTAGE FUEL QUANTITY SOLENOID CIRCUIT...

Page 596: ...e Fuel Quantity Solenoid circuits between the ECM harness connector and the Fuel Quantity Solenoid harness connector Is the resistance below 10 0 ohms for each measurement All Yes Go To 4 No Repair th...

Page 597: ...ELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running...

Page 598: ...LE SENSOR PLAUSIBILITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests w ill be P2203 TORQUE REDUCTION MESSAGE FROM ABS CAN PLAUSIBILITY POSSIBLE CAUSES...

Page 599: ...4 4 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC...

Page 600: ...M TCM CAN PLAUSIBILITY POSSIBLE CAUSES ENGINE CONTROL MODULE TCM DTCS VERIFY TCM COMMUNICATION INTERMITTENT CONDITION TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII attempt to commun...

Page 601: ...UT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent co...

Page 602: ...d NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an active DTC NOTE This DTC indicates a communication problem betw een...

Page 603: ...T WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operati...

Page 604: ...fore erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an active DTC NOTE This DTC indicates a communication problem betw een the TCM a...

Page 605: ...S OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at...

Page 606: ...T P2225 TCM DTC SPEED SENSOR VOLTAGE FAULT PRESENT P2226 TCM DTC EWM CAN MESSAGE FAULT PRESENT P2227 TCM DTC RIGHT REAR WHEEL SPEED IMPLAUSIBLE FAULT PRESENT P2228 TCM DTC TRANSMISSION RATIO ERROR FAU...

Page 607: ...as set in the ECM by the Transmission Control Module to indicate a transmission fault Diagnosis of transmission faults should be done using the Transmission Diagnostic Information NOTE When repairs h...

Page 608: ...cates a communication problem betw een the Steering Angle Sensor and the ECM Turn the ignition on With the DRBIII erase ECM DTCs Perform several engine run cycles turning the ignition off for at least...

Page 609: ...for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Ser...

Page 610: ...he ignition on With the DRBIII attempt to communicate with the CAB NOTE If there are other DTCs set w ith this DTC refer to the Symptom List and repair other stored ECM DTCs before diagnosing this DTC...

Page 611: ...sing the brake pedal several times With the DRBIII select CAB then Sensors Read the Brake Switch input while pressing and releasing the brake pedal several times Is the Brake Switch input operating co...

Page 612: ...Are there any Instrument Cluster DTCs All Yes Refer to symptom list for problems related to Instrument Cluster Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 NOTE If the ECM detects and stores a D...

Page 613: ...s Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technic...

Page 614: ...re diagnosed using the same tests The title for the tests w ill be P2259 TORQUE REDUCTION MESSAGE FROM HVAC PARITY ERROR POSSIBLE CAUSES AUTOMATIC TEMP CONTROL DTC TEST ACTION APPLICABILITY 1 NOTE Thi...

Page 615: ...CLUSTER DTC TEST ACTION APPLICABILITY 1 NOTE This DTC indicates the presents of a problem w ith the Ambient Temp Sensor input to the Instrument Cluster View repair statement All Yes Refer to symptom l...

Page 616: ...in All Yes Go To 2 No Go To 6 2 Turn the ignition off Visually inspect the wiring and connectors associated with the Boost Pressure Sensor and Fuel Pressure Sensor for problems that may result in a sh...

Page 617: ...HEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not prese...

Page 618: ...ignition on With the DRB erase ECM DTCs Turn the ignition off for 10 seconds Turn the ignition on Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 8 2 Turn the ignition off...

Page 619: ...ir the Boost Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 6 Turn the ignition off Disconnect the Boost Pressure Sensor harness connector...

Page 620: ...ness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Tech...

Page 621: ...the ignition on With the DRB erase ECM DTCs Turn the ignition off for 10 seconds Turn the ignition on Monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 8 2 Turn the ignitio...

Page 622: ...the Intake Air Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 6 Turn the ignition off Disconnect the Intake Air Pressure Sensor harness co...

Page 623: ...ness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Tech...

Page 624: ...splayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an active DTC Turn the ignition on With the DRB erase ECM DTCs Tu...

Page 625: ...ion off Disconnect the Engine Oil Sensor harness connector Turn the ignition on With the DRBIII erase ECM DTCs Turn the ignition off for 10 seconds Turn the ignition on With the DRBIII read ECM DTCs D...

Page 626: ...ess Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Techn...

Page 627: ...nditions are displayed on the DRB at the same time the DTC is displayed NOTE Before erasing stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for a...

Page 628: ...y Perform ROAD TEST VERIFICATION VER 2 No Test Complete 7 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEA...

Page 629: ...TC indicates that an error occurred during ECM program ming Turn the ignition on With the DRBIII erase ECM DTCs Refer to the Service Information and attempt to reprogram the ECM Perform several engine...

Page 630: ...t Complete No Go To 2 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditio...

Page 631: ...ULE VERIFY ECM PROGRAMMING TEST ACTION APPLICABILITY 1 Turn the Ignition on With the DRBIII erase the ECM DTCs With the DRBIII verify that the ECM is properly coded for the options and components that...

Page 632: ...er Relay and disconnect the Fuel Lift Pump harness connector Measure the resistance between ground and the Starter Relay control circuit Measure the resistance between ground and the Fuel Lift Pump Re...

Page 633: ...harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any...

Page 634: ...stored DTCs record these conditions Attempting to duplicate these conditions may assist w hen checking for an active DTC NOTE Ensure all turbocharger inlet and outlet tubes are connected prop erly w...

Page 635: ...eplace the Turbocharger assembly in accordance with the Ser vice Information Perform ROAD TEST VERIFICATION VER 2 No Replace the Boost Pressure Servo Motor Perform ROAD TEST VERIFICATION VER 2 6 WARNI...

Page 636: ...06 or P2332 before diagnosing this DTC NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of these conditions are d...

Page 637: ...uit in the EGR Valve harness connector Does the test light illuminate brightly All Yes Go To 5 No Repair the Engine Control Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 5 Turn...

Page 638: ...resent at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while w...

Page 639: ...HEATER ENGINE CONTROL MODULE TEST ACTION APPLICABILITY 1 NOTE If the ECM detects and stores a DTC the ECM also stores the engine vehicle operating conditions under w hich the DTC w as set Some of the...

Page 640: ...the both circuits between the Crankcase Vent Heater harness connector and the ECM harness connector Is the resistance below 10 0 ohms for each measurement All Yes Go To 4 No Repair the Crankcase Vent...

Page 641: ...OTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor...

Page 642: ...is DTC indicates that engine rotation has occurred w ithout an ignition sw itch Start input This can occurred w hen an attempt to start the vehicle using a push start method NOTE Consult w ith the cus...

Page 643: ...ve DTC Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle and monitor the DRB for ECM DTCs Did this DTC set again All Yes Go To 2 No Go To 5 2 Turn the ignition off Disconnect the...

Page 644: ...UR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent conditi...

Page 645: ...33 FUEL INJECTOR 3 READ TOO SMALL P2533 FUEL INJECTOR 3 READ TOO SMALL P2534 FUEL INJECTOR 4 READ TOO LARGE P2534 FUEL INJECTOR 4 READ TOO LARGE P2534 FUEL INJECTOR 4 READ TOO SMALL P2534 FUEL INJECTO...

Page 646: ...Perform ROAD TEST VERIFICATION VER 2 No Go To 2 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE...

Page 647: ...active DTC Turn the ignition on With the DRBIII erase the ECM DTCs Attempt to start the engine With the DRBIII read the ECM DTCs Does the DRB III display this DTC All Yes Go To 3 No Go To 2 2 Turn the...

Page 648: ...6 Turn the ignition off Using the DRB lab scope backprobe both of the CKP Sensor Signal circuits at the CKP Sensor harness connector NOTE Refer to Charts and Graphs to view a correct CKP Sensor signa...

Page 649: ...arness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Te...

Page 650: ...r partially broken wires Repair as necessary Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Repair as necessary Measure the resistance of...

Page 651: ...oken bent pushed out or corroded terminals Repair as necessary Measure the resistance of both Fuel Pressure Solenoid circuits between the ECM harness connector and the Fuel Pressure Solenoid harness c...

Page 652: ...ched or partially broken wires Repair as necessary Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Repair as necessary Measure the resistan...

Page 653: ...T TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check each of the ECM ground circuits in ECM harness connecto...

Page 654: ...Remove and inspect Fuse 17 from Fuse Block No 1 Is the fuse open All Yes Go To 6 No Go To 8 6 Turn the ignition off Disconnect the ECM harness connectors Disconnect the EGR Valve harness connector Dis...

Page 655: ...hese circuits components for shorted circuits Were any problems found All Yes Repair or replace shorted circuit component as necessary Perform ROAD TEST VERIFICATION VER 2 No Replace and program the E...

Page 656: ...ol Relay connector in Fuse Block No 1 and ECM C2 harness connector cavities 1 3 and 5 It may be necessary to replace the Fuse Block No 1 to repair this circuit Perform ROAD TEST VERIFICATION VER 2 No...

Page 657: ...l circuit is shorted to ground or shorted to Sensor Ground Turn the ignition on With the DRBIII read the ECM DTCs Does the DRBIII display any ECM DTCs All Yes Refer to symptom list for problems relate...

Page 658: ...Service Information and perform the fuel pressure test Is the fuel pressure within specification All Yes Go To 7 No Repair as necessary Perform NO START VERIFICATION VER 1 7 Inspect the fuel supply fo...

Page 659: ...each circuit All Yes Go To 10 No Perform Test for DTC P2045 Crankshaft Position Sensor Circuit Dynamic Plausibility Perform NO START VERIFICATION VER 1 10 Refer to the Service Information to ensure t...

Page 660: ...Y 1 Turn the ignition off NOTE The battery must be fully charged before diagnosing a no crank condition Inspect the battery cables for corrosion looseness or other problems Is there evidence of proble...

Page 661: ...he Starter Motor Relay from the Fuse Relay Block Disconnect the Starter Motor Relay Output wire from the Starter Solenoid Connect the Starter Motor Relay Output wire at the Starter to ground Using a 1...

Page 662: ...the DRBIII display any TCM DTCs All Yes Refer to symptom list for problems related to TCM Perform NO START VERIFICATION VER 1 No Go To 11 11 Perform the Checking the ECM Power and Grounds test Were a...

Page 663: ...open Perform NO START VERIFICATION VER 1 14 Turn the ignition off Disconnect the ECM harness connectors Remove the Starter Motor Relay from the Fuse Relay Block Measure the resistance between ground a...

Page 664: ...ord and erase all DTCs from ALL modules Start and run the engine for 2 minutes Operate all functions of the system that caused the original concern 15 Turn the ignition off and wait 5 seconds Turn the...

Page 665: ...lete 4 If the initial or another symptom exists the repair is not complete Check all pertinent Technical Service Bulletins TSBs and return to the Symptom List if necessary 5 For previously read DTCs t...

Page 666: ...NOTES 248...

Page 667: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES 8 2 CONTROLS AND SOLENOIDS C O M P O N E N T L O C A T I O N S 249 COMPONENT LOCATIONS...

Page 668: ...8 3 DA TA LINK CONNECTOR C O M P O N E N T L O C A T I O N S 250 COMPONENT LOCATIONS 8 2 CONTROLS AND SOLENOIDS Continued...

Page 669: ...8 4 SENSORS C O M P O N E N T L O C A T I O N S 251 COMPONENT LOCATIONS...

Page 670: ...C O M P O N E N T L O C A T I O N S 252 COMPONENT LOCATIONS 8 4 SENSORS Continued...

Page 671: ...8 5 SWITCHES C O M P O N E N T L O C A T I O N S 253 COMPONENT LOCATIONS...

Page 672: ...NOTES 254...

Page 673: ...NER LINE 1 3 20BL PASSENGER SEAT BELT TENSIONER LINE 2 4 20BR PASSENGER SEAT BELT TENSIONER LINE 1 5 20BK FUSED IGNITION SWITCH OUTPUT RUN START 6 20BR GROUND 7 20YL AIRBAG WARNING INDICATOR DRIVER 8...

Page 674: ...ESSURE SERVOMOTOR CONTROL 5 CAMSHAFT POSITION SENSOR BLACK CAV CIRCUIT FUNCTION 1 20BR DG CAMSHAFT POSITION SENSOR GROUND 2 20YL GY CAMSHAFT POSITION SENSOR SIGNAL 3 18RD BL EXCEPT OBD CAMSHAFT POSITI...

Page 675: ...UTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR GROUND 26 20WT GY BRAKE PRESSURE SENSOR SIGNAL 27 18BK BL TCS SWITCH ASR SENSE 28 18BR LEFT FRONT WHEEL SPEED SENSOR 29 20BR LEFT REAR WHEEL SPEED SENSOR 30 2...

Page 676: ...R GROUND 5 20BR GROUND 6 7 20BL YL K ECM 8 20BK BL DG FUSED IGNITION SWITCH OUTPUT RUN START 9 20BL BK K ABS SHIFTER ASSEMBLY 10 11 20BL K TCM RADIO 12 20GY DG RD K CTM SSM 13 20BK RD K ACM 14 15 20WT...

Page 677: ...CAMSHAFT POSITION SENSOR SIGNAL 39 20GY O2 1 1 SENSOR CELL SIGNAL 40 20GY WT O2 1 1 VIRTUAL GROUND 49 16BK VT FUEL INJECTOR NO 4 LOW SIDE CONTROL 50 16BK DG FUEL INJECTOR NO 3 LOW SIDE CONTROL 51 16B...

Page 678: ...ENSOR 5 VOLT SUPPLY 25 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 26 18BR BL ACCEL PEDAL POSITION SENSOR GROUND NO 1 28 18BR DG INTAKE AIR TEMPERATURE SENSOR GROUND 31 20BL YL K ECM 32 20DG ENHAN...

Page 679: ...TOR NO 1 HIGH SIDE CONTROL FUEL INJECTOR NO 2 BLACK CAV CIRCUIT FUNCTION 1 14BK VT EXCEPT OBD FUEL INJECTOR NO 2 CONTROL 1 16BK BL OBD FUEL INJECTOR NO 2 LOW SIDE CONTROL 2 14BL EXCEPT OBD COMMON INJE...

Page 680: ...CTOR NO 5 LOW SIDE CONTROL 2 14BL EXCEPT OBD COMMON INJECTOR DRIVER NO 2 2 16BK WT OBD FUEL INJECTOR NO 5 HIGH SIDE CONTROL FUEL PRESSURE SENSOR BLACK CAV CIRCUIT FUNCTION 1 20BR GY FUEL PRESSURE SENS...

Page 681: ...UEL PUMP RELAY OUTPUT 87A FUEL QUANTITY CONTROL VALVE OBD CAV CIRCUIT FUNCTION 1 20BK WT FUEL QUANTITY SOLENOID CONTROL 2 18RD BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY FUEL TEMPERA TURE SENSOR CAV CIR...

Page 682: ...C O N N E C T O R P I N O U T S 264 CONNECTOR PINOUTS...

Page 683: ...FUSED IGNITION SWITCH OUTPUT RUN START 7 15A 16BK YL FUSED IGNITION SWITCH OUTPUT RUN START 8 20A 16RD YL FUSED B 9 15A INTERNAL FUSED B 10 10A 16GY DG RD HEADLAMP SWITCH OUTPUT 11 10A 16GY BK FUSED...

Page 684: ...C O N N E C T O R P I N O U T S 266 CONNECTOR PINOUTS...

Page 685: ...25A 16BK YL OPTIONAL EQUIPMENT RELAY OUTPUT 8 10A 16BK RD OPTIONAL EQUIPMENT RELAY OUTPUT 9 15A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 10 7 5A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 11 7 5A 16RD YL WT FU...

Page 686: ...C O N N E C T O R P I N O U T S 268 CONNECTOR PINOUTS...

Page 687: ...D FUSED B 9 40A 12RD FUSED B 10 30A 12RD GY FUSED B STARTER MOTOR RELA Y FUSE RELA Y BLOCK CAV CIRCUIT FUNCTION 30 12BK YL STARTER MOTOR RELAY OUTPUT 85 18VT DG STARTER MOTOR RELAY CONTROL 86 18RD BL...

Page 688: ...OLTAGE 4 14BK VT GLOW PLUG NO 2 SUPPLY VOLTAGE 5 14BK BL GLOW PLUG NO 1 SUPPLY VOLTAGE 6 INTAKE AIR PRESSURE SENSOR OBD CAV CIRCUIT FUNCTION 1 20BR RD INTAKE PRESSURE SENSOR GROUND 2 20VT DG INTAKE PR...

Page 689: ...0BR YL EXCEPT OBD MASS AIR FLOW SENSOR GROUND 3 20YL BL OBD MASS AIR FLOW SENSOR GROUND 4 20BR BK EXCEPT OBD MASS AIR FLOW SENSOR 5 VOLT SUPPLY 4 20YL DG OBD MASS AIR FLOW SENSOR SIGNAL 5 20YL DG EXCE...

Page 690: ...C O N N E C T O R P I N O U T S 272 CONNECTOR PINOUTS...

Page 691: ...SPEED CONTROL SWITCH CAV CIRCUIT FUNCTION 1 18GY OFF SIGNAL 2 18BK VERIFICATION SIGNAL 3 18BL RESUME SIGNAL 4 18YL DECEL SET SIGNAL 5 18DG ACCEL SET SIGNAL 6 18RD S C SWITCH 12 VOLT SUPPLY WA TER IN F...

Page 692: ...NOTES 274...

Page 693: ...10 0 SCHEMATIC DIAGRAMS 10 1 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 275 SCHEMATIC DIAGRAMS...

Page 694: ...10 2 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 276 SCHEMATIC DIAGRAMS...

Page 695: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 277 CHARTS AND GRAPHS...

Page 696: ...NOTES 278...

Page 697: ...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 698: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 699: ...d Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13...

Page 700: ......

Page 701: ...Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official docum...

Page 702: ...els Van 8 001 to 9 000 lbs class G D7 Sprinter 4042 mm 159 in in connection with 16 wheels Van 8 001 to 9 000 lbs class G 7 8 Engine 41 2 7L 5 cyl Diesel 612 ME9 42 2 7L 5 cyl Diesel 612 MF1 43 2 7L 5...

Page 703: ...strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts Fig 2 and Fig 3 Fig 1 INTERNATIONAL CONTRO...

Page 704: ...Fig 2 FASTENER IDENTIFICATION 4 INTRODUCTION VA...

Page 705: ...Fig 3 FASTENER STRENGTH VA INTRODUCTION 5...

Page 706: ...ION The metric system is based on quantities of one ten one hundred one thousand and one million The following chart will assist in converting metric units to equivalent English and SAE units or vise...

Page 707: ...Meter 1 Cubic Foot 0 03 Cubic Meter 1 Yard 0 9 Meter 1 Cubic Yard 0 8 Cubic Meter 1 Mile 1 6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton meters N...

Page 708: ...Fig 4 METRIC CONVERSION CHART 8 INTRODUCTION VA...

Page 709: ...CES DESCRIPTION Individual Torque Charts appear within many of the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 5 VA I...

Page 710: ...Fig 5 TORQUE SPECIFICATIONS 10 INTRODUCTION VA...

Page 711: ...servicing DaimlerChrysler Corporation vehicles AUTOMA TIC TRANSMISSION FLUID NAG1 NOTE Refer to Service Procedures in this group for fluid level checking procedures Use ATF approved to MB 236 10 MB 2...

Page 712: ...antin G05 BASF AG MOPAR part number 05066386AA or an equivalent Extended Life Coolant with the HOAT inhibitor system This cool ant offers the best engine cooling without corrosion when mixed with 50 a...

Page 713: ...s The following engine oils have been determined to meet DaimlerChrysler requirements DaimlerChrysler Approved En gine Oil SAE Rating MB Sheet Number 76 Pure Syn thetic Motor Oil 5W 40 229 3 76 Royal...

Page 714: ...10W 30 228 3 Ursa Premium TDX 15W 40 228 3 Valvoline Syn Power MXL 0W 30 229 3 1 Engine oil also meets API classification CI 4 Other oils may meet requirements see oil label to determine Use of the a...

Page 715: ...iate 21 TRANSMISSION AUTO MATIC FLUID STANDARD PROCEDURE REAR AXLE 03L 1 oz 8 1 2 1 8 L 4 0 pts FUEL TANK Primary 100 L 26 4 gal Reserve 10 5 L 2 8 gal Nominal refill capacities are shown A variation...

Page 716: ...E BEING USED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION When using another vehicle as a booster do not allow vehicles to touch Electrical systems can be damaged on eith...

Page 717: ...ansmission is Damaged Remove the propeller shafts leading to the drive axles The vehicle can be towed without restriction If the Front Axle is Damaged Raise the front axle Observe the same towing rest...

Page 718: ...e number of days a clock symbol will also appear in the multi function display You should have the maintenance performed within the stated period distance The service indicator will be reset after an...

Page 719: ...filter renewal Every oil service Air cleaner with maintenance indicator Check degree of contamination Air cleaner filter element renewed as necessary Chassis and body Trailer coupling Check operation...

Page 720: ......

Page 721: ...ARM REMOVAL 6 INSTALLATION 7 SPRING REMOVAL 7 INSTALLATION 8 SPRING CLAMP PLATES REMOVAL 8 INSTALLATION 9 SPRING STOP PLATES REMOVAL 9 INSTALLATION 9 STABILIZER BAR DESCRIPTION 9 OPERATION 9 REMOVAL...

Page 722: ...44 Outer Tie Rod End Nut 130 96 Outer Tie Rod End Nut Jam Nut 50 37 SPECIAL TOOLS FRONT SUSPENSION SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 9288 LEAF SPRING WEDGE BLOCK...

Page 723: ...bushing into the control arm using special tool C 4212F and 9302 1 Driver with 9302 2 Sizer cup and 9302 4 Receiver Fig 2 3 Press the bushing in all the way until the lip is seated properly into the...

Page 724: ...heels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the wheel flange ring if equipp...

Page 725: ...icle 2 Remove the front wheels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the hu...

Page 726: ...all joint using special tool 9294 1 Driver with 9294 2 Reciever and C 4212 F Fig 7 INSTALLA TION 1 Install the ball joint into the lower control arm using special tool 9294 3 Installer ring inserted i...

Page 727: ...N 9 Lower the vehicle 10 Remove the spring blocks between the spring and the spring clamp plates While the vehicles wheels are on the ground 11 Roll the vehicle approximately 1 mm forwards and the bac...

Page 728: ...knuckle on the lower ball joint 4 Raise the lower control arm approximately 10 mm with a jack 5 Install both stop plate bolts to the lower control arm 6 Install the strut bolts to the steering knuckl...

Page 729: ...lts retaining the spring stop plate from the lower control arm INSTALLA TION 1 Install the spring stop plate to the lower con trol arm Tighten the bolts to 60 N m 44 ft lbs 2 Install the stabilizer li...

Page 730: ...ver for the upper strut mounting Fig 12 4 Remove the nut on the upper strut mounting Fig 12 5 Raise and support the vehicle 6 Remove the front wheels 7 Raise the lower control arm approximately 10 mm...

Page 731: ...ehicle ride comfort could be affected and premature bush ing wear may occur DIAGNOSIS AND TESTING SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between...

Page 732: ...shock 3 Leaking shock 3 Replace shock SPECIFICA TIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Sway Bar Link 95 60 Sway Bar Clamp To Axle SRW 25 18 Sway Bar Clamp To Axle DRW 7...

Page 733: ...e action throughout each stroke should be smooth and even The shock absorber bushings do not require any type of lubrication Do not attempt to stop bushing noise by lubricating them Grease and mineral...

Page 734: ...t the vehicle 2 Support the rear axle 3 Remove the U bolt and spring plate Fig 3 4 Remove the spring from the front spring bracket Fig 3 5 Remove the rear spring with the spring shackle from the sprin...

Page 735: ...ing Tighten to 90 N m 66 ft lbs 2 Raise the rear axle while installing the spring shackle to the spring bracket Tighten to 85 N m 63 ft lbs 3 Lower the vehicle STABILIZER BAR REMOVAL 1 Raise and suppo...

Page 736: ...ION 1 Install the stabilizer bar to the stabilizer links and tighten to 95 N m 60 ft lbs Fig 4 2 Lower the vehicle 3 Install the stabilizer link to the frame Tighten to 95 N m 60 ft lbs Fig 5 SWAY BAR...

Page 737: ...ents An alignment is considered essential for efficient steering good directional stabil ity and to minimize tire wear The most important measurements of an alignment are caster camber and toe Fig 1 C...

Page 738: ...sure 4 Alignment 4 Align vehicle to specifications EXCESSIVE STEERING EFFORT 1 Loose or worn steering gear 1 Replace steering gear 2 Column coupler binding 2 Replace coupler 3 Tire pressure 3 Adjust t...

Page 739: ...erence Max 1 33 Caster 0 0 5 Steering Knuckle Inclina tion 0 0 5 Steering Knuckle Inclina tion Left to Right Difference Max 1 REAR SPECIFICATIONS DESCRIPTION REAR SPECIFICATION Toe In Max 0 0 25 Cambe...

Page 740: ......

Page 741: ...ON 10 PROPELLER SHAFT DIAGNOSIS AND TESTING PROPELLER SHAFT PROPELLER SHAFT VIBRA TION Out of round tires or wheels that are out of bal ance will cause a low frequency vibration Driveline vibration ca...

Page 742: ...rsal Joint Noise 1 Loose U joint clamp screws 1 Install new clamps and screws and tighten to proper torque 2 Lack of lubrication 2 Replace as U joints as neces sary PROPELLER SHAFT BALANCE NOTE Removi...

Page 743: ...LER SHAFT RUNOUT 1 Clean the propeller shaft surface where the dial indicator will contact the shaft 2 The dial indicator must be installed perpendic ular to the shaft surface 3 Measure runout at the...

Page 744: ...ubble in sight glass and record measurement This measurement w ill give you the transmis sion yoke Output Angle A 6 Rotate propeller shaft 90 degrees and place inclinometer on yoke bearing parallel to...

Page 745: ...propeller shaft angles involved with a two three piece Fig 5 propel ler shaft is the same as those for a one piece propel ler shaft Fig 4 UNIVERSAL JOINT ANGLE EXAMPLE 1 4 9 Angle C 2 3 2 Angle B 3 I...

Page 746: ...rame floor bolt 100 74 Center Bearing support to frame floor bolt 95 70 Center Bearing to support nut 105 77 SPECIAL TOOLS SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 938 BR...

Page 747: ...n at the flange 5 Remove propeller shaft intermediate bearing nuts from retaining bracket and bracket for brake cable NOTE The brake cable bracket is only installed in vehicles with wheelbase 3550 mm...

Page 748: ...Fig 8 2 PIECE PROPELLER SHAFT 1 FLANGE BOLT 6 NUT 2 BEARING 7 BRACKET 3 PROPELLER SHAFT 8 RETAINING BRACKET 4 REAR AXLE 9 COLLARED BOLT 5 CABLE BRACKET 10 TRANSMISSION 3 8 PROPELLER SHAFT VA...

Page 749: ...e 3550 mm 4 Install propeller shaft to rear axle and trans mission flange with installation marks are aligned Tighten bolts to 70 N m 66 ft lbs 5 Install retaining bracket and tighten bolts to 100 N m...

Page 750: ...ring splitter must be positioned behind the thrust washer of the bearing INSTALLA TION 1 Press center bearing on propeller shaft with protective caps and washer with Installer 9275 Fig 14 Fig 11 BOOT...

Page 751: ...2 Install snap ring 3 Coat propeller shaft spline with universal grease 4 Push rubber boot onto propeller shaft 5 Push together propeller shaft Pay attention to alignment markings for installation pos...

Page 752: ...and then acceler ate the vehicle to the speed range where the noise is the greatest Shift out of gear and coast through the peak noise range If the noise stops or changes greatly Check for insufficie...

Page 753: ...he vehicle is shifted into gear or the clutch engaged can be caused by High engine idle speed Transmission shift operation Loose engine transmission transfer case mounts Worn U joints Loose spring mou...

Page 754: ...TOR CONNECTOR 2 U BRACKET 13 BRAKE HOSE 3 PLATE 14 WHEEL BOLT 4 NUT 15 BOLT 5 BRAKE CABLE 16 NUT 6 REAR AXLE 17 PROPELLER SHAFT 7 ABL LEVER 18 BOLT 8 NUT 19 ABS SENSOR 9 SHOCK ABSORBER 20 SENSOR BUSHI...

Page 755: ...move brake cables 9 Remove hand brake cable at relay unit 10 Remove bracket for brake cables at rear axle tube 11 Remove stabilizer bar from axle brackets 12 Remove shock absorber bolts from rear axle...

Page 756: ...ICATOR CONNECTOR 2 U BRACKET 13 BRAKE HOSE 3 PLATE 14 WHEEL BOLT 4 NUT 15 BOLT 5 BRAKE CABLE 16 NUT 6 REAR AXLE 17 PROPELLER SHAFT 7 ABL LEVER 18 BOLT 8 NUT 19 ABS SENSOR 9 SHOCK ABSORBER 20 SENSOR BU...

Page 757: ...wn clips 9 Install and adjust park brake cables 10 Install connection cable of brake pad wear indicator and ABS sensor cable up to the relay unit of the parking brake 11 Install cable ties to the park...

Page 758: ...in SRW Differential Torque to Rotate 20 40 N m 15 30 ft lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Drain Plug 100 74 Fill Plug 100 74 Differential Cover Bolts 65 48 Ring Gear Bolts 180 1...

Page 759: ...N A 8992 FLANGE PULL ER N A 9084 REMOVER N A 9275 INSTALLER 460 589 15 15 00 9276 INSTALLER 741 589 00 35 00 9277 PLATE 741 589 01 15 00 9278 INSTALLER 460 589 01 07 00 9279 WRENCH 309 589 01 07 00 9...

Page 760: ...REMOVER D 103 SCOOTER BLOCK D 115 2A INSTALLER 6448A INSTALLER 8617 FLANGE PULLER 8992 REMOVER 9084 INSTALLER 9275 INSTALLER 9276 3 20 REAR AXLE VA...

Page 761: ...PLATE 9277 INSTALLER 9278 WRENCH 9279 WRENCH 9290 INSTALLER 9291 SPREADER ADAPTERS 9317 INSTALLER 9523 VA REAR AXLE 3 21...

Page 762: ...DIAL INDICATOR 9524 INSTALLER 9548 ARBOR DISC 9571 PINION BLOCK 9572 DUMMY BEARING 9573 3 22 REAR AXLE VA...

Page 763: ...l house 5 Remove brake shoes 2 of parking brake 6 Remove brake control cable lock 7 Remove bearing cap bolts 17 and pull axle shaft out of axle tube 1 Fig 6 8 Remove seal gasket Fig 6 AXLE SHAFT 1 REA...

Page 764: ...pedal several times until brake pads contact brake discs brake pressure built up 10 Install wheels BEARING SEAL AXLE REMOVAL 1 Remove rear axle shaft 2 With a punch 2 and hammer straighten bear ing 4...

Page 765: ...ng cover and tapered roller bearings 2 Fig 13 8 Remove tapered roller bearings 6 sealing ring 7 dust shield 5 and bearing cover 2 from axle shaft 1 Fig 14 9 Remove shaft seal 3 from bearing cover 2 wi...

Page 766: ...de of the locking ring must point towards the nut Fig 17 The locking ring is fitted to ensure the pressing is done over the inner bear ing race only The flat on the locking ring must be aligned with t...

Page 767: ...nch at both grooves in the bearing nut Fig 19 NOTE The grooved nut must be locked in both directions of rotation 11 Install sealing ring 4 onto roller bearing race Fig 19 12 Install rear axle shaft SH...

Page 768: ...VAL 1 Remove brake caliper with support 2 Remove axle shaft 3 Back off parking brakes 4 Remove outer hub nut 1 with Wrench 9290 Fig 22 5 Remove locking plate 2 inner hub nut 1 and thrust washer 3 Fig...

Page 769: ...ar SQ 32 M sealant CAUTION Do not coat seals rubberized sealing sur faces with sealant 5 Install seal 2 into hub with an appropriate installer NOTE Seal ring should be flush with wheel hub or max 3mm...

Page 770: ...el hub constantly Turn back inner nut and then tighten until it touches the thrust washer without play Then tighten 1 8 turn 13 Install locking plate 2 Fig 29 14 Install outer hub nut and tighten with...

Page 771: ...spread CAUTION Never spread over 0 3 mm 0 011 in If the housing is over spread it could be distorted or damaged 8 Remove differential 2 with bearings cups 3 and differential shims Fig 32 9 Mark bearin...

Page 772: ...f differential pinion gears 1 spherical washers and mate shaft 2 Fig 35 4 Remove second set of differential pinion gears 2 spherical washers and mate shaft 1 Fig 36 Fig 33 DIFFERENTIAL COVER 1 BOLTS 2...

Page 773: ...per differential side gear 1 and shim 2 Fig 39 3 Remove differential cross shaft 1 with pinion gears 2 and spherical washers 3 Fig 40 Fig 37 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENTIAL CASE Fig 38 DIFF...

Page 774: ...ntial pinions gears 1 with spherical washers and mate shaft 2 Fig 43 3 Install second pinion gears 2 with spherical washers and mate shaft 1 Fig 44 Fig 41 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENTIAL CA...

Page 775: ...o 45 N m 33 ft lbs Fig 47 7 Check torque to rotate the differential gears with Torque Tool 9744 and a torque wrench Torque should be 20 40 N m 15 30 ft lbs NOTE Shims are available in 0 05 mm 0 002 in...

Page 776: ...49 3 Install upper differential side gear 1 and shim 2 Fig 50 4 Install differential cover with location numbers 1 on differential case 2 aligned Fig 51 Fig 48 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENT...

Page 777: ...ngs cups 3 and shims Fig 53 3 Loosely install differential bearing cap bolts 4 Remove spreader 2 and adapters 1 from housing Fig 54 5 Tighten bearing cap bolts to 70 N m 52 ft lbs 6 Install axle shaft...

Page 778: ...37 3 Fig 55 INSTALLA TION 1 Set differential on Plug C 293 3 2 Install differential 2 bearings 3 with Installer 9523 4 and Handle C 4171 1 Fig 56 3 Install differential case in axle Fig 55 CASE BEARIN...

Page 779: ...icles shavings in the drained oil replace gear assembly 6 Measure and record torque to rotate the pinion 7 Mark pinion position to pinion flange 1 Fig 57 8 Unlock collared nut 9 Hold pinion flange 1 w...

Page 780: ...ion flange NOTE Should bearing not be free of play tighten in increases of 10 N m 88 in lbs to maximun of 130 N m 95 ft lbs If bearing is not free from play at 130 N m 95 ft lbs collapsible spacer mus...

