Dodge ZB 2005 Service Manual Download Page 981

Page: 981 / 1873

(1) With the help of an assistant, carefully place

the instrument panel in place inside of vehicle.

(2) Connect the white electrical connector along

the right side above the location of the right side
grounds.

(3) Position the panel assembly onto the front of

dash panel and install the ten nuts to instrument
panel studs in engine compartment.

(4) Tighten the nuts to 28 N·m (21 ft. lbs.).
(5) Install two bolts and one nut and ground wire

at the wiper cowl.

(6) Place HVAC exterior intake plenum into place

and install four screws.

(7) Install the wiper module. (Refer to 8 - ELEC-

TRICAL/WIPERS/WASHERS/WIPER

MODULE

INSTALLATION)

(8) Connect the two occupant restraint controller

electrical connectors.

(9) Connect

the

occupant

restraint

controller

ground wires.

(10) Connect electrical connectors to radio and

install radio and four retaining screws.

(11) Connect the radio antenna connector to the

windshield.

(12) Place right instrument panel speaker grille

into position over retaining slots and firmly snap into
place.

(13) Place A-pillar trim into position over retaining

slots and firmly snap into place.

(14) Install the right side instrument panel retain-

ing bolts and tighten to 12 N·m (9 ft. lbs.).

(15) Connect the three right side electrical connec-

tors and one ground bolt.

(16) Reach up underneath the instrument panel

and connect the passenger airbag electrical connec-
tor.

(17) Place right cowl kick panel over retaining

slots and firmly snap into place.

(18) Place right sill plate into position over retain-

ing slots and firmly snap into place.

(19) Connect electrical connector at left A-piller.
(20) Place left instrument panel speaker grille into

position over retaining slots and firmly snap into
place.

(21) Place left A-pillar trim into position over

retaining slots and firmly snap into place. Install one
retaining screw.

(22) Install two retaining bolts to instrument

panel at steering column opening and tighten to 12
N·m (9 ft. lbs.).

(23) Install one bolt and one nut to the left brace

to instrument panel and tighten to 28 N·m (21 ft.
lbs.).

(24) Install ground wire nuts at left floor tunnel.
(25) Connect five left side instrument panel electri-

cal connectors.

(26) Connect the pedal servo electrical connector.

Fig. 10 INSTRUMENT PANEL & PAD ASSEMBLY

1 - FRONT OF DASH PANEL

5 - INSTRUMENT PANEL STUD (10)

2 - INSTRUMENT PANEL DEFROSTER DUCT

6 - FLOOR AIR DUCT

3 - INSTRUMENT PANEL & PAD ASSEMBLY

7 - FLOOR PAN TUNNEL

4 - SPEAKER GRILLE

23 - 70

INSTRUMENT PANEL

INSTRUMENT PANEL & PAD ASSEMBLY (Continued)

Summary of Contents for ZB 2005

Page 1: ...RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improveme...

Page 2: ...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 3: ...8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bu...

Page 4: ......

Page 5: ...8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bu...

Page 6: ...R DESCRIPTION 9 VEHICLE CERTIFICATION LABEL DESCRIPTION 10 BODY CODE PLATE DESCRIPTION This vehicle does not require a Body Code Plate due to limited optional equipment and colors E MARK LABEL DESCRIP...

Page 7: ...he Fastener Identification and Fastener Strength Charts BOLT MARKINGS AND TORQUES METRIC Bolt Markings 8 8 8 9 10 9 12 9 Bolt Dia N m Ft Lbs N m Ft Lbs N m Ft Lbs 6 12 105 14 120 16 12 8 25 250 32 23...

Page 8: ...FASTENER STRENGTH ZB INTRODUCTION 3 FASTENER IDENTIFICATION Continued...

Page 9: ...ures INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls The symbols cor...

Page 10: ...t English and SAE units or vise versa CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meter...

Page 11: ...METRIC CONVERSION CHART 6 INTRODUCTION ZB METRIC SYSTEM Continued...

Page 12: ...to the Metric Conversion Chart to convert torque values listed in metric Newton meters N m Also use the chart to convert between millimeters mm and inches in TORQUE REFERENCES DESCRIPTION Individual T...

Page 13: ...TORQUE SPECIFICATIONS 8 INTRODUCTION ZB TORQUE REFERENCES Continued...

Page 14: ...nation of letters and numbers that provide specific information about the vehicle Refer to VIN Code Breakdown table for decoding information VIN CODE BREAKDOWN POSITION INTERPRETATION CODE DESCRIPTION...

Page 15: ...CERTIFICATION LABEL DESCRIPTION A vehicle certification label is attached to the rear shutface of the driver s door Fig 4 This label indi cates date of manufacture month and year Gross Vehicle Weight...

Page 16: ...RD PROCEDURE TOWING 11 VEHICLE STORAGE STANDARD PROCEDURE VEHICLE PREPARATION 11 ENGINE COMPONENT PREPARATION 11 FUEL SYSTEM PREPARATION 12 BRAKE SYSTEM PREPARATION 12 REAR AXLE PREPARATION 12 WHEELS...

Page 17: ...EALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY CONT...

Page 18: ...failures caused by additive package incompatibility with such mixtures ENGINE COOLANT WARNING ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL LOWED OR INHALED IF SWALLOWED DRINK T...

Page 19: ...nsmission 3 8 L 4 qts Differential Including Additive 1 35 L 45 oz Differential Additive 0 1 L 4 oz Brake Fluid 0 3 L 7 5 oz Windshield Washer 1 L 1 qt FLUID CAPACITIES EXPORT DESCRIPTION SPECIFICATIO...

Page 20: ...eck tire pressure and look for unusual wear or damage Inspect the battery and clean and tighten the terminals as required Check the fluid levels of coolant reservoir brake master cylinder power steeri...

Page 21: ...nd rear suspension ball joints X Inspect the brake linings X X Change the rear axle fluid X X Inspect and replace if necessary the air cleaner filter X Replace the spark plugs X Change the transmissio...

Page 22: ...ch fluid X Change the transmission fluid X Flush and replace engine coolant at 60 months if not done at 102 000 miles X Miles 75 000 78 000 81 000 84 000 87 000 90 000 Kilometers 120 000 125 000 130 0...

Page 23: ...maintenance is recommended by DaimlerChrysler Corporation to the owner but is not required to maintain the warranty on the PCV ori fice This maintenance is not required if previously replaced Inspect...

Page 24: ...X Inspect and replace if necessary the engine air cleaner filter X Replace the spark plugs X Change the rear axle fluid X X Inspect and replace the Auto Tension Drive Belt as needed X X X Lubricate th...

Page 25: ...belt condition and tension Fuel fumes or leakage correct if necessary CAUTION If the cause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 Whe...

Page 26: ...nd local rules and regulations before towing a vehicle Do not allow weight of towed vehicle to bear on lower fascia air dams or spoilers VEHICLE STORAGE STANDARD PROCEDURE VEHICLE PREPARATION For shor...

Page 27: ...refer to Owner s Man ual On a vehicle that is to be stored for 90 days or longer the following procedures are recommended to minimize environmental effects on mechanical com ponents and painted or up...

Page 28: ...scribed in the maintenance schedules If used remove desiccant bag from interior of vehicle Clean vehicle as necessary It is possible for the clutch disc to adhere to the engine flywheel The transmissi...

Page 29: ......

Page 30: ...nd fasteners used on this vehicle CAUTION All fastener torque values of the suspen sion system are critical The torque values shown in the text and torque charts should be used when tightening the sus...

Page 31: ...Fig 1 Lubrication Points Overhead View 1 FRONT LOWER BALL JOINTS 2 FRONT UPPER BALL JOINTS 3 REAR LOWER BALL JOINTS 4 REAR UPPER BALL JOINTS 2 2 SUSPENSION ZB SUSPENSION Continued...

Page 32: ...ON 12 LOWER CONTROL ARM REMOVAL 13 DISASSEMBLY LOWER CONTROL ARM ISOLATOR BUSHINGS 14 ASSEMBLY LOWER CONTROL ARM ISOLATOR BUSHINGS 15 INSTALLATION 16 SHOCK ASSEMBLY REMOVAL 16 DISASSEMBLY 16 ASSEMBLY...

Page 33: ...ts Lower and Upper 136 100 Stabilizer Bar Bushing Retainer Bolts 68 50 Stabilizer Link Control Arm Nut 23 17 200 Stabilizer Link Stabilizer Bar Nut 23 17 200 Tie Rod Knuckle Nut 75 55 Tie Rod Adjuster...

Page 34: ...ing is determined to be defective The wheel mounting studs may be replaced separately if necessary DIAGNOSIS AND TESTING HUB AND BEARING FRONT With the wheel disc brake caliper and brake rotor removed...

Page 35: ...HANICAL ROTOR REMOVAL 4 Remove bolt fastening ABS wheel speed sensor head to steering knuckle Fig 2 Remove sensor head from knuckle 5 Remove bolt retaining ABS tone wheel to hub and bearing Fig 3 6 Re...

Page 36: ...fer to 2 SUSPENSION WARNING 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Remove brake caliper from...

Page 37: ...nuckle from upper and lower control arms 14 If hub and bearing needs to be removed from knuckle perform the following a Remove bolt retaining ABS tone wheel to hub and bearing Fig 11 b Remove ABS tone...

Page 38: ...t castle and hole in ball joint stud DO NOT LOOSEN NUT 8 Install cotter pin through lower ball joint castle nut and stud 9 Install ABS wheel speed sensor in steering knuckle Fig 10 Install and tighten...

Page 39: ...nuckle Fig 13 The gasket is required to prevent galvanic corrosion between the hub and bearing and the steering knuckle The corrosion prevention gasket must be used when installing a hub and bearing i...

Page 40: ...LOWER BALL JOINT FRONT Replacement is necessary if more than 0 51 mm 0 02 in axial end play of the ball joint stud exists Refer to the following procedure to inspect the lower ball joint for wear CAUT...

Page 41: ...4150A must be cen tered in end of lower ball joint stud 11 Release lower ball joint from knuckle using Puller Remove tools 12 Move knuckle away from lower ball joint 13 Using a suitable cleaner clean...

Page 42: ...gs and Cautions Refer to 2 SUSPENSION WARNING 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Remove b...

Page 43: ...all joint grease seal 10 Install Puller Special Tool C 4150A over Spacer and knuckle as shown Fig 21 Ball bearing in bolt of Special Tool C 4150A must be cen tered in end of lower ball joint stud 11 R...

Page 44: ...r causing some resistance during tool removal NOTE For bushing installation Refer to 2 SUS PENSION FRONT LOWER CONTROL ARM ASSEM BLY ASSEMBLY LOWER CONTROL ARM ISOLATOR BUSHINGS NOTE The following pro...

Page 45: ...ON 8 Install wheel and tire assembly Refer to 22 TIRES WHEELS INSTALLATION Progressively tighten wheel mounting nuts in proper sequence to 122 N m 90 ft lbs torque 9 Lower vehicle 10 Position vehicle...

Page 46: ...Fig 27 4 Remove the shock absorber out through the bottom of the coil spring Depending on upper hook positioning it may be necessary to release the tension from the coil spring by backing off the com...

Page 47: ...he upper seat is not posi tioned at the upper end of the coil spring Fig 29 6 Slowly release the tension from the coil spring by backing off the compressor drive completely As the tension is relieved...

Page 48: ...Height Stands it is critically important to perform the following Make sure locating pins are inserted in correct wheel diameter holes in Heights Stands or mea surement will be incorrect Front wheels...

Page 49: ...IGHT MEASUREMENT NOTE If loosening the lower control arm mounting bolts is necessary be sure the alignment adjust ment cams do not turn The cams must stay in their original position so the alignment o...

Page 50: ...ing retainer bolts to 68 N m 50 ft lbs torque 7 Install wheel and tire assemblies Refer to 22 TIRES WHEELS INSTALLATION Progressively tighten wheel mounting nuts in proper sequence to 122 N m 90 ft lb...

Page 51: ...stall attaching nut Fig 37 Tighten attaching nut to 23 N m 17 ft lbs torque 2 Install end of stabilizer bar onto stabilizer bar link and install attaching nut Fig 37 Tighten attaching nut to 23 N m 17...

Page 52: ...stud from being damaged when separating it from the lower control arm 5 Remove cotter pin and nut from upper ball joint stud Fig 43 CAUTION Do not strike or apply heat to steering knuckle in an effort...

Page 53: ...to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Remove brake caliper from knuckle and hang out of the way then remove brake...

Page 54: ...ol arm DISASSEMBLY UPPER CONTROL ARM ISOLATOR BUSHINGS NOTE The following procedure can be used for either upper control arm isolator bushing CAUTION Use a vise equipped with soft jaw caps to protect...

Page 55: ...ew Special Tool 6969 3 stationary while rotating Nut Special Tool 6969 4 clockwise This action will draw isolator bushing into control arm 4 Continue to rotate Nut until bushing metal flange squarely...

Page 56: ...HEELS INSTALLATION Progressively tighten wheel mounting nuts in proper sequence to 122 N m 90 ft lbs torque 7 Lower vehicle 8 Position vehicle on alignment rack drive on hoist 9 Set vehicle to design...

Page 57: ...ISOLATOR BUSHINGS 39 INSPECTION LOWER CONTROL ARM 39 ASSEMBLY ISOLATOR BUSHINGS 40 INSTALLATION 40 SHOCK ASSEMBLY REMOVAL 41 DISASSEMBLY 42 ASSEMBLY 43 INSTALLATION 45 STABILIZER BAR REMOVAL 47 INSTAL...

Page 58: ...Assembly Lower Mounting Bolt 136 100 Shock Assembly Upper Mounting Bolt 136 100 Stabilizer Bar Bushing Retainer Bolts 91 67 Stabilizer Link Nuts 23 17 200 Toe Link Adjuster Jam Nut 75 55 Toe Link Inb...

Page 59: ...e The bearing requires no periodic maintenance The hub and bearing is serviced as an assembly if the hub or bearing is determined to be defective The wheel mounting studs may be replaced separately if...

Page 60: ...brake caliper from knuckle and hang out of way then remove brake rotor Refer to 5 BRAKES HY DRAULIC MECHANICAL ROTOR REMOVAL 4 Remove bolt fastening ABS wheel speed sensor head to steering knuckle Fig...

Page 61: ...nd of lower ball joint stud 13 Release lower ball joint from lower control arm using Puller Remove tools Lift ball joint stud from lower control arm 14 Install Puller Special Tool CT 1003 on hub and b...

Page 62: ...5 BRAKES HYDRAULIC MECHANICAL ROTOR INSTALLATION 13 Lower vehicle just enough to gain access to interior Do not lower completely at this time 14 Apply brakes several times to seat brake shoes and actu...

Page 63: ...lange Fig 7 15 Tighten Puller screw against halfshaft yoke pressing yoke out of hub and bearing assembly Remove tool 16 Remove bolts fastening upper control arm to frame Fig 9 17 Pull outward on knuck...

Page 64: ...eed sensor head on knuckle Fig 2 Install bolt fastening speed sensor head to knuckle and tighten to 11 N m 100 in lbs torque 16 Lower vehicle just enough to gain access to interior Do not lower comple...

Page 65: ...removing the link from the lower control arm This will prevent the end of the stud from being damaged when remov ing it from the lower control arm 4 Remove stabilizer bar link from lower control arm...

Page 66: ...ENANCE HOISTING STANDARD PROCE DURE 2 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 3 Remove nut and bolt mounting shock assembly clevis bracket to isolator bushing on lower control...

Page 67: ...C 4150A must be centered in end of lower ball joint stud Fig 14 Upper And Lower Control Arms 1 UPPER CONTROL ARM 2 LOWER CONTROL ARM 3 STABILIZER LINK Fig 15 Stabilizer Link Removal 1 STABILIZER BAR 2...

Page 68: ...l Tool 6969 4 clockwise This action will force isolator bushing out of control arm into Receiver Special Tool 6969 2 4 Remove tools and bushing from arm A small portion of bushing rubber may come loos...

Page 69: ...e 3 Guide lower ball joint into lower control arm and stabilizer link into mounting hole Fig 16 Fig 14 4 Install ball joint castle nut Tighten lower ball joint castle nut to 160 N m 118 ft lbs torque...

Page 70: ...STANDARD PROCE DURE 8 Remove wheel and tire assembly Refer to 22 TIRES WHEELS REMOVAL 9 Remove rear wheelhouse splash shield Refer to 23 BODY EXTERIOR REAR WHEELHOUSE SPLASH SHIELD REMOVAL 10 Remove n...

Page 71: ...s instructions First set the lower hooks on the coil spring Fig 26 then set the upper hooks Fig 27 3 Compress the coil spring until enough room is given to remove the coil spring upper seat 4 Remove t...

Page 72: ...ull back knob on Wrench and remove from shock absorber NOTE For reassembly of the shock assembly Refer to 2 SUSPENSION REAR SHOCK ASSEM BLY ASSEMBLY CAUTION When installing the shock absorber into the...

Page 73: ...ng once compressed 4 Insert the shock absorber up through the bot tom of the coil spring until the lower spring seat con tacts the lower end of the coil spring Rotate the shock until the coil spring e...

Page 74: ...convertible top cover down and install tack strips over mounting studs using care not to pinch carpet under tack strips Fig 21 8 Install tack strip mounting nuts Fig 21 Tighten tack strip nuts to 12 N...

Page 75: ...total to lower vehicle to specified design height Fig 35 23 Jounce vehicle several times each time pay ing special attention to release vehicle at very bot tom of jounce cycle This is very important i...

Page 76: ...BRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove both rear wheel and tire assemblies Refer to 22 TIRES WHEELS REMOVAL 3 Remove nuts attaching stabilizer bar links to each end of stabilizer...

Page 77: ...ng it against retainer ring on bar 2 Slide bushing retainers over bushings 3 Position bushing retainers against frame rails then install four retainer bolts Fig 37 Tighten four stabilizer bar bushing...

Page 78: ...ALIGNMENT STANDARD PROCEDURE REMOVAL NOTE Review all Warnings and Cautions Refer to 2 SUSPENSION WARNING 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove wheel a...

Page 79: ...ounting bolt and nut Make sure shim is correctly orientated or dynamic toe will be incorrect Fig 43 4 Push downward on toe link at outer mounting bracket and while holding toe link in this position ti...

Page 80: ...eable component of the upper control arm If the ball joint is found to be defective replacement of the entire upper control arm is necessary OPERATION The ball joint is a pivotal joint on the control...

Page 81: ...nge Fig 47 Apply hand pressure to the rear of Installer until seal boot flange is pressed squarely against control arm Remove tool 5 Install upper control arm on vehicle Refer to 2 SUSPENSION REAR UPP...

Page 82: ...val NOTE For bushing installation Refer to 2 SUS PENSION FRONT UPPER CONTROL ARM ASSEM BLY INSPECTION UPPER CONTROL ARM Inspect the upper control arm for the following Inspect the control arm for any...

Page 83: ...stationary while rotating Nut Special Tool 6969 4 clockwise This action will draw isolator bushing into control arm 4 Continue to rotate Nut until bushing metal flange squarely contacts control arm D...

Page 84: ...on Proper wheel alignment is essential for efficient steering good directional stabil ity and proper tire wear The method of checking a vehicle s front and rear wheel alignment varies depending on the...

Page 85: ...0 the cross camber would be 0 3 CASTER Caster is the forward or rearward tilt of the steer ing knuckle in reference to the position of the upper and lower ball joints Caster is measured in degrees of...

Page 86: ...g system is designed to make each wheel follow its particular radius circle To accomplish this the front wheels must progressively toe outward as the steering is turned from center This eliminates tir...

Page 87: ...tire wear a lead or pull and a crooked steering wheel Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has 1 2 of the total toe measurement CURB HEIGH...

Page 88: ...1 Replace Wheel Bearing 2 Loose Or Worn Steering Column Shaft Coupling 2 Replace Steering Column Shaft Cou pling 3 Loose Steering Gear Mounting Bolts 3 Tighten Steering Gear Mounting Bolts To Specifie...

Page 89: ...Pump 4 Test Power Steering Pump And Replace If Required 5 Upper Or Lower Ball Joints Require Lubrication 5 Properly Lubricate Ball Joints Or Replace If Required 6 Tie Rod Ends Require Lubrica tion 6 P...

Page 90: ...t mea surement it is necessary to remove the belly pan 5 Remove belly pan from frame Refer to 23 BODY EXTERIOR BELLY PAN REMOVAL 6 Place Adapter Special Tool 8897 over smaller end of one of two Suspen...

Page 91: ...quipment 3 Place vehicle on wheel alignment rack or drive on lift per equipment manufacturer s recom mendations 4 Check all tires for proper inflation pressure and adjust as necessary NOTE In order to...

Page 92: ...e Fig 9 Fig 10 Ensure that gages are correctly attached to inner rim flange at very base of each wheel Fig 9 Height Gage Installed Front Suspension 1 HEIGHT GAGE 6914 WITH EXTENSION 8997 2 WHEEL ALIGN...

Page 93: ...spension Height Gage and each frame rail at forward edge of gage Fig 13 This is the nearest point to the PLP hole 13 Compare recorded measurements to specifica tions Refer to 2 SUSPENSION WHEEL ALIGN...

Page 94: ...ent is to be performed proceed at this point Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE WHEEL ALIGNMENT 18 Install belly pan Refer to 23 BODY EXTE RIOR BELLY PAN INSTALLATION 19 Remove b...

Page 95: ...vement CAMBER ANGLE Camber angle adjustment involves the reposition ing of the lower control arm pivot bolts using the adjustment cams Fig 14 There are 2 cams located on each lower control arm pivot b...

Page 96: ...Fig 16 2 Plug power cable supplied with the DRBIII kit into DRBIII power connector marked VEHI CLE Fig 16 3 Attach two Inclinometers Special Tool 6989 to Switch Box Fig 15 Only two inclinometers are s...

Page 97: ...d of knuckles near ball joints CAUTION Be sure caster pads on knuckles are thoroughly cleaned before mounting Caster Adapt ers to knuckles Caster Adapters must sit flat on caster pads to obtain accura...

Page 98: ...ometer Installed On Right Front Knuckle Left Side Typical 1 UPPER SPRING LOADED HOOK 2 BRAKE CALIPER 3 LOWER SPRING LOADED HOOK 4 INCLINOMETER 6989 5 ADAPTER 8995 ZB WHEEL ALIGNMENT 2 69 WHEEL ALIGNME...

Page 99: ...placing Adapter flats against caster pads cast into trailing side of knuckle Fig 20 3 Mount inclinometers to rear Caster Angle Adapters Fig 20 Fig 21 Make sure inclinometer from left side of Switch Bo...

