NOTE: Do not swap the body control module
between vehicles or body control modules
off the shelf.
Engineering does not recommend that service,
dealers or the plant swap Body Control Modules
(BCM) between vehicles or off the shelf. The BCM
has internal diagnostic capability that assists in
diagnosing the system. When an “Open” or a
“Short” circuit exists, the DRBIII
t
can be used to
read the BCM codes. The codes are very descriptive
in identifying the appropriate feature that has
faulted.
3.3.1
BATTERY SAVE FEATURE
The Battery Save feature provides the customer
with the ability to conserve battery power when
storing the vehicle for long periods of time without
losing radio/Engine Controller memory. This is an
alternative to disconnecting the battery. When the
feature is performed, the driver door exterior han-
dle is the only wakeup circuits available. RKE and
the exterior passenger door handle is disabled while
the BCM is in Sleep Mode. The driver door key
cylinder unlock switch and the interior door han-
dles is an alternative mechanical way of entering
the vehicle. When the driver door outside handle is
pressed, then the BCM exits Sleep Mode and will
allow all features (except interior and exterior light-
ing) to work. The BCM will re-enter Sleep Mode 30
seconds after all doors are closed. Battery Save
Mode is cancelled when the ignition is cycled to
RUN.
3.3.1.1
CUSTOMER NORMAL OPERATING
MODE
The customer starts the battery save feature by
doing the following:
•
Insert key into ignition switch.
•
Cycle the ignition switch from Off to Accessory
four times without going into RUN.
•
Leave the switch in the OFF position after the
fourth cycle without removing the key. This puts
the BCM into the learn mode.
•
The customer then depresses the driver’s side
Power Door Lock switch in the UP direction.
•
A horn chirp will tell the customer that the
process has begun.
•
All interior and exterior lights (if on) will be
turned off.
•
Key may be removed or left in at this point.
•
VTSS may be armed before Sleep Mode by using
the RKE or the door lock switch.
The customer can exit battery save mode by doing
the following:
•
Press the Driver door outside handle (this will
wakeup the vehicle).
•
If the door did not open, then the vehicle must be
locked-press the RKE Unlock.
•
Press the Driver door outside handle.
•
Cycle the ignition key to RUN-this will cancel the
feature.
•
If the ignition is not cycled to RUN, then the BCM
will re-enter Sleep Mode 30 seconds after the last
door is closed.
3.3.1.2
SHIPPING OPERATING MODE
To conserve battery power when the vehicle is
shipped, the BCM will enter Battery Save Mode
immediately after it goes to sleep. This is providing
the following is performed:
•
Radio IOD fuse is pulled (this will set a Radio Bus
Communication DTC).
•
Ignition has been cycled to run or accessory.
•
Ignition is in Lock (with or without key in the
ignition switch).
•
Dome lamps will cancel.
•
Headlamp Battery Save will be performed.
•
Accessory delay will be cancelled.
•
The BCM has recorded less than 50 vehicle miles.
•
VTSS may be armed before Sleep Mode by using
the RKE or the door lock switch.
•
Cycling the ignition to RUN will reset the BCM.
3.4
CHIME WARNING SYSTEM
The Instrument Cluster monitors the PCI bus
and based on information from various modules,
will request chimes from the BCM as well as
illuminating warning indicators. The BCM moni-
tors the door/decklid ajar switches, multifunction
switch, ignition switch, PCI bus, and the DRBIII
t
to perform various chime operations. The BCM uses
a hardwire low-side driver to control the chime
located in the cluster. The chime system provides
the Driver with warning announcements for:
•
Seat belt Reminder
•
Exterior lights on
•
Key-in Ignition
•
Key-in Accessory
•
Engine coolant temperature high or critical
•
Dome light on
•
Low engine oil pressure
•
Engine oil temperature high or critical
•
Charging System faults
•
Low Fuel Warning
•
Any warning lamp announcement
8
GENERAL INFORMATION
Summary of Contents for ZB 2005
Page 4: ......
Page 8: ...FASTENER STRENGTH ZB INTRODUCTION 3 FASTENER IDENTIFICATION Continued...
Page 11: ...METRIC CONVERSION CHART 6 INTRODUCTION ZB METRIC SYSTEM Continued...
Page 13: ...TORQUE SPECIFICATIONS 8 INTRODUCTION ZB TORQUE REFERENCES Continued...
Page 29: ......
Page 103: ...Fig 24 Dynamic Toe Pattern Graph 2 74 WHEEL ALIGNMENT ZB WHEEL ALIGNMENT Continued...
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Page 764: ...Fig 15 X Y AND Z PLANES ZB FRAME BUMPERS 13 13 FRAME Continued...
Page 765: ...Fig 16 FRAME SIDE VIEW FRONT SECTION Z DIMENSIONS 13 14 FRAME BUMPERS ZB FRAME Continued...
Page 766: ...Fig 17 FRAME SIDE VIEW REAR SECTION Z DIMENSIONS ZB FRAME BUMPERS 13 15 FRAME Continued...
Page 767: ...Fig 18 FRAME SIDE VIEW FRONT SECTION X DIMENSIONS 13 16 FRAME BUMPERS ZB FRAME Continued...
Page 768: ...Fig 19 FRAME SIDE VIEW REAR SECTION X DIMENSIONS ZB FRAME BUMPERS 13 17 FRAME Continued...
Page 769: ...Fig 20 FRAME TOP VIEW FRONT SECTION X AND Y DIMENSIONS 13 18 FRAME BUMPERS ZB FRAME Continued...