Page 781: ...jaw 3 Remove ring gear bolts from the differential case 4 Drive ring gear off the differential case with a dead blow hammer Fig 64 5 Unlock collared nut 6 Hold pinion flange with Flange Wrench C 3281...

Page 782: ...him in rear pinion bear ing cup bore 3 Install rear pinion bearing cup with Installer C 4310 and Driver Handle C 4171 4 Install front pinion bearing cup with Installer 8617 and Handle C 4171 5 Install...

Page 783: ...al with Installer 9276 Fig 72 10 Hold pinion flange with Flange Wrench C 3281 11 Screw on the new collared nut 12 Tighten collar nut carefully to a torque to rotate of 2 5 3 N m 22 27 in lbs 13 Cut th...

Page 784: ...l new ring gear bolts and alternately tighten to 180 N m 133 ft lbs Fig 75 CAUTION Do not reuse ring gear bolts the bolts can fracture causing extensive damage Failure to heed caution may result in da...

Page 785: ...6 WHEELS SRW 11 INSTALLATION REAR 16 WHEELS SRW 11 INSTALLATION REAR DRW 11 DISC BRAKE CALIPERS REMOVAL REMOVAL FRONT SRW 11 REMOVAL FRONT DRW 12 REMOVAL REAR SRW 12 REMOVAL REAR DRW 13 INSTALLATION I...

Page 786: ...ise when braking check suspension components J ounce front and rear of vehicle and listen for noise that might be caused by loose worn or damaged suspension or steering components 3 Inspect brake flui...

Page 787: ...tant contact with the rotor or drum Drag can occur at one wheel all wheels fronts only or rears only Drag is a product of incomplete brake shoe release Drag can be minor or severe enough to overheat t...

Page 788: ...ration BRAKE NOISES Some brake noise is common with rear drum brakes and on some disc brakes during the first few stops after a vehicle has been parked overnight or stored This is primarily due to the...

Page 789: ...Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding Do not pressure bleed without a proper master cyl inder adapter The wrong adapter can lead to leak age o...

Page 790: ...4 in Rear Disc Brake Rotor Max Axial Runout DRW 02 mm 0 0007 in Front Disc Brake Rotor New DRW 22 mm 0 866 in Front Disc Brake Rotor Wear Limit DRW 19 mm 0 748 in Front Disc Brake Rotor Max Lateral Ru...

Page 791: ...WD241 WD341 14 mm 0 55 in Rear Disc Brake Rotor Max Lateral Runout Models WD2 YD141 YD241 YD341 YD441 YD541 WD5 WD141 WD241 WD341 1 mm 0 0007 in Rear Disc Brake Rotor Max Axial Runout Models WD2 YD14...

Page 792: ...gency repair when factory replacement parts are not readily available 1 Cut off damaged tube with Tubing Cutter 2 Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on the...

Page 793: ...ake caliper Fig 5 7 Remove the brake pads Fig 5 REMOVAL REAR 16 WHEELS SRW 1 Unscrew the cap from the brake fluid reservoir 2 Raise and support the vehicle 3 Remove the rear wheels Refer to 22 TIRES W...

Page 794: ...ort the vehicle 3 Remove the rear wheels Refer to 22 TIRES WHEELS WHEELS INSTALLATION 4 Remove the wear indicator cable and the wear indicator Fig 8 NOTE Seal off the line ends and connection threads...

Page 795: ...n the guide pins to 25 N m 221 in lbs for M8 bolt or 30 N m 266 in lbs for M10 bolt 4 Install the retaining spring Fig 6 5 Install the rear wheels Refer to 22 TIRES WHEELS WHEELS INSTALLATION 6 Lower...

Page 796: ...racks 5 Remove the brake hose at the brake caliper Fig 10 6 Remove the brake caliper guide bolt Fig 10 7 Remove the brake caliper Fig 10 REMOVAL REAR SRW 1 Unscrew the cap from the brake fluid reservo...

Page 797: ...tor cable and the wear indicator Fig 9 Tighten to 10 N m 89 in lbs 4 Bleed the brake system 5 Check the brake system for any leaks 6 Install the front wheels 7 Lower the vehicle INSTALLA TION FRONT DR...

Page 798: ...EMOVAL 4 Remove the disc brake caliper from the caliper adapter Refer to 5 BRAKES HYDRAULIC ME CHANICAL DISC BRAKE CALIPERS REMOVAL 5 Remove the disc brake pads Refer to 5 BRAKES HYDRAULIC MECHANICAL...

Page 799: ...mum dry boiling point ERBP 500 F minimum wet boiling point WERBP 356 F maximum viscosity 1500 mm2 s conforming to FMVSS 116 and ISO 4925 No other type of brake fluid is recommended or approved for usa...

Page 800: ...d down rod 7 Fill and bleed the brake system Refer to 5 BRAKES STANDARD PROCEDURE 8 Raise the vehicle and adjust the ALB controller Refer to 5 BRAKES HYDRAULIC MECHANICAL ALB CONTROLLER ADJ USTMENTS 9...

Page 801: ...should fall away slightly under light foot pressure then hold firm If no pedal action is discernible power booster vacuum supply or vacuum check valve is faulty Pro ceed to the POWER BOOSTER VACUUM T...

Page 802: ...them to return under spring pressure Continue bleeding operations until air bubbles are no longer visible in fluid REMOVAL 1 Using a suction gun remove as much brake fluid from the reservoir as possi...

Page 803: ...22 Tighten to 23 N m 204 in lbs 2 Reconnect the plug connector for the stop lamp switch Fig 22 3 Install the brake pedal and hook the spring Fig 22 4 Install the retainer and pin for the brake pedal F...

Page 804: ...ter Tighten to 28 N m 248 in lbs 6 Install the brake lines to the master cylinder Tighten to 14 N m 124 in lbs 7 Install the brake level switch electrical connec tor 8 Bleed the base brake system Refe...

Page 805: ...caliper adapter Fig 27 5 Apply the parking brake 6 Install two lug studs to secure the disc brake rotor when the locking bolt is removed 7 Remove the wheel flange ring Fig 27 8 Remove the locking bolt...

Page 806: ...NSTALLA TION FRONT DRW 1 Install the disc brake rotor to the hub and install two lug studs to hold rotor in place 2 Install the locking bolt for the rotor Fig 26 Tighten to 23 N m 204 in lbs 3 Install...

Page 807: ...INSTALLA TION REAR 1 Press the brake support plate with the axle bearing onto the axle shaft Refer to 3 DIFFEREN TIAL DRIVELINE REAR AXLE AXLE BEARINGS INSTALLATION 2 Install the park brake cable to...

Page 808: ...N 1 Push the brake control cable lock onto the brake cable Fig 28 2 Insert the safety bolt and snap shut the brake control cable lock Observe the installation posi tion of the brake control cable lock...

Page 809: ...he brake cable lock for reference on installation 7 Remove the hand brake cable from the anchor plate Fig 31 8 Remove the park brake cable from the vehicle Compress the locking ring on the pulley unit...

Page 810: ...n the bolts to the mounting bracket Tighten to 25 N m 221 in lbs Fig 33 5 Remove the 6 mm diameter drill bit or allen wrench Fig 33 6 Tighten the hand brake lever one notch Fig 33 7 Clamp the eccentri...

Page 811: ...special tool 9280 Fig 36 6 Remove the adjuster Fig 36 7 Remove the pressure springs using special tool 9281 Fig 36 8 Remove the rear park brake shoes Fig 36 Pull the park brake shoes apart at the bott...

Page 812: ...E Preassemble the retracting spring with the short hook eye from the inside together with the adjuster wheel at the bottom Fit the preassembled park brake shoes on the brake carrier 1 Ensure that the...

Page 813: ...e vehicle and test the park brake sys tem to hold the vehicle Fig 38 STAR WHEEL ADJUSTER 1 LEFT HAND PARK BRAKE SHOES APPLIED 2 RIGHT HAND PARK BRAKE SHOES RELEASED 3 FLAT BLADED TOOL Fig 39 ADJUSTING...

Page 814: ...port plate OPERA TION The Wheel Speed Sensor consists of a magnet sur rounded by windings from a single strand of wire The sensor sends a small AC signal to the CAB This signal is generated by magneti...

Page 815: ...h new sensor Fig 2 INSTALLA TION 1 Connect separate wheel speed sensor cables with shrink fit sleeves and shrink fit tubing Fig 2 Only do this step if replacing the sensor 2 Install the clamping bushi...

Page 816: ...ng and the inside of the tone wheel and pry upwards slightly and work your way around the tone wheel until the wheel is loose Fig 4 3 Remove the tone wheel INSTALLA TION 1 Install the tone wheel to th...

Page 817: ...ring Refer to 8 ELECTRI CAL RESTRAINTS CLOCKSPRING INSTALLA TION Fig 6 4 Install the upper and lower steering column covers Fig 6 5 Install the front cover Fig 6 6 Install the steering wheel Refer to...

Page 818: ...connect the yaw rate lateral acceleration sensor electrical connector Fig 11 2 Install the yaw rate lateral acceleration sensor 3 Install the metal cover over top of the sensor 4 Install the screws se...

Page 819: ...ide to side Lateral motion and vehicle rotational sensing how fast the vehicle is turning This is a 6 wire sensor with all six wires connected to the ESP ABS module REMOVAL 1 Disconnect the battery 2...

Page 820: ...essure accumulators inlet valves outlet valves and noise attenuators REMOVAL NOTE Store the Hydraulic Control Unit in an upright position only 1 Disconnect the ground cable at the battery The ignition...

Page 821: ...ulic con trol unit Fig 17 Do not mix up the brake lines Tighten the lines to 16 N m 142 in lbs 3 Reconnect the multiplug to the control module Fig 17 4 Reconnect the ground cable on the battery 5 Blee...

Page 822: ......

Page 823: ...SLOW TRAFFIC TRAFFIC J AMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more...

Page 824: ...ion ing correctly 2 Check gauge Refer to 8 ELECTRICAL INSTRUMENT CLUS TER DIAGNOSIS AND TESTING 3 Air traped in cooling 3 Drain cooling system Refer to 7 COOLING STANDARD PROCE DURE and refill Refer t...

Page 825: ...2 Radiator neck surface damaged 2 Replace radiator HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum created in cooling sys tem on engine cool down is not being relieved through coolant re servi...

Page 826: ...tion 2 Obstruction in heater hoses 2 Remove hoses remove obstruc tion 3 Water pump damaged 3 Replace water pump HEAT ODOR 1 Damaged or missing drive line heat shields 1 Repair or replace damaged or mi...

Page 827: ...the arrow must be within approximately 3 mm 1 8 in of indexing mark Belt is considered new if it has been used 15 minutes or less If this specification cannot be met check for The wrong belt being ins...

Page 828: ...misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace pulley Inspect...

Page 829: ...or rumble is heard or felt while drive belt is in operation 1 Incorrect belt tension 1 Inspect Replace tensioner if nec essary 2 Bearing noise 2 Locate and repair 3 Belt misalignment 3 Align belt pull...

Page 830: ...sen tension adjuster 2 Remove A C compressor drive belt INSTALLATION INSTALLA TION CAUTION When installing the accessory drive belt the belt must be the correct length and routed cor rectly If not eng...

Page 831: ...Maximum protection against freezing is provided with a 68 percent antifreeze concentration which prevents freezing down to 67 7 C 90 F A higher percentage will freeze at a warmer temperature Also a h...

Page 832: ...diator upper hose is warm to touch Aim the commercially available black light tool at components to be checked If leaks are present black light will cause additive to glow a bright green color The bla...

Page 833: ...MOVING TESTER DO NOT TURN TESTER MORE THAN 1 2 TURN IF SYSTEM IS UNDER PRESSURE Operate engine without pressure cap on coolant container until thermostat opens Attach a Pressure Tester to container If...

Page 834: ...d coolant solution CAUTION Do not use coolant additives that are claimed to improve engine cooling DRAINING COOLING SYSTEM WARNING Do not remove the cylinder block drain plug or loosen the radiator dr...

Page 835: ...he container w hen the engine is cold Coolant level in a w arm engine w ill be higher due to thermal expansion To purge the cooling system of all air this heat up cool down cycle adding coolant to col...

Page 836: ...from rotating Fig 5 4 Remove radiator fan shroud and radiator fan Fig 5 NOTE Store the viscous fan clutch in the upright position DO NOT place down flat INSTALLA TION 1 Install fan blade to viscous cl...

Page 837: ...nd eyes from scalding with hot coolant Risk of poisoning from swallowing coolant Do not open cooling system unless coolant temperature is below 90 C Open cap slowly to release pressure Store coolant i...

Page 838: ...pull off locking element and pull out coolant temperature sensor 4 Detach air intake hose at charge air distribu tion pipe 5 Detach coolant hoses at thermostat housing 6 Unscrew cap at oil filter hous...

Page 839: ...CAP SLOWLY TO RELEASE PRESSURE STORE COOL ANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER WEAR PROTECTIVE GLOVES CLOTHES AND EYE WEAR NOTE Capture all residual fluid spillage and store in suitably...

Page 840: ...ring intercooler to radiator 14 Remove screws and upper radiator trim from radiator 15 Move condenser intercooler power steering cooler assembly forward 16 Lift the radiator assembly up and out of the...

Page 841: ...6 Install A C condenser 17 Install front bumper 18 Install front end cross member 19 Refill power steering to proper level 20 Refill transmission to proper level 21 Close radiator drain plug and refil...

Page 842: ...ithin the 124 145 kPa 18 21 psi range for 30 seconds or more If the pointer drops quickly replace the cap CAUTION Radiator pressure testing tools are very sensitive to small air leaks which will not c...

Page 843: ...1 Disconnect the negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove viscous fan clutch 4 Detach fuel lines from the brackets at the water pump...

Page 844: ...washer behind the guide pulley to assure proper alignment 3 Install belt guide pulleys Tighten bolts to 35 N m 26 lbs ft Fig 13 4 Attach the coolant hoses to the water pump and tighten clamps Fig 13...

Page 845: ...rs Refer to 23 BODY INTERI OR HEADLINER REMOVAL 3 Disconnect the antenna and electrical connec tions near the windshield Fig 1 4 Remove the mounting nut 5 Remove the antenna assembly from the roof and...

Page 846: ...to instrument panel wire harness 5 Install glove box Refer to 23 BODY INSTRU MENT PANEL GLOVE BOX INSTALLATION 6 Install the headliner Refer to 23 BODY IN TERIOR HEADLINER INSTALLATION 7 Install the...

Page 847: ...ctor and remove speaker INSTALLA TION 1 Install wire harness connector 2 Place speaker into instrument panel 3 Install speaker grille 4 Install the A pillar trim Refer to 23 BODY INTERIOR A PILLAR TRI...

Page 848: ......

Page 849: ...l sys tem and to the EMIC through the use of a combina tion of soldered splices splice block connectors and many different types of wire harness terminal con nectors and insulators Refer to the approp...

Page 850: ...internal programming and hard wired inputs from the front door ajar switches the key in ignition switch the ignition switch the seat belt switch and the turn signal hazard warning multi function switc...

Page 851: ...vides the optional Remote Keyless Entry RKE system fea tures including support for the RKE Lock with optional horn and park lamps flash Unlock with park lamps flash driver door only unlock and unlock...

Page 852: ...ent panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before perform ing further diagnosis or s...

Page 853: ...ower dash panel and consists of an electronic printed circuit board which is designed as a milliliter board assembly fitted on both sides The routing of the wiring harness connector at the ECM connect...

Page 854: ...electrical appliances Starter control immobilizer cruise control kick down air conditioner Maintenance computer ASSYST optional Glow plug for pre heating post heating and intermittent heating Error c...

Page 855: ...ccelerator pedal module which is equipped with dual hall sensors Measurement of the intake air mass using new mass air flow MAF sensor with increase precision and extended measuring range O2 sensor fo...

Page 856: ...the function mentioned above The high precision of the MAF measurement enables the calculation of the actual injection quantity from the measured air mass and from the oxygen sensor signal in order to...

Page 857: ...ulic prob lems When a problem is sensed the TCM stores a diagnostic trouble code DTC Some of these codes cause the transmission to go into Limp In or default mode Some DTCs cause permanent Limp In and...

Page 858: ...tes SHIFT SCHEDULES The basic shift schedule includes up and down shifts for all five gears The TCM adapts the shift program according to driving style accelerator pedal position and deviation of vehi...

Page 859: ...re in order for shift member to apply These return springs have slightly different values This also affects the application pressure and is compen sated for by fill pressure adaptation Fill Time Adapt...

Page 860: ...C 140 F and less than 70 C 158 F Fail ure to stay within these temperature ranges will void the procedure 2 Drive the vehicle until the transmission tem perature is in the specified range 3 Perform 4...

Page 861: ...INSTALLATION 16 BATTERY TRAY DESCRIPTION 16 OPERATION 16 REMOVAL 16 INSTALLATION 16 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on this model Some veh...

Page 862: ...system In order for the engine to start and the battery to maintain its charge properly all of the components that are used in these systems must perform within specifications It is important that th...

Page 863: ...nal con nections are loose or cor roded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The bat...

Page 864: ...nosis and testing procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which...

Page 865: ...with a sodium bicarbonate baking soda and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film Fig 2 Rinse the battery with clean water Ensure that the clea...

Page 866: ...capacity low maintenance storage batteries are standard factory installed equipment on this model The primary battery is located in the engine compartment on all models A second auxiliary bat tery may...

Page 867: ...ed period A battery must also be able to accept a charge so that its voltage potential may be restored The battery is vented to release excess hydrogen gas that is created when the battery is being ch...

Page 868: ...r to evaluate the battery condition Damage to the battery may result from overcharging CAUTION The battery should not be hot to the touch If the battery feels hot to the touch turn off the charger and...

Page 869: ...very low at first As the battery warms it will accept a higher charging current rate amperage Charger Capacity A battery charger that supplies only five amperes will require a longer charging time A...

Page 870: ...battery In most cases the battery can be charged and returned to service after the excessive IOD condition has been corrected 1 Verify that all electrical accessories are off Turn off all lamps remov...

Page 871: ...h a wire brush before test ing If the battery is equipped with side post termi nals install and tighten the supplied lead terminal stud adapters Do not use steel bolts Failure to prop erly install the...

Page 872: ...e certain that all electrical accessories are turned off 2 Loosen the battery negative cable terminal clamp pinch bolt hex nut 3 Disconnect the battery negative cable terminal clamp from the battery n...

Page 873: ...ghten the terminal clamp pinch bolt hex nut to 7 9 N m 70 in lbs 5 Apply a thin coating of petroleum jelly or chas sis grease to the exposed surfaces of the battery cable terminal clamps and the batte...

Page 874: ...he male terminal posts on the top of the battery The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection...

Page 875: ...terminal clamp Fig 10 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor connection between the battery positive cable terminal cla...

Page 876: ...battery The battery tray sup port supports the battery tray and provides an anchor point for the inboard battery hold down hard ware The battery tray and the battery hold down hardware combine to sec...

Page 877: ...LER 20 REMOVAL 20 INSTALLATION 22 VOLTAGE REGULATOR DESCRIPTION 24 REMOVAL 24 INSTALLATION 26 CHARGING SYSTEM SPECIFICATIONS TORQUE 2 7L DIESEL DESCRIPTION N m Ft Lbs In Lbs B Terminal Nut larger of 2...

Page 878: ...djusted fan drive belt loose mount ing bolts a misaligned drive pulley or a defective sta tor or diode An instrument panel mounted battery charge indi cator lamp is used When the key is in the on posi...

Page 879: ...hematics in Cooling System 8 Install generator drive belt Refer to Cooling System for procedure 9 Connect negative battery cable 10 Check charging system for proper operation GENERATOR DECOUPLER PULLE...

Page 880: ...ry cable 2 Remove generator and accessory drive belt Refer to Generator Removal 3 Position Special Tool 8823 VM 1048 into decoupler Fig 5 4 Determine if end of generator shaft is hex shaped Fig 6 or i...

Page 881: ...UPLER 2 TOOL 8823 VM 1048 Fig 6 END OF GENERATOR SHAFT HEX 1 GENERATOR SHAFT 2 HEX Fig 7 END OF GENERATOR SHAFT SPLINED 1 GENERATOR SHAFT 2 SPLINES Fig 8 DECOUPLER REMOVAL INA HEX 1 DEEP 10 MM SOCKET...

Page 882: ...ler by hand from generator INSTALLA TION INA Decoupler 1 Thread decoupler pulley onto generator shaft by hand right hand threads 2 Position Special Tool 8823 VM 1048 into decoupler Fig 5 3 Determine i...

Page 883: ...nd threads 2 Position Special Tool 8433 Fig 10 into decou pler Align tool to hex end of generator shaft 3 Do not use an adjustable ratcheting click type torque w rench Most click type w renches w ill...

Page 884: ...1 Disconnect and isolate negative battery cable 2 Raise and support vehicle 3 Remove bolt 2 Fig 16 at turbocharger brace 1 Fig 16 4 Loosen bolt 1 Fig 17 at brace 2 Fig 17 Swivel the race 2 to the side...

Page 885: ...nting or tipping 10 Check condition of commutator rings 1 Fig 20 If rings are worn replace generator assembly 11 Check condition of carbon brushes 1 Fig 21 If brushes are worn replace generator assemb...

Page 886: ...e to the carbon brushes 1 Fig 22 slow ly install the voltage regulator straight into the generator w ithout slanting or tipping 4 Install screws 1 3 and 4 Fig 24 5 Install plastic cover 1 Fig 25 screw...

Page 887: ...1 Fig 26 at brace 2 Fig 26 Tighten bolt 1 to 20 N m 15 ft lbs 9 Install bolt 2 Fig 27 at turbocharger brace 1 Fig 27 Tighten bolt 2 to 30 N m 22 ft lbs 10 Lower vehicle 11 Connect negative battery ca...

Page 888: ...rage feed circuit components include the battery the battery cables the contact disc por tion of the starter solenoid and the starter motor itself The low amperage control circuit components include t...

Page 889: ...Relay in Diagnosis and Testing Re place starter relay if required 4 Ignition switch faulty 4 Refer to Ignition Switch and Key Lock Cylinder Re place ignition switch if required 5 Clutch pedal positio...

Page 890: ...n Sw itch and Key Lock Cylinder Park Neutral Position Sw itch Visually inspect park neutral position switch for indications of physical damage and loose or corroded wire harness connections Refer to P...

Page 891: ...ry cable clamp to terminal post connection and positive battery cable The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing tests be certain that following proc...

Page 892: ...esistance tests detect no feed circuit problems refer to Starter Motor in the Diagnosis and Testing CONTROL CIRCUIT TESTING The starter control circuit components should be tested in the order in whic...

Page 893: ...oft jawed bench vise The vise jaws should be clamped on the mounting flange of starter motor Never clamp on starter motor by field frame 3 Connect a suitable volt ampere tester and a 12 volt battery t...

Page 894: ...position wiring harness trough for access to starter 4 Working from under vehicle hood remove 2 starter solenoid wiring harness nuts Fig 10 5 Remove solenoid wire connector from solenoid stud and bat...

Page 895: ...rming to ISO specifications have common physical dimensions cur rent capacities terminal patterns and terminal func tions The starter relay cannot be repaired or adjusted and if faulty or damaged it m...

Page 896: ...he drivers seat See Fuse Relay Block cover for relay identification and location or refer to Fig 12 1 Install relay into Fuse Relay Block 2 Install cover to side of Fuse Relay Block snaps on Fig 13 FU...

Page 897: ...ended The rear window defogger system also known as the electric backlight EBL consists of a backglass with two vertical bus bars linked by a series of grid lines fired onto the inside surface of the...

Page 898: ...ld be detected within three to four minutes of operation 2 If a temperature difference is not detected use a 12 volt DC voltmeter and contact the rear glass heating grid terminal B with the negative l...

Page 899: ...are electromechanical switches that uses a low current input from the rear window defogger module to control the high current output to the rear window defogger grids The movable common feed contact p...

Page 900: ...block as required INSTALLA TION NOTE Refer to the fuse and relay map located on the inner surface of the fuse relay block cover for the left and right rear window defogger EBL relay locations 1 Posit...

Page 901: ...rear window defogger system refer to 8W WIRING DIAGRAM INFORMATION 1 Remove the rear window defogger switch from the instrument panel but leave the switch connected Refer to 8 ELECTRICAL HEATED GLASS...

Page 902: ...ould result in accidental airbag deployment 1 Disconnect and isolate the negative battery cable 2 Remove the cluster bezel from the instrument panel Fig 7 Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZ...

Page 903: ...o exceed 204 C 400 F 6 Allow the epoxy to cure 24 hours at room tem perature or use a heat gun with a 260 to 371 C 500 to 700 F range for 15 minutes Hold the heat gun approximately 254 mm 10 inches fr...

Page 904: ...w defogger terminals are pre soldered and fluxed Do not reuse a terminal if it has been previously heated Place the solder gun onto the new terminal s and heat the terminal until the solder flows Remo...

Page 905: ...ocated behind the glass of each of the outside rear view mirrors is energized when the ignition switch is turned to the Run posi tion The heater grids heat the glass surface of the outside rear view m...

Page 906: ...seat back cushions Refer to heated seat elements later in this section for additional information Heated Seat Relay One heated seat relay is used per vehicle The relay is located in the fuse block and...

Page 907: ...to the Heated Seat Relay through separate hard wired circuits Each switch contains two light emitting diodes LED one for each High and Low setting to let the occupant know that the seat heater system...

Page 908: ...the sensor decreases The heated seat relay uses this temperature sensor input to monitor the temperature of the seat and regulates the cur rent flow to the seat heating elements accordingly DIAGNOSIS...

Page 909: ...l INSTALLA TION 1 Grasp the heated seat relay firmly and push it straight in the fuse block 2 Reconnect the battery negative cable HEATED SEAT SENSOR DESCRIPTION The heated seat temperature sensor is...

Page 910: ...st the heated seat system REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the gear selector bezel trim Refer to the Body section for the procedure 3 Remove the storage bin Refer t...

Page 911: ...3 Connect battery negative cable HORN SWITCH REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the drivers side airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Remo...

Page 912: ......

Page 913: ...If a failure in the glow plug system occurs the glow plug indicator lamp will be illuminated only as long as the fault is current If the failure is no longer present the glow plug indicator lamp will...

Page 914: ...exhaust smoke after cold start Stabilizing of the cold starting speed The glow plug output stage constantly signals the current operating state and faults The following are faults detected and transm...

Page 915: ...UEL GAUGE DESCRIPTION 17 OPERATION 18 GEAR SELECTOR INDICATOR DESCRIPTION 18 OPERATION 18 HIGH BEAM INDICATOR DESCRIPTION 19 OPERATION 19 LOW FUEL INDICATOR DESCRIPTION 19 OPERATION 19 LOW OIL LEVEL I...

Page 916: ...k plastic switch bezel that is integral to the cluster lens and located near the lower edge of the cluster directly below the multi function indicator LCD unit The cluster hood serves as a visor and s...

Page 917: ...CONTROL MODULES COMMUNICATION DESCRIPTION CAN BUS Besides typical instrument cluster gauge and indi cator support the electronic functions and features that the EMIC supports or controls include the f...

Page 918: ...and insulators Refer to the appropriate wir ing information The wiring information includes wiring diagrams proper wire and connector repair Fig 3 Gauges Indicators 1 AIRBAG INDICATOR 16 SEATBELT INDI...

Page 919: ...ndication The EMIC circuitry operates on battery current received through a non switched fused B circuit and on a fused ignition switch output circuit The EMIC circuitry is grounded through a ground c...

Page 920: ...n this service information CLUSTER ILLUMINA TION The EMIC has several general illumination lamps that are illuminated when the exterior lighting is turned on with the multi function switch The illumi...

Page 921: ...rk is functional that all of the modules are sending and receiving the proper electronic messages over the CAN data bus and that the instrument cluster is receiving the proper hard wired inputs and re...

Page 922: ...k down the IC until all of the steps are followed and completed or the new IC may be irreversibly damaged This procedure initial izes and configures the IC for certain optional equipment on the vehicl...

Page 923: ...back of the instru ment cluster rear cover Fig 5 5 Roll the top of the instrument cluster forward to position the instrument cluster into the instru ment panel 6 Install and tighten the two screws th...

Page 924: ...ired Refer to the appropriate diagnostic infor mation ADR INDICATOR DESCRIPTION A constant engine speed ADR indicator is stan dard equipment on all instrument clusters but is only functional on vehicl...

Page 925: ...er detects that the ignition switch is in the On position Therefore the LED will always be off when the ignition switch is in any position except On The LED only illuminates when it is provided a path...

Page 926: ...seconds The ambient temperature sensor located below the front bumper is a Negative Temperature Coefficient NTC thermistor The internal resistance of the sen sor is reduced as the ambient temperature...

Page 927: ...l between ground and the instrument clus ter The brake fluid level switch and the input circuit to the instrument cluster can be diagnosed using con ventional diagnostic tools and methods For proper d...

Page 928: ...charging indica tor for the following reasons Bulb Test Each time the ignition switch is turned to the On position with the engine not run ning the charging indicator is illuminated by the instrument...

Page 929: ...vel switch The cool ant low indicator Light Emitting Diode LED is com pletely controlled by the instrument cluster logic circuit and that logic will only allow this indicator to operate when the instr...

Page 930: ...gauge scale it may indicate that the engine or the engine cooling system require service For proper diagnosis of the engine coolant temperature sensor the ECM the CAN data bus the electronic message i...

Page 931: ...ch is in any position except On The LED only illuminates when it is provided a path to ground by the instrument cluster transistor The instrument cluster will turn on the fuel filter clogged indicator...

Page 932: ...ontrols the fuel gauge a diagnostic scan tool is required Refer to the appropriate diagnostic information GEAR SELECTOR INDICATOR DESCRIPTION An electronic automatic transmission gear selector indicat...

Page 933: ...put circuit to the instrument cluster can be diagnosed using conventional diagnos tic tools and methods For proper diagnosis of the instrument cluster circuitry that controls the high beam indicator a...

Page 934: ...any position except On The LED only illuminates when it is provided a path to ground by the instrument cluster transistor The instrument cluster will turn on the low oil level indi cator for the follo...

Page 935: ...ht of the multi function indicator display The MIL consists of the International Control and Display Symbol icon for Engine imprinted within a rectangular cutout in the opaque layer of the instru ment...

Page 936: ...engine oil level data gear selector indicator PRNDL certain diagnostic information and on vehicles so equipped an optional Active Service SYS Tem ASSYST engine oil maintenance indicator and an optiona...

Page 937: ...d This indicator is controlled by the instru ment cluster circuitry based upon cluster program ming and electronic messages received by the cluster from the Controller Anti lock Brake CAB over the Con...

Page 938: ...pear silhouetted against a red field through the translu cent outer layer of the overlay when the indicator is illuminated from behind by the LED which is sol dered onto the instrument cluster electro...

Page 939: ...he Off position The instrument cluster circuitry controls the gauge needle position and provides the following features Vehicle Speed Message Each time the clus ter receives a vehicle speed message fr...

Page 940: ...from behind by the LED which is soldered onto the instrument clus ter electronic circuit board The traction control indi cator is serviced as a unit with the instrument cluster OPERA TION The tractio...

Page 941: ...ignition switch is turned to the Off position whichever occurs first The CAB continually monitors the traction control ASR system circuits and sensors to decide whether the system is in good operatin...

Page 942: ...n the fuse block or the instrument clus ter circuitry that controls the turn signal indicators and the contactless relay a diagnostic scan tool is required Refer to the appropriate diagnostic infor ma...

Page 943: ...s that the ignition switch is in the On position Therefore the indicator will always be off when the ignition switch is in any position except On The indi cator only illuminates when it is switched to...

Page 944: ...ssage from the ECM indicating that there is excessive water in the fuel filter with the engine running the water in fuel indicator will be illuminated The indi cator remains illuminated until the clus...

Page 945: ...EMOVAL 10 INSTALLATION 10 FOG LAMP BULB REMOVAL 10 INSTALLATION 11 FOG LAMP RELAY REMOVAL 11 INSTALLATION 12 FOG LAMP SWITCH REMOVAL 12 INSTALLATION 13 FRONT LAMP UNIT REMOVAL 13 INSTALLATION 13 ADJUS...

Page 946: ...al to the front lamp units the rear turn lamps that are inte gral to the tail lamp units and a repeater lamp mounted to each front fender just above the front wheel opening Other components of the ext...

Page 947: ...rs turn signals and engine start control module located within the fuse block underneath the steering column the ElectroMechanical Instrument Cluster EMIC the Engine Control Module ECM or the Controll...

Page 948: ...viding battery current to the selected low or high beam bulbs Each front lamp unit includes two integral adjustment screws to be used for static horizontal and vertical aiming of the headlamp beam ref...

Page 949: ...al turn signal flasher at one of two rates to coincide with the flashing of the turn signals The slow rate emulates normal turn signal operation while the fast rate emulates bulb out turn signal opera...

Page 950: ...ng further diagnosis or service This is the only sure way to disable the supplemental restraint sys tem Failure to take the proper precautions could result in accidental airbag deployment 1 Disconnect...

Page 951: ...tion to automatically adjust the brake lamp switch plunger 7 Reconnect the battery negative cable ADJUSTMENTS ADJUSTMENT WARNING To avoid personal injury or death on vehicles equipped with airbags dis...

Page 952: ...crews that secure the CHMSL lamp to the vehicle then remove the lens from the lamp housing Fig 8 3 Push straight in on the CHMSL bulb and rotate it counterclockwise about 30 degrees to remove it from...

Page 953: ...Fig 10 2 Insert the bulb holder into the back of the clearance lamp housing and rotate it clockwise about 30 degrees to lock it into place 3 Reinstall the clearance lamp onto the vehicle Refer to 8 E...

Page 954: ...ght and a left DRL relay are each located in a dedicated connector of the vehicle wire harness Each connector is snapped into an opening in a stamped sheet metal bracket which is secured with screws w...

Page 955: ...y is located in a dedicated connector of the vehi cle wire harness This connector is snapped into an opening in a stamped sheet metal bracket which is secured with screws within the driver side front...

Page 956: ...are fully seated in the relay connector 4 Position the cover panel onto the top of the driver side seat riser Fig 15 5 Install and tighten the two screws that secure the cover panel to the top of the...

Page 957: ...vehicle Refer to 23 BODY EXTERIOR GRILLE REMOVAL 3 Remove the two screws that secure the cover at the inboard side of the front lamp unit Fig 18 4 Remove the cover from the front lamp unit 5 From the...

Page 958: ...ion the vehicle on a level surface 2 Turn On the headlamp low beams or the fog lamps if equipped 3 Open the hood 4 Set up the headlamp adjuster according to the instructions provided by the manufactur...