Page 100: ...where previously removed 2 Remove steering wheel clamp 3 Remove all alignment equipment from vehicle 4 Remove Caster Angle Adapters Inclinometers from front or rear knuckles 5 Install belly pan Refer...

Page 101: ...MOVAL 5 Install wheels 6 Install Suspension Height Gages Special Tools 6914 and 8897 and lower vehicle to design height Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE DESIGN HEIGHT MEASUREME...

Page 102: ...und positions It is typ ical for a shim to have about 1 mm 0 040 in up and down play FRONT TOE PATTERN On the front of the vehicle the tie rods are located in front of the spindles If the steering gea...

Page 103: ...Fig 24 Dynamic Toe Pattern Graph 2 74 WHEEL ALIGNMENT ZB WHEEL ALIGNMENT Continued...

Page 104: ...Tools 6914 and 8997 with the vehicle full of fuel and properly weighted Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE HEIGHT ADJUSTMENTS FRONT SUSPENSION REAR SUSPENSION CURB HEIGHT 50 mm...

Page 105: ...SPECIAL TOOLS WHEEL ALIGNMENT Height Gages Suspension 6914 Adapters Front Caster 8995 Adapters Rear Caster 8996 Extension Height Gage 8997 2 76 WHEEL ALIGNMENT ZB WHEEL ALIGNMENT Continued...

Page 106: ...ion and vibration CAUTION Never allow the propeller shaft to drop or hang from universal joint during removal Suspend the shaft to the vehicles underside with wire to pre vent damage to the universal...

Page 107: ...e indexing the propeller shaft 180 may eliminate some vibrations Clean all the foreign material from the propeller shaft and the universal joints mud undercoating etc Inspect the propeller shaft for m...

Page 108: ...in 0 25 mm NOTE Measure front rear runout approximately 3 inches 76 mm from the weld seam at each end of the shaft tube for tube lengths over 30 inches Under 30 inches the max runout is 0 20 inch for...

Page 109: ...cal alignment of shaft yokes should be kept within 1 5 degrees of each other REMOVAL 1 Raise and support the vehicle 2 Remove exhaust heat shield bolts from the belly pan 3 Remove belly pan bolts and...

Page 110: ...Install belly pan and tighten bolts to 54 N m 40 ft lbs 4 Install exhaust heat shield to the belly pan 5 Remove support and lower vehicle Fig 7 BELLY PAN 1 FRAME ASSEMBLY 2 BOLTS 20 3 BELLY PAN 4 REAR...

Page 111: ...gh torque impact loading this vehicle is capa ble of producing The typical aftermarket u joint is not designed to meet the extreme impact loads associated with this vehicle 1 Apply extreme pressure EP...

Page 112: ...straps slightly deform when torqued in place Reuse of the straps may result in reduced clamp load on the universal joint cap Fig 11 BEARING CAP INSTALLATION 1 DRIVER SOCKET WRENCH 2 YOKE 3 VISE 4 BEAR...

Page 113: ...joint which has allowed the grease to be lost will damage the C V joint SHUDDER VIBRATION DURING ACCELERATION This problem could be a result of a worn damaged inner tripod joint or a sticking tripod...

Page 114: ...half shaft hub nut and tighten to 258 N m 190 ft lbs 8 Install axle shaft yoke spring washer nut lock and cotter pin 9 Install belly pan and tighten bolts to 54 N m 40 ft lbs 10 Install wheel Fig 2 T...

Page 115: ...SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Half Shaft Nut 258 190 SPECIAL TOOLS PULLER 9052 3 10 HALF SHAFT ZB HALF SHAFT Continued...

Page 116: ...ch other and therefore creates pressure in the pump The tun ing of the orifices and valves inside the gerotor pump system includes a torque limiting pressure relief valve to protect the clutch pack wh...

Page 117: ...k is generally caused by a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by...

Page 118: ...clutch Differential Gears Scored 1 Insufficient lubrication 1 Replace scored gears Fill differ ential with the correct fluid type and quantity 2 Improper grade of lubricant 2 Replace scored gears Fil...

Page 119: ...ation 9 Housing not machined properly 9 Replace housing HYDRA LOKT 1 Park the vehicle on a level surface or raise vehicle on hoist so that the vehicle is level 2 Remove the axle fill plug 3 Verify tha...

Page 120: ...lts and flag nuts and tighten bolts to 108 N m 80 ft lbs 3 Install frame mounting bolts and tighten bolts to 135 N m 100 ft lbs 4 Install half shafts 5 Install lower ball joint into knuckle and tighte...

Page 121: ...Fill Plug 20 15 Differential Cover Bolts 47 35 Frame Mounting Bolts 135 100 Pinion Mounting Bolts 108 80 SPECIAL TOOLS INSTALLER 6573 SPANNER WRENCH 6958 SEAL REMOVER 7794 A PULLER C 452 INSTALLER C...

Page 122: ...plate CAUTION If housing cover is not installed within 3 to 5 minutes the cover must be cleaned and new RTV applied or adhesion quality will be compro mised 4 Install the cover and tighten the bolts...

Page 123: ...lapsible spacer or bear ings may result 4 Install a new nut on the pinion gear and tighten nut only enough to remove the shaft end play 5 Measure pinion rotating torque with an inch pound torque wrenc...

Page 124: ...ce marks and install propeller shaft CAUTION The propeller shaft strap bolts incorpo rate a Loctite patch The screws must be replaced or cleaned and Loctite thread locker applied when ever they are re...

Page 125: ......

Page 126: ...FRONT REAR STANDARD PROCEDURE BRAKE SHOE BURNISHING 12 REMOVAL 12 CLEANING 14 INSPECTION 14 INSTALLATION 15 DISC BRAKE CALIPER FRONT REMOVAL 16 DISASSEMBLY 17 ASSEMBLY 20 INSTALLATION 21 DISC BRAKE CA...

Page 127: ...er to 5 BRAKES ABS DESCRIPTION WARNINGS AND CAUTIONS WARNING DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON TAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS BREAT...

Page 128: ...eaks Repair or replace as required 6 ABS malfunction 6 Refer to Appropriate Diagnostic Informa tion BRAKE NOISE CONDITION POSSIBLE CAUSES CORRECTION DISC BRAKE CHIRP 1 Excessive brake rotor runout 1 F...

Page 129: ...ist 2 Refer to Power Brake Booster diag nosis and testing EXCESSIVE PEDAL EFFORT 1 Obstruction of brake pedal 1 Inspect remove or move obstruc tion 2 Low power brake booster assist 2 Refer to power br...

Page 130: ...or replace shoes Repair source of contamination 3 Pinched brake line 3 Replace pinched line 4 Leaking piston seal 4 Replace piston seal or brake cali per 5 Suspension problem 5 Refer to Suspension se...

Page 131: ...t caliper assembly at least ONE FULL TURN or more 3 Bleed 4 to 8 ounces of brake fluid through inboard half of front caliper assembly being bled When an air free flow is maintained in clear plastic ho...

Page 132: ...w and weak fluid discharge and will NOT get all the air out of the hydraulic system 3 Open bleeder screw Fig 2 on inboard half of the front caliper assembly at least ONE FULL TURN or more NOTE When th...

Page 133: ...njo Bolt 31 23 Brake Tube Nuts 17 12 145 Caliper Bleeder Screw 10 88 Caliper Hydraulic Mount ing Bolts 115 85 Master Cylinder Mounting Nuts 28 21 250 Parking Brake Cable Rout ing Clamp Bolts 10 90 Par...

Page 134: ...lipped into the reservoir It can be removed from the reservoir and replaced if necessary OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the b...

Page 135: ...he bottom of the caliper assembly Fig 6 Each caliper half has an individual bleeder screw at the top of the caliper half and each side must be individ ually bled The caliper bolts directly to the stee...

Page 136: ...diately Eventual deterioration of the hose can take place with possible burst failure Faulty installation can cause twisting resulting in wheel tire or chassis interference The steel brake tubing shou...

Page 137: ...rt pin out of caliper Fig 7 4 Remove brake shoe spring clip out from under the upper support pin still in caliper Fig 8 5 Using pin punch and hammer remove upper brake shoe support pin in same fashion...

Page 138: ...brake shoe supports for excess wear or damage If caliper fails inspection it should be removed disassembled cleaned inspected and have new piston seals and dust boots installed on all pistons within...

Page 139: ...AULIC MECHANICAL BRAKE PADS SHOES REMOVAL The brake shoe friction material thickness is to be measured at the thinnest point of the friction mate rial The minimum front brake shoe assembly friction ma...

Page 140: ...s in both brake shoes in the same fashion the upper pin was installed Fig 15 Ensure spring clip is beneath lower support pin and small end of the support pin is in hole in outboard caliper half 6 From...

Page 141: ...ss brake pedal down past first inch of travel and secure in place This will isolate master cylinder reservoir from brake hydraulic system and will not allow brake hydraulic fluid to drain out of reser...

Page 142: ...SHOES REMOVAL 3 Remove transfer brake tube between inboard and outboard caliper halves Fig 20 4 Install M10 X 1 0 threaded plug in flex hose banjo bolt hole Fig 21 This hole needs to be plugged to re...

Page 143: ...in place 10 Transfer C clamp and Installer to cover piston boot and bore where piston was just removed Fig 23 It may be necessary to place a small piece of rubber over hole in center of Installer to...

Page 144: ...OR INTO CENTER AREA OF CALIPER WHEN USING COMPRESSED AIR TO REMOVE PIS TONS FROM BORE OF CALIPER PERSONAL INJURY CAN RESULT FROM SUCH ACTION WARNING UNDER NO CONDITIONS SHOULD HIGH PRESSURE AIR BE US...

Page 145: ...be cleaned using appro priate solvents caliper must be replaced 35 Clean piston bores of caliper using Mopart Non Clorinated Brake Parts Cleaner alcohol or another suitable solvent saturated into a li...

Page 146: ...iper hose port Only hand tighten the flex hose to caliper assembly banjo bolt do not torque Tighten banjo bolt to 31 N m 23 ft lbs torque 4 Install wheel and tire assembly Refer to 22 TIRES WHEELS INS...

Page 147: ...T be used 3 Install brake flex hose on brake caliper as fol lows a Place NEW copper seal washers on each side of banjo fitting located on end of flex hose b Install banjo bolt through washers and banj...

Page 148: ...g 32 Although there is a range the preferred level is at the FULL mark If necessary adjust the brake fluid to the Full mark on the side of the master cylinder fluid reservoir using Mopart Brake Clutch...

Page 149: ...e Bleeder Tube Special Tool 8358 1 into each Adapter Tighten each tube to 17 N m 145 in lbs torque Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible Fig 33 N...

Page 150: ...34 8 Connect battery negative terminal 9 Fill reservoir to proper level with brake fluid 10 Road test vehicle to ensure proper operation of brakes PEDALS ADJUSTABLE DESCRIPTION The brake pedal on thi...

Page 151: ...booster input rod off brake pedal pin Fig 37 7 Hold accelerator pedal up and remove cable retainer and throttle cable from pedal Fig 38 8 Remove nuts that mount accelerator pedal Fig 39 Fig 35 Pump M...

Page 152: ...mounted position and install two nuts that attach pedals assembly to upper dash Fig 40 Do not fully tighten at this time 4 Slide power brake booster mounting studs back through dash and pedals assembl...

Page 153: ...rake booster Fig 42 The power brake booster mounts on the engine side of the dash panel Fig 43 It is externally con nected to the brake system by an input push rod to the brake pedal A vacuum hose con...

Page 154: ...alve that is not the vacuum supply hose com ing from the intake manifold Cap off the open port on the check valve 3 Start the engine 4 Allow the engine to warm up to normal operat ing temperature and...

Page 155: ...move booster from vehicle CAUTION Do not attempt to disassemble power brake unit as this booster is serviced ONLY as a complete assembly INSTALLATION NOTE When installing power brake booster be sure g...

Page 156: ...hicle has not been driven for a period of time the rotor s braking surface will rust in the areas not covered by the brake shoes at that time Once the vehicle is driven noise and chatter from the disc...

Page 157: ...nd in the specification table in this section Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTOR SPECIFICATIONS If runout is in excess of the specification check the lateral runout of the hub face Before re...

Page 158: ...ROTOR STANDARD PROCEDURE STANDARD PROCEDURE BRAKE ROTOR MACHINING NOTE Refacing the rotor is not required each time the brake pads are replaced only when the need is foreseen Any servicing of the rot...

Page 159: ...led in the same location utiliz ing those marks 5 Remove brake rotor from hub and bearing assembly Fig 55 REMOVAL BRAKE ROTOR REAR NOTE Review all Warnings and Cautions Refer to 5 BRAKES WARNING 1 Rai...

Page 160: ...remember to align marked rotor hole with marked wheel mounting stud 2 Install hydraulic brake caliper on knuckle Fig 57 Install brake caliper mounting bolts and tighten to 115 N m 85 ft lbs torque 3...

Page 161: ...0 010 mm 0 0004 in 0 030 mm 0 001 in 15 80 RMS TIR Total Indicator Reading Measured On Vehicle PARKING BRAKE DESCRIPTION The parking brake lever mounts to the floor pan tunnel beneath the center conso...

Page 162: ...brake cables are both prop erly installed in equalizer WARNING THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCKSPRING LOADED TO APPROXIMATELY 19 POUNDS DO NOT RELEASE THE A...

Page 163: ...nch onto retainer until retainer fin gers are collapsed c Push on end of parking brake cable housing pushing it through wrench and out of vehicle body 8 Raise vehicle Refer to LUBRICATION MAINTENANCE...

Page 164: ...orque 4 Insert parking brake caliper end of cable through caliper bracket and slide cable housing into caliper bracket Fig 61 5 Install cable end into apply lever on caliper Fig 61 6 Grasp parking bra...

Page 165: ...brake lever 17 Install center console Refer to 23 BODY IN TERIOR CENTER CONSOLE INSTALLATION 18 Remove blocks from tire and wheel assem blies CALIPER PARKING BRAKE REMOVAL NOTE Review all Warnings an...

Page 166: ...aining boot on opposite end of bore in caliper e Slide steel sleeve bushing back to center in bore then install inner lip of remaining boot into groove on that end of sleeve bushing 3 To install upper...

Page 167: ...KE CABLES AND EQUALIZER ARE CON NECTED TO THE LEVER OUTPUT CABLE KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS I...

Page 168: ...RVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY 5 Grasp parking brake lever output cable by hand and pull upward Continue pulling on cable until a screwdriver pin punch or appropri...

Page 169: ...ON MAINTE NANCE HOISTING STANDARD PROCEDURE 8 Check rear wheels of vehicle They should rotate freely without dragging with lever in released position 9 Fully apply parking brake lever 10 Check rear wh...

Page 170: ...ghten lower mounting bolt to 52 N m 38 ft lbs torque 8 Install wheel and tire assembly Refer to 22 TIRES WHEELS INSTALLATION Progressively tighten wheel mounting nuts in proper sequence to 122 N m 90...

Page 171: ...rtioning EVBP to bal ance front to rear braking when the brakes are applied in the partial braking range For more infor mation on EVBP Refer to 5 BRAKES ABS DESCRIPTION Included in the ABS system is a...

Page 172: ...road surface with patches of ice loose gravel or sand on it Also stop ping a vehicle on a bumpy road surface activates ABS because of the wheel hop caused by the bumps TIRE NOISE AND MARKS Although t...

Page 173: ...module is designed to withstand normal current draws associated with vehicle operation Care must be taken to avoid overloading the CAB circuits CAUTION In testing for open or short circuits do not gr...

Page 174: ...Y INDICATE REDUCED BRAKING ABILITY Before road testing a brake complaint vehicle note whether the red BRAKE warning indicator lamp amber ABS warning indicator lamp or both are turned on If it is the r...

Page 175: ...RQUE DESCRIPTION N m Ft Lbs In Lbs Brake Tube Nuts 17 12 145 CAB Mounting Bolts 2 17 ICU Mounting Bolts 10 85 Tone Wheel Front Mount ing Bolt 17 13 150 Wheel Speed Sensor Head Mounting Bolt 11 100 TON...

Page 176: ...N 6 Install tire and wheel assembly Refer to 22 TIRES WHEELS INSTALLATION Progressively tighten the wheel mounting nuts in the proper sequence to 122 N m 90 ft lbs torque 7 Lower vehicle 8 Road test v...

Page 177: ...rame rail 4 Remove fastener clip securing sensor connector to frame rail 5 Open routing clips along parking brake cable and remove sensor harness 6 Remove bolt fastening sensor head to knuckle Fig 3 C...

Page 178: ...cc accumulator The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle This stored fluid is used by the pump motor to provide build pressure for...

Page 179: ...e The driver is applying the brake pedal which builds pres sure in the brake hydraulic system to engage the brakes and stop the vehicle Fig 4 Normal Braking Hydraulic Circuit 1 OUTLET VALVE 6 TO RIGHT...

Page 180: ...brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion of the...

Page 181: ...RAKES ABS HYDRAULIC MECHANICAL HCU HYDRAULIC CONTROL UNIT OPERA TION REMOVAL NOTE Before proceeding review Warnings and Cautions Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION 1 Using a brake ped...

Page 182: ...RAKE PEDAL HOLDING TOOL 4 STEERING WHEEL 5 DRIVER S SEAT 6 BRAKE PEDAL Fig 9 Brake Tubes At ICU 1 PRIMARY BRAKE TUBE FROM MASTER CYLINDER 2 CHASSIS BRAKE TUBE TO LEFT FRONT BRAKE 3 SECONDARY BRAKE TUB...

Page 183: ...or 5 Install 24 way connector into socket of CAB as follows a Position 24 way connector in socket of CAB and carefully push it down as far as possible b Once connector is fully seated into CAB socket...

Page 184: ...clutch mechanism consists of a flywheel a sin gle dry type disc and a diaphragm style clutch cover Fig 1 A hydraulic linkage is used to operate the clutch release bearing slave cyclinder The flywheel...

Page 185: ...l is depressed the release bearing slave cyclinder is oper ated by the clutch master cylinder Fig 4 The bear ing slave cyclinder then depresses the pressure plate spring fingers thereby releasing pres...

Page 186: ...ing an oil residue on the housing interior and clutch cover and flywheel Heat buildup caused by slippage between the pressuer plate disc and flywheel can bake the oil residue onto the components A gla...

Page 187: ...aft splines 2 Remove grease and apply the correct amount of grease 3 Road splash water entering housing 3 Replace clutch disc Clean pressure plate and reuse if in good condition 4 Slave cylinder leaki...

Page 188: ...heel if necessary Pilot bearing seized loose or rollers are worn 1 Bearing cocked during installation 1 Install and lubricate a new bearing 2 Bearing defective 2 Install and lubricate a new bearing 3...

Page 189: ...d 3 Replace clutch disc 4 Clutch misalignment 4 Check alignment and runout of flywheel disc pressure plate and r clutch housing Correct as necessary STANDARD PROCEDURE CLUTCH SYSTEM BLEED To determine...

Page 190: ...ake fluid Other than D O T 4 will cause system malfunction 3 Open the male quick connect coupling by depressing the poppet in the coupling while depress the clutch pedal to the floor 4 Close the quick...

Page 191: ...e sandpaper then wipe the surface with mineral spirits If the surface is severely scored heat checked or warped replace the flywheel CAUTION Never machine the flywheel face If fly wheel surface is bad...

Page 192: ...le 3 Connect hydraulic line fto slave cylinder 4 Bleed the system FLYWHEEL DIAGNOSIS AND TESTING Common causes of flywheel problems Incorrect bolt tightening Mounting the flywheel on a dirty crankshaf...

Page 193: ...pedal position switch connector 4 Remove mounting screws on clutch fluid reser voir 5 Disconnect hydraulic line quick connector located at clutch bell housing Use special tool 6638 to separate quick...

Page 194: ...con tinuity just before the pedal reaches the end of its travel 4 If the clutch switch shows continuity with clutch pedal up or no continuity with clutch pedal down the switch is defective The switch...

Page 195: ...slightly This will compress the plunger Then push the bot tom of the switch against the rod Failure to install the switch as described or forcing the switch onto the rod will crack the switch 2 Instal...

Page 196: ...F CHILDREN AND PETS DISPOSE OF GLYCOL BASED COOLANT PROP ERLY CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA DO NOT OPEN A COOLING SYS TEM WHEN THE ENGINE IS A...

Page 197: ...SPECIAL TOOLS COOLING Hose Clamp Pliers 8495 Pressure Tester Kit 7700 Coolant Refractometer 8286 7 2 COOLING ZB COOLING Continued...

Page 198: ...subjected to sub stance belt dressing oil ethylene glycol that has reduced friction 5 Replace belt and clean pulleys BELT NOISE OBJECTIONABLE SQUEAL SQUEAK OR RUMBLE 1 Belt slippage 1 Replace belt or...

Page 199: ...and proper belt ten sion Belt replacement under any or all of the following conditions is required Excessive wear Frayed cords Severe glazing The Poly V belt with a back driven pulley may develop min...

Page 200: ...ting nut Fig 2 Torque mounting nut to 41 N m 30 ft lbs 2 Position the drive belt over all pulleys except for the water pump pulley Fig 1 3 Rotate tensioner counterclockwise and slip the belt over the...

Page 201: ...ains engine temperature in a range that will provide satisfactory engine per formance and emission levels under all expected driv ing conditions It also provides a source of hot water coolant for heat...

Page 202: ...lant leaks in radiator cool ing system hoses water pump or engine 1 Pressure test cooling system and repair as necessary DETONATION OR PRE IGNITION NOT CAUSED BY IGNITION SYS TEM GAUGE MAY NOT BE READ...

Page 203: ...agnostic Information Repair as necessary 4 Has undercoating been applied to any unnecessary component 4 Clean undercoating as neces sary 5 Engine may be running rich causing the catalytic converter to...

Page 204: ...OR IS ERRATIC 1 Normal reaction to fan and or thermostat cycle Fig 1 Exam ples B and C During cold weather operation with the heater blower in the high position the gauge read ing may drop slightly F...

Page 205: ...ssure bottle and apply 104 kPa 15 psi pressure If the pressure drops more than 13 8 kPa 2 psi in 2 minutes inspect all points for external leaks All radiator and heater hoses should be shaken while at...

Page 206: ...ops resulting in cooling system aeration Aeration may create the following conditions High reading shown on the temperature gauge Inadequate coolant flow through the heater Engine combustion leaks int...

Page 207: ...zing the upper radiator hose to deter mine if the cooling system is still pressurized 2 Place a shop towel over the pressure cap and turn to the first stop Wait to see if any pressure is released When...