Page 770: ...Fig 21 FRAME TOP VIEW REAR SECTION X AND Y DIMENSIONS ZB FRAME BUMPERS 13 19 FRAME Continued...
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Page 906: ...Vehicle Lead Correction Diagnosis Chart ZB TIRES WHEELS 22 15 TIRES Continued...
Page 911: ......
Page 925: ...Fig 1 EXPLODED VIEW 23 14 CONVERTIBLE TOP ZB CONVERTIBLE TOP Continued...
Page 1009: ...Fig 6 TRUNK OPENING DIMENSIONS 23 98 BODY STRUCTURE ZB OPENING DIMENSIONS Continued...
Page 1011: ...Fig 8 FRONT OF DASH PANEL AND FRAME 23 100 BODY STRUCTURE ZB SEALER LOCATIONS Continued...
Page 1012: ...Fig 9 REAR CLIP FRAME ZB BODY STRUCTURE 23 101 SEALER LOCATIONS Continued...
Page 1016: ...Fig 13 FRONT FRAME STRUCTURE 1 OF 4 23 104 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1017: ...Fig 14 FRONT FRAME STRUCTURE 2 OF 4 ZB BODY STRUCTURE 23 105 WELD LOCATIONS Continued...
Page 1018: ...Fig 15 FRONT FRAME STRUCTURE 3 OF 4 23 106 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1019: ...Fig 16 FRONT FRAME STRUCTURE 4 OF 4 ZB BODY STRUCTURE 23 107 WELD LOCATIONS Continued...
Page 1020: ...Fig 17 FLOOR PAN 1 OF 5 23 108 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1021: ...Fig 18 FLOOR PAN 2 OF 5 ZB BODY STRUCTURE 23 109 WELD LOCATIONS Continued...
Page 1022: ...Fig 19 FLOOR PAN 3 OF 5 23 110 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1023: ...Fig 20 FLOOR PAN 4 OF 5 ZB BODY STRUCTURE 23 111 WELD LOCATIONS Continued...
Page 1024: ...Fig 21 FLOOR PAN 5 OF 5 23 112 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1025: ...Fig 22 REAR FRAME 1 OF 5 ZB BODY STRUCTURE 23 113 WELD LOCATIONS Continued...
Page 1026: ...Fig 23 REAR FRAME 2 OF 5 23 114 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1027: ...Fig 24 REAR FRAME 3 OF 5 ZB BODY STRUCTURE 23 115 WELD LOCATIONS Continued...
Page 1028: ...Fig 25 REAR FRAME 4 OF 5 23 116 BODY STRUCTURE ZB WELD LOCATIONS Continued...
Page 1029: ...Fig 26 REAR FRAME 5 OF 5 ZB BODY STRUCTURE 23 117 WELD LOCATIONS Continued...
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Page 1121: ...NOTES vi...
Page 1136: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15...
Page 1341: ...NOTES 220...
Page 1344: ...8 4 FUEL SYSTEM C O M P O N E N T L O C A T I O N S 223 COMPONENT LOCATIONS...
Page 1345: ...C O M P O N E N T L O C A T I O N S 224 COMPONENT LOCATIONS 8 4 FUEL SYSTEM Continued...
Page 1355: ...C O N N E C T O R P I N O U T S 234 CONNECTOR PINOUTS...
Page 1362: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 241 SCHEMATIC DIAGRAMS...
Page 1363: ...S C H E M A T I C D I A G R A M S 242 SCHEMATIC DIAGRAMS...
Page 1364: ...S C H E M A T I C D I A G R A M S 243 SCHEMATIC DIAGRAMS...
Page 1365: ...NOTES 244...
Page 1368: ...11 4 EELD C H A R T S A N D G R A P H S 247 CHARTS AND GRAPHS...
Page 1369: ...NOTES 248...
Page 1371: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...
Page 1381: ...NOTES x...
Page 1407: ...NOTES 26...
Page 1408: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 27...
Page 1789: ...NOTES 408...
Page 1795: ...NOTES 414...
Page 1803: ...10 2 AUDIO SYSTEM S C H E M A T I C D I A G R A M S 422 SCHEMATIC DIAGRAMS...
Page 1804: ...10 3 CHIME SYSTEM S C H E M A T I C D I A G R A M S 423 SCHEMATIC DIAGRAMS...
Page 1805: ...10 4 COMMUNICATION S C H E M A T I C D I A G R A M S 424 SCHEMATIC DIAGRAMS...
Page 1808: ...10 7 2 REAR FOG LAMPS EXPORT ONLY S C H E M A T I C D I A G R A M S 427 SCHEMATIC DIAGRAMS...
Page 1809: ...10 8 HEATING A C SYSTEM S C H E M A T I C D I A G R A M S 428 SCHEMATIC DIAGRAMS...
Page 1813: ...10 11 INTERIOR LIGHTING S C H E M A T I C D I A G R A M S 432 SCHEMATIC DIAGRAMS...
Page 1814: ...10 12 POWER DOOR LOCKS RKE S C H E M A T I C D I A G R A M S 433 SCHEMATIC DIAGRAMS...
Page 1815: ...10 13 POWER WINDOW SYSTEM S C H E M A T I C D I A G R A M S 434 SCHEMATIC DIAGRAMS...
Page 1817: ...10 15 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 436 SCHEMATIC DIAGRAMS...
Page 1819: ...NOTES 438...
Page 1829: ...NOTES 8...
Page 1830: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...
Page 1868: ...C O N N E C T O R P I N O U T S 47 CONNECTOR PINOUTS...
Page 1871: ...NOTES 50...
Page 1873: ...NOTES 52...