Page 959: ...ate the battery negative cable 2 Locate the turn park side marker bulb holder on the rear outboard side of the front lamp unit housing Fig 24 3 Rotate the bulb holder counterclockwise about 30 degrees...

Page 960: ...ousing and remove the cover Fig 26 3 Disconnect the front lamp unit wire harness connector from the connector receptacle for the head lamp leveling motor Fig 27 4 Rotate the headlamp leveling motor co...

Page 961: ...SWITCH REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat...

Page 962: ...cluster bezel onto the instrument panel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL INSTALLATION 4 Reconnect the battery negative cable HIGH BEAM HEADLAMP BULB REMOVAL 1 Disconnect and isolate the...

Page 963: ...over onto the back of the lamp housing 3 Reinstall the license plate lamp unit to its mounting location Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR LICENSE PLATE LAMP UNIT INSTALLATION 4 Reconnect t...

Page 964: ...w beam headlamp bulb into the integral bulb holder on the front lamp unit reflector Be certain that the lugs on the bulb base are engaged in the recesses of the bulb holder Fig 36 2 Engage the low bea...

Page 965: ...ury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner or instrument panel component...

Page 966: ...d isolate the battery negative cable 2 If the vehicle is so equipped remove the trim from the inside of the right or left rear corner pillar 3 From inside the vehicle use hand pressure to push the two...

Page 967: ...al lamp bulb into the tail lamp socket plate Fig 42 2 Align the socket plate with the mounting hole in the inner rear pillar 3 Using hand pressure push the socket plate gently and evenly into the inne...

Page 968: ...aining clip then pull the rear edge of the lamp outward to disengage it from the mounting hole Fig 45 3 Pull the repeater lamp housing slightly to the rear to disengage the front edge of the unit from...

Page 969: ...unit near the mounting hole on the fender panel Fig 46 2 Reconnect the vehicle wire harness connector to the connector receptacle on the back of the repeater lamp unit 3 Position the repeater lamp len...

Page 970: ...ld result in accidental airbag deployment 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel from the steering column opening cover below the steering column on the ins...

Page 971: ...ted in the terminal cavities in the receptacle of the fuse block and both latches are fully engaged 4 Reinstall the fuse access panel onto the steer ing column opening cover below the steering column...

Page 972: ...e a single incandescent bulb An optional version of these lamps includes an integral three po sition switch that protrudes through the lamp lens Cargo Lamp Sw itch Toggle type remote cargo lamp switch...

Page 973: ...are provided with battery current at all times by a fuse in the fuse block beneath the steering column The front side and rear door jamb switches control a ground path for each of these lamps except...

Page 974: ...into the inboard side of the ash receiver bin allows light from the lamp on the halo ring to also illuminate the ash receiver The ash receiver cigar lighter lamp is ser viced only as a unit with the...

Page 975: ...BEZEL REMOVAL 3 From the back of the accessory switch bezel disconnect the vehicle wire harness connector for the cargo lamp switch from the receptacle on the back of the switch Fig 4 4 From the back...

Page 976: ...LLA TION REAR PILLAR 1 From the front of the switch bezel align the cargo lamp switch body with the opening in the bezel and push the switch into the bezel until the two latches on the outside of the...

Page 977: ...kwise about 30 degrees on the circuit board Fig 7 4 Pull the bulb holder and bulb unit straight out from the mounting hole in the circuit board INSTALLA TION 1 Grasp the dome lamp intrusion sensor uni...

Page 978: ...or jamb switch away from the mounting hole in the pillar far enough to access and disconnect the vehicle wire harness connector from the back of the switch INSTALLA TION 1 Position the door jamb switc...

Page 979: ...on the edge of the entry exit lamp hous ing opposite from the retainer clip into the mounting hole 4 Push firmly and evenly on the notched edge of the entry exit lamp housing until the retainer clip l...

Page 980: ...straint sys tem Failure to take the proper precautions could result in accidental airbag deployment 1 Position the time delay relay to its vehicle wire harness connector within the driver side seat ri...

Page 981: ...r will unlock the drivers door pressing it a second time within 2 5 seconds will unlock all other doors The transmitter has a range of 10 meters A key is inte gral to the transmitter When a transmitte...

Page 982: ...anel center bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL CENTER BEZEL REMOVAL 3 Remove the central locking switch from the bezel Fig 2 INSTALLA TION 1 Install switch to bezel 2 Install in...

Page 983: ...MIRROR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove power mirror switch Refer to 8 ELECTRICAL POWER MIRRORS POWER MIRROR SWITCH REMOVAL 3 Using an ohmmeter test for continuity b...

Page 984: ...remove switch INSTALLA TION 1 Connect electrical harness connector to switch 2 install the mirror switch power window switch trim 3 Install the door handle trim 4 Connect the battery negative cable Fi...

Page 985: ...motor terminal pins will cause the motor to rotate in one direction Reversing current through the motor terminals will cause the motor to rotate in the opposite direction Refer to the appropriate wiri...

Page 986: ...nnectors from switches 5 Remove power window switch from trim INSTALLA TION 1 Install switch to trim 2 Connect wire harness connectors to switches 3 Install power window switch trim to door trim panel...

Page 987: ...OPERATION 17 REMOVAL 18 INSTALLATION 19 FRONT SEAT BELT RETRACTOR REMOVAL 20 INSTALLATION 22 FRONT SEAT BELT BUCKLE REMOVAL 23 INSTALLATION 23 PASSENGER AIRBAG DESCRIPTION 24 OPERATION 24 REMOVAL 25 I...

Page 988: ...raints for this model include Front Seat Belts Both outboard front seating positions are equipped with three point seat belt sys tems employing a lower B pillar mounted inertia latch type retractors h...

Page 989: ...t panel in front of the driver Clockspring The clockspring is located near the top of the steering column directly beneath the steering wheel Driver Airbag The driver airbag is located in the center o...

Page 990: ...ds upon the angle and severity of an impact Deployment is not based upon vehicle speed rather deployment is based upon the rate of deceleration as measured by the forces of gravity G force upon the im...

Page 991: ...als may produce harmful and irritating gases sodium hydroxide is formed in the presence of moisture or combustible compounds An airbag inflator unit may also contain a gas canister pres surized to ove...

Page 992: ...deployment must have the deployed restraints replaced In addition if the driver airbag has been deployed the clockspring and the steering wheel must be replaced If the passenger airbag has been deploy...

Page 993: ...acitor to discharge before performing further diagnosis or service This is the only sure way to disable the supplemental restraint system Failure to take the proper precau tions could result in accide...

Page 994: ...itry of the ACM which includes a microprocessor an electronic impact sensor an electronic safing sen sor and an energy storage capacitor A stamped metal cover plate is permanently secured to the bot t...

Page 995: ...ers that sense the rate of vehicle deceleration which provide verifica tion of the direction and severity of an impact On models equipped with optional side curtain airbags the ACM also monitors input...

Page 996: ...oy the supple mental restraints If an airbag control module is accidentally dropped during service the module must be scrapped and replaced with a new unit Failure to observe this warning could result...

Page 997: ...nsioner impact sensor or instrument panel com ponent diagnosis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before pe...

Page 998: ...he seat riser under the driver side front seat Tighten the screws to 2 N m 18 in lbs 10 Move the driver side front seat back to its driving position 11 Do not reconnect the battery negative cable at t...

Page 999: ...ockspring rotor connects the clockspring to the driver airbag while two single pig tail wires connect to the feed and ground terminals of the horn switch located within the hub cavity of the steering...

Page 1000: ...two clockspring mounting screws far enough so that they extend into the clearance holes in the upper surface of the clockspring rotor preventing the rotor from changing position relative to the clocks...

Page 1001: ...ightened into the clockspring case until the clockspring has been installed on the steering column If the screws are tightened into or removed from the case before the clockspring is installed on a st...

Page 1002: ...r airbag protective trim cover is the most visible part of the driver airbag Fig 18 The driver airbag is located in the center of the steering wheel where it is secured with two screws to the armature...

Page 1003: ...proper electrical signal to the initiator the electrical energy generates enough heat to initiate a small pyrotechnic charge which in turn ignites chemical pellets within the inflator Once ignited th...

Page 1004: ...vehicle Refer to 8 ELECTRICAL RESTRAINTS STANDARD PRO CEDURE SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT WARNING To avoid personal injury or death on vehicles equipped with airbags disable the s...

Page 1005: ...review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle Refer to 8 ELECTRICAL RESTRAINTS STANDARD PRO CEDURE SERVICE AFTER...

Page 1006: ...has been deployed review the rec ommended procedures for service after a supplemen tal restraint deployment before removing the front seat belt and retractor from the vehicle Refer to 8 ELECTRICAL RE...

Page 1007: ...sengage the connector from the seat belt tensioner initiator connector receptacle Improper removal of the con nector insulator can result in damage to the seat belt tensioner circuits or the connector...

Page 1008: ...nd anchors for proper installation oper ation or damage Replace any belt that is cut frayed or torn Straighten any belt that is twisted Tighten any loose fasteners Replace any belt that has a damaged...

Page 1009: ...gtail wire to the seat frame Fig 26 3 On the driver side only pull the seat belt switch pigtail wire out through the clearance hole in the seat riser cover far enough to access and discon nect the pig...

Page 1010: ...air bag mounting bracket that is secured with screws to the tubular steel instrument panel structural support above the glove box opening The end plates are secured to each side of the passenger airba...

Page 1011: ...for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the passenger airbag has been deployed review t...

Page 1012: ...N Do not pull on the wires to disengage the connector from the passenger airbag inflator connector receptacle Improper removal of the con nector insulator can result in damage to the airbag circuits o...

Page 1013: ...1 Carefully position the passenger airbag and airbag door unit to the instrument panel Fig 29 2 When installing the passenger airbag recon nect the vehicle wire harness connector to the airbag inflat...

Page 1014: ...or death during and following any seat belt service carefully inspect all seat belts buckles mounting hardware retractors and anchors for proper installation oper ation or damage Replace any belt tha...

Page 1015: ...he turning loop trim cover and the turning loop bracket 10 Remove the screw that secures the rear seat belt retractor to the bracket on the rear seat cushion frame Fig 35 11 Remove the rear seat belt...

Page 1016: ...f the bracket Fig 32 8 From the front of the turning loop bracket insert the pin through both turning loops and the bracket then secure it from behind the bracket with a new push nut 9 Position the tu...

Page 1017: ...rear seat cushion frame Fig 36 2 Install and tighten the screw that secures either the inboard rear seat belt buckle to the rear seat cushion frame Tighten the screw to 35 N m 26 ft lbs 3 Reinstall t...

Page 1018: ...t belt switch may de diagnosed using conventional diagnostic tools and methods SEAT BELT TENSIONER DESCRIPTION Front seating position seat belt tensioners supple ment the standard driver and optional...

Page 1019: ...he potential for occupant injuries The ACM monitors the condition of the seat belt tensioners through circuit resistance The ACM will illuminate the airbag indicator in the ElectroMe chanical Instrume...

Page 1020: ...Fig 40 5 Remove the nut that secures the front seat belt turning loop to the height adjuster Fig 41 6 Remove the front seat belt turning loop from the height adjuster 7 Remove the two screws that secu...

Page 1021: ...ster Tighten the nut to 35 N m 26 ft lbs 5 Position the height adjuster trim to the upper B pillar so that the driver on the back of the trim engages the lug of the height adjuster Fig 40 6 Reinstall...

Page 1022: ...ARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the side curtain airbag has been deployed review the recommended procedures for service after a supplemental restraint deployment before...

Page 1023: ...r the belt line Fig 47 9 Remove the screw that secures the front of the side curtain airbag to the A pillar Fig 48 10 Remove the screw that secures the rear of the side curtain airbag to the B pillar...

Page 1024: ...ior surfaces In large doses these depos its may cause irritation to the skin and eyes WARNING To avoid personal injury or death use extreme care to prevent any foreign material from entering the side...

Page 1025: ...protect the internal electronic circuitry and components The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the vehicle wire harn...

Page 1026: ...t the vehicle wire harness connector from the side impact sensor connector receptacle Fig 52 4 Remove the two screws that secure the side impact sensor to the forward vertical surface of the step well...

Page 1027: ...ensor connector receptacle 4 Reinstall the trim paneling to the interior of the front door step well Refer to 23 BODY INTE RIOR STEPWELL SCUFF PADS INSTALLATION 5 Do not reconnect the battery negative...

Page 1028: ......

Page 1029: ...the system is accomplished by a 4 position instrument panel mounted switch Fig 1 Sw itch settings Fig 2 are 1 Set Accelerate 2 Resume Set Speed 3 Set Decelerate 4 Off The system is designed to operate...

Page 1030: ...n extremely high rate Once the speed control has been disengaged depressing the RES ACCEL switch when speed is greater than 30 mph restores the vehicle to the tar get speed that was stored in the ECM...

Page 1031: ...LA TION The speed control switch is mounted to the back of the multi function switch Fig 3 1 Position speed control switch to back of multi function switch 2 Install switch mounting screw Fig 4 Refer...

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Page 1033: ...door The key must be held in the locking position for more than two seconds Activation is indicated by the turn sig nal lights flashing once Unlocking the vehicle at one of the other doors will trigge...

Page 1034: ...ness connector 2 Position module Install and tighten mounting fasteners 3 Install driver seat cushion 4 Connect battery negative cable SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION The Sentry Key Remote...

Page 1035: ...ronically coded in the SKREEM and in all programmed transponder keys It is used for immobilization and RKE functions for data security In addition each transponder key will have a unique identificatio...

Page 1036: ...ER CLUS TER INSTALLATION 4 Connect the battery negative cable 5 Verify vehicle and system operation 6 Close hood SENTRY KEY REMOTE ENTRY MODULE TRAN SPONDER RING 1 Maneuver wiring through instrument p...

Page 1037: ...ithin the range of the SKREEM s transponder ring when it is inserted into the ignition lock cylinder When the ignition switch is turned to the ON position the SKREEM communicates with the Sentry Key v...

Page 1038: ......

Page 1039: ...R FLUID LEVEL SWITCH DESCRIPTION 16 OPERATION 16 WASHER HOSES TUBES DESCRIPTION 18 OPERATION 18 WASHER NOZZLE DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATION 19 WASHER PUMP MOTOR DESCRIPTION 19 OP...

Page 1040: ...of the wind shield in the engine compartment Multi Function Sw itch The multi function switch is secured to the top of the steering column just below the steering wheel Only the left lighting control...

Page 1041: ...The wiper linkage module includes the two wiper drive links the wiper motor crank arm the two wiper piv ots and the linkage and motor mounting bracket Wiper Motor The wiper motor is secured to the wi...

Page 1042: ...within the fuse block monitors inputs from the intermittent wipe and washer switch cir cuitry of the multi function switch and the park switch in the wiper motor When the intermittent wipe position is...

Page 1043: ...he down position at the moment the Off position is selected the park switch is an open cir cuit The control module logic circuit directs battery current to the low speed brush of the wiper motor which...

Page 1044: ...eering wheel steering column airbag seat belt tensioner or instrument panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the syste...

Page 1045: ...n the multi function switch and the washer pump as required 3 Faulty washer pump motor 3 Test and replace the washer pump as required 4 Faulty muli function switch 4 Test and replace the multi functio...

Page 1046: ...TION AND NO PULSE FEATURE 1 Faulty low speed request circuit 1 Test and repair the open low speed re quest circuit between the multi function switch and the rain sensor control module as required 2 Fa...

Page 1047: ...Periodic cleaning of the squeegees is suggested to remove any deposits of salt or road film The wiper blades arms and windshield glass should only be cleaned using a sponge or soft cloth and windshiel...

Page 1048: ...er arm if it has comparatively lower spring tension as evi denced by a lower scale reading 4 Inspect the wiper blades and squeegees for any indications of damage contamination or rubber dete rioration...

Page 1049: ...ently freeze and plug the nozzle while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns In addition the check valve prevents washer fluid from s...

Page 1050: ...direct IR light beams at the windshield at an angle When the windshield glass is dry most of this IR light is reflected back to the sensor which uses photocell receivers to measure the intensity of th...

Page 1051: ...the rear view mirror and the rain sen sor from the rain sensor bracket Refer to 8 ELEC TRICAL WIPERS WASHERS RAIN SENSOR REMOVAL 3 Cut diagonally through the nylon mesh fabric from the rear view mirro...

Page 1052: ...ered unusable 9 Remove the rain sensor from the center of the bracket INSTALLA TION WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint syst...

Page 1053: ...art circuit so that the RSCM will operate whenever the ignition switch is in the On or Start positions The RSCM receives ground at all times through its connection to the instrument panel wire harness...

Page 1054: ...TCH DESCRIPTION The optional washer fluid level switch is a single pole single throw switch that is integral to a unique version of the washer pump motor unit located rear ward facing side of the wash...

Page 1055: ...et terminal connector that is secured under a ground screw located near the right headlamp in the engine compartment The switch is connected in series between ground and the washer fluid switch sense...

Page 1056: ...g the under side of the wiper arms to the two washer nozzles Washer hose is available for service only as roll stock which must then be cut to length The molded plastic washer hose fittings cannot be...

Page 1057: ...ator hole on the wiper arm WASHER PUMP MOTOR DESCRIPTION The washer pump motor unit is located in a dedi cated hole on the top of the sump area near the back of the windshield washer reservoir on the...

Page 1058: ...vent hose from the barbed vent nipple near the top of the washer pump motor unit 4 Using hand pressure firmly grasp and pull the washer pump out of the rubber grommet seal in the reservoir Care must...

Page 1059: ...grommet seal for the washer pump motor unit and the filler cap are each available for service replacement OPERA TION The washer fluid reservoir provides a secure on vehicle storage location for a larg...

Page 1060: ...eservoir into the grommet in the dash panel 4 Position the washer reservoir mounting hole over the stud nut on the right inner fender Fig 21 5 Install and tighten the nut and washer that secures the t...

Page 1061: ...l hook Concealed within the stamped steel channel one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end while the other end of the spring is hooked through th...

Page 1062: ...er pivot shaft 4 If necessary use a suitable battery terminal puller to disengage the wiper arm from the wiper pivot shaft Fig 25 5 Remove the wiper arm pivot end from the wiper pivot shaft INSTALLA T...

Page 1063: ...multi function switch to the Off position then check for the correct wiper arm position and readjust as required 5 Engage the pivot cover with the wiper arm hinge pin then push the pivot end of the c...

Page 1064: ...blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring loaded wiper arm along the length of the element The com bination of the w...

Page 1065: ...the left driver side of the windshield 1 Lift the wiper arm off of the windshield glass until the wiper arm hinge is in its over center posi tion 2 Position the wiper blade near the hook forma tion o...

Page 1066: ...Crank Arm The wiper motor crank arm is a stamped steel unit with a round hole on the driven end that is secured to the wiper motor output shaft with a nut and a long ball stud secured to the drive en...

Page 1067: ...from the wiper pivots Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARM REMOVAL 3 Remove the five nuts that secure the ventila tion housing to the dash panel and the underside of the cowl top panel Fig 2...

Page 1068: ...s on the top of the engine 5 Disconnect the wiper motor pigtail wire connec tor from the vehicle wire harness connector 6 Remove the nut and washer that secures each wiper pivot housing to the outside...

Page 1069: ...ehicle wire harness connector 6 Reinstall the ventilation housing onto the dash panel and the underside of the cowl top panel Fig 29 7 Reinstall the wiper arms onto the wiper pivots Refer to 8 ELECTRI...

Page 1070: ...per motor transmission Two input contacts alternately close the wiper park switch sense output circuit contact to ground or to battery current depending upon the position of the wipers on the glass Th...

Page 1071: ...N m 105 in lbs 3 If this wiper motor is being reinstalled position the motor crank arm on the wiper motor output shaft so that the index marks made during the removal procedure are aligned If this is...

Page 1072: ...c field draws the movable relay contact point away from the fixed normally closed contact point and holds it against the fixed normally open contact point When the relay coil is de energized spring pr...

Page 1073: ...sing the latches and pulling it straight down from the receptacle on the bottom of the fuse block INSTALLA TION WARNING To avoid personal injury or death on vehicles equipped with airbags disable the...

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Page 1075: ...8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER 8W 41 1 AIR CONDITIONING HEA TER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 CENTRAL TIMER MODULE 8W 45 1 AUDIO SYSTEM 8W 47 1 REAR W...

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Page 1077: ...s it is important to understand all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of t...

Page 1078: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMA TION VA...

Page 1079: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 VA 8W 01 WIRING DIAGRAM INFORMA TION 8W 01 3...

Page 1080: ...Fig 3 Wiring Diagram Symbols 8W 01 4 8W 01 WIRING DIAGRAM INFORMA TION VA...

Page 1081: ...0 show the entire splice and provide references to other sections the splices serves Section 8W 70 only contains splice dia grams that are not shown in their entirety some where else in the wiring dia...

Page 1082: ...CT WITH HOT PARTS SUCH AS THE RADIA TOR EXHAUST MANIFOLD S TAIL PIPE CATA LYTIC CONVERTER AND MUFFLER WARNING DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRESENT IN AND AROUND THE B...

Page 1083: ...blem area 6 Verify the proper operation For this step check for proper operation of all items on the repaired circuit Refer to the wiring diagrams STANDARD PROCEDURE ELECTROSTA TIC DISCHARGE ESD SENSI...

Page 1084: ...ring diagrams and disconnect or isolate all items on the suspected fused circuit 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ignition switch or re connecting the battery 4 St...

Page 1085: ...st all affected systems DIODE REMOVAL 1 Disconnect the battery 2 Locate the diode in the harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current fl...

Page 1086: ...tant that the cor rect gage be used as shown in the wiring diagrams 1 Remove one half 1 2 inch of insulation from each wire that needs to be spliced 2 Place a piece of adhesive lined heat shrink tub i...

Page 1087: ...abin Heater Module 8W 42 Clockspring 8W 41 43 Controller Antilock Brake 8W 35 Courtesy Lamps 8W 44 Crankcase Heater 8W 30 Crankshaft Position Sensor 8W 30 Component Page Cylinder Lock Switch Driver 8W...

Page 1088: ...Fuses 8W 42 Roof A C Blower Stage Relays 8W 42 Roof A C Blowers 8W 42 Roof A C Compressor Fuse 8W 42 Component Page Roof A C Control Module 8W 42 Roof A C Fan Fuse 8W 42 Roof A C Switch 8W 42 Roof A...

Page 1089: ...W 10 7 12 30 Fuse 21 8W 10 12 13 30 Component Page Fuse Block No 1 8W 10 3 11 12 13 14 15 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 Fuse Block No 2 8W 10 10 17 25 26 Fused Ignition Switch Run St...

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Page 1123: ...eater Timer Auxiliary 8W 11 20 High Idle Switch 8W 11 27 33 Component Page Instrument Cluster 8W 11 18 25 Instrument Panel Socket 8W 11 25 Interior Light Switch 8W 11 22 27 Interior Light Switch Drive...

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Page 1163: ...No 4 8W 15 6 Interior Lamp No 5 8W 15 6 Interior Lamp Left 8W 15 6 Interior Lamp Middle Front 8W 15 5 6 Interior Lamp Middle Rear 8W 15 5 6 Interior Lamp Rear No 2 8W 15 5 Interior Lamp Right 8W 15 5...

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Page 1195: ...3 6 Data Link Connector 8W 18 2 3 4 5 Engine Control Module 8W 18 5 6 Fuse 5 8W 18 2 Fuse 6 8W 18 3 Component Page Fuse Block No 1 8W 18 2 Fuse Block No 2 8W 18 3 G200 8W 18 5 Instrument Cluster 8W 18...

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Page 1201: ...8W 20 2 5 Fuse 6 8W 20 2 5 Fuse 7 8W 20 4 Fuse 9 8W 20 3 Fuse 19 8W 20 3 Component Page Fuse Block No 1 8W 20 4 5 6 Fuse Block No 2 8W 20 3 Fuse Block No 3 8W 20 3 G200 8W 20 2 G202 8W 20 3 4 Generato...

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Page 1207: ...SYSTEM Component Page Battery 8W 21 2 Engine Control Module 8W 21 2 Fuel Pump Relay 8W 21 2 Component Page Fuse Block No 1 8W 21 2 Starter Motor 8W 21 2 Starter Motor Relay 8W 21 2 VA 8W 21 STARTING...

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Page 1209: ...l Pump Relay 8W 30 18 Fuel Quantity Control Valve 8W 30 7 Fuel Shutdown Solenoid 8W 30 7 Fuel Temperature Sensor 8W 30 5 Fuse 5 8W 30 13 19 Fuse 7 8W 30 20 Fuse 12 8W 30 2 Component Page Fuse 16 8W 30...

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Page 1235: ...1 7 Fuse 12 8W 31 8 Fuse 16 8W 31 3 Fuse 17 8W 31 3 Fuse Block No 1 8W 31 3 7 9 Fuse Block No 2 8W 31 2 7 Component Page Fuse Block No 3 8W 31 8 G100 8W 31 8 G202 8W 31 2 7 G203 8W 31 8 9 Locker Switc...

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Page 1245: ...ge Brake Lamp Switch 8W 33 2 Controller Antilock Brake 8W 33 2 Engine Control Module 8W 33 3 Fuse 5 8W 33 2 Component Page Fuse Block No 1 8W 33 2 Shifter Assembly 8W 33 2 Speed Control Switch 8W 33 3...

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Page 1249: ...3 10 Fuse 6 8W 35 5 Fuse 7 8W 35 5 Fuse 9 8W 35 5 Fuse Block No 1 8W 35 3 10 Fuse Relay Block 8W 35 5 G100 8W 35 4 Component Page G200 8W 35 4 7 8 G202 8W 35 7 G203 8W 35 2 G300 8W 35 8 G302 8W 35 4...

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Page 1259: ...0 14 Interior Lamp Right 8W 39 14 Component Page Intrusion Sensor No 1 8W 39 2 3 Intrusion Sensor No 2 8W 39 2 3 Intrusion Sensor No 3 8W 39 2 3 Optional Equipment Relay 8W 39 13 Panic Alarm Switch 8W...

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Page 1273: ...Door J amb Switch Passenger 8W 40 6 Engine Coolant Level Switch 8W 40 7 Fuel Level Sensor 8W 40 3 Fuse 1 8W 40 2 Fuse 6 8W 40 3 Fuse 18 8W 40 2 Component Page Fuse Block No 1 8W 40 2 Fuse Block No 2 8...

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Page 1281: ...8W 41 2 Fuse 7 8W 41 3 Fuse 8 8W 41 2 Fuse Block No 1 8W 41 2 3 Fuse Block No 2 8W 41 2 Fuse Block No 3 8W 41 3 Component Page G200 8W 41 3 G202 8W 41 3 G203 8W 41 2 Horn 8W 41 3 Horn Relay 8W 41 3 Ho...

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Page 1285: ...23 Fuse Block No 1 8W 42 2 6 7 9 18 Fuse Block No 2 8W 42 3 Fuse Block No 3 8W 42 8 11 14 15 20 22 Component Page Fuse Relay Block 8W 42 2 12 G100 8W 42 11 G102 8W 42 2 G200 8W 42 3 5 9 G202 8W 42 2 8...

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Page 1311: ...imer Module 8W 43 2 Clockspring 8W 43 3 Data Link Connector 8W 43 2 Engine Control Module 8W 43 2 Fuse 18 8W 43 2 Component Page Fuse Block No 1 8W 43 2 G201 8W 43 2 G202 8W 43 2 Instrument Cluster 8W...

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Page 1315: ...44 7 8 10 G202 8W 44 5 G203 8W 44 2 11 Interior Lamp No 1 8W 44 6 Component Page Interior Lamp No 2 8W 44 6 Interior Lamp No 3 8W 44 6 Interior Lamp No 4 8W 44 6 Interior Lamp No 5 8W 44 6 Interior La...

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Page 1327: ...Door Lock Motor Ajar Switch Assembly Passenger 8W 45 7 Door Lock Motor Ajar Switch Assembly Rear 8W 45 4 6 Door Lock Motor Ajar Switch Assembly Right Sliding 8W 45 5 6 Component Page Fuse 5 8W 45 3 Fu...

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Page 1335: ...47 2 Fuse 15 8W 47 2 Fuse Block No 1 8W 47 2 G203 8W 47 3 Instrument Cluster 8W 47 2 Component Page Radio 8W 47 2 3 4 5 Radio Antenna 8W 47 3 Radio Cellular Antenna 8W 47 3 Speaker Left Front Door As...

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Page 1341: ...W 48 3 Fuse Block No 2 8W 48 4 Fuse Relay Block 8W 48 2 G202 8W 48 4 Component Page G203 8W 48 3 G300 8W 48 4 Rear Window Defogger Relay 8W 48 2 3 4 Security System Module 8W 48 4 Window Defogger Modu...

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Page 1345: ...14 15 G203 8W 50 9 Component Page Hazard Warning Switch 8W 50 2 Headlamp Adjust Switch 8W 50 7 8 9 Headlamp Assembly Left 8W 50 3 6 7 9 10 11 13 14 Headlamp Assembly Right 8W 50 3 6 8 9 10 11 13 15 H...

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Page 1361: ...3 6 7 8 9 Headlamp Switch 8W 51 4 License Plate Lamp No 1 8W 51 3 Component Page License Plate Lamp No 2 8W 51 3 Marker Lamp Connector 8W 51 2 Marker Lamp Left Rear 8W 51 3 Marker Lamp Right Rear 8W...

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Page 1371: ...ecurity System Module 8W 52 4 6 Component Page Sentry Key Remote Entry Module 8W 52 3 4 Tail Lamp Assembly Left 8W 52 4 Tail Lamp Assembly Right 8W 52 6 Trailer Tow Control Module 8W 52 4 6 Turn Signa...

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Page 1377: ...6 Multi Function Switch 8W 53 2 3 Rain Sensor 8W 53 6 Component Page Rain Sensor Control Module 8W 53 2 3 4 5 6 Washer On Off Switch 8W 53 3 Washer Pump Motor Front 8W 53 3 5 Wiper Motor Front 8W 53 2...

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Page 1383: ...8W 54 3 G202 8W 54 2 G300 8W 54 3 Hazard Warning Switch 8W 54 2 Component Page Lamp Relay Right 8W 54 3 Multi Function Switch 8W 54 2 Shifter Assembly 8W 54 3 Trailer Tow Connector 8W 54 3 Trailer Tow...

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Page 1387: ...55 2 Fuse 13 8W 55 2 Fuse 15 8W 55 4 Fuse Block No 1 8W 55 4 Fuse Block No 3 8W 55 2 Component Page G203 8W 55 2 Microphone Connector 8W 55 2 Optional Equipment Relay 8W 55 2 Radio 8W 55 2 3 4 Radio C...

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Page 1391: ...0 2 3 G203 8W 60 2 3 Optional Equipment Relay 8W 60 2 3 Component Page Power Window Motor Driver 8W 60 2 4 Power Window Motor Passenger 8W 60 4 Power Window Switch Driver 8W 60 2 4 Power Window Switch...

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Page 1395: ...g 8W 61 8 Door Lock Motor Ajar Switch Assembly Driver 8W 61 4 Door Lock Motor Ajar Switch Assembly Left Sliding 8W 61 6 Door Lock Motor Ajar Switch Assembly Passenger 8W 61 5 Component Page Door Lock...

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Page 1403: ...e 8 8W 62 2 Fuse Block No 2 8W 62 2 G203 8W 62 2 3 Optional Equipment Relay 8W 62 2 Component Page Power Mirror Motor Driver 8W 62 2 3 4 Power Mirror Motor Passenger 8W 62 2 4 Power Mirror Switch 8W 6...

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Page 1407: ...3 Fuse Block No 3 8W 63 3 G202 8W 63 4 G203 8W 63 2 3 Component Page Heated Seat Module Driver 8W 63 4 Heated Seat Module Passenger 8W 63 4 Heated Seat Switch Driver 8W 63 2 3 4 Heated Seat Switch Pa...

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Page 1411: ...27 S254 8W 44 6 S255 8W 10 16 S256 8W 11 16 S257 8W 18 5 S258 8W 31 7 S259 8W 18 6 S260 8W 18 6 S261 8W 11 18 Component Page S262 8W 10 29 S300 8W 11 32 S301 8W 11 32 S302 8W 11 32 S303 8W 15 23 S304...

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Page 1413: ...ure Sensor 8W 80 11 Brake Wear Sensor Left Front 8W 80 12 Brake Wear Sensor Left Rear 8W 80 12 Brake Wear Sensor Right Front 8W 80 12 Brake Wear Sensor Right Rear 8W 80 12 C100 8W 80 12 C100 8W 80 13...

Page 1414: ...le C4 Except OBD 8W 80 43 Component Page Engine Control Module C5 Except OBD 8W 80 44 Engine Coolant Level Switch 8W 80 44 Engine Coolant Temperature Sensor 8W 80 44 Engine Oil Sensor 8W 80 44 Evapora...

Page 1415: ...ver Switch Assembly 8W 80 71 Roof A C Control Module 8W 80 72 Roof A C Switch 8W 80 72 Component Page Roof A C Temperature Setting Control 8W 80 72 Roof Fan Motor 8W 80 73 Roof Fan Switch 8W 80 73 Roo...

Page 1416: ...ACCEL PEDAL POSITION SENSOR GROUND NO 1 3 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 4 18BR GY ACCEL PEDAL POSITION SENSOR GROUND NO 2 5 18GY DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 2 ACCELERAT...

Page 1417: ...AV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 3 16BK BL DG FUSED IGNITION SWITCH OUTPUT 4 16VT YL ADDITIONAL HEAT EXCHANGER SWITCH CAV 4 TO ADDITIONAL HEAT EXCHANGER CAV D 5 16BR GROUND 7 16VT BL ADDIT...

Page 1418: ...D K ACM 10 20DG DRIVER AIRBAG SQUIB 1 LINE 2 11 20VT DRIVER AIRBAG SQUIB 1 LINE 1 12 13 20BL DG PASSENGER AIRBAG SQUIB 1 LINE 2 14 20BR DG PASSENGER AIRBAG SQUIB 1 LINE 1 15 16 17 18 19 20 20DG ENHANC...

Page 1419: ...ATER BOOSTER MODE 5 18BR VT WATER CYCLE VALVE CONTROL 6 20RD BL 5 VOLT SUPPLY 7 18BK YL K IC ATC HBM CHM 8 20BL VT D RELAY CONTROL 8 16RD YL WT FUSED D RELAY OUTPUT 9 16GY DG RD LAMP DRIVER 10 16BL CA...