Page 208: ...ell water or suspect water supply in cooling system Use only a 50 50 mixture of the specified ethylene glycol type antifreeze cool ant and distilled water Refer to LUBRICATION MAINTENANCE FLUID TYPES...

Page 209: ...ved install front belly pan Refer to 23 BODY EXTERIOR BELLY PAN INSTALLATION NOTE The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving A...

Page 210: ...tors called HOAT Hybrid Organic Additive Technology is recom mended This coolant offers the best engine cooling without corrosion when mixed with 50 Ethylene Gly col and 50 distilled water to obtain a...

Page 211: ...s off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700 Working the plunger bring the pressure to 104 kPa 15 psi on...

Page 212: ...sure bottle to mounting location Make sure overflow hose is routed properly through hole in fender inner panel and splash shield Fig 12 2 Install coolant pressure bottle fasteners Torque fasteners to...

Page 213: ...rmostat s primary purpose is to maintain engine temperature in a range that will provide sat isfactory engine performance and emission levels under all expected driving conditions The thermostat is un...

Page 214: ...ng a plastic scraper and Mopart Brake Parts Cleaner or the equivalent Take care not to scratch or gouge sealing surfaces 2 Install new thermostat into thermostat hous ing 3 Install new thermostat hous...

Page 215: ...If cooling system hose replacement is necessary replace with the original Mopart equipment hoses Fig 19 RADIATOR FAN DESCRIPTION The hydraulic cooling fan is integral to the fan shroud and is located...

Page 216: ...ssure By monitoring these two parameters the PCM can determine if cooling airflow is required If airflow is required the PCM will slowly ramp up speed up the fan speed until the parameter s are under...

Page 217: ...very line to the vehicles steering gear to provide steering assist Path two sends fluid back to the power steering pump through a low pressure line Fluid exits the steering gear under low pressure and...

Page 218: ...al connector on the fan assembly This ground MUST remain connected at all times Failure to ensure ground wire is connected when engine is operating can cause severe damage to the PCM 1 Position fan dr...

Page 219: ...isconnect the negative battery cable from bat tery 2 Drain the cooling system Refer to 7 COOL ING ENGINE STANDARD PROCEDURE DRAIN ING COOLING SYSTEM 3 Disconnect throttle body air inlet hose remove ai...

Page 220: ...efer to 9 ENGINE AIR INTAKE SYSTEM INSTALLATION 8 Fill the cooling system with coolant Refer to 7 COOLING ENGINE STANDARD PROCEDURE FILLING COOLING SYSTEM 9 Operate the engine until it reaches normal...

Page 221: ...26 3 Install pump to chain case cover Fig 25 4 Tighten water pump bolts in the sequence shown in Fig 27 to 11 N m 95 in lbs 5 Rotate the water pump by hand to check for freedom of movement 6 Install...

Page 222: ...and features of the audio system rely upon resources shared with other electronic modules in the vehicle over the Programmable Com munication Interface PCI bus network The data bus network allows the...

Page 223: ...Repair ground if required 5 Radio amplifier faulty 5 Refer to appropriate Diagnostic Service Man ual 6 Speakers faulty 6 Replace speaker as necessary NO RADIO DISPLAY 1 Fuse faulty 1 Check radio fuse...

Page 224: ...Dirty cassette tape head 3 Clean head with Mopar Cassette Head Cleaner 4 Faulty tape deck 4 Exchange or replace radio if required NO COMPACT DISC OPER ATION 1 Faulty CD 1 Insert known good CD and tes...

Page 225: ...l connections Antenna lead connection at the radio Windshield antenna lead connector at front of the instrument panel Fig 2 Three antenna amplifier connectors 2 Using an ohmmeter check for continuity...

Page 226: ...ent through the coax cable to the radio input DIAGNOSIS AND TESTING ANTENNA MODULE Any diagnosis of the Audio system should begin with the use of a scan tool and the appro priate Diagnostic Service Ma...

Page 227: ...ng antenna connector away from the radio Fig 5 5 Remove the antenna cable from the instrument panel INSTALLATION 1 Install antenna module cable to instrument panel harness and secure 2 Connect instrum...

Page 228: ...nd the mounting fasteners 4 Install the instrument panel center bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL INSTALLATION 5 Install the center console bezel Refer to 23 BODY I...

Page 229: ...installed in the vehicle Loose corroded or improperly soldered wire harness connec tions improperly routed wiring and inadequate audio system component grounding can all contribute to the reception o...

Page 230: ...ttery voltage at the fused B fuse for the power amplifier in the Power Dis tribution Center PDC If OK go to Step 6 If not OK repair the open fused B circuit to the PDC fuse as required 6 Check for bat...

Page 231: ...OVAL 3 Remove the mounting fasteners 4 Disconnect the electrical harness connector and remove speaker Fig 10 SUB WOOFER 1 Disconnect and isolate the battery negative cable 2 Remove the bulkhead quarte...

Page 232: ...Install the bulkhead quarter trim panel Refer to 23 BODY INTERIOR BULKHEAD TRIM PANEL INSTALLATION 4 Connect the battery negative cable SUB WOOFER 1 Connect wire harness connector and position sub woo...

Page 233: ......

Page 234: ...ANTILOCK BRAKE WARNING The ElectroMechanical Instrument Cluster EMIC monitors the ABS message and chimes a single chime warning whenever the ABS module requests the ABS light on If the EMIC does not...

Page 235: ...d to alert the customer of the addition of a new warning However if the enhanced seat belt warn ing feature is currently using the chime when an additional warning announcement chime is requested the...

Page 236: ...The EMIC monitors the PCM message for system voltage and will light the indicator on the gauge and request a chime from the BCM if the oil temperature is out of range WARNING LAMP ANNOUNCEMENT The BC...

Page 237: ......

Page 238: ...has a battery save mode This provides the customer with the ability to conserve battery power when storing the vehicle for up to three months without losing radio and Powertrain Control Module PCM me...

Page 239: ...ignition cylinder 2 Cycle the ignition key from OFF to ACC four times without going to the RUN position 3 Leave the switch in the OFF position after the fourth cycle This puts the BCM into the LEARN...

Page 240: ...s of the vehicle control fluid modulation to the wheel brakes while the system is in ABS mode store diagnostic information provide communication to the DRBIIIt scan tool while in diagnostic mode The C...

Page 241: ...way connector in socket of CAB and carefully push it down as far as possible b Once connector is fully seated into CAB socket push connector lock inward This pulls con nector into socket of CAB and lo...

Page 242: ...sducer Air Conditioning Controls ASD Sense Battery Temperature Battery voltage Brake Switch Camshaft Position Sensor Crankshaft Position Sensor Engine Coolant Temperature Sensor Ignition Switch Intake...

Page 243: ...oolant Temperature sensor Inlet Air Temperature Sensor Manifold Absolute Pressure Sensor Oil Pressure Sensor Throttle Position Sensor STANDARD PROCEDURE OBTAINING DIAGNOSTIC TROUBLE CODES BULB CHECK K...

Page 244: ...C may be set Refer to the appropriate Powertrain Diagnostic Manual and the DRBIIIt scan tool 1 Install PCM and tighten bolts 2 Install the three connector to PCM 3 Install the cleaner assembly refer t...

Page 245: ......

Page 246: ...this vehicle covers the following related components which are covered in further detail later in this section of the service manual Battery The storage battery provides a reli able means of storing a...

Page 247: ...important that the battery starting and charging systems be thor oughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal bat tery discharge overcharging o...

Page 248: ...ions 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 battery has an...

Page 249: ...quired 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electri cal loads 8 Slow driving or prolonged...

Page 250: ...l and the owner s manual it is recommended that these procedures be performed any time the battery or related compo nents must be removed for vehicle service 1 Inspect the battery cable terminals for...

Page 251: ...becomes low this battery must be replaced OPERATION The battery is designed to store electrical energy in a chemical form When an electrical load is applied to the terminals of the battery an electro...

Page 252: ...PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT WARNING EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BAT TERY PERSONAL INJURY AND OR VEHICL...

Page 253: ...stem cleaning procedures and Bat tery System Inspection for the proper battery system inspection procedures CHARGING A COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge...

Page 254: ...of the hydrometer test when a hydrometer is not available or for mainte nance free batteries with non removable cell caps Before proceeding with this test completely charge the battery Refer to 8 ELEC...

Page 255: ...e terminal clamp is lost during any part of the IOD test the electronic timer function will be activated and all of the tests will have to be repeated 5 After about three minutes the high amperage IOD...

Page 256: ...in false battery test readings 4 Using the ARROW key select in or out of vehi cle testing and press ENTER to make a selection 5 If not selected choose the Cold Cranking Amp CCA battery rating Or selec...

Page 257: ...pe terminals are crimped onto the opposite end of the battery cable wire and then solder dipped The battery positive cable wires have a red insulating jacket to provide visual identification of the ba...

Page 258: ...ive cable eyelet terminal at the starter solenoid B terminal stud you are reading the combined voltage drop in the battery positive cable terminal clamp to terminal post connection and the battery pos...

Page 259: ...tion Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery negative cable eyelet terminal connection to the engine block Repeat the test If the reading is still above 0...

Page 260: ...e battery tray also provides the anchor point for the battery holddown hardware The battery tray and the battery hold down hardware combine to secure and stabilize the battery in its mounting location...

Page 261: ...side of the battery tray and makes contacts with the side of the battery REMOVAL 1 Make sure ignition switch is in the OFF posi tion and all accessories are OFF 2 Refer to the Battery section for remo...

Page 262: ...ve bearings Loose or defective drive pulley Incorrect worn damaged or misadjusted drive belt Loose mounting bolts Misaligned drive pulley Defective stator or diode Damaged internal fins REMOVAL 1 Disc...

Page 263: ...ERATION The amount of DC current produced by the gener ator is controlled by EVR circuitry contained within the PCM This circuitry is connected in series with the generators second rotor field termina...

Page 264: ...COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY INSPECTION Before removing any unit from the starting system for repair or diagnosis perform the following inspec tions Batte...

Page 265: ...NG SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 8 FAULTY TEETH ON RING GEAR 8 ROTATE FLYWHEEL 360 AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED 9 PCM DOUBLE START OVERRIDE OU...

Page 266: ...ignition and fuel systems disconnect the Automatic Shutdown Relay ASD The ASD relay is located in the Power Distribution Center PDC Refer to the PDC cover for the proper relay location STARTER SOLENOI...

Page 267: ...continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times If OK go to Step 4 If not OK repair the open circuit to the starter solenoid as required 4 The coil...

Page 268: ...utton after depressing the clutch pedal If voltage reads above 0 2 volt correct poor contact at ground cable attaching point If voltage reading is still above 0 2 volt after correct ing poor contacts...

Page 269: ...in the left side of the engine compartment OPERATION As battery power is applied to the relay from the igni tion switch battery power is applied to the starter motor through the relay to the starter...

Page 270: ...ed to the On position the A C heater control energizes the rear window defogger EBL relay which then directs fused battery current through the relay and to the rear defogger grid lines The grid lines...

Page 271: ...the EBL relay and fuse located in the power distribution center PDC in the engine com partment The relay and fuse must be tight in their receptacles and all electrical connections must be secure Refe...

Page 272: ...e power distribution center PDC The inputs and out puts of the EBL relay include The common feed terminal 86 receives a bat tery current input from a fuse in the PDC through a fused B circuit at all t...

Page 273: ...window defogger switch and the rear win dow defogger LED indicator cannot be repaired and if faulty or damaged the A C heater control must be replaced Refer to 24 HEATING AIR CONDI TIONING CONTROLS A...

Page 274: ...rface to exceed 204 C 400 F 2 If the grid terminal s is broken and a portion of the terminal is still attached to the rear window defogger bus bar apply heat with a solder gun to the portion of the te...

Page 275: ......

Page 276: ...witch is OPEN a 23 second delay will occur before the horns are functional again The horn output operates on battery current received through a fuse in the Power Distribution Center PDC The horn syste...

Page 277: ...rts Horn switch input and the horn relay output 1 Using a scan tool check to see if the Body Con trol Module senses the horn switch input If the input is not OK then check the wiring between the horn...

Page 278: ...adjustable All spark advance is determined by the Powertrain Control Module PCM The distributorless ignition system used on these engines is referred to as the Direct Ignition System DIS The system s...

Page 279: ...Ohms Per Inch 3000 Ohms Per Foot 9 000 Ohms Per Foot IGNITION COIL RESISTANCE 8 3L Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27 C 70 F 80 F Diamond 0 53...

Page 280: ...volts to high 5 volts As the step up returns to the sensor the input voltage switches back to low 0 3 volts The paper spacer is not used on this vehicle Don t use at all it plugs up the oil pickup scr...

Page 281: ...tion damper mount ing bolt and rotate engine until the 1 15 32 inch dimension is attained 6 Install the sensor into the timing case cover with a slight rocking action Do not twist the sensor into posi...

Page 282: ...sfers to the secondary causing the spark The PCM will de energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs REMOVAL 1 Release the fuel pre...

Page 283: ...ten mounting screws to 11 N m 95 in lbs torque 2 Install ignition cables to ignition coil 3 Connect and lock the electrical connector at the ignition coils Fig 7 and Fig 8 4 Install Intake Manifold re...

Page 284: ...erred to as secondary ignition wires The wires transfer electri cal current from the electronic ignition coils to the individual spark plug at each cylinder The nonmetal lic spark plug cables have bui...

Page 285: ...correctly and secure them in the proper retainers Failure to route the cables properly may cause the radio to reproduce ignition noise It could also cause cross ignition of the plugs or may short circ...

Page 286: ...n Tool ASD Fuel System Test to pressurize the fuel system Check for leaks STARTER BUTTON REMOVAL 1 Remove the center bezel Fig 16 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVA...

Page 287: ...TION 1 Install switch into center bezel Fig 18 2 Install the center bezel Fig 16 Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL INSTALLATION Fig 18 START BUTTON REMOVED 8I 10 IGNITION...

Page 288: ...can seek service before damage occurs The instrument cluster has warning lamps and indicators for the following systems that are located within the message centers in the cluster Airbag Antilock Brak...

Page 289: ...ostics Refer to 8 ELECTRICAL INSTRUMENT CLUSTER STAN DARD PROCEDURE SELF DIAGNOSTICS After bulb check with the key in the RUN position and engine running all MODULE warning indicators Airbag ABS MIL C...

Page 290: ...nter stop One button is used to switch the display from trip to total mileage Holding the button when the display is in the trip mode will reset the trip mileage This button is also used to put the cl...

Page 291: ...ll come on when the ignition is turned ON and the engine is OFF Refer to the proper Body Diagnostic Procedures man ual if one or more indicators don t light or a gauge does not appear to be functionin...

Page 292: ...icator will be illuminated The indicator remains illuminated for about six to eight seconds or until the cluster receives a lamp off message from the ORC whichever is longer Communication Error If the...

Page 293: ...to instrument cluster gauge pack lens and separate INSTALLATION Follow all Warnings for airbag component service Refer to 8 ELECTRICAL RESTRAINTS WARN ING 1 Install the two lens retaining screws to th...

Page 294: ...specific recommendations on when to enable or dis able the passenger airbag The passenger airbag ON OFF switch allows the customer to turn the pas senger airbag function ON or OFF to accommodate cert...

Page 295: ......

Page 296: ...IAGNOSIS AND TESTING HIGH INTENSITY DISCHARGE HEADLAMPS 9 REMOVAL 10 INSTALLATION 10 HEADLAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE HEADLAMP UNIT AIMING 11 STANDARD PROCEDURE HEADLAMP UNIT AIMING...

Page 297: ...continuous body ground Wire connectors can make intermittent contact or become corroded Before coupling wire connectors inspect the terminals inside the connector Male ter minals should not be bent or...

Page 298: ...o the tail lamp access panel of the respective side of the vehicle 4 Connect the battery negative cable 5 Place battery access cover into place and install four bolts 6 Close deck lid 7 Verify vehicle...

Page 299: ...procedure Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH INSTALLATION the new switch s adjustment lever is rotated to the adjusted position as indicated This action locks the plunger...

Page 300: ...on new switch should be at a 45 angle from wiring connector If adjustment lever is parallel with wiring connector switch has been preset and must be scrapped DO NOT ATTEMPT TO RESET OR READJUST BRAKE...

Page 301: ...negative cable 4 Remove access panel within wheel well Fig 5 5 Remove the fog lamp by turning 1 4 turn coun terclockwise and pulling straight out 6 Disconnect the electrical connector from the fog la...

Page 302: ...used to make the vehicle more visible from the rear during foggy or low light condi tions The driver controls the rear fog lamp operation through a switch located on the multi function switch FOG LAMP...

Page 303: ...amps while using less energy The lamps are also designed to last 10 times longer than standard halogen lamps OPERATION High Intensity Discharge Headlamps HID rely on an AC alternating current electric...

Page 304: ...rcuit protection If either is sensed the module will not illuminate the headlamps for that key cycle or until the fault is corrected Recycle the ignition and headlamp switch if both headlamps do not i...

Page 305: ...Remove wheel and tire assembly if extra room is needed 5 Remove the three nuts to the headlamp access panel and remove panel 6 Remove the headlamp by turning 1 4 turn counterclockwise and pulling stra...

Page 306: ...to suggested specifications Refer to vehicle Owner s Manual or the vehicle Tire Placard inside the rear edge of the left door 4 Turn the headlamps ON Make sure that the vehicle LOW BEAMS are on and no...

Page 307: ...DLAMP UNIT 11 CENTER OF HORIZONTAL HEADLAMP LINE AND VEHICLE CENTERLINE 4 4 INCHES 12 21 50 INCHES 5 VERTICAL CENTERLINE OF VEHICLE 13 CENTER OF LOW BEAM HIGH INTENSITY 6 VERTICAL CENTERLINE OF RIGHT...

Page 308: ...OF VEHICLE HEADLAMP UNIT 10 FOG LAMP HORIZONTAL ALIGNMENT LINE 4 100 MM 4 IN 11 IMAGE BREAK POINT 5 VERTICAL CENTERLINE OF VEHICLE 12 628 MM 27 72 IN 6 VERTICAL CENTERLINE OF RIGHT HEADLAMP 13 902 MM...

Page 309: ...uver headlamp unit in the wheel well opening and forward into the headlamp unit mount ing slots NOTE If shims were present at removal then rein sert the shims in the same place before tightening headl...

Page 310: ...onnector receptacle with up to twenty terminals is located on the back of the switch housing and connects the switch to the vehicle electrical system through a take out and connector of the instrument...

Page 311: ...the steering wheel past a detent then released to actuate the headlamp beam selection switch Each time the control stalk is actu ated in this manner the opposite headlamp mode from what is currently...

Page 312: ...tery current from a fuse in the Power Distribution Center PDC is provided through a BCM controlled ignition switch output RUN ACC circuit Continuous Wipe Modes When the control knob is in the OFF posi...

Page 313: ...IN FEED WIRE TO SWITCH 3 REPAIR WIRING HARNESS CHECK CONNECTORS 4 FAULTY CONTACT IN SWITCH 4 REPLACE MULTI FUNCTION SWITCH 5 OPEN OR GROUNDED CIRCUIT IN WIRING TO EXTERNAL LAMPS 5 REPAIR WIRING HARNE...

Page 314: ...the battery negative cable 2 Remove the upper and lower steering column shrouds 3 Disconnect the switch connector Using an ohmmeter test for continuity no resis tance between the terminals of the swit...

Page 315: ...AND B 6 TURN SIGNAL IN NEUTRAL HAZARD WARNING SWITCH ON HAZARD ON A 2 AND B 2 A 2 AND B 4 A 2 AND B 5 A 2 AND B 6 A 3 AND A 5 A 3 AND B 7 B 2 AND B 4 B 2 AND B 5 B 2 AND B 6 B 4 AND B 5 B 4 AND B 6 B...

Page 316: ...new multi function switch Refer to 8 ELECTRICAL WIPERS WASHERS WIPER WASHER SWITCH REMOVAL INSTALLATION 1 The windshield wiper washer switch must be transferred to the new multi function switch Refer...

Page 317: ...Fig 20 MULTI FUNCTION SWITCH REMOVE INSTALL 1 MULTI FUNCTION SWITCH CONNECTORS 3 MULTI FUNCTION SWITCH 2 RETAINING SCREWS 8L 22 LAMPS ZB MULTI FUNCTION SWITCH Continued...

Page 318: ...the vehicle electrical system through a take out and connector of the instrument panel wire harness The multi function switch supports the following functions and features Continuous Wipe Modes The c...

Page 319: ...ction switch controls the follow ing headlamp features and provides Headlamp Beam Selection The turn signal control stalk on the left side of the multi function switch is pulled towards the steering w...

Page 320: ...er motor When the control knob is in the OFF position the wiper system completes the cycle and the blades park in the lowest portion of the wipe pattern Intermittent Wipe Mode When the wind shield wip...

Page 321: ...FEED WIRE TO SWITCH 3 REPAIR WIRING HARNESS CHECK CONNECTORS 4 FAULTY CONTACT IN SWITCH 4 REPLACE MULTI FUNCTION SWITCH 5 OPEN OR GROUNDED CIRCUIT IN WIRING TO EXTERNAL LAMPS 5 REPAIR WIRING HARNESS I...

Page 322: ...battery negative cable 2 Remove the upper and lower steering column shrouds 3 Disconnect the switch connector Using an ohmmeter test for continuity no resis tance between the terminals of the switch...

Page 323: ...D B 4 RIGHT TURN A 2 AND B 5 B 1 AND B 4 B 5 AND B 6 TURN SIGNAL IN NEUTRAL HAZARD WARNING SWITCH ON HAZARD ON A 2 AND B 2 A 2 AND B 4 A 2 AND B 5 A 2 AND B 6 A 3 AND A 5 A 3 AND B 7 B 2 AND B 4 B 2 A...

Page 324: ...9 B 18 AND B 19 B 12 AND B 13 MULTI FUNCTION SWITCH DIMMER CONTROL RESISTANCE SWITCH POSITION RESISTANCE VALUE BETWEEN PINS 7 AND 8 DOME ON 150 OHMS PARADE MODE 411 OHMS DIM 6 BRIGHTEST INTENSITY 768...

Page 325: ...her switch must be transferred to the new multi function switch Refer to 8 ELECTRICAL WIPERS WASHERS WIPER WASHER SWITCH REMOVAL INSTALLATION 1 The windshield wiper washer switch must be transferred t...