Page 1420: ...XILIARY HEATER CONTROL CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 16RD YL FUSED B 4 5 6 7 16YL CABIN HEATER CONTROL 8 9 10 16BR GROUND BLOWER MOTOR RESISTOR BLOCK CAV CIRCUIT FUNCTION 1 12YL BK...

Page 1421: ...OTOR FRONT BLACK CAV CIRCUIT FUNCTION 1 12RD BL BLOWER MOTOR 2 12BK GROUND BODY PLUG CONNECTOR CAV CIRCUIT FUNCTION 1 14BL YL D RELAY NO 2 OUTPUT 2 14RD FUSED B 3 14BK YL FUSED IGNITION SWITCH RUN STA...

Page 1422: ...FUNCTION 1 16YL BK FUSED ENGINE CONTROL RELAY OUTPUT 2 16YL WT GROUND 3 4 16YL DG BOOST PRESSURE SERVOMOTOR CONTROL 5 BOOST PRESSURE SOLENOID BLACK CAV CIRCUIT FUNCTION 1 20WT BOOST PRESSURE SOLENOID...

Page 1423: ...P CAV CIRCUIT FUNCTION 1 20WT BRAKE SWITCH OUTPUT 2 16RD BK FUSED IGNITION SWITCH OUTPUT RUN START 3 20BK BL RD BRAKE LAMP SWITCH 4 BRAKE LAMP SWITCH C2 EXCEPT ESP BLACK CAV CIRCUIT FUNCTION 1 16BK BL...

Page 1424: ...WT BRAKE WEAR SENSOR SIGNAL BRAKE WEAR SENSOR RIGHT FRONT CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BR WT BRAKE WEAR SENSOR SIGNAL BRAKE WEAR SENSOR RIGHT REAR CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BR W...

Page 1425: ...6 16BK 7 16BK BL 8 14BK VT 9 10 C101 YELLOW ENGINE SIDE CAV CIRCUIT 1 16WT BL 2 14BK YL 3 16BL DG 4 16BK RD C101 YELLOW MAIN BODY SIDE CAV CIRCUIT 1 20BL 2 12BK YL 3 16BL DG 4 16BK RD C102 EXCEPT OBD...

Page 1426: ...MAIN BODY CAV CIRCUIT 1 20BL 2 12BK YL 3 4 5 6 16YL RD C200 BLACK DASH SIDE CAV CIRCUIT 1 16GY 2 16GY DG 3 16BK YL 4 16DG BL WT 5 16YL BK 6 16BL RD 7 16BK RD 8 16WT BK 9 16WT DG 10 16WT YL 11 16WT RD...

Page 1427: ...6WT YL 11 16WT RD 12 16BK RD 13 18VT YL 14 16BR BK 15 16YL 16 16BR WT 17 16GY RD 18 16BK YL DG 19 16BK YL 20 21 22 C201 DASH SIDE CAV CIRCUIT 1 2 16GY DG RD 3 16RD BL 4 20BL VT 4 16RD YL WT 5 16VT WT...

Page 1428: ...0BL VT 5 16VT WT 6 20BL RD WT 7 16BK RD 8 16RD YL 9 16BK RD 10 18BK BL 11 16YL 12 13 16RD 14 15 18RD BK 16 17 18 19 20 21 22 C202 DASH SIDE CAV CIRCUIT 1 16WT RD 2 16WT BL RD 3 20BK BL RD 4 20BL DG 5...

Page 1429: ...L DG 5 6 18BK DG 7 20DG WT 8 20DG 9 10 11 20YL 12 C203 DASH SIDE CAV CIRCUIT 1 18GY YL 2 18GY BR 3 18GY WT 4 5 6 7 8 9 10 18VT DG 11 16RD 12 C203 BLACK MAIN BODY SIDE CAV CIRCUIT 1 18GY YL 2 18GY BR 3...

Page 1430: ...11 20BR RD 12 20RD BL 13 16RD BK 14 14BK VT 15 16RD C204 GRAY MAIN BODY SIDE CAV CIRCUIT 1 18BK RD 2 18BK YL 3 20DG WT 4 20DG 5 18DG RD 6 18BR VT 7 16BL 8 16BL YL 9 16BL DG 10 18BR BL 11 20BR RD 12 20...

Page 1431: ...VT BK 7 16VT BR 8 16VT 10 16BK RD 11 18BR WT 15 16BK BL WT 18 16VT YL 19 16VT BL 20 18RD BK WT 21 18BK BL C206 MAIN BODY SIDE CAV CIRCUIT 1 16BK BL WT 2 14BK VT 3 16VT DG 4 16VT RD 5 16VT YL 6 16VT BK...

Page 1432: ...YL C207 MAIN BODY SIDE CAV CIRCUIT 11 16DG 12 16YL 17 16RD YL C208 CABIN SIDE CAV CIRCUIT 3 16WT 4 16BK C208 DASH SIDE CAV CIRCUIT 3 16WT 4 16BK C209 CABIN SIDE CAV CIRCUIT 1 16BR BL 2 16WT BL 3 16BR...

Page 1433: ...SIDE CAV CIRCUIT 1 14BR 2 16BK YL 3 16BK YL DG 4 16BK WT 5 16BL WT 6 C210 BLACK MAIN BODY SIDE CAV CIRCUIT 1 14BR 2 16BK YL 3 16BK YL DG 4 16BK WT 5 16BL WT 6 C211 POWER MIRROR SWITCH SIDE CAV CIRCUIT...

Page 1434: ...DG 5 18DG 6 18WT GY C214 LT BLUE CABIN SIDE CAV CIRCUIT 1 16YL 2 16VT 3 16BK 4 16BR 5 6 C214 LT BLUE DASH SIDE CAV CIRCUIT 1 16YL 2 16VT 3 16BK 4 16BR 5 6 C215 BLACK CABIN SIDE CAV CIRCUIT 1 16RD YL 2...

Page 1435: ...BR WT 6 14BR C216 BLACK CABIN SIDE CAV CIRCUIT 1 12RD 2 C216 BLACK MAIN BODY SIDE CAV CIRCUIT 1 12RD 2 C217 CABIN SIDE CAV CIRCUIT 1 16RD YL 2 16YL 3 16DG 4 16YL C217 MAIN BODY SIDE CAV CIRCUIT 1 16RD...

Page 1436: ...6BR WT 2 16BR YL 3 16RD DG 4 16DG YL 5 20DG BK 6 20GY BK 7 20DG WT BL C219 MAIN BODY SIDE CAV CIRCUIT 5 16BK RD 6 16BL RD 7 16YL WT 8 16DG BK 9 16BK RD 10 16BL RD 11 16YL RD 12 16DG YL C219 BLACK CABI...

Page 1437: ...AV CIRCUIT 1 16RD YL 2 16BR 3 16GY DG RD C221 MAIN BODY SIDE CAV CIRCUIT 1 16BL WT 2 16BK YL DG 3 16BK WT C221 PASSENGER DOOR SIDE CAV CIRCUIT 1 16BL WT 2 16BK YL DG 3 16BK WT C224 BLOWER MOTOR SOLENO...

Page 1438: ...OLENOID SIDE CAV CIRCUIT 1 12RD 2 12RD BL 3 16RD C225 DASH SIDE CAV CIRCUIT 1 12RD BL 2 12BL 3 16RD C226 CABIN SIDE CAV CIRCUIT 1 16GY 2 3 16RD DG 4 16RD BL 5 16BK 6 16BR C300 BODY SIDE CAV CIRCUIT 1...

Page 1439: ...RCUIT 1 20DG 2 20BR 3 20BK DG 4 16RD YL C301 BODY SIDE CAV CIRCUIT 1 20RD 2 20YL 3 20WT 4 5 6 7 8 C301 CABIN SIDE CAV CIRCUIT 1 20RD 2 20YL 3 20WT 4 5 6 7 8 C306 ROOF SIDE CAV CIRCUIT 2 14BR VA 8W 80...

Page 1440: ...L YL REST SYSTEM HEATER BOOSTER MODE CABIN HEATER MODULE CHM CAV CIRCUIT FUNCTION 1 14RD FUSED B 2 14BR GROUND 3 16BL YL F AN STAGE 1 RELAY HIGH SIDE CONTROL 4 16DG DOSING PUMP CONTROL 5 16BL RD K IC...

Page 1441: ...K DRIVER DOOR UNLOCK SENSE 2 16BL RD DRIVER DOOR LOCK DRIVER 3 16BK RD DRIVER DOOR UNLOCK DRIVER 4 16YL BK DRIVER DOOR LOCK SENSE 5 16DG BL WT PASSENGER FRONT DOOR UNLOCK SENSE 6 16YL BL PASSENGER FRO...

Page 1442: ...OCK SENSE 11 16YL WT LEFT SLIDING DOOR LOCK SENSE 12 16YL BK REAR DOOR LOCK SENSE 13 16YL RD RIGHT SLIDING DOOR LOCK SENSE 14 16DG YL RIGHT SLIDING DOOR UNLOCK SENSE 15 16 17 16BK RD PASSENGER DOORS U...

Page 1443: ...P DIODE CAV CIRCUIT FUNCTION 3 18DG RD CIRCULATION PUMP RELAY OUTPUT 4 18DG BK CABIN HEATER MODULE CIRCULATION PUMP RELAY OUTPUT 4 18BK EXCEPT PROGRAM TIMER FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CLOCK...

Page 1444: ...EED SENSOR 17 18 19 20 20WT BRAKE SWITCH OUTPUT 21 20BR GROUND 22 23 18BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR GROUND 26 20WT GY BRAKE PRESSURE SENSOR SIGNAL 27...

Page 1445: ...NG DOOR CAV CIRCUIT FUNCTION 1 16RD YL FUSED B 2 16BR WT DOOR AJAR SWITCH SENSE COURTESY LAMP PASSENGER DOOR CAV CIRCUIT FUNCTION 1 16RD YL FUSED B 2 16BR WT FRONT COURTESY LAMPS CONTROL COURTESY LAMP...

Page 1446: ...ANKSHAFT POSITION SENSOR SIGNAL NO 1 2 20DG OBD CRANKSHAFT POSITION SENSOR SIGNAL NO 2 CTEL ANTENNA CONNECTOR CAV CIRCUIT FUNCTION 1 16BK CELLULAR ANTENNA W SHIELD 2 SHIELD CTEL CONNECTOR CAV CIRCUIT...

Page 1447: ...YL K ECM 8 20BK BL DG FUSED IGNITION SWITCH OUTPUT RUN START 9 20BL BK K ABS SHIFTER ASSEMBLY 10 11 20BL K TCM RADIO 12 20GY DG RD K CTM SSM 13 20BK RD K ACM 14 15 20WT GY K IC ATC HBM CHM 16 20RD YL...

Page 1448: ...R AJAR SWITCH ASSEMBLY LEFT SLIDING C1 CAV CIRCUIT FUNCTION 1 16BK RD PASSENGER DOORS UNLOCK DRIVER 2 16BL RD PASSENGER DOORS LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH ASSEMBLY LEFT SLIDING C2 CAV CIRCU...

Page 1449: ...CIRCUIT FUNCTION 3 16YL BK CARGO VAN REAR DOOR LOCK SENSE 4 16DG RD CARGO VAN REAR DOOR UNLOCK SENSE 4 16YL BK PASSENGER VAN REAR DOOR LOCK SENSE 5 16DG RD PASSENGER VAN REAR DOOR UNLOCK SENSE DOOR L...

Page 1450: ...GY MODULATION PRESSURE SOLENOID CONTROL 3 20BL GY N2 INPUT SPEED SENSOR 4 20GY BL TEMPERATURE SENSOR P N SWITCH 5 6 16BK SOLENOID SUPPLY VOLTAGE 7 20BK BL SENSOR SUPPLY VOLTAGE 8 16WT BL 2 3 SOLENOID...

Page 1451: ...20YL GY CAMSHAFT POSITION SENSOR SIGNAL 39 20GY O2 1 1 SENSOR CELL SIGNAL 40 20GY WT O2 1 1 VIRTUAL GROUND 49 16BK VT FUEL INJECTOR NO 4 LOW SIDE CONTROL 50 16BK DG FUEL INJECTOR NO 3 LOW SIDE CONTRO...

Page 1452: ...SENSOR GROUND 10 11 20DG WT CAN C BUS 12 20DG CAN C BUS 13 18BK FUSED IGNITION SWITCH OUTPUT RUN START 14 18DG ACCEL SET SIGNAL 15 16 18YL DECEL SET SIGNAL 17 20DG ENHANCED ACCIDENT REPORT DRIVER 18 1...

Page 1453: ...NGINE RPM 19 18BK FUSED IGNITION SWITCH OUTPUT RUN START 24 18BL RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY 25 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 26 18BR BL ACCEL PEDAL POSITION SENSOR...

Page 1454: ...PRESSURE SENSOR 5 VOLT SUPPLY 18 20YL DG MASS AIR FLOW SENSOR SIGNAL 19 20BR BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY 20 18VT IGNITION SWITCH OUTPUT START 21 22 18BR WT BOOST PRESSURE SENSOR GROUND 23 18...

Page 1455: ...L SENSOR SIGNAL 16 17 20BR BK SENSOR GROUND 18 20RD YL ENGINE OIL SENSOR 5 VOLT SUPPLY 19 20 21 20BK WT FUEL PRESSURE SOLENOID CONTROL 22 18RD BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY 23 24 25 26 20DG...

Page 1456: ...L FUEL INJECTOR NO 1 CONTROL ENGINE COOLANT LEVEL SWITCH BLACK CAV CIRCUIT FUNCTION 1 20DG WT BL ENGINE COOLANT LEVEL SWITCH SIGNAL 2 16BR GROUND ENGINE COOLANT TEMPERATURE SENSOR BLACK CAV CIRCUIT FU...

Page 1457: ...V CIRCUIT FUNCTION 1 14BK BL EXCEPT OBD FUEL INJECTOR NO 1 CONTROL 1 16BK RD OBD FUEL INJECTOR NO 1 LOW SIDE CONTROL 2 14BK EXCEPT OBD COMMON INJECTOR DRIVER NO 1 2 16BL OBD FUEL INJECTOR NO 1 HIGH SI...

Page 1458: ...6BK VT OBD FUEL INJECTOR NO 4 LOW SIDE CONTROL 2 14BK EXCEPT OBD COMMON INJECTOR DRIVER NO 1 2 16BL WT OBD FUEL INJECTOR NO 4 HIGH SIDE CONTROL FUEL INJECTOR NO 5 BLACK CAV CIRCUIT FUNCTION 1 14BK DG...

Page 1459: ...L PRESSURE SOLENOID 12 VOLT SUPPLY FUEL PUMP OBD CAV CIRCUIT FUNCTION 1 14BK FUEL PUMP RELAY OUTPUT 2 14BR GROUND FUEL PUMP RELAY OBD CAV CIRCUIT FUNCTION 30 14RD BK FUSED B 85 18BR RD FUEL PUMP RELAY...

Page 1460: ...TPUT 3 INTERNAL HIGH BEAM SWITCH OUTPUT 4 16RD BL FUSED RIGHT LAMP RELAY OUTPUT 5 INTERNAL HIGH BEAM SELECT 6 INTERNAL FUSED LEFT RELAY OUTPUT 8 INTERNAL LAMP DRIVER 9 INTERNAL FUSED IGNITION SWITCH O...

Page 1461: ...BK YL FUSED IGNITION SWITCH OUTPUT RUN START 8 16BK YL WT FOG LAMP RELAY SIGNAL 9 10 16WT FUSED HIGH BEAM SWITCH OUTPUT 11 16RD YL FUSED IGNITION SWITCH OUTPUT RUN START 12 16BR BK WIPER MOTOR CONTROL...

Page 1462: ...LOW PLUG NO 5 SUPPLY VOLTAGE 2 14BK YL GLOW PLUG NO 4 SUPPLY VOLTAGE 3 14BK RD GLOW PLUG NO 3 SUPPLY VOLTAGE 4 14BK VT GLOW PLUG NO 2 SUPPLY VOLTAGE 5 14BK BL GLOW PLUG NO 1 SUPPLY VOLTAGE 6 HEADLAMP...

Page 1463: ...LAMP ASSEMBLY RIGHT BLACK CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 16YL WT FOG LAMP RELAY OUTPUT 3 16BR GROUND 4 16BR GROUND 5 16VT WT HEADLAMP ADJUST SWITCH OUTPUT 6 16BK DG RIGHT TURN SIGNAL...

Page 1464: ...LAY OUTPUT 4 16VT RD S366 COMMON CIRCUIT 5 16BR GROUND 6 7 16VT DG HEATED SEAT SWITCH DRIVER LOW OUTPUT 8 16VT YL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 9 10 16BR GROUND HEATED SEAT SWITCH PASSENGER CA...

Page 1465: ...WT HEATER TIMER 10 16BK BL DG FUSED IGNITION SWITCH OUTPUT 11 16RD FUSED B 12 16BR GROUND HIGH IDLE SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 18BR WT HIGH IDLE ON SIGNAL 4 18BR WT HIGH...

Page 1466: ...RUMENT CLUSTER C1 CAV CIRCUIT FUNCTION 1 20BR FUEL LEVEL SENSOR SIGNAL RETURN 2 20BR DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN 4 20WT GY K IC ATC HBM CHM 5 20BR BK PARK BRAKE INDICATOR SIGNAL 7 20BK...

Page 1467: ...L 12 13 20BK WT LEFT TURN SIGNAL 14 20BR YL BRAKE FLUID LEVEL INDICATOR SIGNAL 15 20BL GENERATOR MONITOR SIGNAL 16 20YL AIRBAG WARNING INDICATOR DRIVER 17 18 20BL VT D RELAY NO 1 CONTROL 18 20BL VT D...

Page 1468: ...LAMP NO 1 CAV CIRCUIT FUNCTION 1 16DG INTERIOR LAMPS DRIVER 2 16BR GROUND INTERIOR LAMP NO 2 CAV CIRCUIT FUNCTION 1 16DG INTERIOR LAMPS DRIVER 2 16BR GROUND INTERIOR LAMP NO 3 CAV CIRCUIT FUNCTION 1 1...

Page 1469: ...1 16BR GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP MIDDLE FRONT CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP MIDDLE...

Page 1470: ...AR SWITCH SENSE 3 INTERIOR LAMP REAR NO 2 BLACK CAV CIRCUIT FUNCTION 1 16BR WT GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP RIGHT BLACK CAV CIRCUIT FUNCTION 1 16BR GROUND 2...

Page 1471: ...8 9 16DG INTERIOR LAMPS DRIVER 10 16BR GROUND INTERIOR LIGHT SWITCH DRIVER CAV CIRCUIT FUNCTION 1 2 3 16RD YL FUSED B 4 5 6 7 16YL INTERIOR LIGHT SWITCH OUTPUT 8 9 10 INTERIOR LIGHT SWITCH PASSENGER...

Page 1472: ...S DRIVER 3 16BR GROUND 4 16YL INTERIOR LIGHT SWITCH OUTPUT INTRUSION SENSOR NO 1 BLACK CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20DG BK INTRUSION SENSOR 1 SIGNAL 3 20DG YL INTRUSION SENSOR INTERF ACE 4 20...

Page 1473: ...2 18BR EXCEPT OBD SENSOR GROUND 2 18BR OBD GROUND LATERAL ACCELERATION SENSOR CAV CIRCUIT FUNCTION 1 20YL RD SENSOR SIGNAL 2 20YL WT SENSOR SIGNAL 3 20RD BL POWER INPUT 4 20DG YL SENSOR SIGNAL 5 20BK...

Page 1474: ...16BR BK LOCKER SWITCH NO 2 OUTPUT 2 16BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT LOW FUEL PRESSURE SENSOR BLACK CAV CIRCUIT FUNCTION 1 18GY DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY 2 18GY YL LOW FU...

Page 1475: ...LAMP NO 1 LEFT FRONT CAV CIRCUIT FUNCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP NO 1 RIGHT FRONT CAV CIRCUIT FUNCTION 1 16GY RD LAMP DRIVER 2 16BR GROUND MARKER LAMP NO 2 LEFT FRONT CAV CIRC...

Page 1476: ...NCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP LEFT REAR CAV CIRCUIT FUNCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP RIGHT CENTER CAV CIRCUIT FUNCTION 1 16GY RD LAMP DRIVER 2 16BR GRO...

Page 1477: ...EXCEPT OBD MASS AIR FLOW SENSOR SIGNAL MASTER DOOR LOCK SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 16WT DG PASSENGER DOOR AJAR INDICATOR DRIVER 3 16WT YL MASTER DOOR LOCK SWITCH SENSE ALL...

Page 1478: ...ELAY OUTPUT 5 20DG YL O2 1 1 PUMP CELL CONTROL 6 20GY O2 1 1 SENSOR CELL SIGNAL PANIC ALARM SWITCH BLACK CAV CIRCUIT FUNCTION 1 18GY DG RD LAMP DRIVER 2 3 18BR GROUND 4 5 6 7 18GY WT PANIC SWITCH SENS...

Page 1479: ...4 18DG PASSENGER MIRROR VERTICAL MOTOR DRIVER 5 18BL DG PASSENGER MIRROR COMMON DRIVER POWER MIRROR SWITCH CAV CIRCUIT FUNCTION 1 18WT GY PASSENGER MIRROR HORIZONTAL MOTOR DRIVER 2 18WT DG DRIVER MIR...

Page 1480: ...R WINDOW SWITCH MASTER CAV CIRCUIT FUNCTION 1 16BL WT MASTER PASSENGER WINDOW DRIVER DOWN 2 16BK WT MASTER PASSENGER WINDOW DRIVER UP 3 16BR GROUND 4 16BK YL DG FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 5...

Page 1481: ...TART A8 16BR GROUND B1 16BR GY SPEAKER RIGHT REAR B2 16WT GY SPEAKER RIGHT REAR B3 18BR RD SPEAKER RIGHT FRONT B4 18BK SPEAKER RIGHT FRONT B5 18BR DG SPEAKER LEFT FRONT B6 18BR SPEAKER LEFT FRONT B7 1...

Page 1482: ...8BK WIPER STAGE 1 INPUT A4 16BK VT RD WASHER PUMP OUTPUT A5 A6 A7 A8 14BK DG FRONT WIPER MOTOR STAGE 2 OUTPUT B1 B2 18BK GY RD FRONT WIPER MOTOR STAGE 2 INPUT B3 18WT VT NO FUNCTION DEFINED B4 18BK VT...

Page 1483: ...CIRCUIT FUNCTION 1 18BR BL SENSOR GROUND 2 20BR RD REFRIGERANT PRESSURE SENSOR FEEDBACK 3 20RD BL 5 VOLT SUPPLY REMOTE KEYLESS ENTRY ANTENNA CAV CIRCUIT FUNCTION 1 20BR RKE ANTENNA 3 GROUND ROLLOVER...

Page 1484: ...OF A C SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 16RD BK FUSED D RELAY NO 1 OUTPUT 4 16VT A C F AN MOTOR CONTROL HIGH SPEED 5 6 7 16YL A C F AN MOTOR CONTROL LOW SPEED 8 16RD BK FUSED D...

Page 1485: ...NAL EQUIPMENT RELAY OUTPUT 9 10 16BR GROUND ROOF THERMOTRONIC CONTROL MODULE CAV CIRCUIT FUNCTION 1 16DG TEMPERATURE SWITCH SENSE 2 3 16VT ROOF A C F AN RELAY CONTROL 4 16DG ROOF A C TEMPERATURE SETTI...

Page 1486: ...TENSIONER DRIVER YELLOW CAV CIRCUIT FUNCTION 1 20BL DRIVER SEAT BELT TENSIONER LINE 2 2 20BR YL DRIVER SEAT BELT TENSIONER LINE 1 SEAT BELT TENSIONER PASSENGER YELLOW CAV CIRCUIT FUNCTION 1 20BL PASSE...

Page 1487: ...PANIC SWITCH SENSE 16 16BR GROUND 17 18GY BR TOWING SENSOR SWITCH SENSE 18 18GY YL INTRUSION SENSOR SWITCH SENSE 19 20 16BK DRIVER CYLINDER UNLOCK SENSE 21 16RD DRIVER CYLINDER LOCK SENSE SECURITY SYS...

Page 1488: ...YL TURN SIGNAL ANTI THEFT ALARM RELAY LEFT RIGHT CONTROL 11 20BR TRANSPONDER COIL 12 TRANSPONDER COIL SHIFTER ASSEMBLY BLACK CAV CIRCUIT FUNCTION 1 2 20GY DG RD LAMP DRIVER 3 20BL DG K ABS SHIFTER AS...

Page 1489: ...8BL DG SPEAKER LEFT FRONT CTEL SPEAKER LEFT FRONT DOOR ASSEMBLY C2 CAV CIRCUIT FUNCTION 1 18BR DG SPEAKER LEFT FRONT 2 18BR SPEAKER LEFT FRONT SPEAKER LEFT REAR CAV CIRCUIT FUNCTION 1 16BR BL SPEAKER...

Page 1490: ...AL 5 18DG ACCEL SET SIGNAL 6 18RD S C SWITCH 12 VOLT SUPPLY STEERING ANGLE SENSOR CAV CIRCUIT FUNCTION 1 20DG WT CAN C BUS 2 3 20DG CAN C BUS 4 5 20BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 6 20BR G...

Page 1491: ...FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 18BK BL TCS SWITCH ASR SENSE 4 5 6 7 16BK BL DG FUSED IGNITION SWITCH OUTPUT 8 9 10 16BR GROUND TOWING INTRUSION SENSOR ON OFF SWITCH CAV CIRCUIT FUNCTION 1 18GY...

Page 1492: ...NTROL MODULE C1 EXCEPT RETROFIT BLACK CAV CIRCUIT FUNCTION A B C 16BK RD WT STOP TURN SIGNAL LEFT D 16BK DG GY STOP TURN SIGNAL RIGHT E F 14RD BK ELECTRIC BRAKES TRAILER TOW CONTROL MODULE C1 RETROFIT...

Page 1493: ...R GROUND TRANSMISSION CONTROL MODULE C2 BLACK CAV CIRCUIT FUNCTION 12 20BL GY N2 INPUT SPEED SENSOR 13 20BK BL SENSOR SUPPLY VOLTAGE 14 16WT 1 2 4 5 SOLENOID CONTROL 15 16YL 3 4 SOLENOID CONTROL 16 16...

Page 1494: ...L NO 1 RIGHT FRONT BLACK CAV CIRCUIT FUNCTION 1 16BK DG RIGHT TURN SIGNAL 2 16BR GROUND TURN SIGNAL NO 2 LEFT FRONT CAV CIRCUIT FUNCTION 1 16BK WT LEFT TURN SIGNAL 2 16BR GROUND TURN SIGNAL NO 2 RIGHT...

Page 1495: ...TIMER 7 16WT RD WARM AIR AUXILIARY HEATER CONTROL WARM AIR AUXILIARY HEATER ASSEMBLY C2 CAV CIRCUIT FUNCTION 1 16DG RD METERING PUMP DRIVER 2 16BR GROUND WASHER PUMP MOTOR FRONT CAV CIRCUIT FUNCTION...

Page 1496: ...OR 2 18BR LEFT FRONT WHEEL SPEED SENSOR WHEEL SPEED SENSOR LEFT REAR CAV CIRCUIT FUNCTION 1 18WT LEFT REAR WHEEL SPEED SENSOR 2 18BR LEFT REAR WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT FRONT CAV CIR...

Page 1497: ...L 11 12 13 16GY WINDOW DEFOGGER SWITCH REAR OUTPUT 14 15 16GY DG DEFOGGER RELAYS WINDOW DEFOGGER RELAY LEFT REAR CONTROL 15 16GY BL EXCEPT DEFOGGER RE LAYS WINDOW DEFOGGER LEFT REAR OUTPUT 16 16GY DG...

Page 1498: ...EAR CAV CIRCUIT FUNCTION 1 16GY DEFOGGER RELAYS WINDOW DEFOGGER RELAY RIGHT REAR OUTPUT 1 16GY EXCEPT DEFOGGER RELAYS WINDOW DEFOGGER RIGHT REAR SIGNAL 2 16BR GROUND WIPER MOTOR FRONT BLACK CAV CIRCUI...

Page 1499: ...l Heat Exchanger BK NS Additional Heat Exchanger Switch BK NS Air Outlet Temperature Sensor BK Engine Compartment Right Rear 11 33 Airbag Control Module YL Under Driver Seat 17 34 36 Airbag Squib Driv...

Page 1500: ...Wheel 49 Brake Wear Sensor Right Rear On Right Rear Wheel 49 C100 BK Under Driver Seat 36 C101 YL Under Instrument Panel Left 31 C102 Except OBD BK NS C103 BK Lower Left Instrument Panel 29 C200 BK U...

Page 1501: ...eat 29 Circulation Pump Relay Relay Block Under Driver Seat N S Clockspring C1 Steering Wheel 17 Clockspring C2 YL Steering Wheel 17 31 Contact Plate Left Rear License Plate Rear Of Vehicle On Left N...

Page 1502: ...oor Lock Motor Ajar Switch Assembly Rear C2 Right Sliding Door 52 Door Lock Motor Ajar Switch Assembly Right Sliding C1 Cargo Door 45 Door Lock Motor Ajar Switch Assembly Right Sliding C2 Cargo Door 4...

Page 1503: ...o 1 C5 BK Under Fuse Block No 1 31 Fuses Fuse Block No 1 Steering Column 28 Fuses Fuse Block No 2 Under Driver Seat 35 Fuses Fuse Block No 3 Under Driver Seat N S Fuses Fuse Relay Block Under Driver S...

Page 1504: ...Front 48 Interior Lamp No 5 Headliner Front 48 Interior Lamp Left BK Left Upper Side 42 Interior Lamp Middle Front BK Headliner Front 42 Interior Lamp Middle Rear BK Headliner Middle Rear 42 Interior...

Page 1505: ...ock Switch BK Center Of Instrument Panel 20 Metering Pump BK Instrument Panel 27 Microphone Connector Instrument Panel N S Multi Function Switch Steering Wheel 24 Optional Equipment Relay Relay Block...

Page 1506: ...le BK Center Roof A C Unit 40 Seat Belt Switch BK Driver Seat Belt Lock 26 Seat Belt Tensioner Driver YL Driver Seat Back 34 Seat Belt Tensioner Passenger YL Passenger Seat Back 34 36 Security System...

Page 1507: ...hicle On The Right Side 45 Turn Signal Relay Fuse Block No 1 In Fuse Block No 1 N S Turn Signal Anti Theft Alarm Relay Left Re lay Block BK Under Driver Seat N S Turn Signal Anti Theft Alarm Relay Rig...

Page 1508: ...nel 5 G304 Front Center Headliner 5 SPLICES SPLICE NUMBER LOCATION FIG S100 Under Drivers Seat 18 S101 Instrument Panel 18 S102 Under Drivers Seat 18 S103 Under Drivers Seat 18 S104 Near Headlamp Asse...

Page 1509: ...S230 Center Instrument Panel 23 25 S231 Left Plenum 27 S232 Left Plenum 27 S250 Near Turn Signal Anti Theft Alarm Relay Left 18 S251 Near Trailer Tow Control Module 9 S252 Near Trailer Tow Control Mo...

Page 1510: ...r Map Reading Lamp Switch 21 S326 Top Body Front Center 42 S327 Near Security System Module 18 S328 Near Central Timer Module 18 S329 Near Central Timer Module 18 S330 Near Security System Module 18 S...

Page 1511: ...FIG S365 Near A C Fan Switch 21 S366 Near Heated Seat Module Driver 18 S375 Under Driver Seat 23 S376 Above pedals 24 S377 Front Center Headliner 24 S378 Left Plenum 27 VA 8W 91 CONNECTOR GROUND SPLI...

Page 1512: ...Fig 1 ENGINE COMPARTMENT LEFT FRONT 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1513: ...Fig 2 ENGINE COMPARTMENT AND WHEEL SPEED SENSORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 15...

Page 1514: ...Fig 3 FRONT COMPONENTS 1 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1515: ...Fig 4 FRONT COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 17...

Page 1516: ...Fig 5 FRONT COMPONENTS 3 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1517: ...Fig 6 FRONT COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 19...

Page 1518: ...Fig 7 ENGINE COMPARTMENT LEFT 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1519: ...Fig 8 ENGINE COMPARTMENT REAR VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 21...

Page 1520: ...Fig 9 INTERIOR LAMP SPLICES 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1521: ...Fig 10 ENGINE COMPARTMENT OVERVIEW VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 23...

Page 1522: ...Fig 11 FUEL AND AIR COMPONENTS 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1523: ...Fig 12 ENGINE AND INJECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 25...

Page 1524: ...Fig 13 ENGINE SENSORS AND INJECTORS 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1525: ...Fig 14 ENGINE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 27...

Page 1526: ...Fig 15 GLOW PLUGS AND FRONT ENGINE 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1527: ...Fig 16 TRANSMISSION VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 29...

Page 1528: ...Fig 17 FRONT CABIN 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1529: ...Fig 18 BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 31...

Page 1530: ...Fig 19 INSTRUMENT PANEL 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1531: ...Fig 20 CENTER STACK SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 33...

Page 1532: ...Fig 21 INSTRUMENT PANEL SPLICES 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1533: ...Fig 22 INSTRUMENT PANEL AND SHIFTER VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 35...

Page 1534: ...Fig 23 INTERIOR COMPONENTS 1 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1535: ...Fig 24 INTERIOR COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 37...

Page 1536: ...Fig 25 INTERIOR COMPONENTS 3 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1537: ...Fig 26 INTERIOR COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 39...

Page 1538: ...Fig 27 MIRRORS AND INTERIOR 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1539: ...Fig 28 FUSE BLOCK NO 1 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 41...

Page 1540: ...Fig 29 DASH INLINE CONNECTORS 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1541: ...Fig 30 AJAR SWITHES LIGHTER ROOF FAN VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 43...

Page 1542: ...Fig 31 STEERING COLUMN AND PEDALS 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1543: ...Fig 32 STEERING SYSTEM VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 45...

Page 1544: ...Fig 33 HVAC ASSEMBLY 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1545: ...Fig 34 RESTRAINTS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 47...

Page 1546: ...Fig 35 FUSE AND RELAY BLOCKS 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1547: ...Fig 36 UNDER DRIVER SEAT VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 49...

Page 1548: ...Fig 37 INTRUSION SENSORS 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1549: ...Fig 38 ROOF INLINE CONNECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 51...

Page 1550: ...Fig 39 ROOF A C UNIT 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1551: ...Fig 40 ROOF A C RELAYS AND MODULE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 53...

Page 1552: ...Fig 41 ROOF A C FUSES 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1553: ...Fig 42 INTERIOR LAMPS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 55...

Page 1554: ...Fig 43 POWER DOOR LOCKS 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1555: ...Fig 44 WINDOW MOTORS AND SPEAKERS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 57...