Page 326: ...into place and install four bolts 5 Close deck lid 6 Verify vehicle and system operation REAR SIDE MARKER LAMP REMOVAL It is not necessary to remove the tail lamp unit to change lamps 1 Open deck lid...

Page 327: ...ehicle 3 Connect the battery negative cable 4 Place battery access cover into place and install four bolts 5 Close deck lid 6 Verify vehicle and system operation TAIL LAMP UNIT REMOVAL 1 Open deck lid...

Page 328: ...6 SPECIFICATIONS REMOTE KEYLESS ENTRY TRANSMITTER 6 POWER LOCKS DESCRIPTION POWER LOCKS Electric door latches are used to accomplish open ing and closing of the vehicle doors and electronics to accom...

Page 329: ...SWITCH When the Body Control Module BCM receives an input from the lock switch indicating a door lock un lock request is present the BCM will set both doors of the vehicle to virtual lock or unlock If...

Page 330: ...alues are not within the param eters replace the switch EXTERIOR DOOR HANDLE SWITCH DIAGNOSIS AND TESTING EXTERIOR DOOR HANDLE SWITCH Any diagnosis of the Power Locks system should begin with the use...

Page 331: ...within the param eters shown replace the door lock switch DOOR LOCK SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN RESISTANCE VALUE LOCK 2 and 3 1 5K Ohm 5 UNLOCK 2 and 3 249 Ohm 5 UNACTUATED 2...

Page 332: ...Remove the two batteries from the RKE trans mitter 4 Replace the two batteries with new 3V Pana sonic CR2032 or equivalent Install the batteries with the positive terminal up Reference the SIDE UP on...

Page 333: ...oth at the same time A single chime will sound to indicate that the transmitter program ming mode has been entered allow 3 seconds for chime to sound 6 Within 30 seconds of the chime press and release...

Page 334: ...olate the battery negative cable 2 Remove the power mirror switch Refer to 8 ELECTRICAL POWER MIRRORS POWER MIRROR SWITCH REMOVAL 3 Disconnect wire connector from the switch 4 Use two fused jumper wir...

Page 335: ...EL INSTALLATION 3 Connect battery negative cable SIDEVIEW MIRROR DESCRIPTION Each power mirror head contains two electric motors two drive mechanisms and the mirror glass One motor and drive controls...

Page 336: ...up on the seal the BCM drops the glass when the door is opened and returns it to the full up position once the door is closed SMART GLASS FEATURE The Smart Glass feature of the power window sys tem d...

Page 337: ...connector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connectors splices and grounds Remove the switc...

Page 338: ...BCM There is also a 30 Amp fuse in the Power Distribu tion Center PDC to protect the passenger window circuits The BCM protects the driver window circuits 10 amps DIAGNOSIS AND TESTING WINDOW MOTOR 1...

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Page 340: ...REMOVAL 5 INSTALLATION 5 DRIVER AIRBAG DESCRIPTION 6 OPERATION 6 REMOVAL 6 INSTALLATION 6 OCCUPANT RESTRAINT CONTROLLER DESCRIPTION 6 OPERATION 7 REMOVAL 7 INSTALLATION 8 PASSENGER AIRBAG DESCRIPTION...

Page 341: ...OT USE SUBSTI TUTE FASTENERS USE ONLY ORIGINAL EQUIPMENT FASTENERS LISTED IN THE PARTS CATALOG WHEN FASTENER REPLACEMENT IS REQUIRED AIRBAGS SHOULD BE STORED IN A COOL DRY PLACE AWAY FROM EXCESSIVE HE...

Page 342: ...a collision the following MUST be replaced Passenger Airbag All other airbag and vehicle components should be closely inspected following any airbag deployment but are to be replaced only as required...

Page 343: ...pring tape to the movable steering components so that the tape can operate within its designed travel limits However if the clock spring is removed from the steering column or if the steering shaft is...

Page 344: ...ck position and bend to prevent it from falling out INSTALLATION 1 Confirm that The steering wheel position is a half turn 180 degrees to the right clockwise The column is locked with the ignition cyl...

Page 345: ...thin the fabric used to construct the back steering wheel side panel of the airbag cushion REMOVAL Follow all Warnings for airbag component service Refer to 8 ELECTRICAL RESTRAINTS WARN ING CAUTION Wh...

Page 346: ...side front seat belt switch The ORC receives battery current through two cir cuits a fused ignition switch output RUN circuit through a fuse in the Power Distribution Center PDC and a fused ignition...

Page 347: ...instrument panel top pad armature between the two passenger side panel outlets A stamped metal reinforcement is secured to the instrument panel top pad armature near the upper edge of the passenger a...

Page 348: ...uts and remove column from vehicle 17 Disconnect five left side instrument panel electrical connectors 18 Remove ground wire nuts at left floor tunnel 19 Remove one bolt and one nut to the left brace...

Page 349: ...ll the left and right wiper arms on each wiper arm pivot 17 Connect the two occupant restraint controller electrical connectors 18 Connect the occupant restraint controller ground wires 19 Connect ele...

Page 350: ...nition switch is in the RUN position The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch The switch requires only a partial key inserti...

Page 351: ...a trim stick or equivalent pry out rub ber plugs at sport hoop 10 Remove the two bolts attaching the sport hoop to rear bulkhead 11 Remove sport hoop from vehicle 12 Remove three screws retaining the...

Page 352: ...TION 1 Route wire through seat assembly and attach seat belt buckle and bolt to seat assembly Torque bolts to 40 N m 30 ft lbs 2 Place seat assembly in vehicle 3 Connect electrical connector Fig 4 4 M...

Page 353: ...g indicator in the EMIC then store a Diagnostic Trouble Code DTC for any fault that is detected in the seat belt switch circuit To properly diagnose the seat belt switch a DRBIIIt scan tool and the ap...

Page 354: ...the occu pants by the seat belts during a frontal impact fur ther reducing the potential for occupant injuries The ORC monitors the condition of the seat belt tensioners through circuit resistance an...

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Page 356: ...ive fuel shut off the engine will no longer crank on subsequent key cycles The failure must be corrected and a valid communication process between the BCM and the PCM must occur for the engine to cran...

Page 357: ...le 2 Using a flat blade tool pry switch from the bracket on the left fender well 3 Disconnect the wire harness connector from the switch INSTALLATION 1 Connect the wire harness connector to the switch...

Page 358: ...PUMP MOTOR EXPORT REMOVAL 13 INSTALLATION 13 WASHER PUMP MOTOR EXPORT REMOVAL 14 INSTALLATION 14 HEADLAMP WASHER RESERVOIR EXPORT REMOVAL REMOVAL LOWER RESERVOIR 14 REMOVAL UPPER RESERVOIR 15 INSTALLA...

Page 359: ...switch is turned OFF The blades park in the lowest portion of the wipe pattern Push down on the wiper lever to the mist position to activate a single wipe to clear off road mist or spray from a passin...

Page 360: ...circuit as necessary 6 Using a voltmeter with wiper switch con nected connect negative lead to terminal 1 of the motor Connect the positive lead to terminal 4 of the wiper switch connector Fig 3 a If...

Page 361: ...tch If not OK repair wiring as necessary WASHER SYSTEM DIAGNOSIS Whenever a windshield washer malfunction occurs first verify that the washer pump wire harness is properly connected to all connectors...

Page 362: ...mp to reservoir 2 Connect wire harness connector and washer hose 3 Install washer reservoir Refer to 8 ELEC TRICAL WIPERS WASHERS WASHER RESERVOIR INSTALLATION 4 Connect battery negative cable WASHER...

Page 363: ...or non abrasive cleaner If the blades continue to streak or smear they should be replaced The driver blade element is 550 mm in length and the passenger blade element is 475 mm in length REMOVAL 1 Lif...

Page 364: ...nected then start normal diagnosis and repair procedures Refer to the WIPER MOTOR DIAGNOSIS table WIPER MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION WIPER BLADES DO NOT PARK PROPERLY 1 WIPER A...

Page 365: ...S WASHERS WIPER MOTOR REMOVAL WIPER MOTOR WILL NOT RUN 1 BLOWN FUSE 1 REPLACE FUSE AND RUN SYSTEM 2 NEW FUSE BLOWS 2 CHECK FOR SHORT IN WIRING OR SWITCH 3 NEW FUSE BLOWS 3 REPLACE FUSE REMOVE MOTOR CO...

Page 366: ...witches 2 Install the two retaining screws to the Wiper Washer Switch 3 Install the Multi Function Switch from the vehicle Refer to Electrical Lamps Lighting Exte rior Multi Function Switch Installati...

Page 367: ...tend out from the fascia when pressur ized with fluid Fig 8 OPERATION The headlamp washer system utilizes a separate high pressure pump that is attached to the wind shield washer reservoir The headlam...

Page 368: ...EFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 3 HEADLAMP WASHER HOSE NOT FLOWING FLUID 3 ASSURE WASHER HOSE IS NOT PINCHED LOOSE BROKEN OR DISCONNECTED IF NOT OK PROPERLY ROUTE OR REPAIR WASHER HO...

Page 369: ...on the headlamp washer hose and install the retaining clamps 2 Install the front bumper reinforcement Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REINFORCEMENT INSTALLATION 3 Operate the headlamp w...

Page 370: ...ozzle to its at rest position so the nozzle cover is flush with the front fascia HEADLAMP WASHER PUMP MOTOR EXPORT REMOVAL 1 Remove the right front wheel and tire Refer to 22 TIRES WHEELS REMOVAL 2 Re...

Page 371: ...HER RESERVOIR EXPORT REMOVAL REMOVAL LOWER RESERVOIR 1 Remove the front bumper reinforcement Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REINFORCEMENT REMOVAL 2 Remove right front tire Refer to 22...

Page 372: ...head lamp washer pump and horn electrical connectors 6 Install the right front brake vent tube 7 Install the front bumper reinforcement Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REINFORCEMENT INS...

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Page 374: ...8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 OCCUPANT RESTRAINT SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 BODY CONTROL MODULE 8W 45 1 AUDIO SYSTEM 8W 47 1 REAR WINDO...

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Page 376: ...g content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagrams...

Page 377: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION ZB WIRING DIAGRAM INFORMATION Continued...

Page 378: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 ZB 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Page 379: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION ZB WIRING DIAGRAM INFORMATION Continued...

Page 380: ...Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and color Fig 4...

Page 381: ...cular group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can h...

Page 382: ...eral warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER A V...

Page 383: ...for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify...

Page 384: ...r lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with...

Page 385: ...round has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of t...

Page 386: ...moved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pi...

Page 387: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION ZB CONNECTOR Continued...

Page 388: ...APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPE...

Page 389: ...ected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire fr...

Page 390: ...of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION...

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Page 392: ...rt Accessory Fuse 8W 10 Exterior Door Handle Switches 8W 61 Fog Lamps Front 8W 50 Fog Lamps Rear 8W 51 Footwell Lamps 8W 44 Fuel Injectors 8W 30 Component Page Fuel Pump Relay 8W 30 Fuel Tank Module 8...

Page 393: ...Speakers 8W 47 Splices 8W 70 Starter Motor 8W 21 Starter Motor Relay 8W 21 Tail Lamps 8W 51 Component Page Tail Stop Lamps 8W 51 Throttle Position Sensor 8W 30 Tire Pressure Monitor Module 8W 45 Turn...

Page 394: ...20 Fuse C2 8W 10 13 14 Component Page Fuse C4 8W 10 13 Fuse C6 8W 10 13 Fuse C8 8W 10 11 Fuse C10 8W 10 12 Fuse C12 8W 10 12 Fusible Link 8W 10 7 G100 8W 10 11 G302 8W 10 7 Gauge Cluster 8W 10 13 Gene...

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Page 414: ...Box Lamp 8W 15 9 Headlamp Washer Pump Motor 8W 15 2 Hid Lamp Left 8W 15 4 Hid Lamp Right 8W 15 4 High Beam Headlamp Left 8W 15 4 High Beam Headlamp Right 8W 15 4 Horn High Note 8W 15 5 Horn Low Note 8...

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Page 426: ...W 18 2 3 Controller Antilock Brake 8W 18 2 3 Data Link Connector 8W 18 2 3 Fuse B12 8W 18 2 G100 8W 18 2 Component Page G201 8W 18 2 Instrument Cluster 8W 18 2 3 Power Distribution Center 8W 18 2 Powe...

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Page 430: ...Battery 8W 20 2 Battery Temperature Sensor 8W 20 3 Fuse B11 8W 20 2 Fusible Link 8W 20 2 3 Component Page G302 8W 20 2 Generator 8W 20 2 3 Power Distribution Center 8W 20 2 Powertrain Control Module...

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Page 434: ...3 Fuse B2 8W 21 2 Fuse C4 8W 21 2 Fusible Link 8W 21 3 G302 8W 21 2 Component Page Generator 8W 21 3 Ignition Switch 8W 21 2 Power Distribution Center 8W 21 2 Powertrain Control Module 8W 21 3 Push Bu...

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Page 438: ...5 Fuel Injector No 10 8W 30 4 Fuel Pump Relay 8W 30 8 Fuel Tank Module 8W 30 8 Fuse B11 8W 30 2 7 Fuse B14 8W 30 6 9 Component Page Fuse B21 8W 30 15 Fuse B22 8W 30 8 Fuse C2 8W 30 6 8 9 G103 8W 30 2...

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Page 454: ...nk Connector 8W 35 2 Fuse B2 8W 35 2 Fuse B7 8W 35 2 G101 8W 35 2 Component Page Power Distribution Center 8W 35 2 Powertrain Control Module 8W 35 3 Wheel Speed Sensor Left Front 8W 35 3 Wheel Speed S...

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Page 458: ...Driver 8W 39 2 Door Latch Motor Passenger 8W 39 2 Door Lock Switch Driver 8W 39 3 Door Lock Switch Passenger 8W 39 4 Component Page Exterior Door Handle Switch Driver 8W 39 3 Exterior Door Handle Swi...

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Page 464: ...l Switch 8W 40 3 Data Link Connector 8W 40 2 4 Fuse C4 8W 40 2 7 G103 8W 40 3 G201 8W 40 2 Component Page G202 8W 40 2 7 Gauge Cluster 8W 40 2 5 6 7 Instrument Cluster 8W 40 2 3 4 5 6 7 Multi Function...

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Page 472: ...1 3 Clockspring 8W 41 2 Fuse B12 8W 41 3 Fuse B17 8W 41 3 Fuse B19 8W 41 2 G106 8W 41 2 Component Page G202 8W 41 3 Horn Relay 8W 41 2 Horn Switch 8W 41 2 Horn High Note 8W 41 2 Horn Low Note 8W 41 2...

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Page 476: ...2 Blower Motor Resistor Block 8W 42 2 Body Control Module 8W 42 2 4 Data Link Connector 8W 42 4 Fuse B1 8W 42 2 Fuse B11 8W 42 7 Component Page Fuse B20 8W 42 5 Fuse C2 8W 42 5 G100 8W 42 2 G103 8W 42...

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Page 484: ...Passenger 8W 43 3 Body Control Module 8W 43 2 Clockspring 8W 43 3 Data Link Connector 8W 43 2 Fuse B24 8W 43 2 Component Page Fuse C6 8W 43 2 G203 8W 43 2 Gauge Cluster 8W 43 2 Power Distribution Cent...

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Page 488: ...l Lamp Right 8W 44 4 G201 8W 44 3 G202 8W 44 3 4 5 Gauge Cluster 8W 44 3 Glove Box Lamp 8W 44 5 Component Page Illuminated Rear View Mirror 8W 44 5 Instrument Cluster 8W 44 3 Key In Switch Halo Lamp 8...

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Page 494: ...G201 8W 45 10 17 Glove Box Lamp 8W 45 13 Component Page Headlamp Relay 8W 45 18 Headlamp Washer Pump Relay 8W 45 14 High Beam Headlamp Left 8W 45 6 High Beam Headlamp Right 8W 45 6 Horn Relay 8W 45 3...

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Page 512: ...Amplifier 8W 47 3 4 5 Power Distribution Center 8W 47 2 4 Component Page Radio 8W 47 2 3 Remote Radio Switch Left Provision 8W 47 4 Remote Radio Switch Right Provision 8W 47 4 Speaker Left Door 8W 47...

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Page 518: ...ge A C Heater Control 8W 48 2 Body Control Module 8W 48 2 Fuse B15 8W 48 2 G303 8W 48 2 Component Page Power Distribution Center 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2...

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Page 520: ...0 2 Headlamp Washer Pump Motor 8W 50 6 Component Page Headlamp Washer Pump Relay 8W 50 6 Hid Lamp Left 8W 50 3 Hid Lamp Right 8W 50 4 High Beam Headlamp Left 8W 50 3 High Beam Headlamp Right 8W 50 4 I...

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Page 526: ...p Left Rear 8W 51 6 Fog Lamp Right Rear 8W 51 6 Fuse B21 8W 51 2 G300 8W 51 3 4 5 G306 8W 51 6 Component Page License Lamp Left 8W 51 5 License Lamp Right 8W 51 5 Marker Lamp Left Rear 8W 51 3 Marker...

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Page 532: ...2 2 Marker Lamp Left Front 8W 52 3 Component Page Marker Lamp Right Front 8W 52 4 Multi Function Switch 8W 52 2 Park Turn Lamp Left 8W 52 3 Park Turn Lamp Right 8W 52 4 Power Distribution Center 8W 52...

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Page 536: ...nent Page Fuse C8 8W 53 2 G102 8W 53 3 G103 8W 53 3 G201 8W 53 2 Component Page Power Distribution Center 8W 53 2 Washer Pump Motor 8W 53 2 3 Wiper Control Module 8W 53 2 3 Wiper Motor 8W 53 2 3 ZB 8W...

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Page 540: ...ENIENCE SYSTEMS Component Page Adjustable Pedals Motor 8W 56 2 Adjustable Pedals Switch 8W 56 2 Fuse B5 8W 56 2 Component Page G200 8W 56 2 Power Distribution Center 8W 56 2 ZB 8W 56 CONVENIENCE SYSTE...

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Page 542: ...60 3 Power Distribution Center 8W 60 4 Power Window Motor Driver 8W 60 3 Component Page Power Window Motor Passenger 8W 60 3 4 Power Window Switch Driver 8W 60 2 Power Window Switch Passenger 8W 60 2...

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Page 546: ...tor 8W 61 5 Door Latch Motor Driver 8W 61 2 Door Latch Motor Passenger 8W 61 2 Door Lock Switch Driver 8W 61 3 Component Page Door Lock Switch Passenger 8W 61 4 Exterior Door Handle Switch Driver 8W 6...

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Page 552: ...Page Body Control Module 8W 62 2 Fuse B18 8W 62 2 G201 8W 62 2 Power Distribution Center 8W 62 2 Component Page Power Mirror Switch 8W 62 2 Power Mirror Driver 8W 62 2 Power Mirror Passenger 8W 62 2 Z...

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Page 554: ...W 10 8 S146 8W 50 4 S147 8W 50 4 S148 8W 52 4 S149 8W 15 4 S200 8W 10 18 S201 8W 18 2 S202 8W 18 2 S203 8W 18 3 Component Page S204 8W 10 10 S205 8W 10 13 S206 8W 40 3 S207 8W 52 2 S208 8W 52 2 S209 8...

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Page 558: ...8W 80 21 C108 Export 8W 80 21 C108 Export 8W 80 22 C200 8W 80 22 C200 8W 80 23 C201 8W 80 23 Component Page C201 8W 80 24 C202 8W 80 24 C202 8W 80 24 C203 8W 80 25 C203 8W 80 25 C204 8W 80 25 C204 8W...

Page 559: ...ft Bank Down 8W 80 50 Component Page Oxygen Sensor 2 1 Right Bank Up 8W 80 50 Oxygen Sensor 2 2 Right Bank Down 8W 80 50 Park Brake Switch 8W 80 51 Park Turn Lamp Left 8W 80 51 Park Turn Lamp Right 8W...

Page 560: ...6 Wheel Speed Sensor Left Front 8W 80 67 Wheel Speed Sensor Left Rear 8W 80 67 Wheel Speed Sensor Right Front 8W 80 67 Component Page Wheel Speed Sensor Right Rear 8W 80 67 Window Down Relay Passenger...

Page 561: ...A C PRESSURE TRANSDUCER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 F888 18BR PK 5V SUPPLY 3 C18 20LB BR A C PRESSURE SIGNAL 4 A C HEATER CONTROL C1 BLACK 10 WAY CAV CIRCUIT FUNCT...

Page 562: ...RECIRCULATION DOOR DRIVER 13 14 15 C80 20DB LB REAR WINDOW DEFOGGER RELAY CONTROL 16 D25 20WT VT PCI BUS ADJUSTABLE PEDALS MOTOR WHITE 2 WAY CAV CIRCUIT FUNCTION A Q52 16OR GY ADJUSTABLE PEDALS MOTOR...

Page 563: ...8 9 R58 20LB GY PASSENGER SEAT BELT SWITCH SENSE 10 R60 20LB TN PASSENGER SEAT BELT SWITCH GROUND 11 12 13 14 15 16 17 18 19 20 21 22 23 R59 20LG TN DRIVER SEAT BELT SWITCH GROUND 24 R57 20LG GY DRIVE...

Page 564: ...RETURN 19 R4 20OR LB PASSENGER AIRBAG MUX SWITCH SENSE 20 R166 20LG TN PASSENGER AIRBAG INDICATOR DRIVER 21 22 23 D25 20WT VT PCI BUS 24 F12 20PK FUSED IGNITION SWITCH OUTPUT RUN START 25 R63 20LG WT...

Page 565: ...R SQUIB 2 LINE 2 2 R61 20LG VT DRIVER SQUIB 2 LINE 1 AIRBAG SQUIB PASSENGER YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R44 20LB OR PASSENGER SQUIB 1 LINE 1 2 R42 20LB BR PASSENGER SQUIB 1 LINE 2 3 R64 20LB W...

Page 566: ...2 Z1 20BK GROUND 3 AJAR SWITCH PASSENGER DOOR BLACK 4 WAY CAV CIRCUIT FUNCTION A G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE B C Z1 20BK GROUND D AMPLIFIER ANTENNA NATURAL 1 WAY CAV CIRCUIT FUNCTION...

Page 567: ...T GRAY 3 WAY CAV CIRCUIT FUNCTION 1 L1 20WT LG BACK UP LAMP SWITCH OUTPUT 2 3 Z1 20BK GROUND BATTERY TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K25 20DB VT BATTERY TEMPERATURE SENSOR SIGNAL...