Page 1556: ...Fig 45 DOORS AND TURN SIGNALS 8W 91 58 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1557: ...Fig 46 DOOR LOCK MOTOR AJAR SWITCH VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 59...

Page 1558: ...Fig 47 UNDERBODY SPLICES 8W 91 60 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1559: ...Fig 48 INTERIOR LAMPS ANTENNA VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 61...

Page 1560: ...Fig 49 BRAKE SENSORS 8W 91 62 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1561: ...Fig 50 INTERIOR BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 63...

Page 1562: ...Fig 51 UNDERBODY 8W 91 64 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1563: ...Fig 52 BODY GROUNDS AND AJAR SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 65...

Page 1564: ...Fig 53 REAR LIGHTING 8W 91 66 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Page 1565: ...ses Cartridge fuses Relays Following are general descriptions and theory of operation for the major components in the power dis tribution system Refer to Wiring for the location of complete circuit di...

Page 1566: ...ltage supply circuits These circuit breakers can protect the systems from a short circuit or from an overload condition caused by an obstructed or stuck power window regulator or switch The circuit br...

Page 1567: ...integral to the body wire harness If any internal circuit or the fuse block housing is faulty or damaged the entire fuse block and body wire harness unit must be replaced OPERA TION All of the circuit...

Page 1568: ...secures the receptacle base to the instrument panel 4 Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the reta...

Page 1569: ...he fuse block fuse as required 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally...

Page 1570: ......

Page 1571: ...TANDARD PROCEDURE CHECKING CAMSHAFT POSITION 28 STANDARD PROCEDURE INSPECTING TAPPET CLEARANCE 30 REMOVAL 30 INSTALLATION 32 CYLINDER HEAD COVER S REMOVAL 33 INSTALLATION 34 VALVE STEM SEALS DESCRIPTI...

Page 1572: ...INSTALLATION 69 TIMING CHAIN COVER REMOVAL 70 INSTALLATION 71 TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL TENSIONING AND SLIDE RAILS 72 REMOVAL INTERMEDIATE GEAR 73 REMOVAL TIMING CHAIN TENSIONING RAI...

Page 1573: ...ster and adapter from cylinder head 11 Install glow plugs Refer to 8 ELECTRICAL IGNITION CONTROL GLOW PLUG INSTALLA TION 12 Install engine cover Refer to 9 ENGINE INSTALLATION COMPRESSION SPECIFICATIO...

Page 1574: ...der Head Gasket AIR LOSS THROUGH AIR INTAKE AREA 1 Sealing Sur faces 1 Remove Cyl inder Head for Further Inspec tion CONDITION POSSIBLE CAUSES CORRECTION 2 Intake Valves and Seats 2 Replace Valves Gui...

Page 1575: ...LEASE PRESSURE STORE COOL ANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER WEAR PROTECTIVE GLOVES CLOTHES AND EYE WEAR 1 Disconnect the negative battery cable NOTE REPLACE THE AIR CONDITIONING DRIER...

Page 1576: ...er 17 Remove the change air cooler A C conderser and fan as an assembly 18 Disconnect the charge air hose at the intake manifold Fig 3 19 Remove the radiator assembly 20 Disconnect the high pressure a...

Page 1577: ...the vehicle 28 Disconnect the front exhaust at the turbo charger Fig 4 29 Disconnect the electrical connector at the transmission Fig 4 TURBOCHARGER INLET 1 CCV BREATHER 5 MAF SENSOR 2 OIL LEVEL INDI...

Page 1578: ...smission jack 39 Place a wood block between the transmission housing and the front frame cross over 40 Remove the transmission jack 41 Remove the exhaust bracket right side 42 Remove the engine ground...

Page 1579: ...is opened to the atmo sphere 1 Install the engine lifting fixture special tool 9308 to the engine lifting eyelets 2 Attach the engine hoist 3 Install the engine assembly into the vehicle engine compar...

Page 1580: ...nnect the fuel lines at the filter assembly Fig 9 25 Connect the power steering hoses 26 Install the radiator charge air cooler and hose s assemblies Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 27...

Page 1581: ...ming Case Cover 20 15 Bolt Front Cover to Cylin der Head 14 124 12m Bolt Cylinder Head to Crankcase 3 stages torque torque angle torque angle 60 90 90 44 90 90 Crankcase Timing Case Cover End Cover Bo...

Page 1582: ...ss Fly wheel to Crankshaft 2 stage 1 torque 1 torque angle 45 90 33 90 Turbo Charger Bolt Oil Feed Line to Cyl inder Head 9 22 80 194 Bolt Oil Feed Line to Tur bo Charger 30 22 Bolt Turbo Charger Sup...

Page 1583: ...to Cylinder Head Cover 11 97 Nut Bolt Crankshaft Posi tion Sensor to Engine Block 8 70 Pre Glow System Cylinder Head to Glow Plug 12 106 Starter Bolt Starter to Crankcase 42 31 Nut Connection of Circu...

Page 1584: ...10 15 Bolt Thremostat Housing to Cylinder Head 9 80 Coolant Drain Plug to Crankcase 30 22 Engine Suspension Engine Mount Engine Bracket Bolt Engine Bracket to Crankcase 2 stage torque torque angle 20...

Page 1585: ...0 5 Nut Exhaust Bracket to Threaded Plate of Center Exhaust Pipe 20 177 Support Exhaust Bracket on Transmission 20 177 Refrigerant Compressor Bolt Refrigerant Compres sor to Timing Case Cover 20 177 B...

Page 1586: ...ine to Rail Injector New Reused 22 25 16 18 5 Nut Pressure Line to High Pressure Pump Rail 22 16 Screw Tensioning Claw to Injector 2 stage 1 torque 1 torque angle 7 90 62 90 Rail Pressure Sensor to Ra...

Page 1587: ...00 8940 VIBRATION DAMPER RE MOVER N A 8941 SLIDE HAMMER 611 589 00 15 00 8942 OIL JET INSTALLER 611 589 01 14 00 8944 REAR MAIN SEAL IN STALLER N A 9312 1 CHAIN SEPARATOR RIV ETING TOOL 9312 4 THRUST...

Page 1588: ...8932 CRANKSHAFT LOCK 8936 FRONT CRANKSHAFT SEAL INSTALLER 8938A EXTRACTION CLAW 8940 VIBRATION DAMPER REMOVER 9 18 ENGINE VA...

Page 1589: ...8941 SLIDE HAMMER 8942 OIL JET INSTALLER 8944 REAR MAIN SEAL INSTALLER 9307 VALVE SERVICE TOOLS VA ENGINE 9 19...

Page 1590: ...8951 ASSEMBLY LINKS 9285 FUEL LINE WRENCH 9286 GLOW PLUG PLIERS 9295 COMPRESSION HOSE ADAPTOR 9525 TIMING CHAIN GUIDE 9539 FUEL LINE PLIERS 9 20 ENGINE VA...

Page 1591: ...the negative battery cable 2 Remove the heat shield 3 Remove the air flow sensor Refer to 14 FUEL SYSTEM FUEL INJ ECTION MANIFOLD AIR FLOW MAF SENSOR REMOVAL 4 Disconnect the air intake pressure sens...

Page 1592: ...ow plugs arranged slant wise The intake and exhaust valves have solid valve stems and conical valve springs The cylinder head is not ser viceable and must be replaced should a repair become necessary...

Page 1593: ...y cable 2 Position piston of cylinder 1 to ignition TDC 3 Raise and support vehicle 4 Install retaining lock 8932 for crankshaft starter ring gear WARNING RISK OF INJURY TO SKIN AND EYES FROM SCALDING...

Page 1594: ...engine harness con nected 18 Remove the turbocharger oil supply line at the cylinder head and turbocharger Fig 14 19 Disconnect the turbocharger at the exhaust manifold Fig 14 20 Unbolt the transmiss...

Page 1595: ...BELT CHAIN TENSIONER PULLEY REMOVAL WARNING NO FIRE OPEN FLAMES OR SMOKING SERVICE VEHICLE IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES RISK OF POISON ING FROM INHALING AND SWALLOWING FUEL RIS...

Page 1596: ...driver of inlet camshaft sprocket 8 Remove top guide rail INSTALLATION INSTALLA TION CYLINDER HEAD WARNING Refer to 14 FUEL SYSTEM WARN ING NOTE Thoroughly clean all mating surfaces with appropriate s...

Page 1597: ...housing with tappets to cylinder head Fig 14 14 Install camshafts Refer to 9 ENGINE CYL INDER HEAD CAMSHAFT S INSTALLATION 15 Install top guide rail Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN A...

Page 1598: ...USE EXTREME CAUTION 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 CLOTHES 7 Start the engine and inspec...

Page 1599: ...hole in the left inlet camshaft sprocket Fig 19 NOTE The two markings in the inlet camshaft sprockets must be positioned opposite and mark ings of camshaft and camshaft bearing cap must be aligned If...

Page 1600: ...s 5 Use a pressing tool and apply pressure to the tappet by hand Fig 20 6 If the tappet drops faster in comparison to the other tappets remove the camshaft and replace the tappet REMOVAL NOTE Tappets...

Page 1601: ...aring caps 13 Paint mark or scribe each camshaft bearing cap identifying which camshaft and which position 14 Remove the camshaft bearing caps at exhaust camshaft bearing cap 1 3 4 and 6 in sequence 1...

Page 1602: ...fts at axial bearing Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S STANDARD PROCEDURE NOTE Pay attention to markings on camshaft bear ing caps CAUTION Do not rotate engine counter clockwise 3 Position th...

Page 1603: ...recesses 15 Clean and install injectors Refer to 14 FUEL SYSTEM FUEL INJ ECTION FUEL INJ EC TOR STANDARD PROCEDURE Refer to 14 FUEL SYSTEM FUEL INJ ECTION FUEL INJ EC TOR INSTALLATION 16 Reconnect neg...

Page 1604: ...tive battery cable WARNING Refer to 14 FUEL SYSTEM WARN ING WARNING USE EXTREME CAUTION WHEN ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH FAN DO NOT PUT YOUR HANDS NEAR PUL LEYS BELTS OR FAN...

Page 1605: ...for each cylinder being serviced Failure to do so may result in damage to the vehicle or personal injury 9 Install crankshaft lock special tool 8932 10 Seal injector hole with adaptor 9534 and retain...

Page 1606: ...ig 27 7 Remove valve stem seals Fig 28 8 Repeat steps 5 through 9 for each valve as nec essary 9 Remove cylinder head from assembly board WARNING Valves springs and retainers must be kept in order of...

Page 1607: ...G 21 Install engine cover Refer to 9 ENGINE COVER INSTALLATION INSTALLA TION VALVES WARNING Valves must be kept in their original positions in cylinder head Failure to do so will result in engine dama...

Page 1608: ...de the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system can be refilled and the vehicle placed in service immediately STANDARD PROCEDURE MEASURING CYLIN DER BOR...

Page 1609: ...fter any bearing damage occurred remove all debris which is present in the main oil gallery connecting rod bores and in the crankshaft and oil galleries Include removal of the inserting steel ball of...

Page 1610: ...AL REAR REMOVAL 4 Remove pistons Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECTING ROD REMOVAL CAUTION The crankshaft bearing caps are num bered consecutively beginning with the first crank shaft beari...

Page 1611: ...manual for specifications 8 Fill the cooling system with the proper coolant to the proper level Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 9 Connect the negative battery cable WARNING USE E...

Page 1612: ...tall the fly wheel and tighten bolts in two stages Fig 33 45N m 33 lbs ft then 90 5 Install the oil pan drain plug and tighten to 25N m 18 lbs ft 6 Lower the vehicle 7 Fill the crankcase with the corr...

Page 1613: ...ation damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 3 Remove the retaining lock for the crankshaft ring gear 4 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE...

Page 1614: ...CAUTION WHEN THE ENGINE IS IN OPERATION 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 CLOTHES 5 Start the vehicle INSTALLA TION CRANK...

Page 1615: ...ction pressures Oil jets in the engine block lubricate and cool the pis ton and pin assembly The connecting rods have a pressed in place wrist pin bushing featuring specially adjusted lubrication groo...

Page 1616: ...bore repair as necessary Fig 38 NOTE If excessive wear is present press in new connecting rod bushings 4 Measure connecting rod bushing inner diame ter Fig 38 5 Inspect wristpin bushing 6 Measure pist...

Page 1617: ...urface it is then necessary to measure the piston protrusion Measure protrusion between piston crown and cyl inder head contact surface without the head gasket installed The measurment must be carried...

Page 1618: ...osits The carbon deposits on the pistons must be removed NOTE If the arrows indicating the driving direction on the piston are no longer visible they must be marked again 9 Remove the connecting rod t...

Page 1619: ...bushing CAUTION Assemble the piston and connecting rod so that the arrow is pointing in the direction of travel in the opposite direction of power flow The marking on the connecting rod is pointing t...

Page 1620: ...otate the crankshaft sufficiently so that the connecting rod does not touch the connecting rod journal when the piston is pushed onto the cyl inder bore 8 Install piston with arrow pointing in the dir...

Page 1621: ...ENGINE LU BRICATION OIL PUMP INSTALLATION 14 Install engine oil pan and oil pan drain plug Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION CAUTION Install a cylinder head gasket of standard thickne...

Page 1622: ...ate the ring in the groove It must move freely around circumference of the groove RING SIDE CLEARANCE CHART ITEM SPECIFICATION Top Compression Ring 0 012 0 016 mm 0 0047 0 0063 in Second Compression R...

Page 1623: ...able 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Install retaining lock for crankshaft ring gear Fig 47 4 Remove crankshaft center bolt and washer Fig 47 NOT...

Page 1624: ...D IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 8 Start vehicle and inspect for leaks VACUUM PUMP DESCRIPTION The vacuum pump is operated...

Page 1625: ...ixture 8534 with adap tors 8534 16 and raise the engine slightly 2 Raise and support the vehicle 3 Remove the engine mount bolts Fig 49 4 Lower the vehicle 5 Using the engine support fixture 8934 rais...

Page 1626: ...ine mount and tighten bolt to 83 N m 61 lbs ft Fig 50 7 Remove the engine support fixture and adap tors OIL REMOVAL OIL SEPARA TOR 1 Disconnect breather hose 2 Remove the separator retaining bolts 3 T...

Page 1627: ...clean and inspect cap gasket replace as necessary 3 Remove oil filter Fig 52 INSTALLA TION 1 Inspect oil filter cap gasket if all right lubri cate with clean engine oil 2 Install oil filter 3 Screw oi...

Page 1628: ...ully seated into engine block Fig 55 4 Reassemble engine 5 Install engine into vehicle OIL PAN REMOVAL 1 Drain engine oil 2 Remove the sway bar retaining bolts and swing sway bar down and out of the w...

Page 1629: ...Disconnect the oil level sensor 8 Remove the transmission cooler lines from the oil pan bolts and carefully position the lines aside 9 Remove the oil pan bolts 10 Remove oil pan and gasket Fig 57 Fig...

Page 1630: ...ting surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly 1 Slide the oil pan into position 2 Slide the gasket into position 3 Add sealant to the joints...

Page 1631: ...LOOSE CLOTHES 16 Start the engine and inspect for leaks OIL PUMP REMOVAL REMOVAL 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 Remove the oil pump bolts Fig 57 3 Press the chai...

Page 1632: ...engine oil Refer to LUBRICATION MAINTENANCE FLUID TYPES SPECIFICA TIONS WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE C...

Page 1633: ...stall insert on riveting tool Fig 64 NOTE The outer plate is held in place magnetically by riveting tool 10 Insert new outer plate into the moving assem bly insert 11 Position riveting tool so that sp...

Page 1634: ...tes on the capacitance principle features an integrated electronic circuit which analyzes the three signals the signals are con stantly relayed to the ECM and over the CAN bus to the instrument cluste...

Page 1635: ...ig 67 4 Rotate front stabilizer bar upward and secure to axle beam Tighten to 22 lbs ft 30 N m 5 Lower the vehicle 6 Lower the engine into the mounts 7 Remove engine support fixture 8 Raise and suppor...

Page 1636: ...block between cyl inders 1 and 2 Fig 68 7 Disconnect the charge air hose at the intake manifold Fig 69 Fig 68 FUEL INJECTORS AND HIGH PRESSURE FUEL LINES 1 FUEL RAIL 2 HIGH PRESSURE FUEL INJECTOR LIN...

Page 1637: ...th fuel lines at the fuel filter Fig 69 12 Remove the lower intake manifold support bracket Fig 70 13 Raise and support the vehicle 14 Remove the rear intake manifold mounting bolts while accessible f...

Page 1638: ...ON 7 Connect the coolant hose at the EGR valve Fig 69 8 Secure the engine wiring harness and cable duct to the intake manifold tighten fastener to 9N m 80 in lbs 9 Connect the EGR wiring harness conne...

Page 1639: ...raight edge 2 Inspect exhaust manifold for cracks or distor tion 3 Install new exhaust manifold gasket over the studs 4 Position the exhaust manifold over to studs and tighten retaining nuts to 30 N m...

Page 1640: ...o 9 ENGINE REMOVAL 9 Remove front cover at cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 10 Remove accessory drive belt 11 Remove the high pressure fuel pump Refer to 14 FUEL SYSTEM FUEL DELIV...

Page 1641: ...olt in two stages 200N m 147 lbs ft then 90 M10 9 bolt 325N m 240 lbs ft then 90 10 Remove the engine support fixture 11 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 12 Inst...

Page 1642: ...arm they are always replaced together 1 Disconnect negative battery cable 2 Remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL NOTE Remove timing case cover carefully Care must be taken not...

Page 1643: ...ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 6 Insert locking pin through first camshaft bear ing cap into hole in inlet camshaft sprocket to lock inlet camshaft 7 Remove timing chain tensioner...

Page 1644: ...m bearing pin Fig 77 REMOVAL TIMING CHAIN 1 Remove cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL NOTE Cover the timing chain area Care must be taken not to drop any...

Page 1645: ...ensure that the thrust pin is positioned at the left timing chain pin of a chain link 4 Install special tool 9312 onto timing chain link Fig 79 NOTE Cover the timing chain area Care must be taken not...

Page 1646: ...re that no grease or oil is present during reassembly CAUTION ENSURE THAT THE SPRING IS COR RECTLY INSTALLED ON THE TENSIONING CLAMP AND SLIDE RAIL 1 Install rail on bearing pin Fig 75 2 Install timin...

Page 1647: ...OVER S INSTALLATION WARNING NO FIRE FLAMES OR SMOKING SER VICE VEHICLE IN WELL VENTILATED AREA RISK OF INJURY FROM INHALING OR SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL WE...

Page 1648: ...of old timing chain evenly as it becomes free to the same extent that new tim ing chain is drawn in 2 Draw in new timing chain with the oil holes facing up by rotating the crankshaft slowly in direc...

Page 1649: ...ing tool by inserting pieces 9312 7 and 9312 10 Fig 86 NOTE Ensure that the riveted link and riveting tool are aligned 7 Press in new riveted link as far as the stop Fig 87 8 Remove guide link and riv...

Page 1650: ...ly insert 9312 11 to 9312 1 17 Position riveting tool exactly over middle of pin 18 Tighten riveting tool spindle to end of travel Fig 89 19 Repeat procedure for both riveting pins Fig 89 20 Inspect r...

Page 1651: ...timing chain tensioner Fig 91 INSTALLA TION NOTE Carefully clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly 1 Install timing chain tens...

Page 1652: ......

Page 1653: ...EXHAUST SYSTEM DESCRIPTION 2 7L DIESEL CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edge...

Page 1654: ...Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten replace exhaust manifold to cyli...

Page 1655: ...tab is inserted into the alignment slot 2 Install mounting bracket and nuts Fig 1 3 Install clamp 4 Lower the vehicle 5 Start the vehicle and inspect for exhaust leaks Repair exhaust leaks as necessar...

Page 1656: ...low speeds the flow cross section is reduced by closing the guide vanes Fig 2 Consequently the speed at which the exhaust gas impacts on the tur bine wheel is increased as a result of which the speed...

Page 1657: ...py water check the air inlet ducts rubber sleeves charge air cooler and intake manifold for leaks REMOVAL 1 Remove front bumper 2 Remove headlamp assemblies 3 Remove front cross member together with f...

Page 1658: ...for turbo charger boost pressure It generates a control vacuum in response to a PWM signal from the ECM Vacuum is achieved by mixing the system vacuum from the vacuum pump with atmospheric pressure to...

Page 1659: ...arger Fig 6 5 Remove the vacuum line from the turbocharger vacuum unit Fig 6 6 Separate the oil supply at the cylinder head and turbocharger Fig 6 7 Separate the oil return flow line at the turbo char...

Page 1660: ...22 lbs ft 30 N m at turbocharger Fig 6 4 Replace gaskets and install oil return line at turbocharger Tighten bolt to 80 lbs in 9 N m Fig 6 NOTE Counterhold the connection at the turbo charger when ti...

Page 1661: ...stall the retaining bolts Tighten bolts to 70 lbs in 8 N m 2 Connect vacuum hoses 3 Connect electrical connector 4 Install air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING I...

Page 1662: ......

Page 1663: ...CATIONS FRAME DIMENSIONS 3 SPECIFICATIONS TORQUE 8 ENGINE CRADLE CROSSMEMBER REMOVAL 8 INSTALLATION 10 REAR CROSSMEMBER TRANSMISSION REMOVAL 11 INSTALLATION 11 TRAILER HITCH REMOVAL 11 INSTALLATION 12...

Page 1664: ...ets 5 Disconnect electrical connector INSTALLA TION 1 Connect outside temperature sensor electrical connector 2 Slide fascia onto the support brackets 3 Install fascia screws and tighten to 23 N m 17...

Page 1665: ...fascia INSTALLA TION 1 Install fascia and seat the corners over the sup port brackets 2 Seat bumper support brackets clips below end panel firmly 3 Install the four plastic rivets to the bumper step i...

Page 1666: ...INDEX DESCRIPTION FIGURE 05 FRAME DIMEN SIONS 1 5 05 FRAME DIMEN SIONS 2 6 FRAME DIMENSIONS 7 13 4 FRAME BUMPERS VA...

Page 1667: ...Fig 5 05 FRAME DIMENSIONS 1 VA FRAME BUMPERS 13 5...

Page 1668: ...Fig 6 05 FRAME DIMENSIONS 2 13 6 FRAME BUMPERS VA...

Page 1669: ...Fig 7 FRAME DIMENSIONS VA FRAME BUMPERS 13 7...

Page 1670: ...mount bolts nuts 45 33 WARNING Microencapsulated bolts and self lock ing nuts may only be used once If you use microencapsulated bolt or self locking nuts more than once the self locking function is...

Page 1671: ...ect brake lines from body side at the couplings Fig 12 13 Support engine cradle with suitable lifting device 14 Remove four cradle support bolts from each side of the cradle Fig 13 Fig 9 FRONT DISC BR...

Page 1672: ...r Refer to 2 SUSPEN SION FRONT STABILIZER BAR INSTALLATION 5 Install heat shield and nuts 6 Install jounce bumpers and install nuts 7 Install support clips and brake lines 8 Raise engine cradle into p...

Page 1673: ...mount cover Fig 16 4 Remove crossmember nuts and crossmember INSTALLA TION 1 Install crossmember and install nuts 2 Tighten crossmember nut to 45 N m 33 ft lbs 3 Remove transmission support 4 Install...

Page 1674: ...the bolts and nuts are greased the trailer hitch may become detached from the vehicle possibly resulting in a serious risk of injury and or damage to property including damage to the vehicle 1 Raise...

Page 1675: ...detached from the vehicle possibly resulting in a serious risk of injury and or damage to property including dam age to the vehicle 3 Install the angle bracket microencapsulated bolts nuts and hand t...

Page 1676: ......

Page 1677: ...ULD GASOLINE BE MIXED WITH DIESEL FUEL NOT EVEN DURING WINTER THE HIGH PRESSURE PUMP IS LUBRICATED BY DIESEL FUEL IMMEDI ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS ING REPLACEMENT AND FLUSHING OF THE COMPL...

Page 1678: ...al Fuel Pres sure Start the engine and observe the Fuel Pressure Set Point and the Actual Fuel Pressure If the Actual Fuel Pressure Oscillates above and below the Fuel Pressure Set Point in a regular...

Page 1679: ...onds a maximum of five gradua tion lines 40 ml of the large test vial may be reached If the level has exceeded the five graduation line replace that affected cylinder s injector clear the memory using...

Page 1680: ...d fuel filter If no problem is found with the fuel sys tem replace the low pressure fuel pump 1 Disconnect the negative battery cable 2 Connect a fuel gauge to the low pressure fuel supply to the high...

Page 1681: ...till below specification replace the fuel pump If the fuel pressure is within the specification replace the fuel filter and retest at the high pressure pump to verify system function Fig 6 FUEL PRESSU...

Page 1682: ...7 INSTALLATION HIGH PRESSURE PUMP 17 FUEL PUMP MODULE DESCRIPTION 18 REMOVAL 18 INSTALLATION 20 FUEL QUANTITY CONTROL VALVE DESCRIPTION 21 OPERATION 21 REMOVAL 21 INSTALLATION 21 FUEL RAIL DESCRIPTION...

Page 1683: ...rail pressure Engine is switched off Calculating Pre injection Quantity The pre injec tion quantity is calculated on the basis of Engine speed Atmospheric pressure Coolant temperature Boost air tempe...

Page 1684: ...ng Maximum Engine Speed The ECM determines the engine speed based on the signal supplied by the crankshaft sensor and lim its this by interrupting the operation of the fuel injectors Fuel Quantity Con...

Page 1685: ...ing Unstable fuel rail pressure This can manifest itself as instability of idle speeds excessive under shoot overshoot at engine start up or excessive undershoot overshoot when the engine operating co...

Page 1686: ...ptied The water drain plug and water in fuel WIF sensor are located on the top of the filter Water is drained by using the in tank electric fuel pump to generate flow attach a hose to the drain plug T...

Page 1687: ...rimp clamps using special tool 9539 Fig 2 5 Connect the WIF wiring harness connector Fig 2 6 Connect negative battery cable 7 Cycle ignition several times to build pressure 8 Start engine and inspect...

Page 1688: ...driveability concern 5 Start engine run for a few minutes turn engine off and inspect for leaks Refer to 14 FUEL SYSTEM WARNING Refer to 14 FUEL SYS TEM DIAGNOSIS AND TESTING FUEL RAIL PRESSURE SEN SO...

Page 1689: ...pressure pump is mounted to the front of the cylinder head and must be replaced as an assem bly should a failure occur Fig 5 DESCRIPTION LOW PRESSURE PUMP The electric fuel pump is located in the fue...

Page 1690: ...s the fuel pressure which exists at the fuel quantity control valve 11 to approximately 5 bar 72 5 psi If the pressure is exceeded the pressure relief valve opens and passes the fuel to the return flo...

Page 1691: ...eccentric shaft 9 and the fuel is compressed The valve 2 disk shuts off the delivery volume to the fuel supply Once the fuel pressure in the cylinder rises beyond the pressure which exists in the hig...

Page 1692: ...e pump will begin running immediately supplying fuel through fuel filter and onto the high pressure pump The lift pump and low pressure fuel circuit operate at a pressure between 3 8 5 5 bar 55 80 psi...

Page 1693: ...p and remove pump Fig 8 INSTALLA TION HIGH PRESSURE PUMP Refer to 14 FUEL SYSTEM WARNING CAUTION Clean sealing surfaces with appropriate solvents and replace all seals NOTE Inspect then attach high pr...

Page 1694: ...he following components Electric fuel pump transfer or lift pump Fuel reservoir Fuel gauge sending unit fuel level sensor Fuel supply line connection Fuel return line connection Fuel is supplied to th...

Page 1695: ...float assembly to fall into fuel tank 8 While holding float rod remove fuel pump module from fuel tank 9 Remove float assembly from fuel tank 10 Remove and discard rubber gasket seal from pump module...

Page 1696: ...l pump module into opening in fuel tank 8 Position locknut over top of fuel pump module Install locknut finger tight 9 The fuel line fittings should be pointed to the right side of the vehicle Rotate...

Page 1697: ...f the sensors In order to adapt the quantity injected either the rail pressure can be adjusted by way of the pressure regulator valve and the quantity control valve or the actuation time of the soleno...

Page 1698: ...the fuel rail 6 Remove injector high pressure lines Fig 19 7 Remove fuel rail retaining bolts Fig 19 CAUTION When slackening and tightening fuel injection line union nuts counter hold with wrench at t...

Page 1699: ...nspect for leaks Refer to 14 FUEL SYSTEM WARNING FUEL TANK DESCRIPTION The plastic fuel tank Fig 20 is mounted to the frame rails under the left center side of the vehicle The fuel tank contains a ser...

Page 1700: ...el Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Filler Tube 10 Vent Hose 11 Hose 12 Clamps 13 Cushioning Material 14 Two Way Valve Fig 21 FUEL COOLER LINES 1 Expansion Tank 2 Top of Tank...

Page 1701: ...odule 7 Disconnect fuel supply line at tank 8 Disconnect fuel return line at tank 9 Continue to carefully lower tank for removal 10 If fuel pump module is to be removed thor oughly clean area at top o...

Page 1702: ...k 4 Raise tank until positioned near body Fig 23 FUEL TANK ASSEMBLY 1 Strap Bolts 2 2 Hose not with all engines 3 Fuel Outlet Line 4 Fuel Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Fill...

Page 1703: ...d snug to body 8 Install and position both fuel tank support straps 7 Fig 26 to mounting bolts 1 9 Install 2 fuel tank strap nuts 8 Refer to Torque Specifications 10 Remove hydraulic jack 11 Connect f...

Page 1704: ...TANK ASSEMBLY 1 Strap Bolts 2 2 Hose not with all engines 3 Fuel Outlet Line 4 Fuel Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Filler Tube 10 Vent Hose 11 Hose 12 Clamps 13 Cushioning M...

Page 1705: ...umbers 5 To remove sending unit from pump module press on plastic locking tabs 1 Fig 30 while slid ing sending unit 4 on its tracks INSTALLA TION 1 Noting their previous positions connect wires from 2...

Page 1706: ...s probes to close the electronic circuit when water is present in the system When diesel fuel is present in the system it s dielectric does not conduct electricity well properties do not allow any ele...

Page 1707: ...JECTOR CLASSIFICATION 37 CLEANING FUEL INJECTORS 38 REMOVAL 38 INSTALLATION 39 FUEL PRESSURE SENSOR DESCRIPTION 39 OPERATION 39 REMOVAL 39 INSTALLATION 40 FUEL PRESSURE SOLENOID DESCRIPTION 40 OPERATI...

Page 1708: ...is injected into the engine The accelerator pedal position sensor is serviced as an assembly with the accelerator pedal assembly REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the APP se...

Page 1709: ...Refer to On Board Diagnostics in Emissions Con trol System for a list of Diagnostic Trouble Codes DTC s for certain fuel system components REMOVAL 1 Disconnect the negative battery cable 2 Unplug the...

Page 1710: ...y the camshaft position sensor the vehicle will not start because cylinder order can not be detected REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover 3 Disconnect camshaft position se...

Page 1711: ...can occur at exactly the right moment The engine speed signal is also processed by the ECM from the crankshaft sen sor This signal is then transferred to other control modules over the CAN bus If the...

Page 1712: ...bleed orifice seat The rail s high pressure build up in the valve control chamber and the same pressure is also present in the nozzle s chamber volume The rail pressure applied at the control plunger...

Page 1713: ...its downward movement it can overspring with the return spring so that it exerts no downwards acting forces on the armature and the ball The closing of the bleed orifice lead to pressure build up in t...

Page 1714: ...MOVAL WARNING NO SPARKS OPEN FLAMES OR SMOK ING RISK OF POISONING FROM INHALING AND SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL POUR FUELS ONLY INTO SUITABLE AND APPROPRI AT...

Page 1715: ...en injectors are removed re enter all injector six digit codes 8 Program all injector codes into the ECM using the scan tool 9 Start engine allow to run turn engine off and inspect for leaks Refer to...

Page 1716: ...sent in the fuel rail flows to the ball seat of the pressure solenoid Fig 16 The specified pressure required by the system is built up in the rail by the fuel pressure solenoid building up a magnetic...

Page 1717: ...pair Refer to 14 FUEL SYSTEM WARNING WARNING NO SPARKS OPEN FLAMES OR SMOK ING RISK OF POISONING FROM INHALING AND SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL POUR FUELS ONL...

Page 1718: ...e controller quantity of the pressure regulat ing valve is reduced and the fuel temperature is lowered REMOVAL NOTE Capture and properly store all fluid seepage in appropriately marked containers 1 Di...

Page 1719: ...ocking tabs seat the sensor to the pipe and release tabs Fig 21 3 Connect negative battery cable INTAKE AIR PRESSURE SEN SOR DESCRIPTION An absolute pressure sensor is mounted to the air cleaner housi...

Page 1720: ...ng resistor in the rear so that it is 320 F 160 C higher than the temperature of the intake air The temperature at the heating resistor is mea sured by a sensor resistor in between Because the incomin...

Page 1721: ...r is a planar zirconium dioxide ZrO2 dual cell limiting current probe with a integral heater The term wide ban refers to the ability of the O2 sensor to generate a clear signal over a wide air fuel ra...

Page 1722: ...hen the oxygen level on the supply side reaches zero the current stops The ECM activates the integral heater element to raise the temperature of the sensor to 700C 192 F for the ZrO2 to become conduct...

Page 1723: ...ration in the gas sample chamber is high The sensor cell measures the differ ence between the oxygen concentrations in the sam pler chamber and the reference air channel A voltage lower than 450mV is...

Page 1724: ...TION 1 Install the oxygen sensor Fig 28 2 Install the heatshield and tighen fasteners to 9N m 80 lbs in Fig 27 3 Properly position the oxygen sensor wiring har ness and connect the electrical connect...

Page 1725: ...e rotation of the pinion moves the gear rack from side to side This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels Fig 1 Power assist is provided...

Page 1726: ...nternal pump noise 3 Replace pump 4 Air in fluid 4 Check for lekas Evacuate air from P S system SUCKING AIR SOUND 1 Loose return line clamp 1 Replace clamp 2 O ring missing or damaged on hose fitting...

Page 1727: ...bricate suspension compnents 4 High friction in steering gear 4 Replace gear LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING WHEEL 1 Worn or loose suspen...

Page 1728: ...g wheel and lock the steering wheel in the straight ahead position The position of the steering gear must not be altered again for the entire duration of the w ork procedure 4 Remove the electrical ce...

Page 1729: ...spring for the brake pedal to the steering column 6 Reconnect the electrical connector to the igni tion lock 7 Install the combination switch 8 Install the clockspring 9 Install the steering wheel 10...