Page 568: ...R BLOWER MOTOR ORANGE 2 WAY CAV CIRCUIT FUNCTION 1 C7 12DB BLOWER MOTOR RELAY OUTPUT 2 C75 12DB GY BLOWER MOTOR HIGH DRIVER BLOWER MOTOR RESISTOR BLOCK BLACK 4 WAY CAV CIRCUIT FUNCTION 1 C72 16OR BLOW...

Page 569: ...0BR OR PASSENGER WINDOW UP RELAY CONTROL 10 P129 18LG TN DRIVER DOOR UNLATCH RETURN 11 P128 18LG DG PASSENGER DOOR UNLATCH RETURN 12 13 14 15 Z20 18BK WT GROUND 16 P901 20OR LB DRIVER DOOR SWITCH RETU...

Page 570: ...UNLOCK SWITCH MUX 15 Q3 20OR TN PASSENGER WINDOW SWITCH MUX 16 G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE 17 M1 20YL VT IOD B 18 19 20 G4 20LB VT FUEL LEVEL SENSOR SIGNAL 21 P97 20LG YL DRIVER DOOR...

Page 571: ...WASHER SWITCH SENSE 17 J3 18VT WT EXPORT REAR FOG LAMP RELAY CONTROL 18 F921 20PK YL FUSED IGNITION SWITCH OUTPUT RUN 19 20 G20 20BR VT IGNITION SWITCH SENSE 21 L107 20WT BK PARK LAMP SWITCH SENSE 22...

Page 572: ...Z11 18BK LG 8 F13 18PK 9 D25 18WT VT 10 D20 18WT LG 11 D21 18WT BR 12 D24 20DB WT 13 X4 20DG WT 14 G70 20VT LB 15 G11 20VT TN 16 L61 20LG 17 A1 14RD 18 L60 20TN 19 A114 18GY RD 20 F89 20RD WT 21 L33...

Page 573: ...13 X4 20DG WT 14 G70 20VT LB 15 G11 20VT TN 16 L61 20LG 17 A1 14RD 18 L60 20TN 19 A114 20GY RD 20 F89 20RD WT 21 L33 20LG BR 22 L89 20WT 23 T141 20YL OR 24 L34 20WT GY 25 L124 20WT DB 26 L63 20WT DG 2...

Page 574: ...18WT 4B J3 18VT WT EXPORT 4A J5 18DB WT EXPORT 5B 5A M28 20YL TN EXCEPT EXPORT 6A 6B 7B W3 16BR 7A A102 12WT RD 8A A101 14VT RD 8B W5 16BR LG 9B W110 16BR WT 9A A21 14RD OR 10A 10B F30 16PK YL 11A 11B...

Page 575: ...RD 8A A101 14VT RD 8B W5 16BR LG 9B W110 16BR WT 9A A21 14RD OR 10A 10B F30 16LG EXCEPT EXPORT 10B F30 14LG EXPORT 11A 11B 12A 12B 13A A103 20GY RD 13B L50 20WT TN 14A 14B 15A A15 20RD TN 15B A22 18B...

Page 576: ...1 F20 20PK WT 2 K25 20DB VT 3 Q2 18WT 4 K106 20VT YL 5 K107 20VT WT 6 K125 18BR DG 7 K33 20DB LG 8 K136 20LB BK 9 10 L7 20WT YL 11 L63 20WT DG 12 G4 20LB VT 13 G78 20VT OR 14 L62 20WT RD C103 LT GRAY...

Page 577: ...25 18BR DG 16 F202 18PK GY 17 C18 18LB BR 18 K42 18DB YL 19 K242 18BR YL 20 C104 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 2 G7 18VT OR 3 F888 18BR PK 4 K900 18DB DG 5 K136 18LB BK 6 K41 18DB LB 7 K1...

Page 578: ...L33 20LG BR 6 Z1 18BK C107 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 L7 20WT YL 2 L60 20TN 3 4 L44 18WT TN 5 L34 20WT GY 6 Z1 18BK C107 BLACK RIGHT HEADLAMP JUMPER SIDE CAV CIRCUIT 1 L7 20WT YL 2 L6...

Page 579: ...20LG GY 1A 2B R59 20LG TN 2A 3B R58 20LB GY 3A X209 18GY OR 4B R60 20LB TN 4A X299 18GY 5A X201 18GY VT 5B X51 20DG DB 6B X57 20DG OR 6A X291 18GY YL 7A A116 14YL RD 7B X53 20DG 8B X55 20DG BR 8A 9A...

Page 580: ...T 6A X291 18GY YL 6B X57 20DG OR 7B X53 20DG 7A A116 14YL RD 8A 8B X55 20DG BR 9A 9B X54 20VT 10A X208 18GY DG 10B X56 20GY BR 11A X298 18GY LG 11B X52 20GY DB 12A X202 18DG VT 12B X58 20DB OR 13A X29...

Page 581: ...GY 5 P74 20TN OR 6 P70 20TN LB 7 A114 20GY RD 8 Z1 20BK 9 G163 20VT LB 10 M1 20YL VT 11 Q301 20WT 12 P901 20OR LB 13 Q11 18OR DB C202 NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 G75 20VT 2 F71 20PK T...

Page 582: ...AL PASSENGER DOOR SIDE CAV CIRCUIT 1 G74 20VT WT 2 F71 20PK TN 3 P96 20LG LB 4 P72 20TN GY 5 P74 20TN OR 6 P70 20TN LB 7 8 Z1 20BK 9 10 M1 20YL VT 11 Q302 20OR LG 12 P900 20LG OR 13 Q112 14OR BR C204...

Page 583: ...C72 16OR 10 C33 20LB BR 11 12 13 C205 BLACK INSTRUMENT PANEL SIDE CAV CIRCUIT A Z1 20BK B M24 20BK BR C M27 20BK DB D G69 20BK OR C205 BLACK MIRROR JUMPER SIDE CAV CIRCUIT A Z1 20BK B M24 20BK BR C M...

Page 584: ...Q122 14OR YL 4 P126 18LG OR 5 X202 18DG VT 6 X292 18DG YL 7 8 C207 NATURAL PASSENGER DOOR SIDE CAV CIRCUIT 1 2 P128 18LG DG 3 Q122 14OR YL 4 P126 18LG OR 5 X202 18DG VT 6 X292 18DG YL 7 8 C208 GREEN I...

Page 585: ...ACK BODY SIDE CAV CIRCUIT 1 F20 20PK WT 2 L1 20WT LG 3 K33 20DB LG 4 F242 20PK 5 K136 20LB BK 6 C300 BLACK TRANSMISSION SIDE CAV CIRCUIT 1 F20 20PK WT 2 L1 20WT LG 3 K33 20DB LG 4 F242 20PK 5 K136 20L...

Page 586: ...SIDE CAV CIRCUIT 1 Z1 18BK 2 L7 20WT YL 3 L50 20WT TN 4 L62 20WT RD 5 6 L1 20WT LG C302 BLACK RIGHT TAIL LAMP SIDE CAV CIRCUIT 1 Z1 18BK 2 L7 20WT YL 3 L50 20WT TN 4 L62 20WT RD 5 6 L1 20WT LG C303 BL...

Page 587: ...BLACK REAR FOG LAMP SIDE CAV CIRCUIT 1 J1 18WT 2 Z1 18BK C304 EXPORT BLACK BODY SIDE CAV CIRCUIT 1 J1 16WT DB 2 Z1 16BK DG CAMSHAFT POSITION SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K44 18DB GY CAMSH...

Page 588: ...CUIT FUNCTION 1 R45 20LG OR DRIVER SQUIB 1 LINE 2 2 R43 20LG BR DRIVER SQUIB 1 LINE 1 3 R63 20LG WT DRIVER SQUIB 2 LINE 2 4 R61 20LG VT DRIVER SQUIB 2 LINE 1 5 6 X920 20GY OR RADIO CONTROL MUX RETURN...

Page 589: ...4 15 16 Z127 12BK DG GROUND 17 18 L50 20WT TN BRAKE LAMP SWITCH OUTPUT 19 B3 18DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12V SUPPLY 21 22 B8 18DG TN LEFT FRO...

Page 590: ...D23 20WT OR FLASH PROGRAM ENABLE 10 D24 20DB WT FLASH ABS 11 12 13 14 15 16 A105 18DB RD FUSED B DECKLID RELEASE MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION A Q2 18WT DECKLID RELEASE DRIVER B Z1 20BK GROUN...

Page 591: ...DOOR LOCK SWITCH PASSENGER BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F71 20PK TN IGNITION FEED 2 P96 20LG LB PASSENGER DOOR SWITCH MUX 3 P900 20LG OR PASSENGER DOOR SWITCH RETURN ENGINE COOLANT TEMPERATURE S...

Page 592: ...URGE SOLENOID CONTROL 2 F202 20PK GY FUSED IGNITION SWITCH OUTPUT RUN START EXHAUST SOLENOID EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 J12 18DG RD EXHAUST SOLENOID RELAY OUTPUT 2 Z1 18BK GROUND EXHAUS...

Page 593: ...DOOR SWITCH RETURN EXTERIOR DOOR HANDLE SWITCH PASSENGER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P96 20LG LB PASSENGER DOOR SWITCH MUX 2 P900 20LG OR PASSENGER DOOR SWITCH RETURN FOG LAMP LEFT FRONT BLACK...

Page 594: ...RT 2 WAY CAV CIRCUIT FUNCTION 1 J1 20WT REAR FOG LAMP RELAY OUTPUT 2 Z1 20BK GROUND FOOTWELL LAMP LEFT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M21 20YL BR FOOTWELL LAMPS DRIVER 2 Z1 20BK GROUND FOOTWELL LA...

Page 595: ...ELAY OUTPUT FUEL INJECTOR NO 3 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K13 18BR DG FUEL INJECTOR NO 3 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 4 BLACK 2 WAY CAV CIRCUIT FUNCT...

Page 596: ...LAY OUTPUT FUEL INJECTOR NO 8 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K28 18BR LB FUEL INJECTOR NO 8 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 9 BLACK 2 WAY CAV CIRCUIT FUNCTI...

Page 597: ...COMMON 2 7 G130 20VT LG COOLANT TEMPERATURE GAUGE SIGNAL 8 G131 20LG VT COOLANT TEMPERATURE GAUGE RETURN 9 G127 20VT DB OIL TEMPERATURE GAUGE SIGNAL 10 G128 20DB VT OIL TEMPERATURE GAUGE RETURN 11 G5...

Page 598: ...NCTION 1 M28 20YL TN GLOVE BOX LAMP DRIVER 2 Z1 20BK GROUND HEADLAMP WASHER PUMP MOTOR EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 14BK GROUND 2 J15 14TN HEADLAMP WASHER PUMP RELAY OUTPUT HEADLAMP WA...

Page 599: ...EADLAMP RELAY OUTPUT B Z1 20BK GROUND HIGH BEAM HEADLAMP LEFT BLACK 2 WAY CAV CIRCUIT FUNCTION A L33 20LG BR LEFT HIGH BEAM OUTPUT B Z1 20BK GROUND HIGH BEAM HEADLAMP RIGHT BLACK 2 WAY CAV CIRCUIT FUN...

Page 600: ...ULE BLACK 3 WAY CAV CIRCUIT FUNCTION 1 C240 18LB TN HYDRAULIC COOLING FAN CONTROL 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 Z1 18BK GROUND IDLE AIR CONTROL MOTOR BLACK 4 WAY CAV CIRCUIT FUNCTI...

Page 601: ...B TN IGNITION COIL NO 2 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K18 18DB OR IGNITION COIL NO 3 DRIVER IGNITION SWITCH BLACK 5 WAY CAV CIRCUIT FUNCTION 1 G900 20VT OR SENSE RETURN 2 G2...

Page 602: ...RE GAUGE SIGNAL 3 G131 20LG VT COOLANT TEMPERATURE GAUGE RETURN 4 G130 20VT LG COOLANT TEMPERATURE GAUGE SIGNAL 5 G913 20VT OR GAUGE COMMON 2 6 G133 20VT VOLTMETER RETURN 7 G132 20VT DG VOLTMETER SIGN...

Page 603: ...CIRCUIT FUNCTION 1 P97 20LG YL DRIVER DOOR SWITCH MUX 2 P901 20OR LB DRIVER DOOR SWITCH RETURN INTERIOR DOOR HANDLE SWITCH PASSENGER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P96 20LG LB PASSENGER DOOR SWIT...

Page 604: ...LEAK DETECTION PUMP BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 K125 18BR DG GENERATOR SOURCE 3 K106 20VT YL LEAK DETECTION PUMP SOLENOID CONTROL 4 K107 20VT WT LEAK DETECTION PUMP SWITCH SENSE LICENSE LAMP...

Page 605: ...P LEFT FRONT DK GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L7 20WT YL PARK LAMP SWITCH OUTPUT 2 L61 20LG LEFT TURN SIGNAL MARKER LAMP LEFT REAR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L7 20WT YL PARK LAMP SWITCH...

Page 606: ...CAV CIRCUIT FUNCTION 1 2 L61 20LG LEFT TURN SIGNAL 3 F71 20PK TN IGNITION FEED 4 L63 20WT DG LEFT REAR TURN SIGNAL DRIVER 5 L62 20WT RD RIGHT REAR TURN SIGNAL DRIVER 6 L60 20TN RIGHT TURN SIGNAL 7 G9...

Page 607: ...20BK GROUND 3 K900 20DB DG SENSOR GROUND 4 K141 18TN WT OXYGEN SENSOR 1 2 SIGNAL OXYGEN SENSOR 2 1 RIGHT BANK UP BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K80...

Page 608: ...TURN LAMP LEFT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L61 20LG LEFT TURN SIGNAL 2 L7 20WT YL PARK LAMP SWITCH OUTPUT 3 Z1 20BK GROUND PARK TURN LAMP RIGHT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L60 20TN RIGHT...

Page 609: ...D RIGHT INSTRUMENT PANEL SPEAKER 3 X390 18DG BR AMPLIFIED LEFT REAR WOOFER 4 X300 18GY BR AMPLIFIED LEFT REAR WOOFER 5 X303 18DG TN AMPLIFIED LEFT REAR SPEAKER 6 X393 18DG GY AMPLIFIED LEFT REAR SPEAK...

Page 610: ...MIRROR DRIVER WHITE 3 WAY CAV CIRCUIT FUNCTION 1 P71 20TN DG DRIVER MIRROR UP DRIVER 2 P73 20TN VT DRIVER MIRROR COMMON DRIVER LEFT DOWN 3 P75 20TN LG DRIVER MIRROR RIGHT DRIVER POWER MIRROR PASSENGER...

Page 611: ...WINDOW HALL SIGNAL 3 Z1 20BK GROUND 4 Q122 14OR YL PASSENGER WINDOW DOWN RELAY OUTPUT 5 Q112 14OR BR PASSENGER WINDOW UP RELAY OUTPUT 6 POWER WINDOW SWITCH DRIVER GRAY 3 WAY CAV CIRCUIT FUNCTION 1 F7...

Page 612: ...CONTROL NO 2 DRIVER 12 13 14 15 K21 18LG DB INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K2 18VT OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 17 F855 18PK YL 5V SUPPLY 18 K44 18DB GY CAMSHAFT POSITION SENSO...

Page 613: ...INJECTOR NO 6 DRIVER 13 K28 18BR LB FUEL INJECTOR NO 8 DRIVER 14 K116 18BR LG FUEL INJECTOR NO 10 DRIVER 15 K12 18BR DB FUEL INJECTOR NO 2 DRIVER 16 K14 18BR TN FUEL INJECTOR NO 4 DRIVER 17 C240 18LB...

Page 614: ...CTION PUMP SWITCH SENSE 15 K25 18DB VT BATTERY TEMPERATURE SENSOR SIGNAL 16 K80 18BR TN OXYGEN SENSOR 2 1 HEATER CONTROL 17 K90 18LB TN STARTER MOTOR RELAY CONTROL 18 K242 18BR YL KNOCK SENSOR NO 2 SI...

Page 615: ...60 20DG RD RADIO 12V OUTPUT 14 D25 20WT VT PCI BUS 15 16 17 18 X51 20DG DB LEFT REAR SPEAKER 19 X57 20DG OR LEFT REAR SPEAKER 20 X58 20DB OR RIGHT REAR SPEAKER 21 X52 20GY DB RIGHT REAR SPEAKER 22 Z51...

Page 616: ...RD COMMON DOOR DRIVER REMOTE KEYLESS ENTRY MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 G96 20VT DG REMOTE KEYLESS ENTRY INTERFACE 2 D9 20WT GY RKE MODULE PROGRAM ENABLE 3 Z2 20BK LG GROUND 4 5 6 M1 20Y...

Page 617: ...242 20PK FUSED B B K136 20LB BK REVERSE LOCK OUT SOLENOID CONTROL SEAT BELT SWITCH DRIVER WHITE 2 WAY CAV CIRCUIT FUNCTION 1 R57 20LG GY DRIVER SEAT BELT SWITCH SENSE 2 R59 20LG TN DRIVER SEAT BELT SW...

Page 618: ...AT BELT TENSIONER LINE 2 2 R56 20LB DG PASSENGER SEAT BELT TENSIONER LINE 1 SHUTTER MOTOR LEFT WHITE 2 WAY CAV CIRCUIT FUNCTION 1 L33 20LG BR LEFT HIGH BEAM OUTPUT 2 Z1 20BK GROUND SHUTTER MOTOR RIGHT...

Page 619: ...SED B B K33 20DB LG SKIP SHIFT SOLENOID CONTROL SPEAKER LEFT DOOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X201 18GY VT AMPLIFIED LEFT DOOR SPEAKER 2 X291 18GY YL AMPLIFIED LEFT DOOR SPEAKER SPEAKER LEFT IN...

Page 620: ...G WT AMPLIFIED RIGHT REAR WOOFER SPEAKER RIGHT DOOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X202 18DG VT AMPLIFIED RIGHT DOOR SPEAKER 2 X292 18DG YL AMPLIFIED RIGHT DOOR SPEAKER SPEAKER RIGHT INSTRUMENT PA...

Page 621: ...T STARTER MOTOR BATTERY EYELET 1 WAY CAV CIRCUIT FUNCTION 1 A0 2RD B STARTER MOTOR GENERATOR EYELET 1 WAY CAV CIRCUIT FUNCTION 1 A11 4BK GY FUSED B TAIL LAMP LEFT LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1...

Page 622: ...P SWITCH OUTPUT 3 L50 20WT TN BRAKE LAMP SWITCH OUTPUT TAIL STOP LAMP RIGHT DK GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 L7 20WT YL PARK LAMP SWITCH OUTPUT 3 L50 20WT TN BRAKE LAMP SWITCH OUT...

Page 623: ...CIRCUIT FUNCTION 1 L63 20WT DG LEFT REAR TURN SIGNAL DRIVER 2 3 Z1 20BK GROUND TURN SIGNAL LAMP RIGHT REAR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L62 20WT RD RIGHT REAR TURN SIGNAL DRIVER 2 3 Z1 20BK GRO...

Page 624: ...GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B7 18DG VT RIGHT FRONT WHEEL SPEED SENSOR 12V SUPPLY 2 B6 18DG WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR RIGHT REAR LT GRAY 2 WAY CAV CIRCUIT FUNCT...

Page 625: ...W5 16BR LG WIPER PARK SWITCH SENSE 2 Z1 18BK GROUND 3 W110 16BR WT WASHER SWITCH SENSE 4 F13 18PK FUSED RUN ACC RELAY OUTPUT 5 W4 16BR OR WIPER SWITCH HIGH SPEED OUTPUT 6 W3 16BR WIPER SWITCH LOW SPEE...

Page 626: ...1 2 Adjustable Pedals Motor WT Under Left Side of Instrument Panel N S Adjustable Pedals Switch WT Right Side of Steering Column 19 Airbag Control Module ORC C1 YL Front of Center Console 19 23 Airbag...

Page 627: ...Right Toe Box 22 24 C201 YL Right Toe Box 22 24 C202 NAT Under Left Side of Instrument Panel 20 26 C203 NAT Under Right Side of Instrument Panel 22 27 C204 LT GY Right Toe Box 16 17 22 C205 BK Under...

Page 628: ...ide of Rear Facia N S Fog Lamp Right Front BK Right Front Corner of Vehicle 5 Fog Lamp Right Rear BK Right Front Corner of Vehicle N S Footwell Lamp Left BK Under Left Side of Instrument Panel 18 19 F...

Page 629: ...ke Air Temperature Sen sor BK On Air Cleaner 9 Interior Door Handle Switch Driver BK Top of Left Door 26 Interior Door Handle Switch Passenger BK Top of Right Door 27 Key In Switch Halo Lamp WT On Ste...

Page 630: ...10 Powertrain Control Module C2 BK WT Left Front of Engine Compartment 6 10 Powertrain Control Module C3 BK GY Left Front of Engine Compartment 1 6 Power Window Motor Driver BK Bottom Rear of Left Do...

Page 631: ...Bottom of Right Door 27 Speaker Right Instrument Panel WT Right Side of Instrument Panel 18 Speaker Right Rear WT Right Side of Rear Deck 24 Starter Motor NAT Left Rear Engine Compartment 1 11 13 Tail...

Page 632: ...elwell 2 G104 On Left Front Frame Rail Near T O for High Note Horn 1 3 G105 On Right Front Frame Rail Near Washer Pump Motor 4 G106 On Left Front Frame Rail Near T O for High Note Horn 1 3 G107 Engine...

Page 633: ...O for C102 and C103 1 S119 In T O for Horns 5 S120 In T O for High Note Horn 4 S121 Near T O for Low Note Horn 1 S122 Near T O for Washer Pump Motor 4 S123 Near T O for C104 1 S124 Near T O for G103...

Page 634: ...Near T O for Glove Box Lamp N S S213 In T O for Radio N S S214 Near T O for Brake Lamp Switch 18 19 S215 Near T O for Glove Box Lamp 18 S216 Near T O for Power Outlet 23 S217 Near T O for Instrument C...

Page 635: ...for G205 25 S314 Passenger Door 27 S315 Near T O for Door Lock Switch Passenger 27 S316 Near T O for Speaker Right Door 27 S317 Near T O for Power Window Motor Driver 26 S318 Near T O for Power Window...