Page 1730: ...ound cable on the battery 2 Remove the air bag module from the steering wheel 3 Turn the steering wheel and lock the steering wheel in the straight ahead position Fig 7 4 Remove the steering wheel bol...

Page 1731: ...ION FRONT SPRING CLAMP PLATES REMOVAL 8 Remove both the high pressure and return hoses from the steering gear Refer to 19 STEER ING PUMP HOSES REMOVAL Fig 2 9 Remove the steering shaft clamping bolt f...

Page 1732: ...er tie rod ends to the steer ing knuckle Fig 2 Tighten to 130 N m 96 ft lbs 8 Install the upper stabilizer bar link to the sta bilizer bar 9 Install the front wheels 10 Fill and bleed the power steeri...

Page 1733: ...front tires 3 Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator 4 Position indicator plunger on the topside of the outer tie rod end NOTE The dial indicat...

Page 1734: ...LLA TION 1 Install the outer tie rod end by screwing it onto thew inner tie rod end Fig 1 2 Install the outer tie rod end into the steering knuckle Fig 1 3 Tighten the outer tie rod end nut Fig 1 Tigh...

Page 1735: ...uid cooler NOTE Power steering pumps are not interchange able with pumps installed on other vehicles OPERA TION Hydraulic pressure is provided for the power steer ing gear by the belt driven power ste...

Page 1736: ...ack and forth NOTE Do not contact or hold the wheel against the steering stops 7 Run a quart of fluid through the system then stop the engine and install the return line lines 8 Fill the system with f...

Page 1737: ...ll power steering cap tightly 7 Test the system for leaks and proper operation FLUID COOLER TUBE REMOVAL 1 Siphon as much power steering fluid as possi ble out of the reservoir 2 Remove the grille Ref...

Page 1738: ...onnect the return hose from the gear 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 4 Remove the left headlight assembly 5 Disconnect the return line at the cooler tube 6 Remove the ret...

Page 1739: ...2 DISASSEMBLY 97 ASSEMBLY 99 INPUT CLUTCH K3 DISASSEMBLY 102 ASSEMBLY 103 ELECTROHYDRAULIC UNIT DESCRIPTION 105 OPERATION 112 REMOVAL 120 DISASSEMBLY 121 ASSEMBLY 125 INSTALLATION 129 FLUID AND FILTER...

Page 1740: ...SHIFT MECHANISM DESCRIPTION 168 OPERATION 168 REMOVAL 169 INSTALLATION 170 SOLENOID DESCRIPTION 171 OPERATION 174 TEMPERATURE SENSOR PARK NEUTRAL CONTACT DESCRIPTION PARK NEUTRAL CONTACT 176 TRANSMISS...

Page 1741: ...three multi disc holding clutches three multi disc driving clutches and two freewheel ing clutches Electronic transmission control enables precise adaptation of pressures to the respective operating...

Page 1742: ...ic control unit comprises the shift plate made from light alloy for the hydraulic control and an electrical control unit The electrical control unit comprises of a supporting body made of plastic into...

Page 1743: ...e extent the hydraulic control can be used to engage 2nd gear or reverse using the following pro cedure Stop the vehicle Move selector lever to P Switch off engine Wait at least 10 seconds Start engin...

Page 1744: ...AR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETARY...

Page 1745: ...rn on the fixed sun gear 23 and increase the torque from the annulus gear 11 to the planetary carrier 15 The planetary carrier 15 moves at a reduced speed in the running direction of the engine Center...

Page 1746: ...lanetary pinion gears 18 turn on the fixed sun gear 22 and increase the torque from the annulus gear 10 to the planetary carrier 14 The output shaft 26 connected to the planetary carrier 14 turns at a...

Page 1747: ...CH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER...

Page 1748: ...g direction of the engine Center Planetary Gear Set The annulus gear 10 is driven at the same speed as the rear planetary carrier 15 as a result of a mechanical connection The sun gear 22 is held agai...

Page 1749: ...gear 10 to the planetary carrier 14 The output shaft 5 connected to the planetary carrier 14 turns at a reduced speed in the running direction of the engine VA AUTOMA TIC TRANSMISSION NAG1 SERVICE IN...

Page 1750: ...ING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 1...

Page 1751: ...held against the housing by the multiple disc holding clutch B2 6 The planetary pinion gears 18 turn on the fixed sun gear 22 and increase the torque from the annulus gear 10 to the planetary carrier...

Page 1752: ...INION GEARS 6 HOLDING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PL...

Page 1753: ...rns at the input speed as a result of the engaged multiple disc clutch K2 9 The multiple disc clutch K3 12 connects the sun gears 22 and 23 of the rear and center planetary gearset The planetary gears...

Page 1754: ...AR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETARY...

Page 1755: ...lus gear 11 and the sun gear 23 The sun gear 23 moves at an increased speed in the running direction of the engine Center Planetary Gear Set The annulus gear 10 turns at the input speed as a result of...

Page 1756: ...s 18 turn between the annulus gear 10 and the sun gear 22 The speed of the planetary carrier 14 and the output shaft connected to the planetary carrier 5 lies between that of the annulus gear 10 and t...

Page 1757: ...REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETAR...

Page 1758: ...planetary car rier 15 so that the sun gear 23 turns in the oppo site direction to the running direction of the engine Center Planetary Gear Set The annulus gear 10 is held against the housing by the...

Page 1759: ...r 10 and increase the torque from the sun gear 22 to the planetary carrier 14 The output shaft 26 con nected to the planetary carrier 14 turns at a reduced speed in the opposite direction to the run n...

Page 1760: ...RS 6 HOLDING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY S...

Page 1761: ...to the planetary carrier 15 The sun gear 22 turns backwards due to the engaged multiple disc clutch K3 12 The planetary gears 18 turn on the fixed annulus gear 10 and increase the torque from the sun...

Page 1762: ...1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING CLUTCH K1 3 1 2 4 5 SHIFT PRESSURE SHIFT VALVE 7 HOLDING CLUTCH B1 4 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 8 SHIFT PR...

Page 1763: ...zed via the solenoid valve for 1 2 and 4 5 shift 1 Because of the holding pressure shift valve 4 the working pressure p A is present at the multiple disc holding clutch B1 7 Clutch K1 6 is unpressuriz...

Page 1764: ...moved and the shift pressure p S coming from the shift pressure shift valve 3 is Fig 17 Shift Phase 1 2 Shift Phase 1 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING...

Page 1765: ...utch pressure the shift pressure in clutch K1 The controlled pressure in clutch B1 7 is inversely proportional to the capacity of the clutch being engaged The rising shift pressure p S at clutch K1 6...

Page 1766: ...ng valve 4 and the holding valve downshifts The line pressure is then routed to the command valve 5 Fig 18 Shift Phase 1 2 Shift Phase 2 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVER...

Page 1767: ...ts basic position Via the holding pressure shift valve 4 the working pressure p A now passes via the Fig 19 Second Gear Engaged 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE...

Page 1768: ...h K1 6 The multiple disc holding clutch B1 7 is deactivated unpressurized The spring of the shift pressure shift valve 3 pushes the valve back to its basic position 21 30 AUTOMA TIC TRANSMISSION NAG1...

Page 1769: ...e coming from the 1 2 4 5 shift valve 3 is routed to the holding clutch B1 7 via the command valve Fig 20 Shift Phase 2 1 Shift Phase 1 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERL...

Page 1770: ...it disen gages is controlled during the shift phase depending on engine load via the modulating pressure p MOD and the shift pressure in clutch B1 7 The increasing shift pressure in clutch B1 which a...

Page 1771: ...allows line pressure p A to pass through the com mand valve 5 Fig 21 Shift Phase 2 1 Shift Phase 2 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING CLUTCH K1 3 1 2 4...

Page 1772: ...ownshifts the valve to its initial position The line pressure p A is switched to the holding clutch B1 7 and the Fig 22 First Gear Engaged 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OV...

Page 1773: ...e of the holding valve by the downshifted com mand valve The upshifted holding valve also allows the remaining pressure in clutch K1 6 to be vented VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION...

Page 1774: ...CH B1 11 PRESSURE HOLDING VALVE 2 DRIVING CLUTCH K1 12 3 4 HOLDING PRESSURE SHIFT VALVE 3 HOLDING CLUTCH B3 13 3 4 COMMAND VALVE 4 DRIVING CLUTCH K3 14 3 4 SHIFT PRESSURE SHIFT VALVE 5 HOLDING CLUTCH...

Page 1775: ...tivation of the multiple disc hold ing clutch B2 Fig 24 Activation Sequence 1 HOLDING CLUTCH B1 11 PRESSURE HOLDING VALVE 2 DRIVING CLUTCH K1 12 3 4 HOLDING PRESSURE SHIFT VALVE 3 HOLDING CLUTCH B3 13...

Page 1776: ...0 is ener gized This allows shift valve pressure p SV to enter the spring chamber of the shift valve B2 9 and to reach the end face of the 3 4 command valve 13 The shift valve B2 9 is held in the uppe...

Page 1777: ...note following a If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and che...

Page 1778: ...Filter 2 Oil Pump 2 Replace Oil Pump WHINING SINGING 1 Gear Set Noises in 1st 2nd 5th Gear 1 Replace Transmission 2 Intermediate Bearing Of The Drive Shaft At 0 km h Only When Cold 2 Replace Intermedi...

Page 1779: ...er Not Installed 2 Install Oil Filter 3 Free Wheeling Clutch F2 Defec tive 3 Replace Free Wheeling Clutch F2 Hollow Shaft and Rear Sun Gear Inner Disc Car rier K3 GRABBING 2 3 COAST ING UPSHIFT AND OR...

Page 1780: ...eal Ring Installed 2 Install Drain Plug Correctly 3 Weld Seam Of Torque Converter Leaky 3 Replace Torque Converter 4 Radial Sealing Ring Oil Pump Defective 4 Replace Sealing Ring 5 O Ring Oil Pump Def...

Page 1781: ...ion a Remove bracket for the oil cooler feed and return lines 1 Fig 29 from engine oil pan flange Detail shows right side of motor Position is mirrored for the left side of engine b Detach bracket of...

Page 1782: ...er bracket When pulling out cable press together hooks of shift cable retainer at the points shown arrows c Pull shift cable out of ball socket Ball socket can remain on transmission lever Fig 29 Cool...

Page 1783: ...driving plate 13 Remove torque converter drain plug and drain automatic transmission oil into a clean container Re install the drain plug and torque the plug to 14 N m 130 in lbs 14 Support engine Ins...

Page 1784: ...transmission 21 Remove the transmission towards the rear and lower Ensure that the converter remains in the transmission housing when the transmission is removed 22 Remove the torque converter DISASS...

Page 1785: ...output shaft nut 9 Remove the nut holding the propeller shaft flange to the output shaft and remove the flange 10 Remove the transmission rear oil seal with a suitable slide hammer and screw 11 Remov...

Page 1786: ...16 Remove the geartrain end play shim from the output shaft Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged Fig 43 Slide Remover 9082 Col...

Page 1787: ...Remove the transmission housing from the converter housing 21 Remove output shaft with center and rear gear set and clutch K3 3 Fig 45 22 Remove thrust needle bearing 4 and thrust washer 5 Fig 45 23 R...

Page 1788: ...crew Torx socket bolts 1 Fig 46 and remove multiple disc holding clutch B1 5 from con verter housing Screw two opposed bolts into the multiple disc holding clutch B1 5 and separate from the converter...

Page 1789: ...ginal position on top of the spring washer 30 Unscrew Torx socket bolts 7 Fig 47 31 Remove multiple disc holding clutch B2 4 Fig 47 from transmission housing The externally toothed disc carrier for mu...

Page 1790: ...stall B2 B3 and Parking Gear 1 SNAP RING 5 PARK GEAR 2 HOLDING CLUTCH B3 DISCS 6 TRANSMISSION HOUSING 3 SPRING WASHER 7 BOLTS M8X60 4 HOLDING CLUTCH B2 Fig 49 Measure B3 Clutch Clearance 1 OUTER DISC...

Page 1791: ...Apply only light pressure less than 10 N 3 lbs of force to the clutch pack when measuring the clutch clearance with the feeler gauge Applying excessive force to the clutch will give an incorrect readi...

Page 1792: ...he bolts to hold clutch B1 5 Fig 51 to the converter housing 9 Securely tighten multiple disc holding clutch B1 5 on converter housing 2 to 10 N m 88 5 in lbs 10 Install new torque converter hub seal...

Page 1793: ...12 Install oil pump 6 and securely tighten Tighten the oil pump bolts to 20 N m 177 in lbs VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 55...

Page 1794: ...tput shaft with center and rear gear set and clutch K3 3 Fig 53 Fig 53 Install K1 K2 and K3 Clutches 1 DRIVING CLUTCH K1 5 THRUST WASHER 2 SUN GEAR OF FRONT PLANETARY GEAR SET 6 FRONT PLANETARY GEAR S...

Page 1795: ...0 in 25 Install the selected end play shim 26 Screw in Torx socket bolts through the con verter housing into the transmission housing Tighten the bolts to 20 N m 177 in lbs 27 Install output shaft bea...

Page 1796: ...t shaft in and out and record read ing End play should be 0 3 0 5 mm 0 012 0 020 in Adjust as necessary 33 Install the output shaft washer onto the out put shaft 34 Install a new transmission rear sea...

Page 1797: ...71 in lbs 42 Install oil filter 4 Fig 62 43 Install oil pan 5 Fig 62 Tighten the bolts to 8 N m 71 in lbs 44 Install guide bushing 12 Fig 62 Fig 61 Stake Output Shaft Nut 1 STAKING TOOL 9078 2 PROPEL...

Page 1798: ...aulic transmis sion jack and raise the transmission into position Secure transmission on hydraulic jack with a strap or ask an assistant to hold it 7 Move the transmission into position on the dowel p...

Page 1799: ...of bolts 2 are in front of opening Rotate engine for wards at crankshaft Install and torque the bolts to 50 N m 37 ft lbs e Rotate engine by hand and tighten the first two bolt pairs to 50 N m 37 ft l...

Page 1800: ...ine oil pan flange Detail shows right side of motor Position is mirrored for the left side of engine b Attach the bracket for the cable retainer 4 Fig 74 to the threaded shank of a engine oil pan bolt...

Page 1801: ...nto position b Push lower connection of oil filler pipe 1 Fig 77 into the fill hole in the side of the trans mission housing c Install bolts 2 Fig 77 to cylinder head Tighten the bolts to 8 N m 71 in...

Page 1802: ...h cor rect automatic transmission fluid Refer to 21 TRANSMISSION AUTOMATIC NAG1 FLUID AND FILTER STANDARD PROCEDURE 23 Road test the vehicle and verify the repair Fig 77 Fill Tube 1 FILL TUBE 2 BOLTS...

Page 1803: ...SCHEMA TICS AND DIAGRAMS HYDRAULIC FLOW IN PARK VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 65...

Page 1804: ...HYDRAULIC FLOW IN REVERSE FAILSAFE 21 66 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1805: ...HYDRAULIC FLOW IN REVERSE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 67...

Page 1806: ...HYDRAULIC FLOW IN NEUTRAL DEFAULT 21 68 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1807: ...HYDRAULIC FLOW IN NEUTRAL VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 69...

Page 1808: ...HYDRAULIC FLOW IN NEUTRAL TO DRIVE TRANSITION 21 70 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1809: ...HYDRAULIC FLOW IN DRIVE FAILSAFE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 71...

Page 1810: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 72 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1811: ...HYDRAULIC FLOW IN DRIVE FIRST TO SECOND GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 73...

Page 1812: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 74 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1813: ...HYDRAULIC FLOW IN DRIVE SECOND TO THIRD GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 75...

Page 1814: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR 21 76 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1815: ...HYDRAULIC FLOW IN DRIVE THIRD TO FOURTH GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 77...

Page 1816: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR 21 78 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1817: ...HYDRAULIC FLOW IN DRIVE FOURTH TO FIFTH GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 79...

Page 1818: ...HYDRAULIC FLOW IN DRIVE FIFTH GEAR 21 80 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1819: ...HYDRAULIC FLOW IN DRIVE FIFTH GEAR EMCC VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 81...

Page 1820: ...HYDRAULIC FLOW IN DRIVE FIFTH TO FOURTH GEAR TRANSITION 21 82 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1821: ...HYDRAULIC FLOW IN DRIVE FOURTH TO THIRD GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 83...

Page 1822: ...HYDRAULIC FLOW IN DRIVE THIRD TO SECOND GEAR TRANSITION 21 84 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Page 1823: ...HYDRAULIC FLOW IN DRIVE SECOND TO FIRST GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 85...

Page 1824: ...5 B3 Clutch Snap rings 3 2 3 5 3 8 4 1 4 4 and 4 7 0 126 0 138 0 150 0 162 0 173 0 185 COMPONENT METRIC mm INCH in K1 Clutch Clearance Double Sid ed Friction Discs 3 Disc 2 7 3 1 0 106 0 122 4 Disc 3...

Page 1825: ...alve Body Hous ing Side Cover 4 35 Bolt Shift Plate 8 71 Bolt Solenoid Leaf Spring 8 71 Plug Oil Pan Drain 20 177 Nut Shifter Mechanism to Floor Pan 7 65 SPECIAL TOOLS AUTOMA TIC TRANSMIS SION NAG1 SP...

Page 1826: ...iversal C 4171 Bar Gauge 6311 End Play Set 8266 Adapter Geartrain End play 8266 18 Dipstick 8863B Compressor Multi use Spring 8900 Tool Pressing 8901 21 88 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA...

Page 1827: ...Installer Seal 8902A Tool Staking 9078 Remover Bearing 9082 Installer Bearing 9287 VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 89...

Page 1828: ...LUTCH 13 K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 3 EXTERNALLY TOOTHED DISC 14 K2 CLUTCH PISTON 4 INTERNALLY TOOTHED DISC 15 FRONT PLANETARY GEARSET PLANETARY CARRIER 5 K3 CLUTCH 16 FRONT PLANETARY G...

Page 1829: ...nnulus gear 11 turn at the same speed as the input shaft 21 If the multi plate clutch K3 5 is actuated via the piston 7 the piston compresses the disc set The sun gear 12 of the center planetary gear...

Page 1830: ...scs are re used this disc must be returned to its original position on top of the spring plate Fig 81 Input Clutch K1 Components 1 K1 OUTER DISC CARRIER 7 DISC SPRING 2 FREEWHEELING CLUTCH F1 8 SPRING...

Page 1831: ...carefully blowing compressed air into the drilled oil feed passage 6 Remove snap ring 3 and take out front free wheeling clutch F1 2 Take care when removing the F1 clutch to prevent the clutch sprags...

Page 1832: ...spring plate 8 Insert spring plate with the curvature towards the sun gear Check sealing ring 9 replace if necessary Fig 83 Input Clutch K1 Components 1 K1 OUTER DISC CARRIER 7 DISC SPRING 2 FREEWHEEL...

Page 1833: ...e outer mul tiple disc carrier 7 Insert snap ring 11 8 Measure the K1 clutch pack clearance by mounting Pressing Tool 8901 1 Fig 85 on outer multiple disc 9 Using a lever press compress pressing tool...

Page 1834: ...the groove in the outer multiple disc carrier 3 17 The correct clutch clearance for transmissions with single sided friction discs is 2 4 2 8 mm 0 095 0 110 in for six friction disc versions 2 6 3 0 m...

Page 1835: ...used this disc must be returned to its original position on top of the disc spring 6 Take out disc spring 14 Fig 88 Fig 88 Input Clutch K2 Components 1 NEEDLE ROLLER BEARING 11 SPRING RETAINER SEALIN...

Page 1836: ...ess until snap ring 2 is released 8 Remove snap ring 2 Fig 88 9 Take out disc spring 10 and pull piston 9 out of outer multiple disc carrier Fig 89 Compress K2 Clutch Spring 1 MULTI USE SPRING COMPRES...

Page 1837: ...if necessary Fig 90 Input Clutch K2 Components 1 NEEDLE ROLLER BEARING 11 SPRING RETAINER SEALING O RING 2 K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR SET 12 SPRING RETAINER 3 THRUST BEARING 13 S...

Page 1838: ...1 1 Fig 92 on outer multiple disc 9 Using a lever press compress pressing tool as far as the stop then the marking ring is still visible see small arrow 10 Using a feeler gauge determine the play L Fi...

Page 1839: ...13 Adjust with snap ring 6 if necessary Snap rings are available in thicknesses of 2 3 mm 0 091 in 2 6 mm 0 102 in 2 9 mm 0 114 in 3 2 mm 0 126 in 3 5 mm 0 138 in and 3 8 mm 0 150 in 14 Insert axial...

Page 1840: ...to its original position on top of the spring plate 3 Place Multi use Spring Compressor 8900 9 Fig 94 on disc spring 5 and compress the spring until the snap ring 4 is exposed 4 Remove snap ring 4 5 R...

Page 1841: ...h single sided friction discs an externally lugged disc is installed first followed by an inter nally lugged disc and continuing on until all the required discs are installed All single sided discs ar...

Page 1842: ...a feeler gauge to determine the play L Fig 98 at three points between the snap ring 7 and outer multiple disc 2 14 During the measurement the snap ring 7 must contact the upper bearing surface of the...

Page 1843: ...nnection 2 establishes the connection to the vehicle side cable harness and to the transmission control module TCM With the exception of the solenoid valves all other electric components are fixed to...

Page 1844: ...regulated at the regulating valve pressure regulating valve in relation to the working pressure p A up to a maximum pres sure of 8 bar 116 psi It supplies the modulating pressure regulating solenoid v...

Page 1845: ...the torque converter lockup clutch and distribution of the lubri cating oil Fig 102 Torque Converter Lockup Clutch Regulating Valve 1 TORQUE CONVERTER LOCK UP CLUTCH 2 TORQUE CONVERTER OUTPUT 3 TORQU...

Page 1846: ...e shift valve housing the 2 3 and 3 4 overlap regulating valves are installed in the valve housing The overlap regulating valve regulates the pressure reduction during a shift phase Fig 103 Overlap Re...

Page 1847: ...shift valve housing the 3 4 command valve is installed in the valve housing The command valve switches the shift group from the stationary phase to the shift phase and back again Fig 104 Command Valve...

Page 1848: ...valves are installed in the shift valve housing the 3 4 holding pressure shift valve is installed in the valve housing The holding pressure shift valve allocates the working pressure to one actuator o...

Page 1849: ...the valve housing of the electrohy draulic control module The valve controls the fluid to lubricate and cool the mechanical part of the transmission and limits the pressure in the torque converter Shi...

Page 1850: ...12 starter interlock contact 9 and transmission oil temperature sensor 8 of the electric valve control unit 7 supply the TCM with input sig nals The solenoid valves are controlled by the TCM and trigg...

Page 1851: ...4 Fig 112 in relation to load modulating pressure p Mod and gear K1 or K2 pressure 1 The spring in the work ing pressure regulating valve sets a minimum pres sure level basic pressure Fig 112 Working...

Page 1852: ...surized In its regulating position slipping torque converter lockup clutch pressurized a reduced volume of lubricating oil flows through the annular passage 7 bypassing the torque converter and passin...

Page 1853: ...ing pressure p Mod and the pressure in the activating actuator The reg ulated pressure is inversely proportional to the trans fer capacity of the activating shift actuator regulated overlap Fig 114 Ov...

Page 1854: ...m mand valve Fig 115 is subjected to the shift valve pressure p SV shift phase then the shift pressure p S is switched to the activating element and the overlap pressure p is switched to the deactivat...

Page 1855: ...igher pres sure taking into account the spring force and the effective surface area The other element of the shift group is then unpressurized The valve switches over only during the shift phase and o...

Page 1856: ...during the stationary and shift phases so the shift state is maintained during the shift phase in this case too Lubrication Pressure Regulating Valve At the working pressure regulating valve surplus...

Page 1857: ...to the working pressure p A as far as the maximum pressure Shift Valve Pressure Regulating Valve The non constant regulating valve pressure p RV is regulated to a constant shift valve pressure p SV at...

Page 1858: ...13 pin plug connector 1 Fig 124 Turn bayonet lock of guide bushing 2 anti clock wise 6 Loosen guide bushing 2 and remove from transmission housing Fig 122 Remove Electrohydraulic Unit 1 HEAT SHIELD 2...

Page 1859: ...end away retaining lug on stiffening rib on transmission oil temperature sensor 7 Remove electrohydraulic control module 12 from the shift plate 13 Fig 125 Remove Electrohydraulic Unit 1 HEAT SHIELD 2...

Page 1860: ...and blown out with compressed air noting that parts may be blown away 9 Unbolt leaf spring 5 Fig 128 10 Unscrew Torx bolts 1 Fig 128 11 Remove valve housing 2 from valve body 4 Fig 128 12 Remove seal...

Page 1861: ...e from plastic 4 and eight from steel 1 3 15 Note the location of all check balls 1 3 4 Fig 131 and the central strainer 2 for re installa tion Remove all check balls 1 3 4 and the central strainer 2...

Page 1862: ...ALVE BODY 8 SHIFT VALVE PRESSURE REGULATING VALVE 2 1 2 4 5 COMMAND VALVE 9 B2 SHIFT VALVE 3 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 10 2 3 HOLDING PRESSURE SHIFT VALVE 4 1 2 4 5 SHIFT PRESSURE SHIFT VAL...

Page 1863: ...noting that parts may be blown away 1 Install the pressure supply valve 1 Fig 135 into the valve body Fig 133 Valve Housing Components 1 2 3 OVERLAP REGULATING VALVE SLEEVE AND PISTON 6 3 4 SHIFT PRE...

Page 1864: ...nents 1 VALVE BODY 8 SHIFT VALVE PRESSURE REGULATING VALVE 2 1 2 4 5 COMMAND VALVE 9 B2 SHIFT VALVE 3 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 10 2 3 HOLDING PRESSURE SHIFT VALVE 4 1 2 4 5 SHIFT PRESSURE...

Page 1865: ...Fig 137 Valve Housing Components 1 2 3 OVERLAP REGULATING VALVE SLEEVE AND PISTON 6 3 4 SHIFT PRESSURE SHIFT VALVE 2 VALVE HOUSING 7 3 4 OVERLAP REGULATING VALVE SLEEVE AND PISTON 3 SELECTOR VALVE 8...

Page 1866: ...Fig 140 Tighten the bolts to 8 N m 71 in lbs 11 Install leaf spring 5 Fig 140 12 Install the strainers 1 2 for the modulating pressure and shift pressure control solenoid valves Fig 141 into the valv...

Page 1867: ...cle INSTALLA TION 1 Position the electrohydraulic unit in the trans mission housing 2 Insert selector valve 1 Fig 143 in driver of detent plate 2 When installing the electrohydraulic control module in...

Page 1868: ...ise to connect plug connector 1 10 Position the heat shield 2 Fig 146 onto the transmission housing and install the screw 1 and bolt 3 to hold the shield in place 11 Fill the transmission with the cor...

Page 1869: ...d by the rotating parts and flows back into the oil gallery 2 through the upper opening arrow DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air al...

Page 1870: ...if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only...

Page 1871: ...mine the height of the oil level on the dipstick and using the height the transmission temperature and the Transmission Fluid Graph Fig 150 determine if the transmission oil level is correct 9 Add or...

Page 1872: ...lug 8 Fig 153 is aligned with the access hole NOTE Clean the area around the drain plug to pre vent dirt from entering the torque converter 5 Using a suitable drain pan to catch the fluid remove the t...

Page 1873: ...ing elements 3 and a cage 6 for these locking elements OPERA TION The freewheeling clutch Fig 155 optimizes indi vidual gearshifts They lock individual elements of a planetary gear set together or aga...

Page 1874: ...F2 3 3 Remove snap ring 2 Fig 156 for freewheel 4 Press freewheeling clutch 3 out of sun gear 5 Check O rings 6 replace if necessary Fig 156 Freewheeling Clutch F2 1 HOLLOW SHAFT 4 K3 INNER DISC CARR...

Page 1875: ...etary sun gear for damage Replace as necessary Fig 157 Freewheeling Clutch F2 Anti Friction Bearing 1 K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR 2 ANTI FRICTION BEARING 3 FREEWHEELING CLUTCH F2...

Page 1876: ...clutch F2 When the assembly is held with the F2 clutch snap ring upward it should be possible to rotate the hollow shaft counter clockwise 6 Install retaining ring 5 onto hollow shaft 1 GEARSHIFT CAB...

Page 1877: ...Remove bottom 2 Fig 160 of the center sec tion of instrument panel 4 Pry ball socket of transmission shift cable off ball knob at the shift lever assembly SLA Use a suitable slotted screwdriver 5 Rais...

Page 1878: ...cket 3 Lower vehicle 4 Install the transmission shift cable onto the ball knob at the SLA 5 Install the bottom section 2 Fig 163 of the center section of instrument panel 6 Install the top section 3 F...

Page 1879: ...he transmission housing Fig 165 Holding Clutches 1 B1 CLUTCH 10 CENTER PLANETARY GEARSET ANNULUS GEAR 2 EXTERNALLY TOOTHED DISC 11 CENTER PLANETARY GEARSET PINION GEARS 3 INTERNALLY TOOTHED DISC 12 CE...

Page 1880: ...e planetary pin ion gears 11 turn on the sun gear 12 If the multiple disc holding clutch B3 4 is actu ated via the piston 6 the planetary carrier 9 and the annulus gear 10 are locked When the multiple...

Page 1881: ...H B1 DISASSEMBL Y 1 Remove the teflon rings 1 Fig 167 from the B1 plate carrier hub 2 Fig 167 Remove the Teflon Rings 1 TEFLON RINGS 2 PLATE CARRIER HUB VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA...

Page 1882: ...ring 4 Place the Multi use Spring Compressor 8900 8 Fig 168 on disc spring 3 and compress the spring until the snap ring 4 is exposed 5 Remove snap ring 4 6 Remove piston 2 from the outer multiple dis...

Page 1883: ...ck snap ring for correct seat 3 Insert snap ring 4 Fig 169 4 Insert disc spring 2 Fig 170 in the outer multiple disc carrier Observe the disc spring 2 installation position The lugs of the disc spring...

Page 1884: ...uter multiple disc 7 Using a lever press Fig 171 compress press ing tool as far as the stop then the marking ring is still visible see small arrow 8 For transmissions using double sided friction discs...

Page 1885: ...c versions 11 Adjust with snap ring 5 if necessary Snap rings are available in thicknesses of 2 6 mm 0 102 in 2 9 mm 0 114 in 3 2 mm 0 126 in 3 5 mm 0 138 in 3 8 mm 0 150 in and 4 1 mm 0 162 in 12 Ins...

Page 1886: ...p of the disc spring 3 Place the Multi use Spring Compressor 8900 on the spring disc 14 and compress the spring until the groove for the snap ring is exposed 4 Remove snap ring 16 Fig 175 5 Remove spr...

Page 1887: ...Press piston guide ring 13 out of the B2 pis ton 10 8 Separate piston guide 4 from the B3 piston 8 by blowing compressed air into the bore A Fig 176 Fig 176 B2 Clutch Oil Supply Locations A B3 PISTON...

Page 1888: ...aling rings 2 4 6 must point outwards Fig 177 Holding Clutch B2 B3 Seals 1 PISTON GUIDE RING 4 B2 PISTON SEALING RING 2 PISTON GUIDE RING SEALING RING 5 B3 PISTON B2 OUTER DISC CARRIER 3 PISTON GUIDE...

Page 1889: ...Fig 178 in B3 piston 8 Fig 178 Holding Clutch B2 1 SNAP RING 9 B2 PISTON SEALING RING 2 MULTIPLE DISC PACK 10 B2 PISTON 3 DISC SPRING 11 PISTON GUIDE SEALING RING 4 B2 AND B3 PISTON GUIDE 12 PISTON G...

Page 1890: ...friction multiple discs in ATF fluid for one hour before installing 8 Insert disc spring 3 and multiple disc pack 2 in the B2 outer multiple disc carrier 9 Insert snap ring 1 NOTE During the measureme...

Page 1891: ...The speed sensors are pressed against the transmission housing 2 by a spring 7 which is held against the valve housing of the shift plate 5 This ensures a defined distance between the speed sensors an...

Page 1892: ...g behind the torque con verter and is driven by the drive flange of the torque converter The pump creates the oil pressure required for the hydraulic procedures OPERA TION When the engine is running t...

Page 1893: ...ng a flat plate across the mounting face of the pump housing and measuring the distance between the plate and the gears Acceptable side clearance Inner gear 0 064 mm 0 0025 in max Outer gear 0 069 mm...

Page 1894: ...shaft nut 4 Remove the nut holding the propeller shaft flange to the output shaft and remove the flange 5 Remove the transmission rear oil seal with a suitable slide hammer and screw 6 Remove the tran...

Page 1895: ...aring inner race Retrieve the shim from the bearing and install over the output shaft and against the park gear 10 Remove the output shaft bearing 3 Fig 194 Fig 192 Position Remover 9082 On Bearing 1...

Page 1896: ...er ring must be installed Retaining rings are available in thick nesses of 2 0 mm 0 079 in 2 1 mm 0 083 in and 2 2 mm 0 087 in 5 Install the output shaft washer onto the output shaft 6 Install a new t...

Page 1897: ...ft flange to the output shaft and remove the flange 4 Remove the output shaft seal with suitable screw and slide hammer INSTALLA TION 1 Position the new output shaft seal over the out put shaft and ag...

Page 1898: ...lever to position D 3 Remove top section 3 Fig 203 of the center section of instrument panel 4 Remove bottom section 2 Fig 204 of the cen ter section of instrument panel Fig 202 Stake Output Shaft Nut...

Page 1899: ...u ment panel between the steering column and the shift lever assembly SLA 2 Install the park lock cable 2 Fig 208 to the ignition switch 3 Tighten the park lock cable 2 Fig 209 to the ignition switch...

Page 1900: ...onnect battery Fig 209 Tighten Park Lock Cable to Ignition Switch 1 IGNITION SWITCH 2 PARK LOCK CABLE Fig 210 Engage Park Lock Cable to SLA 1 PARK LOCK CABLE COUPLING 2 LOCK TAB 3 BOLT 4 SHIFT LEVER A...

Page 1901: ...n Several kinds of seals are used to accomplish this within a transmission These include but are not limited to O rings D rings lip seals sealing rings or extremely close tolerances between the piston...

Page 1902: ...smaller piston moves ten inches This principle is true in other instances also A common garage floor jack is a good example To raise a car weighing 2000 lbs an effort of only 100 lbs may be required F...

Page 1903: ...r moving gear wheels or shift collars When two components of the planetary gear set are locked together the planetary gear set is locked and turns as a closed unit The torque and engine speed are conv...