Page 636: ...Fig 1 LEFT ENGINE COMPARTMENT ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 11 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 637: ...Fig 2 LEFT FRONT ENGINE COMPARTMENT 8W 91 12 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 638: ...Fig 3 FRONT LIGHTING ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 639: ...Fig 4 RIGHT ENGINE COMPARTMENT Fig 5 RIGHT FRONT ENGINE COMPARTMENT 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 640: ...Fig 6 POWERTRAIN CONTROL MODULE Fig 7 LEFT REAR ENGINE COMPARTMENT ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 641: ...Fig 8 LEFT FRONT ENGINE COMPARTMENT EXPORT Fig 9 LEFT FRONT ENGINE 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 642: ...Fig 10 LEFT REAR ENGINE ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 643: ...Fig 11 FRONT ENGINE 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 644: ...Fig 12 RIGHT FRONT ENGINE Fig 13 REAR ENGINE COMPARTMENT ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 645: ...Fig 14 LEFT REAR TRANSMISSION Fig 15 RIGHT TRANSMISSION 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 646: ...Fig 16 HVAC TOP Fig 17 HVAC SIDE ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 647: ...Fig 18 REAR INSTRUMENT PANEL 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 648: ...Fig 19 CENTER INSTRUMENT PANEL ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 649: ...Fig 20 LEFT KICK PANEL Fig 21 CLOCKSPRING 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 650: ...Fig 22 RIGHT KICK PANEL Fig 23 FRONT CENTER BODY ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 651: ...Fig 24 REAR BODY 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 652: ...Fig 25 BODY UNDER SEATS ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 653: ...Fig 26 LEFT DOOR 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 654: ...Fig 27 RIGHT DOOR ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 655: ...Fig 28 RIGHT REAR CHASSIS 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 656: ...Fig 29 LEFT REAR CHASSIS ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 657: ...Fig 30 RIGHT REAR BODY Fig 31 REAR LIGHTING 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION ZB CONNECTOR GROUND SPLICE LOCATION Continued...

Page 658: ...Fig 32 DECKLID ZB 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 659: ......

Page 660: ...e bezel 5 Hold the outer clamp while turning shell INSTALLATION 1 Assemble cigar lighter 2 install cigar lighter to center console bezel 3 Install cigar lighter element 4 Install center console bezel...

Page 661: ...each of the engine compartment wire harness connectors 5 Torque nut retaining positive battery cable at PDC to 96 141 N m 85 130 in lbs 6 Reconnect the battery negative remote cable POWER OUTLET REMO...

Page 662: ...NSPECTION 30 INSTALLATION 31 CYLINDER HEAD S REMOVAL CYLINDER HEAD S 31 CLEANING INSPECTION 32 INSTALLATION CYLINDER HEAD S 32 CYLINDER HEAD COVER S REMOVAL 33 INSTALLATION 34 ROCKER ARMS REMOVAL 34 I...

Page 663: ...MEASURING PISTON RING CLEARANCES 60 REMOVAL 60 INSTALLATION 60 CONNECTING ROD BEARINGS DESCRIPTION 61 STANDARD PROCEDURE CONNECTING ROD BEARING FITTING 61 MEASURING CONNECTING ROD BEARING CLEARANCE 62...

Page 664: ...nctions not detected and remedied by routine maintenance These malfunctions may be classified as either mechanical e g a strange noise or performance e g engine idles rough and stalls Refer to 9 ENGIN...

Page 665: ...the appropri ate Diagnostic Information for ignition sys tem diagnosis 2 No fuel 2 Perform fuel pressure test Refer to the appropriate Diagnostic Information for fuel system diagnosis 3 Low or no eng...

Page 666: ...tem and replace fuel filter 4 Burned warped or pitted valves 4 Install new or reface valves as neces sary 5 Faulty coil s 5 Test and replace as necessary ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE...

Page 667: ...learance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check No 3 bearing for wear on flanges 6 Crankshaft journal out of round and or worn 6 Grind journals or re...

Page 668: ...emoved check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future reference 6 Be sure throttle blade is fully open during the compression che...

Page 669: ...ders follow the proce dures in Cylinder Compression Pressure Test in this section An engine cylinder head gasket leaking between adjacent cylinders will result in approxi mately a 50 70 reduction in c...

Page 670: ...avy click A light noise is usually caused by exces sive leak down around the unit plunger which will necessitate replacing the tappet or by the plunger partially sticking in the tappet body cylinder A...

Page 671: ...while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth...

Page 672: ...to seal the area between the bedplate and cyl inder block without disturbing the bearing clearance or alignment of these components The material cures slowly in the absence of air when torqued between...

Page 673: ...oving them from the engine This will catch any fluid that may possibly be in the cylinder under pressure 4 With all spark plugs removed rotate engine crankshaft using a breaker bar and socket 5 Identi...

Page 674: ...wire from stud at left side frame rail 15 Remove windshield wiper arms Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARMS REMOVAL 16 Remove cowl cover Refer to 23 BODY EX TERIOR COWL COVER REMOVAL 17 Dis...

Page 675: ...al Tool 6638 disconnect hydraulic clutch line quick connector at the transmission bell housing For Special Tool identification Refer to 9 ENGINE SPECIAL TOOLS 32 Disconnect transmission electrical con...

Page 676: ...ll Special Tool 9057 Engine Lifting Bracket to left front cylinder head boss Fig 11 and Fig 13 Fig 11 Engine Lift Bracket Installation 1 CYLINDER HEAD BOSS 2 SPECIAL TOOL 9057 Fig 12 Engine Lift Brack...

Page 677: ...19 Install under body stone shields 20 Lower vehicle 21 Install left and right side sill panels Refer to 23 BODY EXTERIOR ROCKER PANEL COVER INSTALLATION Fig 6 22 Install gear shift lever and gear shi...

Page 678: ...96 in Compression Pressure 1069 1172 kPa 155 170 psi Engine Weight Approx 284 Kilograms 625 Lbs CYLINDER BLOCK DESCRIPTION SPECIFICATION Metric Standard Cylinder Bore Diameter 102 356 102 368 mm 4 029...

Page 679: ...iston Ring Groove Depth No 3 92 53 92 79 mm 3 643 3 653 in PISTON PINS DESCRIPTION SPECIFICATION Metric Standard Clearance in Piston 0 009 0 022 mm 0 0004 0 0009 in Clearance in Connecting Rod 0 017 0...

Page 680: ...in CYLINDER HEAD VALVE SEAT DESCRIPTION SPECIFICATION Metric Standard Seat Angle 44 44 5 Runout Max 0 038 mm 0 002 in Width Finish Intake and Exhaust 1 02 1 52 mm 0 040 0 060 in Guide Bore Diameter S...

Page 681: ...ION SPECIFICATION Metric Standard Inner Rotor Thickness Min 18 92 mm 0 744 in Clearance Max 0 19 mm 0 007 in Diameter Min 82 45 mm 3 246 in Thickness Min 18 92 mm 0 744 in Tip Clearance Between Rotors...

Page 682: ...erature Sensor 8 5 75 Power Steering Pump Mounting Bolts 23 200 Rear Crankshaft Seal Retainer Bolts 11 95 Rocker Arm Bolts 35 26 Spark Plugs 27 20 Starter Mounting Bolts 41 30 Throttle Body Bolts 11 9...

Page 683: ...2 Crankshaft Pilot Bearing Installer 9058 Driver Handle C 4171 Front Crankshaft Seal Remover C 4679A Front Crankshaft Seal Installer MD 998306 Rear Crankshaft Seal Installation Guide 9060 Valve Spring...

Page 684: ...ressure Tester Kit 7700 Bloc Chek Kit C 3685 A Clutch Hydraulic Line Disconnect Tool 6638A Disconnect Tool 9005 DRB IIIT with PEP Module OT CH6010A Pressure Transducer OT CH7059 Adaptor 8116 ZB ENGINE...

Page 685: ...ver screws Fig 16 and release the top of the air cleaner assembly 2 Pull the air filter element up and off of the noz zle assembly Fig 17 the assembly is held in by the lips in the housing Fig 18 for...

Page 686: ...mbly 4 Disconnect the intake air temperature sensor electrical connector 5 Unscrew the rear lower fastener Fig 20 6 Remove the 2 front mounting screws Fig 21 7 Remove air cleaner assembly INSTALLATION...

Page 687: ...e mount INSTALLATION NOTE This procedure covers either the left or right engine mount 1 With engine raised position engine mount onto engine and install bolts Tighten bolts to 41 N m 30 ft lbs Fig 22...

Page 688: ...e dure before attempting any repairs Refer to 14 FUEL SYSTEM FUEL DELIVERY STANDARD PROCEDURE FUEL SYSTEM PRESSURE RELEASE PROCEDURE 2 Open trunk lid Remove battery cover Discon nect negative battery...

Page 689: ...head fuel injectors MAP sensor Engine Coolant Temperature ECT Sensor Idle Speed Control Sensor ISC Throttle Position Sensor TPS Right cylinder head fuel injectors 10 Carefully separate the fuel injec...

Page 690: ...ine Install intake manifold bolts and tighten ini tially to 1 N m 10 in lbs Tighten bolts starting at the center and working outward to 11 N m 95 in lbs Fig 30 4 Connect CCV hoses to left and right cy...

Page 691: ...r right exhaust manifold 1 Open trunk lid Remove battery cover Discon nect negative battery cable 2 Remove left or right side cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER...

Page 692: ...be taken to protect the intake manifold and cylinder head covers powder coating from scrapes and abrasions This procedure covers either the left or right cylinder head The aluminum alloy cylinder hea...

Page 693: ...ssages 3 Check cylinder head for flatness Fig 34 4 Inspect all surfaces with a straightedge 2 if there is any reason to suspect leakage If out of flat ness exceeds 0 019 mm 0 00075 in times the span l...

Page 694: ...NTENANCE FLUID TYPES DESCRIPTION Refer to LUBRICATION MAIN TENANCE FLUID TYPES SPECIFICATIONS 19 Fill the cooling system Refer to 7 COOL ING ENGINE STANDARD PROCEDURE FILL ING COOLING SYSTEM 20 Connec...

Page 695: ...e to the intake manifold port RIGHT CYLINDER HEAD COVER 1 Inspect cylinder head cover gasket Replace as necessary 2 Place cylinder head cover onto cylinder head Fig 37 3 Connect spark plug wires Posit...

Page 696: ...ver s Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION VALVE SPRINGS SEALS DESCRIPTION The valve spring is of cylindrical design made out of ovate wire with an internal flat ribbon d...

Page 697: ...ve spring being serviced to prevent the valve retaining locks from entering the engine once the valve spring is compressed 7 Using valve spring compressor MD998772 A with insert 6716 A 1 compress valv...

Page 698: ...t all related valvetrain components for damage to prevent engine misfire NOTE Black valve seals are intake Brown valve seals are exhaust Fig 45 1 Install valve seals 1 Fig 45 2 Coat the valve stems wi...

Page 699: ...ter the valves are refaced Refer to 9 ENGINE SPECIFICATIONS VALVE SEATS CAUTION Do not un shroud valves during valve seat refacing Fig 49 1 When refacing valve seats it is important that the correct s...

Page 700: ...tions ream to next oversize 3 Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored 4 Service valves with oversize stems and over...

Page 701: ...E ENGINE BLOCK VIBRATION DAMPER REMOVAL 13 Disconnect heater hose 14 Disconnect oil cooler line using Special Tool 9005 Refer to 9 ENGINE LUBRICATION OIL COOLER LINES STANDARD PROCEDURE 15 Remove A C...

Page 702: ...N DARD PROCEDURE 17 Connect heater hose 18 Install crankshaft damper and pulley Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 19 Connect coolant bottle inlet hose at thermo stat housing...

Page 703: ...crankshaft Fig 57 Lubricate the end of Special Tool 8194 with wheel bearing grease or equivalent NOTE Lubricate the threads of Special Tool 5048 using MoparT Nickel Anti seize Compound or equiv alent...

Page 704: ...should line up If timing marks do not line up remove cam sprocket and realign 7 Measure camshaft end play Refer to 9 ENGINE SPECIFICATIONS If not within specifi cations install new thrust plate 8 Inst...

Page 705: ...will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures 4 If the leakage occurs at the rear oil seal area refer to the section Inspection for Rea...

Page 706: ...ile the vehicle is on level ground will improve the accuracy of the oil level reading Remove the engine oil dipstick Fig 61 The dipstick is calibrated for 2 quarts within the SAFE zone Fig 62 Fig 61 F...

Page 707: ...and inspect for leaks 12 Stop engine and inspect oil level Adjust oil level as necessary OIL FILTER SPECIFICATION All DaimlerChrysler Corporation engines are equipped with a high quality full flow di...

Page 708: ...ly seated and rotates freely Fig 64 Dust cap 4 will only snap over quick connect fitting 1 when the cooler line 3 is properly installed NOTE If dust cap will not snap into place repeat assembly step 2...

Page 709: ...efer to 9 ENGINE LUBRICATION OIL COOLER LINES STANDARD PROCEDURE Fig 66 and Fig 67 4 Connect oil cooler coolant hoses Fig 65 5 Install air cleaner housing assembly connect throttle body air inlet hose...

Page 710: ...urfaces Inspect oil pan gasket Replace as necessary 2 Apply an 1 8 in bead of Mopar Engine RTV at the two joints between the cylinder block to timing chain case cover and the two joints between the re...

Page 711: ...s serviced with the timing chain cover Fig 70 1 Remove timing chain cover 1 Refer to 9 ENGINE VALVE TIMING TIMING CHAIN COVER REMOVAL 2 Disassemble oil pump 3 Refer to 9 ENGINE LUBRICATION OIL PUMP DI...

Page 712: ...re thickness and diameter of rotors if the outer rotor diameter is 82 45 mm 3 246 in or less replace rotor set Fig 74 and Fig 75 3 If either rotor thickness measures 18 92 mm 0 744 in or less replace...

Page 713: ...specifications 9 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other reasons for oil pressure loss ASSEMBLY 1 Assemble pump using new parts as required...

Page 714: ...NGINE BLOCK DESCRIPTION The cylinder block is made of a sand cast alumi num alloy The cylinder block has interference fit cast iron cylinder liners The cylinder liners are thermally installed during b...

Page 715: ...to wash parts with a solution of hot water and deter gent Dry parts thoroughly Use a clean white lint free cloth to check that the bore is clean Oil the bores after cleaning to prevent rusting CLEANI...

Page 716: ...e installation in original loca tion 2 Remove tappet aligning yoke bolt 1 Fig 84 3 Remove tappets 3 from bores CAUTION Do not disassemble tappets INSTALLATION 1 Lubricate tappets 2 Install tappets in...

Page 717: ...careful not to damage camshaft bearing surfaces with the cam lobes Fig 86 INSTALLATION 1 Lubricate camshaft lobes and camshaft bearing journals 2 Install camshaft being careful not to damage camshaft...

Page 718: ...90 degrees to piston pin axis at size location shown in Fig 87 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 88 Ref...

Page 719: ...nder identification Identify them if nec essary using a permanent ink or paint marker Fig 92 CAUTION Care must be taken not to damage the fractured rod and cap joint surfaces as engine damage may occu...

Page 720: ...engine oil slide the ring compressor over the piston Be sure position of rings does not change dur ing this operation 3 Rotate crankshaft so that the connecting rod journal is at the bottom of it s st...

Page 721: ...ng a suitable ring expander remove upper and intermediate piston rings Fig 97 2 Remove the upper oil ring side rail lower oil ring side rail and then oil ring expander from piston 3 Clean ring grooves...

Page 722: ...nsure correct assembly The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps Limits of taper or out of round on any crankshaft journals should be held...

Page 723: ...place the crankshaft must be rotated until the connecting rod being checked starts moving toward the top of the engine Only then should the cap be assembled and torqued to specifications Do not rotat...

Page 724: ...10 Using a bolt grip type universal puller remove the crankshaft damper Fig 106 Fig 104 Engine Mount to Frame Nuts Left Side Shown Right Side Typical 1 ENGINE MOUNT STUD 2 NUT Fig 105 Crankshaft Inse...

Page 725: ...OIL SEAL FRONT REMOVAL 1 Remove air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL...

Page 726: ...e surfaces are clean and free of oil 2 Install Special Tool 9060 1 seal guide onto end of crankshaft Fig 110 Align hole in tool with dowel pin on crankshaft 3 Carefully position retainer oil seal 1 to...

Page 727: ...d by removing the weight of the crankshaft This can be accomplished by either of two methods PREFERRED METHOD 1 Shimming the bearings adjacent to the bearing to be checked in order to remove the clear...

Page 728: ...e way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface Do not loosen main bearing cap 2 Use a feeler gaug...

Page 729: ...SPROCKETS REMOVAL 8 Remove oil pump pick up tube Fig 117 9 Remove crankshaft oil scraper Fig 118 CAUTION DO NOT use a number stamp or a punch to mark connecting rods Damage to connecting rod could occ...

Page 730: ...rankshaft journals should be held to 0 025 mm 0 001 in Journal grinding should not exceed 0 508 mm 0 020 inch under the standard journal diameter DO NOT grind thrust faces of No 3 main bearing DO NOT...

Page 731: ...way to the front of its travel c Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft counter weight This will hold the crankshaft in it s most forward position Step A...

Page 732: ...TIMING TIMING CHAIN COV ER S INSTALLATION 15 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 16 Install crankshaft damper and pulley Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPE...

Page 733: ...earing Install bearing with part number markings 1 facing out Fig 125 1 Install pilot bearing with Special Tools 9058 1 and C 4171 2 Fig 126 2 Install flywheel and clutch Refer to 6 CLUTCH CLUTCH DISC...

Page 734: ...ARY RESONATOR UPPER LEFT 16 REMOVAL AUXILIARY RESONATOR LOWER LEFT HANGER 16 INSTALLATION INSTALLATION AUXILIARY RESONATOR UPPER LEFT 16 INSTALLATION AUXILIARY RESONATOR LOWER LEFT HANGER 16 EXHAUST S...

Page 735: ...ORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CON VERTER RISES TO A H...

Page 736: ...clamps are spot welded to exhaust system If a band clamp must be replaced the spot weld must be ground off ADJUSTMENTS EXHAUST SYSTEM ALIGNMENT A misaligned exhaust system is usually indicated by a v...

Page 737: ...ating surfaces of the manifold and the catalytic converter pipe together This seals and supports the joint NOTE The V band clamp must be replaced when removed Band clamps are also used to secure exhau...

Page 738: ...TC The combustion reaction caused by the catalyst releases additional heat in the exhaust system Under severe operating conditions this causes tem perature increases in the area of the reactor Severe...

Page 739: ...resonator Fig 10 9 Remove catalytic converter from resonator NOTE When replacement is required on any com ponent of the exhaust system it is important that original equipment parts be used for the fo...

Page 740: ...ONVERTER 4 9A9 PILLAR SUPPORT ISOLATOR 5 BRACKET 6 BOLT S 7 DOWNSTREAM OXYGEN SENSOR Fig 9 Oxygen Sensors and Connectors Right Side Shown Left Side Typical 1 EXHAUST MANIFOLD 2 UPSTREAM OXYGEN SENSOR...

Page 741: ...lbs Fig 8 6 Starting from the front of exhaust system align each component to maintain position and proper clearance with body parts 7 Tighten A and B pillar support isolators to 28 N m 250 in lbs 8...

Page 742: ...ps Fig 11 and Fig 12 5 Remove B pillar support isolator Fig 11 6 Separate spout assembly from resonator 7 Separate spout assembly from H Pipe 8 Remove spout assembly INSTALLATION NOTE This procedure c...

Page 743: ...ssary 8 Check the exhaust system for contact with the body panels Make the necessary ajustments if needed Fig 12 H Pipe and Spout Assemblies 1 H PIPE 2 RIGHT SIDE SPOUT ASSEMBLY 3 BAND CLAMP 4 LEFT SI...

Page 744: ...eft spout assembly to left resonator Fig 11 Do not tighten band clamp at this time 6 Install left side B pillar support isolator Tighten bolts to 28 N m 250 in lbs Fig 11 7 Install right side B pillar...

Page 745: ...ll the rear extension belly pan Refer to 23 BODY EXTERIOR BELLY PAN INSTALLATION 6 Lower the vehicle 7 Start the engine and inspect for exhaust leaks Repair exhaust leaks as necessary 8 Check the exha...

Page 746: ...as necessary 8 Check the exhaust system for contact with the body panels Make any necessary adjustments if needed H PIPE EXPORT REMOVAL REMOVAL H PIPE 1 Remove the H pipe extension pipes Refer to 11 E...

Page 747: ...and clamps to 54 N m 40 ft lbs 5 Start the engine and inspect for exhaust leaks Repair exhaust leaks as necessary 6 Check the exhaust system for contact with the body panels Make any necessary adjustm...

Page 748: ...ing worked on NOTE Do not tighten the band clamps until all of the exhaust connections are in place 1 Connect the diverter pipe to the spout assem bly Fig 18 Loosely install the band clamp 2 Connect t...

Page 749: ...lower left hanger Fig 20 INSTALLATION INSTALLATION AUXILIARY RESONATOR UPPER LEFT 1 Slide the upper left hanger onto the muffler 2 Position the hanger and install the bolts Fig 19 Tighten to 28 N m 28...

Page 750: ...enoid from the bracket Fig 21 INSTALLATION 1 Position the exhaust solenoid on the bracket and install the screw 2 Connect the inlet and outlet vacuum hoses to the solenoid 3 Connect the exhaust soleno...

Page 751: ......

Page 752: ...10 FRAME SIDE SILL ASSEMBLY 11 REAR UPPER FRAME RAIL ASSEMBLY 11 SPECIFICATIONS FRAME DIMENSIONS 12 SPECIFICATIONS WELDING 20 REAR TRANSMISSION CROSSMEMBER REMOVAL 21 INSTALLATION 21 FRAME BUMPERS SPE...

Page 753: ...SCREW 6 SPRING NUT 7 HEADLAMP MOUNT SUPPORT 8 STUD WITH FENDER ASSEMBLY 9 FASCIA TO FENDER NUT Fig 2 FRONT FASCIA 1 PUSH ON SPRING NUT 2 FRAME ASSEMBLY 3 RIVET NUT 4 NUT 5 BOLTS 6 BUMPER REINFORCEMEN...

Page 754: ...he nuts attaching the fascia to the fender Fig 3 5 Remove the remaining wheel opening fasten ers 6 Remove the upper screws and remove the fas cia 7 Disconnect the fog lamps INSTALLATION EXPORT NOTE Wh...

Page 755: ...LLATION 1 Install the reinforcement and install the nuts 2 Tighten the nuts to 54 N m 40 ft lbs 3 Install the hood release handle and install the bolts 4 Install the front fascia Refer to 13 FRAME BUM...

Page 756: ...PLASH SHIELD REMOVAL 2 Remove the tail lamp units and position aside Refer to the LAMPS LIGHTING EXTERIOR of the service manual 3 Remove the nuts attaching fascia to the rear quarter Fig 8 4 Remove th...

Page 757: ...R QUARTER PANEL 1 FASCIA TO REAR QUARTER PANEL NUT 2 REAR QUARTER PANEL RETAINER 3 BODY ASSEMBLY 4 REAR FASCIA 5 ROUND SPRING NUT 6 FASCIA RETAINER Fig 9 REAR FASCIA 1 BODY ASSEMBLY 2 PUSH PIN 3 REAR...

Page 758: ...rear bumper foam Refer to 13 FRAME BUMPERS BUMPERS REAR BUMPER FOAM REMOVAL 2 Remove the bumper nuts and remove the bumper beam Fig 12 INSTALLATION 1 Install the bumper beam and install the nuts 2 Ti...

Page 759: ...l the front bumper reinforcement Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REINFORCEMENT INSTALLATION 3 Install the front fascia Refer to 13 FRAME BUMPERS BUMPERS FRONT FASCIA INSTAL LATION BRACK...

Page 760: ...ails can result Do not anchor or support vehicle on powertrain components during frame straightening operations Damage to powertrain can result Protect wire harness and plastic components from excessi...

Page 761: ...r other suitable means Installation 1 Clean and prep all rails and braces 2 Tack weld new front frame assembly in place using flux core wire Refer to 13 FRAME BUMPERS FRAME SPECIFICATIONS WELD ING 3 M...

Page 762: ...l sealer from the component surfaces Installation 1 Fit the new side sill assembly into place and check for fit and alignment 2 Apply sealer to toe box attaching area 3 Install bolts at toe box attach...

Page 763: ...ane extends from the center line C L of the vehicle outward The Z plane extends from Datum 312 mm 12 28 in below the frame rails upward Most Y plane dimen sions are symmetric to the C L Frame dimensio...

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...

Page 771: ...s 0 045 Tubular 0 035 Solid 3 329 Electrode Stick Out 3 89 1 29 1 29 5 89 N A Polarity Electrode 9 9 Work Piece 9 9 Electrode 9 9 Work Piece 9 9 Electrode 9 9 Work Piece 9 9 Shielding Gas Self Shielde...

Page 772: ...g schedules should come from the man ufacturer REAR TRANSMISSION CROSSMEMBER REMOVAL 1 Raise and support the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove the belly pan...

Page 773: ......

Page 774: ...INES HOSES AND CLAMPS DESCRIPTION FUEL TUBES LINES HOSES AND CLAMPS 5 STANDARD PROCEDURE HOSES AND CLAMPS 6 FUEL PRESSURE REGULATOR DESCRIPTION 6 OPERATION 6 REMOVAL 6 INSTALLATION 7 ELECTRIC FUEL PUM...

Page 775: ...is is designed to reduce the emission of fuel vapors into the atmo sphere The description and function of the Evapora tive Control System is found in the Emission Control Systems STANDARD PROCEDURE FU...

Page 776: ...gs in this section 5 Remove the fuel filter mounting bolt Fig 1 6 Remove the fuel filter from mounting clamp INSTALLATION 1 Install the fuel filter with mounting clamp 2 Install the fuel filter mounti...

Page 777: ...nector from the bottom of the fuel pump module electrical connector Fig 3 2 Pull out the locking wedge Fig 4 3 Using a small screwdriver lift locking finger away from terminal and push terminal out of...

Page 778: ...igher fuel pressures and the possibility of contami nated fuel in this system If it is necessary to replace these lines tubes hoses only those marked EFM EFI may be used If equipped The hose clamps us...

Page 779: ...RIPTION A fuel pressure regulator is used on all gas pow ered engines It is located inside the fuel pump mod ule It contains a diaphragm calibrated springs and a fuel return valve OPERATION The pressu...

Page 780: ...essure output of approximately 880 kPa 130 psi The regulator adjusts fuel system pressure to approximately 379 kPa 55 psi FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied...

Page 781: ...5 and Fig 16 10 Unlock and disconnect the electrical connector from the fuel pump module 11 Clean the area round the fuel pump module 12 Mark fuel pump module location on tank 13 Disconnect the fuel l...

Page 782: ...he electrical connector to the fuel pump module 7 Connect fuel line to the fuel pump module Refer to Quick Connect Fittings in the Fuel Delivery Section of this group 8 Fill fuel tank 9 Connect negati...

Page 783: ...el Pressure Release Procedure in this section 2 Remove the battery cover and disconnect nega tive battery cable 3 Remove the air cleaner assembly refer to the Engine Air Intake System Air Cleaner Hous...

Page 784: ...line quick connector Fig 23 9 Remove the bolts for the fuel rail Fig 24 10 Pull fuel rail and injectors straight up and out of the intake manifold Fig 25 Fig 22 FUEL INJECTOR CONNECTOR Fig 23 FUEL CO...

Page 785: ...Install the wiring harness to the wiring clips under the throttle body Fig 21 9 Connect fuel supply tube to fuel rail Fig 23 Refer to Quick Connect Fittings in the Fuel Delivery section 10 Install th...

Page 786: ...f the panel 3 Measure in 1 2 inch from the outline of the closeout panel CAUTION Do not protrude more than 1 2 inch thru the panel The fuel tank is behind this panel 4 Cut on the 1 2 inch line marked...

Page 787: ...nch in from the panel outline 5 Cut closeout panel hole for fuel tank Fig 32 and Fig 33 and panel removed Fig 34 6 Fuel tank and the EVAP system Fig 35 7 Drill holes 17 holes 8 Remove the convertible...

Page 788: ...rd and out of the way 11 Roll deck lid carpet forward and out of the way NOTE Be careful the sealer on the cover will make it difficult to remove the cover Fig 35 FUEL TANK EVAP CANISTER Fig 36 CONVER...

Page 789: ...a scraper or long knife cut the sealer under the cover to remove it from the vehicle 14 Remove the foam block from the top of the fuel pump module Fig 41 and Fig 42 Fig 39 FUEL PUMP MODULE COVER Fig...

Page 790: ...p module locknut Fig 45 20 Lift module up to remove being careful not to spill the residual fuel that is left in it The float arm of the level sensor catches on the inside of the fuel tank while remov...

Page 791: ...47 and Fig 48 26 Disconnect the vapor line at fuel filler tube Fig 49 27 Remove the fastener for fuel tank strap 28 Lower vehicle 29 Remove the left side fuel tank strap nut and remove the strap Fig...

Page 792: ...the EVAP canister 33 Pull wiring harness Fig 54 for heated back glass down and out of the way from the top of the fuel tank NOTE You may have to trim some of the trunk panel to make room for removal o...

Page 793: ...ank Fig 56 35 Remove the fuel tank from vehicle Fig 57 and Fig 58 36 Clean vehicle 37 Make sure that the fuel tank heat shield Fig 59 and Fig 60 is not damaged Fig 55 FUEL TANK REMOVAL INSTALL Fig 56...

Page 794: ...ial Tool 6856 to install fuel pump module locknut Fig 45 18 Connect fuel line to the fuel pump module Refer to Quick Connect Fittings in the Fuel Delivery Section of this group 19 Connect fuel pump mo...

Page 795: ...nect fitting assembly off of fuel tube nipple The retainer will remain on fuel tube INSTALLATION CAUTION Never install a quick connect fitting with out the retainer being either on the fuel tube or al...

Page 796: ...fitting from fuel system component being serviced The plastic retainer will remain on component being serviced after fitting is discon nected The O rings and spacer will remain in quick connect fittin...

Page 797: ...tainer ring will remain with quick connect fitting connector body 6 Inspect fitting connector body plastic retainer ring and fuel system component for damage Replace as necessary 7 Prior to connecting...

Page 798: ...OSITION SENSOR DESCRIPTION 41 OPERATION 41 REMOVAL 41 INSTALLATION 42 FUEL INJECTION OPERATION OPERATION INJECTION SYSTEM All engines used in this section have a sequential Multi Port Electronic Fuel...

Page 799: ...waiting time 3 O2 sensor voltage must stay below 1 02 Volts 4 The engine is NOT in decel fuel shut off or WOT mode 5 The engine speed is below 3808 RPM The multi port fuel injection systems has the f...

Page 800: ...ning the individual ground paths to the injectors On and Off The PCM adjusts engine idle speed and ignition timing The PCM adjusts the air fuel ratio according to the oxygen content in the exhaust gas...

Page 801: ...M monitors the air fuel ratio by using the input voltage from the O2 Sensor When the voltage reaches its preset high or low limit the PCM begins to add or remove fuel until the sensor reaches its swit...

Page 802: ...4 2 0 2 6 3 3 3 9 Fuel Correction Diagnostics There are two fuel correction diagnostic routines Fuel System Rich Fuel System Lean A DTC is set and the MIL is illuminated if the PCM detects either of...

Page 803: ...n this section REMOVAL CAUTION When servicing the accelerator pedal do not damage or kink the core wire inside the cable sheathing For the removal of the pedal assembly refer to Brakes section and the...

Page 804: ...nce Once crankshaft posi tion has been determined the PCM begins energizing the injectors in sequence The PCM determines igni tion timing from the crankshaft timing sensor REMOVAL The sensor is locate...

Page 805: ...Procedure in this section 2 Remove the battery cover and disconnect nega tive battery cable 3 Remove the air cleaner assembly refer to the Engine Air Intake System Air Cleaner Housing for more informa...

Page 806: ...ts for the fuel rail Fig 9 10 Pull fuel rail and injectors straight up and out of the intake manifold 11 Move the fuel rail forward and out from under the intake manifold and throttle body Fig 10 Fig...

Page 807: ...l system Check for leaks FUEL PUMP RELAY DESCRIPTION The relay is located in the PDC Check electrical terminals for corrosion and repair as necessary OPERATION The fuel pump relay supplies battery vol...

Page 808: ...trical connector from IAC motor INSTALLATION The IAC motor is inserted into a housing at the front of the intake manifold Fig 12 The IAC motor and housing are serviced together 1 Attach electrical con...

Page 809: ...sensor reads updates barometric pressure A normal range can be obtained by monitoring known good sensor in your work area As the altitude increases the air becomes thinner less oxygen If a vehicle is...

Page 810: ...diagnostic trouble code and illuminates the malfunction indica tor lamp MIL The O2 sensors produce voltages from 0 to 1 volt depending upon the oxygen content of the exhaust gas When a large amount o...

Page 811: ...convertor efficiency Also used to establish the upstream O2 goal voltage switching point REMOVAL 8 3L UPSTREAM 1 1 2 1 1 Raise and support vehicle 2 Disconnect heated oxygen sensor electrical con nec...

Page 812: ...o the throttle body linkage arm A factory adjusted set screw is used to mechani cally limit the position of the throttle body throttle plate Never attempt to adjust the engine idle speed using this sc...

Page 813: ...ve battery cable and install the battery cover THROTTLE CABLE REMOVAL 1 Disconnect cable from throttle cam Fig 22 2 From inside the vehicle hold the accelerator pedal up and remove the cable retainer...

Page 814: ...the position of the throttle blade changes the resistance of the TPS changes The PCM supplies approximately 5 volts to the TPS The TPS output voltage input signal to the PCM represents throttle blade...

Page 815: ...crew holes in the throttle body If the sensor will not rotate into place install the sensor with the throttle shaft on the other side of the socket tangs The TPS has slight tension when rotated to ali...

Page 816: ...anytime a power steering system problem is present and the second as necessary once the first test is completed These tests will determine if the power steering pump hydraulic fan or power steer ing g...

Page 817: ...dle 10 Check Analyzer gauge pressure Initial pres sure reading should be 345 552 kPa 50 80 psi If pressure is higher inspect hoses for restrictions and repair as necessary 11 Increase engine speed to...

Page 818: ...ts 1 Inspect power steering gear mounting bolts Replace as necessary Tighten to the specified torque 2 Loose tie rod outer or inner 2 Check tie rod pivot points for wear Replace worn loose parts as re...

Page 819: ...mn shroud rubbing 1 Realign shrouds as necessary 2 Steering column intermediate shaft rubbing 2 Move or realign item rubbing shaft 3 Clockspring noisy 3 Remove clockspring Reinstall wheel If noise is...

Page 820: ...t tensioner 6 Check and replace automatic drive belt tensioner Replace belt if worn or glazed STEERING CATCHES STICKS IN CERTAIN POSITIONS OR IS DIFFICULT TO TURN 1 Low power steering fluid level 1 Fi...

Page 821: ...6 High internal leak in power steering gear Follow Power Steering System Flow and Pressure Test procedure 6 Replace power steering gear STEERING WHEEL RESISTS RETURNING TO CENTER POSITION 1 Tires not...

Page 822: ...ing or knuckle as necessary 9 Loose outer tie rod end 9 Replace outer tie rod end that has excessive free play 10 Worn inner tie rod 10 Replace power steering gear 11 Defective steering gear rotary va...

Page 823: ...lace cause of air leak 3 Cracked power steering pump housing 3 Replace the power steering pump RESERVOIR FLUID OVERFLOW AND FLUID THAT IS MILKY IN COLOR 1 Water contamination 1 Drain the power steerin...

Page 824: ...STEERING Analyzer Power Steering 6815 Adapters Power Steering 6893 Hose Power Steering Analyzer 6959 Disconnect Cooler Line 8875 Adapters Power Steering 9091 Remover Ball Joint C 4150A ZB STEERING 19...

Page 825: ...TTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENT...

Page 826: ...ion surface for the puller to work against 9 Thread wheel retaining bolt back into end of steering shaft until approximately 13 mm 0 5 in of thread is showing between wheel and head of bolt 10 Install...

Page 827: ...Remove clockspring from column c Remove two screws securing multi function windshield wiper switch to steering column Fig Fig 2 Steering Column And Components 1 STEERING WHEEL 2 CLOCKSPRING 3 STEERING...

Page 828: ...n Fig 8 c Install halo lamp on column until its tabs snap into place on ignition cylinder housing d Position multi function windshield wiper switch onto top of column and install two screws securing s...

Page 829: ...haft missing spline area and push wheel onto shaft Make sure clockspring lines up with back of steering wheel and does not bind 14 Install steering wheel retaining bolt and tighten it until wheel is f...

Page 830: ...ca tion refer to the Wiring Diagrams sections 1 Disconnect negative cable from battery 2 Place key cylinder in RUN position Through the hole in the lower shroud depress lock cylinder retaining tab and...

Page 831: ...4 Install the multi function switch and tighten the 2 screws Fig 12 5 Install upper and lower shrouds 6 Install key cylinder cylinder retaining tab will depress only in the RUN position 7 Connect nega...

Page 832: ...er the vehicle has been involved in an under carriage impact which results in any type of damage or bending of front suspension components or the frame of the vehicle Under any conditions which result...

Page 833: ...to 19 STEERING COLUMN INTERMEDI ATE SHAFT DIAGNOSIS AND TESTING REMOVAL NOTE Review all Warnings and Cautions Refer to 19 STEERING WARNING 1 Disconnect negative cable from battery and isolate cable 2...

Page 834: ...are fully seated in the threaded holes on the steering wheel If the bolts are not fully seated in the threaded holes the threads may be stripped out of the steer ing wheel when attempting to remove t...

Page 835: ...ag into position and install three mounting screws Tighten mounting screws to 12 N m 105 in lbs torque NOTE When reconnecting the battery on a vehicle that has had the driver airbag removed the follow...

Page 836: ...indicator lamp fails to light blinks on and off or goes on and stays on there is an air bag system malfunction Refer to Appropriate Diag nostic Information to diagnose a system malfunction 8 Turn key...

Page 837: ...using a steering wheel holder 3 Remove air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 4 Siphon power steering fluid from fluid reser voir 5 Remove power steering...

Page 838: ...maged Shims available in various sizes are mounted between the steering gear and its mount Fig 2 A maximum of 11 mm 0 43 in or 7 16 in shimming is allowed between the steering gear and its mount 1 Ins...

Page 839: ...le to battery negative post CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 15 Fill power steering pump reservoir to correct...

Page 840: ...rque jam nut until wheel alignment toe has been set 2 Install outer tie rod onto steering knuckle Fig 3 Install NEW tie rod nut Tighten nut to 75 N m 55 ft lbs torque 3 Install wheels and tire assembl...

Page 841: ...3 Slowly fill the power steering reservoir to the FULL COLD level Leave the filler cap off the res ervoir 4 With the engine off rotate the steering wheel back and forth lock to lock at least 20 times...

Page 842: ...pump pressure fitting Fig 7 Drain excess power steering fluid from line 6 Disconnect A C clutch coil wire connector Fig 1 7 Remove return hose from radiator fan at power steering pump reservoir Fig 7...

Page 843: ...l hose clamp on return hose past upset bead on power steering reservoir fitting 5 Install power steering pressure hose in power steering pump pressure fitting Fig 7 Tighten pres sure hose quick connec...

Page 844: ...he system with fresh fluid and perform the Power Steering Pump Initial Operation proce dure listed in this section of the service manual Refer to 19 STEERING PUMP STANDARD PRO CEDURE 9 Start the engin...

Page 845: ...ble 2 Remove air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING REMOVAL 3 Siphon power steering fluid from fluid reser voir 4 Unthread power steering pressure hose quick conne...

Page 846: ...NE AIR INTAKE SYSTEM INSTALLATION 7 Connect the battery negative cable to bat tery negative battery terminal CAUTION Do not use automatic transmission fluid in power steering system Use only MoparT Po...

Page 847: ...ill power steering pump reservoir to correct fluid level Refer to 19 STEERING PUMP FLUID STANDARD PROCEDURE 7 Perform Power Steering Pump Initial Opera tion procedure Refer to 19 STEERING PUMP STANDAR...

Page 848: ...ntry of foreign material into the components dur ing servicing 1 Disconnect negative cable from battery and isolate cable 2 Remove air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER H...

Page 849: ...OR BELLY PAN INSTALLATION 4 Lower vehicle 5 Position radiator and install mounting screws Fig 8 Tighten mounting screws to 5 N m 45 in lbs torque 6 Thread return hose tube nut on gear end of hose into...

Page 850: ...into place Fig 7 3 Install front extension belly pan Refer to 23 BODY EXTERIOR BELLY PAN INSTALLATION 4 Lower vehicle 5 Position radiator and install mounting screws Fig 8 Tighten mounting screws to 5...

Page 851: ...ips making sure each tab locks into place on housing 5 Install power steering pump on vehicle Refer to 19 STEERING PUMP INSTALLATION 6 Fill power steering pump reservoir to correct fluid level Refer t...

Page 852: ...n aluminum exterior case and six forward gear ratios All gears including reverse are synchronized The gear ratios are as follows First Gear 2 66 Second Gear 1 78 Third Gear 1 30 Fourth Gear 1 00 Fifth...

Page 853: ...ronizer hub and the main shaft The gear ratio for third gear is 1 30 1 4TH GEAR The 3 4 synchronizer sleeve moves forward to engage with the clutch teeth of the fourth speed gear Fig 3 Input power is...

Page 854: ...io for reverse gear is 2 90 1 DIAGNOSIS AND TESTING MANUAL TRANSMISSION LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak inadequate lubricant fill or an incor r...

Page 855: ...operation Rotating gears generate a mild whine that is audible but generally only at extreme speeds Severe highly audible transmission noise is gener ally the initial indicator of a lubricant problem...

Page 856: ...lation 15 Slide transmission back so that the input shaft clears bell housing Then lower transmission DISASSEMBLY 1 Remove shift cover bolts and remove shift cover 2 Remove roll pin from rear offset l...

Page 857: ...ust washer from mainshaft Fig 11 Fig 8 TAIL HOUSING BOLT 1 TAIL HOUSING 2 BOLTS Fig 9 TAIL HOUSING PRY POINTS 1 TAIL HOUSING 2 PRY POINT 3 REAR SEAL 4 PRY POINT Fig 10 MAINSHAFT BEARING AND SPACERS 1...

Page 858: ...rd snap ring 12 Remove reverse synchronizer sleeve snap ring Fig 15 Fig 12 REVERSE GEAR AND BEARING 1 BLOCKER RING 2 WAVE WASHER 3 REVERSE GEAR 4 MAINSHAFT 5 BEARING Fig 13 REVERSE SYNCHRONIZER 1 PUNC...

Page 859: ...ler Fig 18 16 Remove fifth gear snap ring from countershaft Fig 19 Fig 16 REVERSE SHIFT FORK AND SYNCHRONIZER 1 SHIFT FORK 2 SYNCHRONIZER Fig 17 5 6 SHIFT FORK SNAP RING 1 SHIFT FORK 2 SNAP RING Fig 1...

Page 860: ...olts 9378 and Bridge 9382 Fig 22 20 Remove shift fork and 5 6 synchronizer sleeve Fig 23 Fig 20 FIFTH GEAR THRUST WASHER 1 FIFTH GEAR 2 THRUST WASHER Fig 21 FIFTH GEAR 1 FIFTH GEAR 2 COUNTERSHAFT Fig...

Page 861: ...rust washer from countershaft Fig 26 24 Remove top cover plate bolts and pry off cover Fig 27 Fig 24 5 6 SYNCHRONIZER 1 SYNCHRONIZER HUB 2 COUNTERSHAFT Fig 25 SIXTH GEAR STOP RING 1 STOP RING 2 COUNTE...

Page 862: ...Fig 30 30 Remove clutch slave cylinder from transmis sion 31 Remove all front adapter bolts Fig 31 except one to hold the front adapter in place 32 Stand transmission on Fixture 9387 and bolt adapter...

Page 863: ...lever from shift rail and case from adapter plate Fig 32 35 Remove reverse rail assembly Fig 33 Fig 32 TRANSMISSION CASE 1 CASE 2 ADAPTER Fig 33 REVERSE SHAFT RAIL ASSEMBLY 1 MAINSHAFT 2 REVERSE SHIFT...

Page 864: ...blies out of adapter plate Fig 34 37 Remove countershaft assembly Fig 35 Fig 34 MAINSHAFT AND SHIFT RAIL 1 MAINSHAFT 2 SHIFT RAIL 3 ADAPTER 4 COUNTERSHAFT Fig 35 COUNTERSHAFT 1 COUNTERSHAFT 2 INPUT SH...

Page 865: ...TE O ring is used to hold mainshaft bearing in place during manufacturing only 2 Remove rear mainshaft bearing Fig 38 Fig 36 INPUT SHAFT 1 BEARING 2 INPUT SHAFT 3 ADAPTER Fig 37 MAINSHAFT O RING 1 BEA...

Page 866: ...d synchronizer hub off mainshaft with Splitter 9375 Fig 42 Fig 39 FIRST GEAR 1 FIRST GEAR 2 BEARING Fig 40 1 2 SYNCHRONIZER SNAP RING 1 1 2 SYNCHONIZER 2 SNAP RING 3 SECOND GEAR Fig 41 1 2 THRUST WASH...