Page 1904: ...move rear gear set 5 with integrated tubu lar shaft of center gear set from output shaft 6 Remove thrust washer 4 Fig 219 Output Shaft with Center and Rear Planetary Geartrain 1 TEFLON RINGS 7 DRIVING...

Page 1905: ...h K3 7 6 Mount retaining ring shim thrust needle bear ing and thrust washer 8 11 Fig 220 7 Using grease insert the upper two Teflon rings 1 in the groove so that the joint remains together Fig 220 Out...

Page 1906: ...ion can be overriden see operator s manual Reverse inhibitor As soon as the vehicle speed exceeds approx 4 mph it is no longer possible to move the selector lever from position N to posi tion R OPERA...

Page 1907: ...her The shift range is increased by one gear each time and the increased shift range is displayed in the instrument cluster possibly the transmission upshifts to a faster gear Tipping the selector lev...

Page 1908: ...ON 1 Position the shift lever assembly SLA onto the vehicle 2 Install the bolts to hold the SLA to the vehicle Tighten the bolts to 6 N m 53 in lbs 3 Connect the park lock cable coupling 1 Fig 226 to...

Page 1909: ...otion The solenoids used in transmission applications are attached to valves which can be classified as nor mally open or normally closed The normally open solenoid valve is defined as a valve which a...

Page 1910: ...ibilities include variable force pulse width modulated con stant ON or duty cycle The variable force and pulse width modulated versions utilize similar methods to control the current flow through the...

Page 1911: ...the shell of the elec tric valve control unit and pressed against the shift plate by a spring The PWM solenoid valve 1 for the torque con verter lockup controls the pressure for the torque converter...

Page 1912: ...l the attraction is removed and the plunger will return to its original position due to spring pressure The plunger is made of a conductive material and accomplishes this movement by providing a path...

Page 1913: ...ontrolled by the TCM into the appropriate hydraulic control pressure p S TCC Fig 234 Modulating Pressure Control Solenoid Valve 1 MODULATING PRESSURE CONTROL SOLENOID VALVE 2 CONTACT SPRING 3 CONDUCTO...

Page 1914: ...ze selector valve and selec tor lever positions P and N The park neutral con tact consists of the plunger 2 the permanent magnet 3 the dry reed contact 4 TRANSMISSION TEMPERA TURE SENSOR Fig 236 Shift...

Page 1915: ...cuit to the starter in the selector lever positions P and N is closed TRANSMISSION TEMPERA TURE SENSOR The temperature of the transmission oil has a con siderable effect on the shifting time and there...

Page 1916: ...elec tronically applied converter clutch The converter clutch provides reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatur...

Page 1917: ...of the converter As the converter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 243 Impeller 1 ENGINE FLEXPLATE 4...

Page 1918: ...ted through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 244 T...

Page 1919: ...zero slippage condition could be obtained A hydraulic piston with friction material was added to the turbine assembly to provide this mechanical lock up In order to reduce heat build up in the transmi...

Page 1920: ...over running clutch to its shaft Fig 249 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter...

Page 1921: ...ed for and actuated During Partial EMCC some slip does occur Partial EMCC will usually occur at low speeds low load and light throttle situations FULL EMCC During Full EMCC operation the TCM increases...

Page 1922: ...converter is fully seated 7 If necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recomme...

Page 1923: ...DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 9 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 9 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 10 STANDARD PROCEDURE REPAIRING LEAKS 12 CLEANING 12 SPECIFICATIONS TI...

Page 1924: ...oceed to Method 2 METHOD 2 RELOCA TE TIRE ON WHEEL NOTE Rotating the tire on wheel is particularly effective when there is runout in both tire and wheel 1 Remove tire from wheel and mount wheel on ser...

Page 1925: ...he high spot Place a mark on the tire at the valve stem location Fig 4 3 Break down the tire and remount it 180 degrees on the rim Fig 5 4 Measure the total indicator runout again Mark the tire to ind...

Page 1926: ...eel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balan...

Page 1927: ...Fig 7 Static Unbalance Balance 1 HEAVY SPOT 2 CENTER LINE OF SPINDLE 3 ADD BALANCE WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP VA TIRES WHEELS 22 5...

Page 1928: ...n be used but may not provide the same tire longevity benefits CAUTION 3500 Dual rear tires have a new tire rota tion pattern This is to accommodate the asymmet rical design of the ON OFF road tires a...

Page 1929: ...tire rotation inter val shown in the section on Tire Rotation Refer to 22 TIRES WHEELS STANDARD PROCEDURE This will help to achieve a greater tread life TIRE IDENTIFICA TION Tire type size aspect rat...

Page 1930: ...e driven at continuous speeds above 75 mph 120 km h For emergency vehicles that are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct in...

Page 1931: ...re gauge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight DIAGNOSIS AND TESTING TIRE NOISE OR VIBRA TION Radial ply tires are sensitive to force imp...

Page 1932: ...IS AND TESTING TIRE VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Cor rection Chart to diagnose and correct a vehicle lead or drift problem Fig 16 Fig 15 Tire Wear Patterns 22 10 TIRES WHE...

Page 1933: ...Fig 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART VA TIRES WHEELS 22 11...

Page 1934: ...deteri oration of the tires To remove the protective coating apply warm water and let it soak for a few minutes Afterwards scrub the coating away with a soft bristle brush Steam cleaning may also be u...

Page 1935: ...THE RIM COULD FAIL WITH OUT WARNING STANDARD PROCEDURE STANDARD PROCEDURE WHEEL REPLACE MENT The wheel stud lugs are designed for specific appli cations They must be replaced with equivalent parts Do...

Page 1936: ...ame number sequence Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS Tighten lug nuts in same numbered sequence a second time to the specified torque This will ensure that the wheels are thoroughly mate...

Page 1937: ...riations 3 Install the hub cap to the wheel then install snugly the lug nuts to hold the hub cap to the wheel DRW Fig 23 4 Install the wheel lug nuts DRW and tighten to specification Refer to 22 TIRES...

Page 1938: ......

Page 1939: ...when the ignition is OFF Damage to electrical system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol...

Page 1940: ...cted use a suitable mirror to gain visual access A mirror can also be used to deflect light to a limited access area to assist in locating a leak point BRIGHT LIGHT LEAK TEST METHOD Some water leaks i...

Page 1941: ...e The one difference is the material used for the repair The materials must be specific for each substrate rigid repair material for rigid plastic repair semi rigid repair material for semi rigid plas...

Page 1942: ...CARBONATE LEXAN MERLON CALIBRE MAKROLON PC TAIL LIGHT LENSES IP TRIM VALANCE PANELS PC ABS PC ABS ALLOY GERMAX BAY BLENDS PULSE DOORS INSTRUMENT PAN ELS PPO POLYPHENYLENE OXIDE AZDEL HOSTALEN MAR LEX...

Page 1943: ...BODY TRIMS TPE THERMO POLYETHYLENE TPE HYTREL BEXLOY V FASCIAS BUMPERS CLAD DINGS TPO THERMOPOLYOLEFIN POLYTROPE RENFLEX SANTOPRENE VISAFLEX ETA APEX TPO SHIELDS CLADDINGS BUMPERS END CAPS TEL CAR RUB...

Page 1944: ...trate through and make a good bond between the panel and the adhesive Structurally the more dry wall tape used the stronger the repair Another kind of repair that can be done to repair large cracks an...

Page 1945: ...l that has extensive puncture type damage can be repaired by cutting out the damaged material Fig 7 Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is dam age...

Page 1946: ...y panel with adhesive sandwiched between the panel and squares Fig 9 12 Position patch in cutout against support squares and adjust patch until the gap is equal along all sides Fig 10 13 Drill 3 mm 0...

Page 1947: ...CUTOUT AND ALIGN 1 CUTOUT 2 SUPPORT SQUARES Fig 11 APPLY ADHESIVE TO SUPPORT SQUARES 1 APPLICATOR 2 SUPPORT SQUARES 3 ADHESIVE Fig 12 INSTALL SCREWS 1 PATCH 2 GAP Fig 13 GRIND SURFACE 1 PATCH 2 GAP 3...

Page 1948: ...ed to eliminate noises caused by metal plastic and vinyl components Long life lubricants and greases can also be used on a vari ety of components Refer to the Buzz Squeak Rat tle Kit table for materia...

Page 1949: ...rubber When access is not possible oil will migrate to condition Vinyl rubber plastic metal Examples Convertible top bushings pull cups trim panel inserts 30 to 400 Fahr enheit 34 to 205 Cel sius Kry...

Page 1950: ...crews 10 89 Sliding door center roller arm bolt 45 33 Sliding door center track bolts nuts 10 89 Sliding door inside handle screw 10 89 Sliding door latch screws 10 89 Sliding door latch lock control...

Page 1951: ...LLATION 21 WINDOW REGULATOR MANUAL REMOVAL 21 INSTALLATION 22 CHECK REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Rem...

Page 1952: ...s Fig 3 4 Remove the bolts and disconnect the door check from the a pillar Fig 4 5 Support door with a suitable device 6 Loosen the hinge set screws Fig 5 7 Remove door by lifting off hinge pins INSTA...

Page 1953: ...ODY DOOR FRONT LATCH STRIKER REMOVAL 3 Remove side view mirror Refer to 23 BODY EXTERIOR SIDE VIEW MIRROR REMOVAL 4 Loosen hinge bolts and adjust door gap and align ridge pattern as necessary 5 Tighte...

Page 1954: ...TALLA TION 1 Position front of handle into front slot in door Fig 10 2 Position rear of handle into latch opening and engage lock and latch actuation levers with the latch levers Fig 11 3 Slide exteri...

Page 1955: ...and remove hinge Fig 14 INSTALLA TION 1 Install hinge and install bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Tighten hinge set bolts 4 Install side view mirror Refer to 23 BODY EXTERIOR SIDE VIEW MIR...

Page 1956: ...remove the striker Fig 16 INSTALLA TION 1 Install striker and install bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Check door for flush and adjust the striker hor izontally if necessary Refer to 23 BOD...

Page 1957: ...pped 6 Open pocket door Fig 19 7 Using a trim stick C 4755 or equivalent sepa rate window frame molding from door Fig 20 Fig 17 TRIM PANEL HANDLE 1 SWITCH BEZEL 2 HANDLE COVER Fig 18 TRIM PANEL FASTEN...

Page 1958: ...REGULATOR POWER REMOVAL 1 Lower front window approximately 2 cm 3 4 in 2 Disconnect and isolate battery negative cable 3 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 4 Discon...

Page 1959: ...5 Remove glass support 6 Connect the electrical connector 7 Connect battery negative cable 8 Verify correct window operation 9 Install trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION W...

Page 1960: ...10 N m 89 in lbs 4 Remove glass support 5 Connect battery negative cable 6 Verify correct window operation 7 Install trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION Fig 26 GLASS SUPPORT...

Page 1961: ...llar trim if equipped Refer to 23 BODY INTERIOR D PILLAR TRIM REMOVAL 4 Remove the rivets and remove the receiver INSTALLA TION 1 Install the receiver and replace the rivets 2 Install d pillar trim if...

Page 1962: ...Fig 2 CHECK STRAP 1 RECEIVER 2 DOOR CHECK Fig 3 DOOR HINGES 1 DOOR 2 TORX BOLTS 2 PER HINGE 3 ALLEN BOLTS 1 PER HINGE 23 24 DOORS REAR VA...

Page 1963: ...move bolts 2 and remove top closing wedge 1 8 Remove bolts 9 and remove door check 10 Refer to 23 BODY DOORS REAR CHECK REMOVAL 9 Remove the bolts 3 and remove the door hinges 4 Refer to 23 BODY DOORS...

Page 1964: ...m closing wedge 21 10 Remove rear door seal 8 11 Remove the four screws 9 14 from the lock rod actuator 12 Using locking pliers hold upper lock rod 2 and remove lock rod actuator 13 Remove clips 15 14...

Page 1965: ...RIOR HANDLE INSTALLATION 6 Install the latch assembly 14 Refer to 23 BODY DOORS REAR LATCH INSTALLATION 7 Install trim panel 20 Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 8 Install door Refer...

Page 1966: ...or and install switches 17 12 Connect electrical connectors and install license plate lighting 18 19 13 Install trim panel 20 Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 14 Install door Refer...

Page 1967: ...ach door individually 3 Close the door and check gap measurement 4 Loosen allen screw through hole in hinge Fig 9 NOTE Adjust so that bottom closing wedges make contact and door gaps are uniform all t...

Page 1968: ...w 2 at top hinge turn in adjustment screw 2 at bottom hinge Retaining magnet strikes too hard against mat ing plate Turn in adjustment screw 1 at top and bottom hinge Retaining magnet does not make co...

Page 1969: ...t of door Fig 14 NOTE Front door shown rear door similar 3 Pull rear of handle out away from door and dis engage the latch levers 4 Slide handle towards the rear of door and remove INSTALLA TION 1 Pos...

Page 1970: ...MOVAL NOTE It is not necessary to remove the door to replace the hinges if they are replaced one at a time 1 Using a grease pencil or equivalent mark the position of the hinge on the door 2 Remove the...

Page 1971: ...latch cable 2 Install handle and screws 3 Install trim cover LATCH REMOVAL 1 Disconnect and isolate battery negative cable 2 Remove right side trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVA...

Page 1972: ...pin fasteners if equipped 3 Using a trim stick C 4755 or equivalent remove the lower trim panel 4 Remove rivets and remove upper trim panel if equipped INSTALLA TION 1 Install upper trim panel and re...

Page 1973: ...CK CONTROL REMOVAL 38 INSTALLATION 39 REAR LATCH REMOVAL 40 INSTALLATION 40 REAR LATCH STRIKER REMOVAL 40 INSTALLATION 40 SLIDING DOOR REMOVAL 40 DISASSEMBLY 42 ASSEMBLY 43 INSTALLATION 44 ADJUSTMENTS...

Page 1974: ...rear of vehicle and remove from back of track INSTALLA TION 1 Install roller arm into upper track from back 2 Position roller arm on door and install the bolts 3 Tighten bolts to 25 N m 18 ft lbs 4 A...

Page 1975: ...l scuff pad Fig 5 2 Remove the door screws and remove the roller arm Fig 6 INSTALLA TION 1 Install roller arm and install door screws 2 Tighten screws to 25 N m 18 ft lbs 3 Install stepwell scuff pad...

Page 1976: ...w center track and apply pressure of approximately 40 p s i over the entire surface of the track 5 Install the front bolts and tighten to 10 N m 89 in lbs 6 Install the interior nuts and tighten to 10...

Page 1977: ...bolts to 10 N m 89 in lbs 4 Connect electrical connectors 5 Install trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL INSTALLATION 6 Connect battery negative cable Fig 9 ELECTRICAL CONNECTORS 1 CO...

Page 1978: ...R LATCH STRIKER REMOVAL 1 Open door 2 Remove bolts and remove striker Fig 14 INSTALLA TION 1 Install striker and bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Adjust striker if necessary Refer to 23 BOD...

Page 1979: ...Fig 15 SLIDING DOOR 1 STOP BUMPER 2 SCREWS 2 3 SCREWS 2 4 LOWER ROLLER ARM 5 END PIECE 6 SCREWS 2 VA DOORS SLIDING 23 41...

Page 1980: ...NG EXTERIOR HANDLE REMOVAL 10 Remove center roller arm 20 Refer to 23 BODY DOORS SLIDING LOWER ROLLER ARM REMOVAL 11 Remove stabilizer wedges 6 Refer to 23 BODY DOORS SLIDING STABILIZER REMOVAL 12 Rem...

Page 1981: ...Y DOORS SLIDING REAR LATCH INSTALLA TION 9 Install lock rod 25 and connect to latch lock control 10 Install the lock knob 27 11 Install the trim panel 24 Refer to 23 BODY DOORS SLIDING TRIM PANEL INST...

Page 1982: ...body sealant should be used when removing or moving the hinges 1 Remove bolts and remove striker Fig 18 2 Check gaps and ridge pattern on door all the way around Refer to 23 BODY BODY STRUC TURE GAP...

Page 1983: ...zer closing wedge screws Fig 22 9 Close sliding door to adjust closing wedge 10 Open door and tighten screws to 10 N m 89 in lbs Door Stop Bumper Adjust 1 Loosen door stop bumper bolts 2 Open sliding...

Page 1984: ...o receive the glass and weatherstrip seal 2 Start at an inside upper corner Separate the seal from the window opening Push the glass and seal outward from the window opening Remove the glass and seal...

Page 1985: ...rify that the seal is seated in the window opening Fig 25 7 Test the window for water leaks Refer to 23 BODY DIAGNOSIS AND TESTING WATER LEAKS Fig 25 Glass Weatherstrip Seal Installation 1 BODY PANEL...

Page 1986: ...connect the filler cap tether 4 Remove two bolts and remove filler door INSTALLA TION 1 Install the door and bolts 2 Connect filler cap tether 3 Close doors GRILLE REMOVAL 1 Remove screw rivets Fig 1...

Page 1987: ...river s Side 1 Disconnect and isolate battery negative cable 2 Remove trim plug Fig 3 NOTE If the vehicle is not equipped with power mirrors skip to step 5 3 Remove trim panel Refer to 23 BODY DOOR FR...

Page 1988: ...with power mir rors skip to step 6 4 Connect the electrical connector 5 Connect dust boot to a pillar 6 Install trim plug 7 Connect battery negative cable SIDE VIEW MIRROR GLASS REMOVAL 1 Disconnect...

Page 1989: ...eference marks 2 Install cowl bolts and tighten to 23 N m 17 ft lbs 3 Install hood nuts and tighten to 23 N m 17 ft lbs 4 Check and adjust hood if necessary Refer to 23 BODY HOOD HOOD ADJ USTMENTS HOO...

Page 1990: ...am bumpers up or down if nec essary LATCH REMOVAL 1 Remove bolts and remove latch Fig 3 2 Disconnect latch cable INSTALLA TION 1 Connect latch cable and install latch 2 Install the bolts and tighten L...

Page 1991: ...nd install the nut and washer 3 Connect spring and prop onto hood and install the retaining spring SAFETY LATCH REMOVAL 1 Open hood 2 Using a grease pencil or equivalent mark the position of the safet...

Page 1992: ...INSTALLA TION 1 Install the latch and install the bolts 2 Adjust the latch if necessary Refer to 23 BODY HOOD HOOD ADJ USTMENTS Fig 6 SAFETY LATCH 1 SAFETY LATCH 2 BOLTS 23 54 HOOD VA...

Page 1993: ...BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIV...

Page 1994: ...HIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Move selector lever to position...

Page 1995: ...TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Install the bezel and install the screws 2 Install the...

Page 1996: ...THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Install bottom section and ins...

Page 1997: ...SSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN...

Page 1998: ...cover Fig 13 Fig 9 STEERING COLUMN SHROUD 1 SHROUD 2 SCREWS 2 3 NUT Fig 10 POWER DISTRIBUTION CENTER 1 BOLT 2 POWER DISTRIBUTION CENTER 3 GROUND NUT 4 WASHER 5 NUT 6 GROUND WIRE Fig 11 POWER DISTRIBUT...

Page 1999: ...move brake pedal spring Fig 17 Fig 13 SIDE COVERS NOZZLES 1 LEFT SIDE COVER 2 RIGHT SIDE COVER 3 BRACKET 4 OUTER AIR NOZZLE 5 INNER AIR NOZZLE 6 INNER AIR NOZZLE 7 OUTER AIR NOZZLE Fig 14 PROTECTIVE M...

Page 2000: ...position 25 Remove steering column support bolts Fig 19 26 Remove the screws and remove instrument panel Fig 20 Fig 17 BRAKE PEDAL SPRING 1 STEERING COLUMN 2 SPRING Fig 18 IGNITION TRANSPONDER 1 COLUM...

Page 2001: ...OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERVICED WITH DOORS IN THE ORIGINAL COL...

Page 2002: ...NSTRUMENT PANEL GLOVE BOX INSTALLATION 28 Install radio Refer to 8 ELECTRICAL AU DIO RADIO INSTALLATION 29 Connect battery negative cable TOP COVER CLUSTER REMOVAL WARNING ON VEHICLES EQUIPPED WITH AI...

Page 2003: ...NECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABL...

Page 2004: ...IT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS...

Page 2005: ...E PASSENGER AIRBAG DOOR FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERV...

Page 2006: ...ARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT 1 Position top cover and slide toward front of vehicle NOTE Observe cable routing for radio The leads should not be located above the a...

Page 2007: ...ATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO T...

Page 2008: ...ACKET 75 STEPWELL SCUFF PADS REMOVAL 75 INSTALLATION 76 SUN VISOR REMOVAL 76 INSTALLATION 76 INTERIOR CAUTION CAUTION Do not attempt to remove interior trim panels moldings without first removing the...

Page 2009: ...1 Install the handle and install the screws B PILLAR TRIM REMOVAL 1 Remove the lower seat belt anchor bolt Fig 4 2 Pull door opening weatherstrip away from flange along the b pillar Fig 5 3 Using a tr...

Page 2010: ...TS REMOVAL Cargo Passenger Van Front 1 Remove the stepwell scuff pads Refer to 23 BODY INTERIOR STEPWELL SCUFF PADS REMOVAL 2 Remove the three bolts and tray behind drivers seat 3 Remove cup holder Re...

Page 2011: ...2 Remove the sun visors Refer to 23 BODY INTERIOR SUN VISOR REMOVAL 3 Remove the b pillar trim Refer to 23 BODY INTERIOR B PILLAR TRIM REMOVAL 4 Remove the assist handle Refer to 23 BODY INTERIOR ASSI...

Page 2012: ...trical connector and install the front duct work cover 7 Install the push pin fasteners 8 Install the second and third row seats Refer to 23 BODY SEATS SEAT INSTALLATION 9 Connect battery negative cab...

Page 2013: ...vial to saturate the felt applicator b Remove the paper sleeve c Apply accelerator to the contact surface on the bracket d Allow the accelerator to dry for five minutes e Do not touch the bracket con...

Page 2014: ...racket if necessary SUN VISOR REMOVAL 1 Remove the support screws and remove the visor Fig 10 INSTALLA TION 1 Position visor and support on header 2 Install the screws Fig 9 SLIDING DOOR SCUFF PAD 1 T...

Page 2015: ...or color can result PAINT TOUCH UP DESCRIPTION When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use MOPAR Scr...

Page 2016: ...PTION CAUTION Do not remove more than 5 mils of clearcoat finish if equipped Basecoat paint must retain clearcoat for durability Use a Paint Thickness Gauge PR ETG 2X or equiv alent to determine film...

Page 2017: ...T CUSHION COVER REAR REMOVAL 83 INSTALLATION 83 ARMREST REMOVAL 1 Remove the screws and remove the armrest cover 2 Remove the three bolts and remove the arm rest from the seat back INSTALLA TION 1 Ins...

Page 2018: ...uring installation operate the seat back release lever once 3 Install the spline side seat back bolt 4 Install remaining seat back side NOTE It may be necessary to press the guide tabs apart slightly...

Page 2019: ...Remove the seat cushion Refer to 23 BODY SEATS SEAT CUSHION FRONT REMOVAL 4 Remove the four bolts attaching adjust to seat track INSTALLA TION 1 Install the adjuster onto the seat track and install t...

Page 2020: ...fer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT RETRACTOR REMOVAL 4 Remove seat belt buckles as necessary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT BUCKLE REMOVAL 5 Remove the headrests Refer to 2...

Page 2021: ...the lower seat belt anchors as neces sary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT RETRACTOR REMOVAL 4 Remove seat belt buckles as necessary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT BUC...

Page 2022: ...dow opening 3 Position the glass and seal in the trim panel opening 4 Pull the installation cord outward and force the seal lip over the panel flange around the edge of the opening Fig 1 5 Seat the se...

Page 2023: ...NI CAL DATA SHEETS AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212 TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBL...

Page 2024: ...e is cured Water leaks can result The windshield fence should be cleaned of most of its old urethane bonding material A small amount of old urethane approximately 1 mm in height should remain on the f...

Page 2025: ...ss to be re glued with a suitable glass preparation solvent and rag 8 Using a flash light verify that glass primer is without damage 9 Re prime any damaged area If old adhesive has been exposed for mo...

Page 2026: ...ening 2 Level old bead of windshield opening adhesive to a thickness of approximately 1 mm 0 04 in and remove loose adhesive Fig 10 3 Clean and dry area of windshield opening to be re glued with a sui...

Page 2027: ...neously on both sides CAUTION Roll down the left and right front door glass and open the rear glass slider if available before installing windshield to avoid pressurizing the passenger compartment if...

Page 2028: ...move channel 3 Remove outer belt weatherstrip INSTALLA TION 1 Install outer belt weatherstrip 2 Install glass run channel and install the screws 3 Install the door glass Refer to 23 BODY DOOR FRONT DO...

Page 2029: ...NT DOORS 1 SLIDING DOORS 2 REAR DOORS 3 NOTE All measurements are in mm LOCATION GAP FLUSH 1 Door at top 7 0 5 FLUSH 2 Door at upper b pil lar 7 0 5 Up to max 1 mm recessed at rear with 1 mm overlap w...

Page 2030: ...FLUSH 3 Door ridge at b pillar and side panel FLUSH without offset NOTE All measurements are in mm LOCATION GAP FLUSH 1 Rear doors at top 13 0 5 FLUSH 2 Right rear door to left rear door 8 0 5 FLUSH...

Page 2031: ...OPENING DIMENSIONS SPECIFICA TIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 4 Fig 4 WINDSHIELD OPENING VA BODY STRUCTURE 23 93...

Page 2032: ......

Page 2033: ...obstructions in front of the radiator or A C condenser will reduce the performance of the A C and engine cooling systems The engine cooling system includes the radiator thermostat radiator hoses and...

Page 2034: ...air The automatic temperature control ATC system controls interior temperature by taking actual values from the temperature sensors and the CAN bus and comparing them to the nominal value of the tempe...

Page 2035: ...he amount of moisture in the air is not wasted Wring ing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers Although an owner may expect too much from their...

Page 2036: ...se 2 Check the fuses in the Power distribution block and junction block Repair the shorted circuit or component and replace the fuses if required Refer to Group 8 3 Faulty A C compressor clutch coil 3...

Page 2037: ...t system if required 6 Engine overheating 6 Test the engine cooling system and repair if required Refer to Group 7 Cooling The low side pressure is too high and the high side pres sure is too low 1 Ac...

Page 2038: ...ing system connections Inoperative or stuck heater water valve Plugged heater core If proper coolant flow is verified and heater floor outlet air temperature is insufficient a mechanical problem may e...

Page 2039: ...Compres sor Denso 10S17 ND 8 PAG oil Freeze up Con trol Evaporator Tem perature Sensor Input to rear A C control module evaporator fin mounted cycles clutch off below 1 6 C 35 F cycles clutch back on...

Page 2040: ...18 REMOVAL 18 INSTALLATION 18 BLOWER MOTOR SWITCH DESCRIPTION 19 OPERATION 19 DIAGNOSIS AND TESTING BLOWER MOTOR SWITCH 19 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 19 OPERATION 19 REMOVAL 20 INSTALL...

Page 2041: ...t Check the air gap in four or more places on the clutch plate to verify that the air gap is still correct Spin the clutch pulley before making the final air gap check A C COMPRESSOR CLUTCH BREAK IN A...

Page 2042: ...pulley to the front of the compressor then slide the pulley off of the com pressor Fig 4 8 Remove the screw that secures the clutch coil wire harness connector bracket and ground clip to the top of th...

Page 2043: ...uch coil wire harness leads are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil NOTE A new snap ring must be used to secure the clutch...

Page 2044: ...BIII scan tool PRELIMINARY CHECKS 1 If no diagnostic trouble codes DTCs are found in the A C heater control or the powertrain control module PCM go to Step 2 If any DTCs are found repair as required 2...

Page 2045: ...o discharge before performing further diagnosis or service This is the only sure way to disable the supplemental restraint system Failure to take the proper precau tions could result in accidental air...

Page 2046: ...essor clutch and the auxiliary radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage The A C pressure transducer input to the ATC m...

Page 2047: ...stem Refer to 24 HEATING AIR CONDITION ING PLUMBING STANDARD PROCEDURE 2 Disconnect and isolate the battery negative cable 3 Disconnect the wire harness connector from the A C pressure transducer Fig...

Page 2048: ...trol module makes adjust ments to maintain the requested interior temperature by cycling both the A C compressor and solenoid heater valve on and off The air outlet temperature sensor is diagnosed by...

Page 2049: ...ged it must be replaced REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the front license plate bracket Refer to 23 BODY EXTERIOR LICENSE PLATE BRACKET REMOVAL 3 Disconnect the wi...

Page 2050: ...ation views for the various wire harness connectors splices and grounds 1 Disconnect and isolate the negative battery cable 2 Disconnect the wire harness connector from the blower motor resistor 3 Che...

Page 2051: ...onditioned air downstream of the A C evaporator Fig 18 The evaporator temperature sensor is an electrical thermistor within a molded plastic case that is inserted into the HVAC housing near the coldes...

Page 2052: ...e harness connector from evaporator temperature sensor Fig 19 15 Remove evaporator temperature sensor from HVAC housing INSTALLA TION 1 Install the probe of the evaporator temperature sensor between t...

Page 2053: ...stic Procedures For circuit descriptions and diagrams refer to the appro priate wiring information MODE DOOR CABLES REMOVAL The air distribution control cables mode door cables can be removed and inst...

Page 2054: ...l solenoid The electrical solenoid is connected to the A C heater control through the vehicle electrical sys tem by a dedicated two wire lead and connector The output shaft of the recirculation door a...

Page 2055: ...le INSTALLA TION 1 Connect the actuator shaft to the recirculation door pivot lever 2 Install the two screws that secure the recircu lation door actuator to the ventilation housing Tighten the screws...

Page 2056: ...ESTING REAR A C TEMPERATURE CONTROL 39 REMOVAL 39 INSTALLATION 40 TEMPERATURE SENSOR DESCRIPTION 40 OPERATION 40 DIAGNOSIS AND TESTING REAR TEMPERATURE SENSOR 40 REMOVAL 40 INSTALLATION 41 SUPPRESSOR...

Page 2057: ...arallel with the relay coil and helps to dissipate voltage spikes and electromag netic interference that can be generated as the elec tromagnetic field of the relay coil collapses The rear A C clutch...

Page 2058: ...r A C condenser fan relay is an electrome chanical device that uses a low current input to con trol the high current output to the A C condenser fan for the rear heating A C system The rear A C conden...

Page 2059: ...d of the relay coil collapses The rear A C condenser fan relay terminals are connected to the vehicle electrical system through a receptacle in the relay block located in the rear A C evaporator housi...

Page 2060: ...A C temperature control and the temperature sensor The rear A C control module is located in the upper left side of the rear A C evaporator housing OPERA TION The rear A C control module is supplied f...

Page 2061: ...diagrams REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo rator housing Refer to 24 HEATING AIR CON DITIONING DISTRIBUTION REAR AIR FILTER R...

Page 2062: ...disengagement and control rear A C condenser cooling fan operation Fig 7 The rear A C control module will disengage the rear A C clutch if the rear refrigerant system pres sure exceeds approximately...

Page 2063: ...ver the refrigerant from the rear refriger ant system Refer to 24 HEATING AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refe...

Page 2064: ...ar suction line pressure rises to approximately 234 to 262 kPa 34 to 38 psi or above Lower ambient temperatures below approximately 1 C 30 F will also cause the rear A C low pressure switch contacts t...

Page 2065: ...l dimensions current capacities terminal functions and patterns The rear blower motor relays are elec tromechanical devices that switches fused battery current directly to the rear blower motors The r...

Page 2066: ...e rear blower motor relays cannot be repaired and if faulty or damaged they must be replaced Refer to the appropriate wiring information for diag nosis and testing of the ISO standard relay and for co...

Page 2067: ...3 The rear A C blower motor switch allows the selection of one of two blower motor speeds and an Off position OPERA TION With the front A C switch activated the rear blower motor speed can be selected...

Page 2068: ...of the ohmmeter to terminal 10 and the positive ohmmeter lead to terminals 1 7 and 4 To check the switch s integral light emitting diodes reverse the ohmmeter leads 4 Check for continuity between the...

Page 2069: ...e sensor is located in the rear A C evaporator housing OPERA TION The rear evaporator temperature sensor signals the rear A C control module to cycle the rear A C clutch off if the rear evaporator tem...

Page 2070: ...ol for the optional rear A C system is a thumbwheel type control mounted in the switch panel on the instrument panel Fig 17 The rear A C temperature control allows the selection of four temperature se...

Page 2071: ...rol 3 Check for continuity between terminal 9 and terminals 3 and 5 of the A C temperature control In all instances there should be continuity NOTE To check the switch s internal circuits con nect the...

Page 2072: ...f faulty or damaged it must be replaced DIAGNOSIS AND TESTING REAR TEMPERA TURE SENSOR 1 Disconnect and isolate the negative battery cable 2 Disconnect the wire harness connector from the rear tempera...

Page 2073: ...or the three rear blower motor relays The suppression filters also impede the prop agation of RF interference into the vehicles electrical system by the rear blower motors to ensure interfer ence free...

Page 2074: ...HVAC wiring diagrams REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the cover from the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVA...

Page 2075: ...terference suppression filter Fig 23 for the rear A C condenser fan protects the rear A C control circuits and the vehicles electrical system from volt age spikes which may be generated by the rear co...

Page 2076: ...uts that secure the rear condenser fan suppression filter to the rear A C condenser housing and remove the sup pression filter INSTALLA TION 1 Position the rear condenser fan suppression fil ter to th...

Page 2077: ...y 4 Install the insulation blanket onto the ventila tion housing AIR OUTLETS REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint sys...

Page 2078: ...ide air outlets install the air outlet retaining bracket to the right side of the instrument panel Tighten the screw to 2 N m 17 in lbs 4 If servicing the passenger side air outlets install the passen...

Page 2079: ...23 BODY INSTRUMENT PANEL REMOVAL 2 Remove the screw that secures the left and or right side defroster duct to the heater housing depending on the duct being removed Fig 5 3 Remove the defroster duct...

Page 2080: ...IONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The HVAC housing...

Page 2081: ...LECTRICAL RESTRAINTS PASSENGER AIRBAG REMOVAL 20 Disconnect the wire harness connector from the evaporator temperature sensor and air outlet temperature sensor Fig 8 21 Remove the wire harness from th...

Page 2082: ...TALLA TION NOTE High pressures are produced in the refriger ant system when the A C compressor is operating Extreme care must be exercised to make sure that each of the refrigerant system connections...

Page 2083: ...E 26 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE INSTRUMENT PANEL DUCTS REMOVAL 1 Remove the instrument panel Refer to 23...

Page 2084: ...IONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo...

Page 2085: ...reservoir ports 11 Remove the eight nuts and washers that secure the rear A C condenser housing to the roof panel 12 Carefully separate the body sealer between the rear A C condenser housing and the r...

Page 2086: ...gerant oil of the type recommended for the rear A C compressor in the vehicle 7 Connect the rear liquid line to the rear refrig erant reservoir outlet Tighten the liquid line nut to 35 N m 26 ft lbs 8...

Page 2087: ...secure the rear A C evaporator cover to the rear of the evaporator housing and remove the cover INSTALLA TION 1 Position the rear A C evaporator cover to the rear A C evaporator housing 2 Install the...

Page 2088: ...f the way 9 Remove the nut that secures the positive wire lead to the rear A C system terminal block and posi tion the wire lead out of the way 10 Remove the insulating tape from around the rear evapo...

Page 2089: ...vap orator housing and install the four bolts and washers and four damping washers that secure the evapora tor housing to the roof panel Tighten the bolts to 25 N m 18 ft lbs 5 Install the nine screws...

Page 2090: ...tor housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 22 Install the cover onto the rear A C condenser housing Refer to 24 HEATING AIR CONDI TIONI...

Page 2091: ...connect the wiring harness connectors to the suppression filter and to the rear blower motor being serviced 5 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONI...

Page 2092: ...VALVE DESCRIPTION 73 OPERATION 73 DIAGNOSIS AND TESTING A C EXPANSION VALVE 74 REMOVAL 74 INSTALLATION 74 ELECTRIC COOLANT PUMP DESCRIPTION 75 OPERATION 75 REMOVAL 75 INSTALLATION 76 HEATER CORE DESC...

Page 2093: ...ed by qualified service personnel Severe per sonal injury or death may result from improper service procedures WARNING Avoid breathing the refrigerant and refrigerant oil vapor or mist Exposure may ir...

Page 2094: ...open the refrigerant system or uncap a replacement component until you are ready to ser vice the system Immediately after disconnecting a component from the refrigerant system seal the open fittings w...

Page 2095: ...erant dye STANDARD PROCEDURE REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING Eye protection must be worn when ser vicing an A C refrigerant system Turn off rotate clockwise all valves on the equipment be...

Page 2096: ...the proper care and use of this equipment REFRIGERANT SYSTEM EVACUA TE WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEAT...

Page 2097: ...make contact with the bottom surfaces of the evaporator inlet and outlet tubes 3 Open all of the windows or doors of the passen ger compartment 4 Set the A C button on the A C Heater controls to the o...

Page 2098: ...The A C compressor is driven by the engine through an electric clutch drive pulley and belt arrangement The A C compressor is lubricated by refrigerant oil that is circulated throughout the refrigeran...

Page 2099: ...ONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE If the high pressure relief valve still does not seat properly replace the a c compressor Refer to 24 HEATING AIR CONDITIONING PLUMBI...

Page 2100: ...or Fig 5 6 Remove the bolts that secure the underbody suction and discharge lines to the A C compressor 7 Disconnect the underbody suction and dis charge lines from the A C compressor and remove and d...

Page 2101: ...engine com partment and loosely install the three compressor retaining bolts Tighten the bolts using the following sequence to 20 N m 14 ft lbs The upper bolt at the front of the compressor The lower...

Page 2102: ...ver the opened liquid line fitting and the condenser ports 9 Disconnect the wire harness connector from the auxiliary fan 10 Remove the auxiliary fan and upper bracket assembly 11 Remove the auxiliary...

Page 2103: ...e line fitting and discard 7 Install plug in or tape over the opened dis charge line fitting and the condenser inlet port 8 Remove the bolt that secures the discharge line fitting to the top of the co...

Page 2104: ...g refrigerant through the A C evaporator The A C evaporator tubes are connected and sealed to the A C expansion valve by use of rubber O rings and a tapping block The A C evaporator is serviced by rem...

Page 2105: ...TIONING DISTRIBUTION HVAC HOUSING INSTALLATION A C EXPANSION VALVE DESCRIPTION The A C expansion valve controls the amount of refrigerant entering the A C evaporator and is of a thermostatic expansion...

Page 2106: ...e performing the fol lowing operation Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions cou...

Page 2107: ...t near the battery and is controlled by the A C heater control The electric coolant pump housing contains two coolant hose connections and an electric motor which drives the vane type pump using a mag...

Page 2108: ...engine is transferred to the heater core fins and tubes Air directed through the heater core picks up the heat from the heater core fins The heater water valve controls the heater output air temperat...

Page 2109: ...G ASSEMBLY NOTE If the heater core is being replaced flush the cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM CLEANING RE VERSE FLUSHING 5 Install the HVAC housing Refer to 24 HEA...

Page 2110: ...BING REFRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM RECOV ERY 2 Disconnect and isolate the negative battery cable 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 4 Remove the nut that...

Page 2111: ...he liquid and suction line fittings the receiver drier outlet port and both expansion valve ports 3 Lubricate new rubber O ring seals with clean refrigerant oil and install them onto the suction and l...

Page 2112: ...ts 4 Lubricate new rubber O ring seals with clean refrigerant oil and install them on the liquid line fit tings 5 Connect the front and rear sections of the liq uid line to the receiver drier 6 Instal...

Page 2113: ...ant system This ensures proper lubrica tion of the A C compressor Too little oil will result in damage to the A C compressor Too much oil will reduce the cooling capacity of the A C system It will not...

Page 2114: ...com pressor 5 Install the bolt that secures the A C suction line to the A C compressor Tighten the bolt to 23 N m 17 ft lbs 6 Remove the tape or plugs from the liquid and suction line fittings and bo...

Page 2115: ...nd remove the water valve from the rubber mounts 9 If necessary remove the rubber mounts from the bracket or water valve INSTALLA TION 1 If removed install the rubber mounts to the heater water valve...

Page 2116: ...personal injury or death 1 Remove the rear A C evaporator housing and place it on a workbench Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION REAR REAR A C EVAPORATOR HOUSING REMOVAL 2 Remove the f...

Page 2117: ...ION The rear A C expansion valve controls the amount of refrigerant entering the rear A C evaporator Fig 24 The rear A C expansion valve is of an externally equalized thermostatic expansion valve TXV...

Page 2118: ...nt system Refer to 24 HEATING AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the insulating tape from around the area of the rear A C expansion valve Fig 25 5 Disconnect t...

Page 2119: ...to the rear A C expansion valve Tighten the nut to 35 N m 26 ft lbs 6 Connect the equalizer tube to the rear evapora tor outlet tube Tighten the nut to 10 N m 88 in lbs 7 Position the rear expansion v...

Page 2120: ...ve the cover from the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system...

Page 2121: ...underneath of the vehicle 13 Disconnect the rear A C discharge line from the underbody discharge line and remove and discard the O ring seal 14 Remove the foam rubber seal from the open ing in the flo...

Page 2122: ...ee foam insulators to the right inner quarter panel 9 Install the right quarter trim panel Refer to 23 BODY INTERIOR QUARTER TRIM PANEL INSTALLATION 10 Connect the rear discharge line to the rear A C...

Page 2123: ...warnings and cau tions could result in possible personal injury or death CONDENSER TO RECEIVER DRIER 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo...

Page 2124: ...to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER REMOVAL 5 Disconnect the rear liquid line from the reser voir and remove and discard the O ring seal Fig 32 6 Disconnect the rear...

Page 2125: ...R CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 10 Install the cover onto the rear A C condenser housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLAT...

Page 2126: ...bracket that secures the rear receiver drier to the rear A C con denser housing and remove the receiver drier 8 Install plugs into or tape over the opened rear liquid line fitting and reservoir and re...

Page 2127: ...he air filter from the rear A C evapo rator housing Refer to 24 HEATING AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 H...

Page 2128: ...ser housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION REAR SUCTION LINE DESCRIPTION The rear A Csuction line is the refrigerant line that carries refrig...

Page 2129: ...ft quarter trim panel Refer to 23 BODY INTERIOR QUARTER TRIM PANEL REMOVAL 8 Remove the three foam insulators from the left inner quarter panel 9 Remove the foam rubber seal from the opening in the fl...

Page 2130: ...NG STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the rear refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 12 Install the cove...

Page 2131: ...Push the A C line disconnect tool into the open side of the coupler cage to expand the garter spring Once the garter spring is expanded and while still pushing the disconnect tool into the open side o...

Page 2132: ...cted the A C compres sor Two sections of the underbody suction line low side are connected together by a tapping block with an O ring seal The underbody A C dis charge line uses a spring lock type ref...

Page 2133: ...derbody suction line 6 Disconnect the front section of the underbody suction line from the rear section and remove and discard the O ring seal 7 Install plug in or tape over all of the opened suction...

Page 2134: ...w rubber O ring seal with clean refrig erant oil install it onto the discharge line fitting and install the bolt that secures the discharge line to the compressor Tighten the bolt to 21 N m 15 ft lbs...

Page 2135: ...on line to the rear section of the suction line and install the retaining bolt Tighten the bolt to 25 N m 18 ft lbs 8 Lower the vehicle 9 Evacuate the rear refrigerant system Refer to 24 HEATING AIR C...

Page 2136: ...tional heat depending on engine coolant temperature OPERA TION The supplemental cabin heater is activated by using the temperature control on the A C heater con trol The supplemental cabin heater is a...

Page 2137: ...ntrol module using the DRBIII scan tool and the procedures listed in Vehicle Performance under Cabin Heater Diagnosis in Group 18 Loss of coolant Leakage or heater develops smoke during combustion ope...

Page 2138: ...6 Lower the vehicle FUEL DOSING PUMP DESCRIPTION The dosing pump is a combined delivery dosing and shut off system for the fuel supply to the supple mental cabin heater from the vehicle fuel tank OPE...

Page 2139: ...the fuel pump by depressing the integral spring and pushing the connector towards the dosing pump Pull the con nector towards the cabin heater to verify the instal lation 5 Verify function of the supp...

Page 2140: ...AL 1 Raise and support the vehicle Take note of the location of the flexible section of the cabin heater exhaust tube NOTE Have an approved fuel holding device ready to capture any diesel fuel that dr...

Page 2141: ...el tank and tighten the connection securely 3 Install the fuel line at the dosing pump and tighten the connection securely 4 Lower the vehicle NOTE Failure to prime the dosing pump after drain ing the...

Page 2142: ...open port NOTE Utilize an approved fuel storage container to catch any residual fuel 9 Loosen the two fasteners at the rail Take care to notice that the exhaust tube bracket tab is on top of the heate...

Page 2143: ...r wire harness from the left side between the heater unit and the heater shield 2 Install the two wiring harness retainers to the cabin heater shield 3 Route the wiring harness along the underside of...

Page 2144: ...all and tighten the retaining clamp securely 4 Install the cabin heater tubes to the lower heater connection and the lower EGR cooler connec tion and tighten the retaining clamps 5 Lower the vehicle 6...

Page 2145: ...ield 3 Disconnect the CCV heater wiring harness con nector 4 Using a slight twisting motion separate the CCV breather tube from the heater 5 Separate the CCV heater from the turbo charger air inlet du...

Page 2146: ...n passage into the cylinder head cover Fig 2 The oil separator removes oil from the blow by gasses to reduce MAF sensor contamination For service procedures refer to Refer to 25 EMISSIONS CON TROL EVA...

Page 2147: ...s to 11 N m 97 in lbs Fig 3 4 Connect the CCV breather outlet hose Fig 3 5 Install the engine cover Refer to 9 ENGINE INSTALLATION Fig 3 CCV BREATHER 1 FUEL RAIL 6 CAM POSITION SENSOR 2 FUEL RAIL PRES...

Page 2148: ...g high engine idle to avoid carbon build up on the valve The EGR also deactivates if the EGR temperature is too high The EGR also has a self cleaning function that opens and closes twice after the eng...

Page 2149: ...reduced because the exhaust gas is low in oxygen The result is that the combustion rate is reduced as is the combustion temperature This reduces the quantity of NOx that are emitted in the exhaust gas...

Page 2150: ...connect the electrical connector at the EGR positioner Fig 3 5 Disconnect the EGR cooler hose 6 Remove the EGR fasteners and EGR with cooler assembly Fig 3 INSTALLA TION 1 Clean all gasket mating surf...

Page 2151: ...d Cooler are serviced as an assembly refer to Refer to 25 EMISSIONS CON TROL EXHAUST GAS RECIRCULATION VALVE REMOVAL Fig 4 EGR AND COOLER 1 EGR VALVE 2 EGR COOLER 3 INTAKE MANIFOLD VA EXHAUST GAS RECI...

Page 2152: ......

Page 2153: ...SC BRAKE CALIPERS 5 11 DOME LAMP INTRUSION SENSOR BULB 8L 33 DOME LAMP INTRUSION SENSOR 8L 33 DOME READING LAMP BULB 8L 32 DOME READING LAMP UNIT 8L 32 DOOR GLASS 23 15 23 30 23 46 DOOR JAMB SWITCH 8L...

Page 2154: ...ATION DOOR ACTUATOR 24 22 REFRIGERANT LINE COUPLER 24 98 REFRIGERANT OIL 24 81 REFRIGERANT 24 80 RELAY 8W 97 4 REMOTE KEYLESS ENTRY TRANSMITTER 8N 1 REPEATER LAMP BULB 8L 23 REPEATER LAMP UNIT 8L 24 R...

Page 2155: ...___________________________________________________ ______________________________________________________________________________________ _____________________________________________________________...

Page 2156: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 2157: ...ODE ERASURE 5 3 4 USING THE DRBIII 5 3 5 DRBIII ERROR MESSAGES 5 3 5 1 DRBIII DOES NOT POWER UP BLANK SCREEN 5 3 5 2 DISPLAY IS NOT VISIBLE 5 4 0 DISCLAIMERS SAFETY AND WARNINGS 5 4 1 DISCLAIMERS 5 4...

Page 2158: ...42 ABS RR SENSOR MESSAGE 44 ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT 46 CAN BUS CIRCUIT 48 CAN MESSAGE FROM ECM FROM SLA 53 CONTROL MODULE TCM IS NOT CODED 55 ENGINE CAN MESSAGE INCORRECT 56 ENGINE C...

Page 2159: ...8 0 COMPONENT LOCATIONS 129 8 1 ENGINE CONTROL MODULE 129 8 2 TRANSMISSION CONTROL MODULE 129 8 3 TRANSMISSION SOLENOID ASSEMBLY 129 9 0 CONNECTOR PINOUTS 131 ELECTROHYDRAULIC CONTROL UNIT BLACK 131...

Page 2160: ...NOTES iv...

Page 2161: ...ears are actuated electronically hydraulically The electronic control system enables precise adaptation of pres sures to the respective operating conditions and to the engine output during a shift pha...

Page 2162: ...d or may result in engine or transmission failure the transmission will be placed in the neutral position Improper Ratio Input Sensor Overspeed or Engine Overspeed DTC s will cause the loss of drive C...

Page 2163: ...nhibitor is part of the Shift Lever Assembly and is controlled by the Shift Lever Assembly module Trans temp sensor P N Sw itch circuit The TCM will detect the selector lever in park and neutral posit...

Page 2164: ...lems can be misinterpreted as a transmission prob lem Ensure that the engine is running properly and that no ECM DTC s are present that could cause a transmission complaint If there is a communicatio...

Page 2165: ...n ignition cycle which will place the DTC in an intermittent status Stored DTC When there are no diagnostic trouble codes stored in memory the DRBIII w ill display NO DTC s DETECTED 3 4 USING THE DRBI...

Page 2166: ...asses without failure 4 2 3 SERVICING SUB ASSEMBLIES Some components of the Transmission system are intended to be serviced in assembly only Attempt ing to remove or repair certain system sub componen...

Page 2167: ...rs performed fixed the vehicle correctly Always operate and observe the vehicle under ac tual driving conditions J ust as important as the road test is there are preliminary inspections that should be...

Page 2168: ...ically Modulated Converter Clutch PWM Pulse width modulated SKREEM Sentry Key Remote Entry Module SLA Shift Lever Assembly SW Switch TCC Torque Converter Clutch TCM Transmission Control Module TP Thro...

Page 2169: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...

Page 2170: ...orted condition Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Shifter Assembly harness connector Disconnect the DRBIII from th...

Page 2171: ...at of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K ABS Shifter Assembly circuit for a short to voltage Perform NAG1 TRANSMISSION VERIFICATION TEST VE...

Page 2172: ...EST VER 1 No Go To 2 2 Turn the ignition off Disconnect the TCM harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K TCM circuit Is the resistance belo...

Page 2173: ...ween the TCM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace the Transmission Control Module in accordance with the Service Information Perform NAG1 TRANSMISSION VERIFICATION TE...

Page 2174: ...ever Assembly harness connector Isolate the Backup Lamp circuit remove the Backup Lamp bulbs NOTE Check Backup Lamp bulbs and socket for a short or corrosion Measure the resistance between ground and...

Page 2175: ...ge above 0 5 volts All Yes Repair the Backup Lamp circuit for a short to voltage No Replace the Shift Lever Assembly per the Service Information 3 Turn the ignition off to the lock position Disconnect...

Page 2176: ...a 12 volt test light connected to ground check the Fused Ignition Switch Output circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the batter...

Page 2177: ...f the ECM is reporting a CAN bus failure refer to its respective test first No Go To 2 2 Turn the ignition off to the lock position Disconnect the ECM harness connector Disconnect the SLA harness conn...

Page 2178: ...e per the Service Information Ignition on engine not running With the DRBIII erase Transmission DTCs Start the engine and with the brakes firmly applied place the gear selector into Drive With the DRB...

Page 2179: ...INTERNAL CONTROLLER POSSIBLE CAUSES INTERNAL CONTROLLER Repair Instructions INTERNAL CONTROLLER The Shift Lever Assembly has detected an internal fault Replace the Shift Lever Assembly 19 SHIFT LEVER...

Page 2180: ...CAN bus or Wheel Speed Sensor DTCs present All Yes Refer to the ABS category and perform the appropriate symptom No Go To 2 2 Replace the ABS Control Module per the Service Information Verify if the D...

Page 2181: ...off to the lock position Disconnect the Shift Lever Assembly harness connector Start the engine and raise the engine speed to 1500 RPM Measure the Transmission Relay Output voltage at the Shift Lever...

Page 2182: ...CAN bus or Wheel Speed Sensor DTCs present All Yes Refer to the ABS category and perform the appropriate symptom No Go To 2 2 Replace the ABS Control Module per the Service Information Verify if the D...

Page 2183: ...rm the appropriate symptom No Go To 2 2 Turn the ignition off to the lock position Disconnect the Shift Lever Assembly harness connector Start the engine Increase the Engine Speed to 1500 RPM Measure...

Page 2184: ...id open solenoid or an open or shorted solenoid control circuit driver in the TCM 1 2 4 5 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Page 2185: ...2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 1 2 4 5 SOLENOID CIRCUIT reset All Yes Go To 3 No Go To 7 3...

Page 2186: ...ectors Clean repair as necessary Measure the resistance between the 1 2 4 5 Solenoid Control circuit and the Solenoid Supply Voltage Circuit in the Transmission Control Module C2 harness connector Is...

Page 2187: ...lenoid open solenoid or an open or shorted solenoid control circuit driver in the TCM 2 3 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Page 2188: ...ue Go To 2 2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 2 3 SOLENOID CIRCUIT reset All Yes Go To 3 No Go...

Page 2189: ...nnectors Clean repair as necessary Measure the resistance between the 2 3 Solenoid Control circuit and the Solenoid Supply Voltage circuit in the Transmission Control Module C2 harness connector Is th...

Page 2190: ...lenoid open solenoid or an open or shorted solenoid control circuit driver in the TCM 3 4 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Page 2191: ...ue Go To 2 2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 3 4 SOLENOID CIRCUIT reset All Yes Go To 3 No Go...

Page 2192: ...ectors Clean repair as necessary Measure the resistance between the 3 4 Solenoid Control circuit and the Solenoid Supply Voltage circuit in the Transmission Control Module C2 harness connector Is the...

Page 2193: ...smission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagra...

Page 2194: ...ce and program the ABS Control Module With the DRBIII erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selector into drive With the DRBIII read Transmission DTCs...

Page 2195: ...minal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle...

Page 2196: ...TY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw...

Page 2197: ...r NOTE Check connectors Clean repair as necessary Measure the resistance of the CAN Bus circuit between the ABS harness connector and the TCM C2 harness connector Measure the resistance of the CAN Bus...

Page 2198: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Page 2199: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Page 2200: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Page 2201: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Page 2202: ...prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Page 2203: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Page 2204: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Page 2205: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Page 2206: ...d repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engi...

Page 2207: ...there any Accel Pedal DTCs present All Yes Refer to the Driveability category and perform the appropriate symptom Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 6 6 Replace the Transmissio...

Page 2208: ...CAN C Bus circuit CAN C Bus circuit shorted to CAN C Bus circuit or a TCM failure Note All CAN message missing DTCS will also be present which indicates a Bus Failure POSSIBLE CAUSES CAN BUS CIRCUITS...

Page 2209: ...y Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII read the active and stored DTCs for all modules that use CAN Bus communication NOTE Due to capabilities of ce...

Page 2210: ...Bus module the vehicle is equipped with Monitor and note the voltmeter reading NOTE Repeat the above step for each CAN Bus module until all the modules have been disconnected NOTE Refer to the w irin...

Page 2211: ...nect the SKREEM harness connector Disconnect the ECM harness connectors Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit Is the resistance below 50 0 ohms after disconnec...

Page 2212: ...20 0 ohms 5 0 ohms All Yes Replace the Sentry Key Remote Entry Module per the Service Information Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Repair the CAN C Bus and or CAN C Bus circuit for...

Page 2213: ...iagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a g...

Page 2214: ...Turn the ignition off to the lock position Disconnect the Shift Lever harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Shift Lever harness conne...

Page 2215: ...ODED POSSIBLE CAUSES TRANSMISSION CONTROL MODULE FLASH TEST ACTION APPLICABILITY 1 View repair All Repair Flash the Transmission Control Module to the proper level Perform NAG1 TRANSMISSION VERIFICATI...

Page 2216: ...transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring di...

Page 2217: ...into drive With the DRBIII read Transmission DTCs Did the DTC ENGINE CAN MESSAGE INCORRECT reset All Yes Go To 4 No Test Complete Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 4 If there are no po...

Page 2218: ...ir the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTC...

Page 2219: ...n repair as necessary Measure the resistance of the CAN Bus circuit between the ECM harness connector and the TCM C2 harness connector Measure the resistance of the CAN Bus circuit between the ECM har...

Page 2220: ...s prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DT...

Page 2221: ...echanical problems and be operating normally before proceeding w ith this test Turn the ignition off to the lock position Replace and program the PCM ECM Control Module per the Service Information Wit...

Page 2222: ...ion symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram sch...

Page 2223: ...ignition off to the lock position Replace and program the ECM per the Service Information With the DRBIII erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selecto...

Page 2224: ...vice information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transm...

Page 2225: ...Temperature Sensor DTCs present All Yes Refer to the Driveability category and perform the appropriate symptom Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Replace and program the EC...

Page 2226: ...the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as neces...

Page 2227: ...ts With the DRBIII read Transmission DTCs Did the DTC ENGINE TORQUE MESSAGE INCORRECT reset All Yes Go To 4 No Test Complete Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 4 If there are no possibl...

Page 2228: ...djust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engin...

Page 2229: ...it open All Yes Repair the CAN C BUS or circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Ignition on engine not running With the DRBIII read Engine DTCs Are there any...

Page 2230: ...agnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a gu...

Page 2231: ...4 4 Turn the ignition off to the lock position Disconnect the Instrument Cluster C1 harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Instrument C...

Page 2232: ...ecessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be se...

Page 2233: ...r an open 6 NOTE If vehicle is equipped w ith Air Conditioning diagnose the ATC system first Ignition on engine not running With the DRBIII read Instrument Cluster or Automatic Temp Control DTCs Are t...

Page 2234: ...ION APPLICABILITY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service infor...

Page 2235: ...ansmission Valve Body and Electrohydraulic Control Unit Assembly per the Service Information NOTE This DTC is usually set due to a internal transmission problem such as but not limited to stuck soleno...

Page 2236: ...OTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays p...

Page 2237: ...ction procedures Is there any Debris plugged Transmission Oil filter or signs of an Internal Transmission problem All Yes Refer to the Service Information for the proper repair procedure Pay particula...

Page 2238: ...level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnos...

Page 2239: ...nsmission problem All Yes Repair Internal Transmission as necessary Pay particular atten tion to the Electrohydraulic Control unit Refer to the Service Information for proper repair procedures Perform...

Page 2240: ...arged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Tra...

Page 2241: ...d Transmission Oil Filter or signs of an Internal Transmission problem All Yes Repair Internal Transmission as necessary Pay particular atten tion to the Electrohydraulic Control unit Refer to the Ser...

Page 2242: ...is Internal Controller DTC is set with any Solenoid DTC s repair the Solenoid DTC s first erase all DTC s then verify the Internal Controller DTC sets before replacing the TCM POSSIBLE CAUSES TCM INTE...

Page 2243: ...s a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run Note Verify flash level...

Page 2244: ...locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII rea...

Page 2245: ...Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Mod Pr...

Page 2246: ...Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Replace the Mod Press Solenoid per the Service Information Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set this...

Page 2247: ...from the ABS system Set Condition If the N2 input speed sensor is equal to 0 rpm or a short to ground short to battery open input speed sensor faulty input speed sensor open sensor supply circuit POS...

Page 2248: ...To 2 2 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid harness connector NOTE Check connectors Clean repair as necessary Measure...

Page 2249: ...or Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disco...

Page 2250: ...and increase vehicle speed to engage 2nd gear CAUTION BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Compare the Scope Pattern on the DRBIII with a typical 5 volt square wave pattern Does th...

Page 2251: ...d gear is 3rd or 4th and the detected gear is the actual vehicle gear Set Condition If the N3 input speed sensor is equal to 0 rpm or a short to ground short to battery open input speed sensor faulty...

Page 2252: ...To 2 2 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid harness connector NOTE Check connectors Clean repair as necessary Measure...

Page 2253: ...r Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Discon...

Page 2254: ...and increase vehicle speed to engage 2nd gear CAUTION BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Compare the Scope Pattern on the DRBIII with a typical 5 volt square wave pattern Does th...

Page 2255: ...perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics Wi...

Page 2256: ...cessary Measure the resistance of the Sensor Supply circuit to chassis ground in the Transmission Solenoid Assembly harness connector Is the resistance below 5 0 ohms All Yes Repair the Sensor Supply...

Page 2257: ...ram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run Note Ver...

Page 2258: ...e resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Shift Lever harness connector Is the resistance 60 ohms 3 0 ohms All Yes Replace the Shift Lever Assembly per the service in...

Page 2259: ...roblems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid f...

Page 2260: ...ion Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Sh...

Page 2261: ...Control Module Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Replace the Shift Pressure Solenoid Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set this DTC ar...

Page 2262: ...t by driving the vehicle such that all diagnostic monitors have run Note Verify flash level of transmission controller Some problems are corrected by softw are upgrades to the transmission controller...

Page 2263: ...h a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and re...

Page 2264: ...Yes Repair the Solenoid Supply Voltage circuit for a short to ground or high resistance Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Discon...

Page 2265: ...d the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as nece...

Page 2266: ...r circuits in the TCM harness connector Is the resistance below 5 0 ohms between Solenoid Supply and any other circuit All Yes Repair the Solenoid Supply circuit short to other circuits Perform NAG1 T...

Page 2267: ...orming transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wi...

Page 2268: ...ors Clean repair as necessary Start the engine Increase the Engine Speed to 1500 RPM Measure the voltage of the Transmission Relay Output circuit in the TCM C1 harness connector Is the voltage below 1...

Page 2269: ...l engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connection...

Page 2270: ...e of the Transmission Relay Output circuit in the TCM C1 harness connector Is the voltage below 9 0 volts All Yes Repair the Transmission Relay Output circuit for an open or high resistance Perform NA...

Page 2271: ...OTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DT...

Page 2272: ...n check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and rep...

Page 2273: ...the TCC Solenoid Control circuit for a short to ground Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Disconnect the Transmission Control Mod...

Page 2274: ...ing and connectors specific to this circuit Wiggle the wires while checking for shorts and open circuits NOTE Check for any Technical Service Bulletins that may apply Were there any problems found All...

Page 2275: ...l per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to perf...

Page 2276: ...tor Measure the resistance between ground and the TCC Solenoid Control circuit Is the resistance below 5 0 ohms All Yes Repair the TCC Solenoid Control circuit for a short to ground Perform NAG1 TRANS...

Page 2277: ...the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs...

Page 2278: ...or and the Transmission Solenoid Assembly harness connector Is the resistance above 5 0 ohms All Yes Repair the Transmission Temp Sensor P N Switch circuit for an open Perform NAG1 TRANSMISSION VERIFI...

Page 2279: ...nition off to the lock position Disconnect the TCM C2 harness connector NOTE Make sure the Transmission Solenoid Assembly harness connector is connected or the results of the test w ill be invalid Wit...

Page 2280: ...d and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and co...

Page 2281: ...e Service Information Perform W5J 400 TRANSMISSION VERIFICATION TEST VER 1 Did the DTC TRANS TEMP SENSOR ERRATIC reset All Yes Replace the Transmission Control Module Perform NAG1 TRANSMISSION VERIFIC...

Page 2282: ...charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all...

Page 2283: ...is procedure With the gear selector in park attempt to start the vehicle Does the vehicle start All Yes Replace the Transmission Temperature Sensor P N Switch Assembly per the Service Information Perf...

Page 2284: ...ILITY 8 If there are no possible causes remaining view repair All Repair Replace the Transmission Control Module Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 124 TRANSMISSION NAG1 TRANS TEMP SENS...

Page 2285: ...ABILITY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOT...

Page 2286: ...for the proper procedures Were there any problems found All Yes Refer to the Service Information for proper repair procedures Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Determine...

Page 2287: ...airs w ere performed and the shift quality is still poor it may be necessary to check the internal repair Also check for any TSBs and or Controller Flash updates that may apply 9 ROAD TEST PROCEDURE 1...

Page 2288: ...NOTES 128...

Page 2289: ...8 0 COMPONENT LOCATIONS 8 1 ENGINE CONTROL MODULE 8 2 TRANSMISSION CONTROL MODULE 8 3 TRANSMISSION SOLENOID ASSEMBL Y C O M P O N E N T L O C A T I O N S 129 COMPONENT LOCATIONS...

Page 2290: ...NOTES 130...

Page 2291: ...6YL BL TCC SOLENOID CONTROL 12 20PK SENSOR GROUND 13 16WT 1 2 4 5 SOLENOID CONTROL SHIFTER ASSEMBL Y BLACK CAV CIRCUIT FUNCTION 1 2 20GY DG RD LAMP DRIVER 3 20BL DG K ABS SHIFTER ASSEMBLY 4 18BR GROUN...

Page 2292: ...NTROL 16 16WT BL 2 3 SOLENOID CONTROL 17 16YL BL TCC SOLENOID CONTROL 33 20PK SENSOR GROUND 34 20GY BL TEMPERATURE SENSOR P N SWITCH 35 20BL DG N3 INPUT SPEED SENSOR 36 16BR GY MODULATION PRESSURE SOL...

Page 2293: ...LA Y RELA Y BLOCK CAV CIRCUIT FUNCTION 30 16BK DG TRANSMISSION RELAY OUTPUT 85 16BR GROUND 86 16BK YL FUSED IGNITION SWITCH OUTPUT RUN START 87 16RD FUSED B 87A C O N N E C T O R P I N O U T S 133 CON...

Page 2294: ...NOTES 134...

Page 2295: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 135 SCHEMATIC DIAGRAMS...

Page 2296: ...NOTES 136...

Page 2297: ...11 0 CHARTS AND GRAPHS 11 1 5 VOLT SQUARE WA VE TYPICAL PA TTERN C H A R T S A N D G R A P H S 137 CHARTS AND GRAPHS...

Page 2298: ...11 2 TRANSMISSION TEMP SENSOR C H A R T S A N D G R A P H S 138 CHARTS AND GRAPHS...

Page 2299: ...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 2300: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 2301: ...crobat Reader Main Page Creating Shortcuts from the CD Downloading CD onto your hard drive Troubleshooting Click on any tab for additional information The Main Page tab will take you back to the Main...

Page 2302: ...er from the Adobe Website Alternately you may visit http www adobe com products acrobat readstep2 html to download the latest version of the reader After accessing the Adobe site exit out of the Acrob...

Page 2303: ...en type 2005 or the correct Model Year and press the Enter key 2 Insert CD into CD Drive 3 Launch Windows Explorer by right clicking on the Start Button start button is located in the lower left corne...

Page 2304: ...ck once on the first book folder to view the contents of that folder In the right hand pane of the explorer window right click on the welcome pdf and drag down to Copy 5 Now double click on the deskto...

Page 2305: ...bat 5 0 Reader in conjunction with CD 6 Right click within this window and select Paste Shortcut Page 3 of 3 Installing Acrobat Reader Main Page Creating Shortcuts from the CD Downloading CD onto your...

Page 2306: ...select New Folder then type 2005 and press the Enter key 2 Insert CD into CD Drive 3 Launch Windows Explorer by right clicking on the Start Button start button is located in the lower left corner of...

Page 2307: ...olders and drag them to your newly created desktop folder Page 2 of 3 5 Now open each folder and select the welcome pdf 6 Right click with your mouse and drag down to Copy Next Installing Acrobat Read...

Page 2308: ...ste Shortcut Page 3 of 3 8 Rename shortcut to Model Year Model 2005 an pdf 9 Repeat for each manual This will launch the default Acrobat Reader from your hard drive the CD no longer has to be in the C...

Page 2309: ...hes and the welcome pdf is displayed but I can t access any other data Using your mouse move over the document until the cursor changes from an open hand to a pointing finger This indicates where the...

Page 2310: ...FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to mak...

Page 2311: ...ear safety goggles w henever w ork ing on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to...

Page 2312: ...ren Michigan 48092 U S A MILLER SPECIAL TOOLS SPX Corporation Telephone 1 800 801 5420 FAX 1 800 578 7375 INTERNATIONAL The special service tools referred to herein are required for certain service op...

Page 2313: ...ion that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manua...

Page 2314: ...In order to serve you better valuable information links and tips are available to you on this disc Please choose the option that best meets your needs Help Helpful Informatio n Troublesh ooting and FA...

Page 2315: ...Welcome 2006 VA Sprinter Technical Publications Click on the icon for the desired manual Service Manual Body Chassis Transmission Powertrain...

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