Page 867: ...ainshaft Fig 45 10 Remove mainshaft tapered bearing with bear ing Splitter 9386 and press Fig 46 Fig 43 3 4 SYNCHRONIZER SNAP RING 1 SYNCHRONIZER 2 SNAP RING Fig 44 THIRD GEAR 1 THIRD GEAR 2 SYNCHRONI...

Page 868: ...tter 9384 and a press Fig 49 2 Remove input shaft bearing cup with Remover 9381 and Slide Hammer C 3752 Fig 50 Fig 47 COUNTERSHAFT ADAPTER BEARING 1 SPLITTER 2 BEARING 3 PRESS ADAPTER Fig 48 COUNTERSH...

Page 869: ...ng Fig 53 5 Remove mainshaft race with Remove 7794 A and Slide Hammer C 637 Fig 54 Fig 51 IDLER GEAR BRACKET BOLTS 1 EXTENSION HOUSING 2 BRACKET BOLTS Fig 52 THRUST WASHER GEAR AND BEARING 1 TAIL HOUS...

Page 870: ...Remove shift rail bushings with Remover 9367 and Slide Hammer C 3752 2 Remove countershaft Fig 58 and mainshaft bearing Fig 59 cups with Remover 9369 and Han dle C 4171 Fig 55 COUNTERSHAFT BEARING CA...

Page 871: ...ynchro must be replaced as and assembly 4 Inspect blocker rings and fiction cones replace if worn damaged or if friction material is burned 5 Inspect shift forks for wear and distortion Check fit of t...

Page 872: ...171 2 Install mainshaft bearing cup with Installer 9373 and Handle C 4171 Fig 64 3 Install countershaft bearing cup with Installer 9373 and Handle C 4171 Fig 65 Fig 62 SELECT SHIM 1 SHIM 2 BEARING CUP...

Page 873: ...r gear bracket and install bolts with Loctitet 242 Fig 69 Tighten bolts to 24 N m 18 ft lbs INPUT SHAFT 1 Install input shaft bearing cup with Installer 9380 and Handle C 4171 Fig 70 2 Install input s...

Page 874: ...2 BRACKET BOLTS Fig 70 INPUT SHAFT CUP 1 INSTALLER 2 HANDLE Fig 71 INPUT SHAFT BEARING 1 TUBE 2 INSTALLER 3 BEARING Fig 72 COUNTERSHAFT BEARING 1 INSTALLER 2 BEARING 3 COUNTERSHAFT ZB MANUAL TRANSMISS...

Page 875: ...er hub Fig 75 onto the mainshaft with Splitter 9375 4 Install 3 4 synchronizer sleeve 5 Install 3 4 synchronizer original or new snap ring Fig 76 Fig 73 MAINSHAFT BEARING INSTALLER 1 INSTALLER 2 BEARI...

Page 876: ...shaft Fig 79 9 Install first gear and bearing on main shaft Fig 80 Fig 77 SECOND GEAR 1 SECOND GEAR 2 1 2 SYNCHRONIZER Fig 78 THRUST WASHER AND BLOCKER RING 1 BLOCKER RING 2 1 2 SYNCHRONIZER 3 SECOND...

Page 877: ...t shaft seal into adapter plate with Installer 9366 2 Install input shaft into adapter plate Fig 82 3 Install countershaft assembly into adapter Fig 83 Fig 81 MAINSHAFT BEARING 1 BEARING 2 FIRST GEAR...

Page 878: ...stall guide plate and tighten torx bolts to 22 N m 16 ft lbs 7 Apply Mopart Gasket Maker to adapter sealing surface Fig 84 MAINSHAFT AND SHIFT RAIL 1 MAINSHAFT 2 SHIFT RAIL 3 ADAPTER 4 COUNTERSHAFT Fi...

Page 879: ...n to 34 N m 25 ft lbs 10 Install two torx screws on top of transmission case Fig 88 11 Drive roll pin down into offset lever Fig 89 Fig 86 TRANSMISSION CASE 1 CASE 2 ADAPTER Fig 87 ADAPTER BOLTS 1 INP...

Page 880: ...o 20 N m 15 ft lbs 16 Install sixth gear bearing and gear Fig 91 17 Install sixth gear stop ring Fig 92 18 Install 5 6 synchronizer on countershaft Fig 93 19 Install 5 6 synchronizer snap ring Fig 90...

Page 881: ...stall fifth gear stop ring 24 Install fifth gear bearing and gear on counter shaft Fig 97 Fig 94 5 6 SYNCHRONIZER SLEEVE 1 SHIFT FORK 2 SYNCHRONIZER SLEEVE Fig 95 5 6 SHIFT FORK SNAP RING 1 SHIFT FORK...

Page 882: ...th Installer 9391 bolt bearing and washer and 1 3 16 half inch drive socket Fig 101 Fig 98 FIFTH GEAR THRUST WASHER 1 FIFTH GEAR 2 THRUST WASHER Fig 99 FIFTH GEAR SNAP RING 1 FIFTH GEAR 2 SNAP RING Fi...

Page 883: ...nstall reverse gear thrust washer and snap ring Fig 105 Fig 102 SYNCHRONIZER SNAP RING 1 SYNCHRONIZER 2 SNAP RING Fig 103 SHIFT FORK SNAP RING 1 REVERSE SHIFT FORK 2 SNAP RING 3 SNAP RING PLIERS Fig 1...

Page 884: ...tail housing nuts on top of trans mission tail housing Fig 108 38 Slide offset lever onto shaft Fig 109 Fig 106 MAINSHAFT BEARING AND SPACERS 1 REVERSE GEAR 2 SPACERS 3 MAINSHAFT 4 BEARING Fig 107 TAI...

Page 885: ...ts to 61 N m 45 ft lbs 6 Remove transmission support 7 Install hydraulic clutch quick connector to the transmission bell housing 8 Install propeller shaft CAUTION The drive shaft strap bolts must be r...

Page 886: ...t shaft bearing cup in the front adapter COUNTERSHAFT BEARINGS PRELOAD 1 Install countershaft with original shim into adapter 2 Install case and bolt together using all bolts 3 Rotate countershaft to...

Page 887: ...olts 61 45 Trans Mount Bolts 41 30 Trans To Eng Bolts 3 8 41 30 Trans To Eng Bolts 7 16 68 50 Trans To Oil Pan 5 16 23 200 U joint Clamp Bolts 19 14 170 Needs application of LoctiteT 242 SPECIAL TOOLS...

Page 888: ...transmission from the vehicle 2 Measure output shaft end play and record number 3 Remove clutch slave cylinder from transmission adapter plate 4 Remove front adapter plate bolts Fig 116 5 Pry front c...

Page 889: ...g install a thinner shim 7 After the correct shim has been installed remove the adapter plate and apply Mopar Gasket Maker to the sealing surfaces 8 Install adapter and tighten adapter bolts to 34 N m...

Page 890: ...ly 5 Reinstall shift console SKIP SHIFT SOLENOID DESCRIPTION The skip shift solenoid is located on the drivers side of the transmission case The skip shift solenoid prevents the operator from shifting...

Page 891: ......

Page 892: ...LLATION 19 TIRES WHEELS DIAGNOSIS AND TESTING TIRE AND WHEEL RUNOUT Radial runout is the vertical distance between the high and low points on the tire or wheel edge Lateral runout is the horizontal mo...

Page 893: ...al runout of the wheel Fig 4 The radial runout of the wheel should be no more than 0 62 mm 0 024 inch Check the lateral runout of the wheel Fig 5 The lateral runout should be no more than 0 800 mm 0 0...

Page 894: ...7 and Fig 8 Off vehicle bal ancing is necessary Wheel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire TI...

Page 895: ...ANCE WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 8 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 2 ADD BALANCE WEIGHTS HERE 3 CORRECTIVE WEIGHT LOCATION 4 HEA...

Page 896: ...w high spot is within 102 mm 4 0 in of the first spot on the wheel the wheel may be out of specifications Refer to 22 TIRES WHEELS WHEELS DIAGNOSIS AND TESTING If the new high spot is NOT within 102 m...

Page 897: ...ION The TPM system utilizes these main components Tire Pressure Monitoring Module Tire Pressure Sensor Transmitters Four One in each wheel Cluster Odometer Message LO TIRE Body Control Module communic...

Page 898: ...e TPM module output toggles one 1 second low then one 1 second open for 10 seconds the BCM registers Critical Tire Pressure matured fault and sends a bus message to the cluster The cluster will flash...

Page 899: ...Monitor followed by Miscellaneous 4 Select the appropriate function from the next screen displaying the following options Program LF Pressure Sensor Program RF Pressure Sensor Program RR Pressure Sen...

Page 900: ...aused by moisture As listed earlier these conditions can affect the ability of the tire pressure transmitter to send the radio frequency signal to the TPM module CAUTION Be sure that an original equip...

Page 901: ...Failure to do this will greatly increase the risk of damaging the pressure transducer when servicing the tire 6 Remove nut mounting valve stem of pressure sensor transmitter to the wheel Fig 16 Drop...

Page 902: ...oper procedure must be used Not using the proper procedure will result in damage to the wheel and tire 3 Mount the upper bead of the tire on the wheel 4 Install the original or an OEM replacement valv...

Page 903: ...e excellent reliability traction skid resis tance and tread life Driving habits will have more effect on tire life than any other factor Careful driv ers will obtain in most cases much greater mileage...

Page 904: ...ors are molded into the bottom of the tread grooves When tread depth is at 1 6 mm 1 16 in the tread wear indicators will appear as a 13 mm 1 2 in band across the tread groove in the tire Tire replacem...

Page 905: ...tside shoulder If this type of tread wear occurs measure the camber angle If the camber angle is within the specified lim its caution the owner about excessive speed when turning An incorrect wheel to...

Page 906: ...Vehicle Lead Correction Diagnosis Chart ZB TIRES WHEELS 22 15 TIRES Continued...

Page 907: ...IRE PRESSURE FOR HIGH SPEED OPERATION WARNING OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING THE TIRE CAN FAIL SUDDENLY RESULTING IN LOSS OF VEHICLE CONTROL DaimlerChrysler Corporation advoc...

Page 908: ...r these raised sections In case of tire failure the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop The cast aluminum wheels used on this ve...

Page 909: ...olish oven cleaner a car wash that uses carbide tipped wheel clean ing brushes SPECIFICATIONS WHEELS Front Wheel Size 18 inch x 10 inch Rear Wheel Size 19 inch x 13 inch Mounting Stud Size 1 2 20 UNF...

Page 910: ...bearing assembly Refer to 2 SUSPENSION REAR HUB BEARING REMOVAL 2 If possible install a standard type wheel mounting nut on the wheel stud to be removed just far enough so the threads on the outer end...

Page 911: ......

Page 912: ...Disconnect the negative cable clamp from the battery when servicing electrical components that are live when the ignition is OFF Damage to electri cal system can result Do not use abrasive chemicals o...

Page 913: ...r accelerating stopping turning or when on an incline MIRROR INSPECTION METHOD When a leak point area is visually obstructed use a suitable mirror to gain visual access A mirror can also be used to de...

Page 914: ...lastics Examples of flexible plastic use Fascias Body Moldings and upper and lower Fascia Covers Repair Procedure The repair procedure for all three categories of plastics is basically the same The on...

Page 915: ...POLYES TER RYNITE TRIM PBT PPO PBT PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT PBTP POCAN VALOX WHEEL COVERS FENDERS GRILLES PBTP EEBC POLYBUTYLENE THEREPTHALATE EEBC ALLOY BEXLOY...

Page 916: ...PANELS B PILLARS QUARTER PANELS SPORT BAR TRIM LIFTGATE TRIM DECKLID TRIM SCUFF PLATES KICK PANELS CONSOLES PP EPDM PP EPDM ALLOY PP EPDM SPOILERS GRILLES PUR POLYURETHANE COLONELS PUR PU FASCIAS BUM...

Page 917: ...o dry before moving on with the repair PANEL REINFORCEMENT Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing Reinforcements can be made wit...

Page 918: ...e damaged area must be removed from the panel to achieve a successful repair All spider web cracks leading away from a damaged area must be stopped or removed To stop a running crack in a panel drill...

Page 919: ...mm 0 5 in in from edge of cutout hole Fig 7 6 Drill 4 mm 0 160 in holes 13 mm 0 5 in away from edge of patch across from holes drilled around cutout 7 Drill 3 mm 0 125 in holes in the support squares...

Page 920: ...wall tape over gaps around patch Fig 14 19 Mix enough adhesive to cover the entire patch area 20 Apply adhesive over the mesh around patch and smooth epoxy with a wide spreader to reduce fin ish grind...

Page 921: ...rews or a combination of these fasteners Service repair is enhanced as all exterior panels can be easily removed RIM Reaction Injection Molding SMC Sheet Molded Compound TPO Thermo Plastic Olefin AL A...

Page 922: ...lti Purpose Lube NLGI Grade 2 Window System Components MoparT Spray White Lube Lock Cylinders MoparT Spray White Lube Parking Brake Mechanism MoparT Spray White Lube SPECIFICATIONS TORQUE TORQUE SPECI...

Page 923: ...2 9 Instrument panel mounting nuts 28 21 Quarter panel door sill screws 6 55 Quarter panel rear screws 6 55 Quarter panel to fascia screws 6 55 Quarter panel top screws 6 55 Side view mirror nuts 7 65...

Page 924: ...PS REMOVAL 17 INSTALLATION 18 BOW CENTER 3 REMOVAL 18 INSTALLATION 18 BOW REAR 4 REMOVAL 18 INSTALLATION 18 CLOTH SUPPORT PANEL REMOVAL 19 INSTALLATION 19 HEADER ASSEMBLY REMOVAL 19 INSTALLATION 19 TA...

Page 925: ...Fig 1 EXPLODED VIEW 23 14 CONVERTIBLE TOP ZB CONVERTIBLE TOP Continued...

Page 926: ...er and trim off the excess material 2 Position the new cover and adjust the fit if required 3 Reglue the side of the cover 4 Adjust the fit of the side panels if required 5 Install new rivets attachin...

Page 927: ...e the sidearm linkage assembly Fig 5 8 Remove the top assembly INSTALLATION 1 Position the top assembly onto the vehicle 2 Insert wooden dowel rods or equivalent as alignment pins into the sidearm lin...

Page 928: ...he side panels onto the tack strips 5 Staple the side panels into place 6 Install the tack strips over the studs and install the nuts 7 Tighten the tack strip nuts to 12 N m 9 ft lbs 8 Connect the rea...

Page 929: ...NTER 3 REMOVAL 1 Roll down both door windows 2 Unlatch the convertible top 3 Remove the four bolts and remove the center 3 bow Fig 8 INSTALLATION 1 Install the center 3 bow and install the bolts 2 Tig...

Page 930: ...ION CABLE REMOVAL 2 Remove the cover assembly rivets to the rear of the header assembly 3 Remove the rivets attaching the stay pad straps to the header assembly 4 Remove the four linkage bolts and rem...

Page 931: ...of cover assembly to the linkage 3 Remove the tension cable rivet Fig 11 4 Remove the upper anchor and guide rivets Fig 12 5 Pull tension cable through the cover assembly and remove the cable Fig 9 TR...

Page 932: ...e the bulkhead trim panel Refer to 23 BODY INTERIOR BULKHEAD TRIM PANEL REMOVAL 2 Remove the bolts that secure the sidearm link age to the center 3 and rear 4 bows Fig 14 3 Remove the two pivot bolts...

Page 933: ...bs 10 Install the center 3 bolts and tighten the bolts to 5 N m 45 in lbs 11 Install the rear 4 bolts and tighten the bolts to 6 N m 55 in lbs 12 Install the bulkhead trim panel Refer to 23 BODY INTER...

Page 934: ...thin end connected to the body side of the hinge and the upper retaining clip snapping into place 3 Close lower ball socket retaining clip fully HINGE REMOVAL 1 Release decklid latch and open decklid...

Page 935: ...GAP AND FLUSH SPECIFICA TIONS 7 Install splash shields 8 Install rear wheels and tighten to specified torque Refer to 22 TIRES WHEELS INSTALLA TION Fig 2 UPPER SUPPORT CYLINDER RETAINING CLIP 1 RETAI...

Page 936: ...ignment and adjust if necessary Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICA TIONS LATCH STRIKER REMOVAL 1 Open the decklid 2 Using a grease pencil or equivalent mark the location of the st...

Page 937: ...bracket screws SLAM BUMPER REMOVAL 1 Release decklid latch and open decklid 2 Rotate slam bumper counterclockwise and remove the slam bumper from the decklid Fig 10 INSTALLATION 1 Position slam bumpe...

Page 938: ...and pull the harness from the hinge pillar Fig 2 3 Support door on suitable lifting device 4 Using a grease pencil or equivalent mark out line of door hinge on hinge pillar and door shut face 5 Remove...

Page 939: ...hinge pillar fasteners or the hinge to door fasteners and moving the door to the correct position 1 Support the door with a suitable lifting device 2 Remove the three screws and remove the door hinge...

Page 940: ...ge the front glass to the regulator lift plate 4 Install the two rear screws and tighten to 4 N m 35 in lbs 5 Lower the glass 6 Disconnect and isolate the battery negative cable 7 Install the watershi...

Page 941: ...engaging into the weather strip 6 Install door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION UP DOWN AND FORE AFT ADJUSTMENTS 1 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM...

Page 942: ...tainer lip during door closing with glass full up position 4 If any of the above conditions are found adjust the door glass as necessary to cure the condition OUTSIDE DOOR HANDLE REMOVAL 1 Open the do...

Page 943: ...se pencil or equivalent mark out line of door hinge on hinge pillar and door shut face 4 Remove bolts attaching door hinge to hinge pil lar Fig 12 5 Remove bolts attaching door hinge to door shut face...

Page 944: ...the locking tabs fully 2 Install the remote lock cylinder assembly and install the nut 3 Connect the electrical connector and the release cable 4 Install the access panel LATCH REMOVAL 1 Remove the do...

Page 945: ...to aid installation 2 Remove screws attaching door latch striker to lock pillar Fig 18 3 Remove striker and shims from lock pillar INSTALLATION 1 Position striker and shims to lock pillar 2 Install sc...

Page 946: ...dis engage the two vertical spring clips attaching top flange of the trim panel to door inner panel by prying trim panel upward to release clips Fig 22 11 Using a small flat bladed tool or equivalent...

Page 947: ...he center pin back through the push pin to the open position Next install push pin fastener into the open ing and push the center pin in flush with the head of the push pin to the lock position Fig 28...

Page 948: ...OR TRIM PANEL 1 DOOR ASSEMBLY 2 SPRING NUT 3 DOOR TRIM PANEL 4 TRIM PLUG SCREW CAP 5 SCREW Fig 27 DOOR TRIM HANDLE APPLIQUE 1 DOOR ASSEMBLY 2 DOOR TRIM PANEL 3 PUSH PIN FASTENER 4 HANDLE SCREW 5 DOOR...

Page 949: ...Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR RE PEATER LAMP REMOVAL 2 Remove the 3 screws and the hinge cover Fig 30 INSTALLATION 1 Cut a hole for the side repeater lamp using the supplied template...

Page 950: ...AL 48 INSTALLATION 48 SIDE VIEW MIRROR REMOVAL 50 INSTALLATION 50 GLASS OUTSIDE REARVIEW MIRROR REMOVAL 50 INSTALLATION 50 TRUNK PAN REMOVAL 51 INSTALLATION 51 FRONT FENDER REMOVAL 52 INSTALLATION 54...

Page 951: ...REAR EXTENSION BELLY PAN Fig 3 FRONT EXTENSION BELLY PAN 1 FRAME ASSEMBLY 2 FRAME BOLTS 4 3 FRONT EXTENSION BELLY PAN 4 FRONT FASCIA 5 FASCIA BOLTS 9 6 HEADLAMP MOUNT SUPPORT 7 SPRING NUT 8 HEADLAMP M...

Page 952: ...he frame bolts to 28 N m 21 ft lbs INSTALLATION REAR EXTENSION BELLY PAN 1 Install the pan and install the screws 2 Tighten the screws to 4 N m 35 in lbs 3 Tighten the frame bolts to 28 N m 21 ft lbs...

Page 953: ...INSTALLATION FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1 Remove the front wheel Refer to 22 TIRES WHEELS REMOVAL 2 Remove the two screws and two push pin fas teners Fig 8 3 Remove the front splash shiel...

Page 954: ...the three door opening screws Fig 11 and Fig 12 8 Using a hole saw or equivalent cut an access hole in the door surround panel where indicated Fig 13 9 Remove the screw from within the hole cut pre vi...

Page 955: ...1 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION 12 For the right side quarter panel connect the fuel filler tube Refer to 14 FUEL SYSTEM FUEL DE...

Page 956: ...NEL 4 REAR QUARTER PANEL TO REAR CLIP BRACKET 5 REAR CLIP Fig 13 QUARTER PANEL FRONT FASTENERS 1 QUARTER PANEL 2 ADJUSTMENT BRACKET 3 DOOR SURROUND CUT LOCATION 4 DOOR SURROUND PANEL 5 ADJUSTMENT BRAC...

Page 957: ...ching the two shields together then tighten the remaining 11 screws SILL PANEL REMOVAL 1 Remove the three screws and remove the door hinge cover Fig 16 2 Remove the screws attaching the fender grille...

Page 958: ...ower sill screws 7 Install the fender grille and install the upper screw attaching the grille to the fender 8 Install the lower grille screw at the sill 9 Install the door hinge cover and install the...

Page 959: ...STALLATION 1 Position the sill onto the vehicle 2 Tighten the sill to fender support nuts 3 Install the screws into the door surround panel 4 Install the rear screw into the frame near the quarter pan...

Page 960: ...CAL LAMPS LIGHTING EXTERIOR RE PEATER LAMP INSTALLATION Fig 20 SILL PANEL BOLTS 1 SILL PANEL 2 SPLASH SHIELD 3 FENDER GRILLE 4 FRAME ASSEMBLY Fig 21 SILL PANEL 1 FRAME ASSEMBLY 2 SILL PANEL 3 FENDER A...

Page 961: ...ass holder if equipped INSTALLATION CAUTION It is important to make sure the motor is square to the glass holder attaching fingers prior to glass holder attachment otherwise the glass holder could be...

Page 962: ...of the wheelhouse 10 Remove the trunk pan INSTALLATION 1 Replace any necessary trunk pan seals Refer to 23 BODY BODY STRUCTURE SEALER LOCA TIONS SPECIFICATIONS 2 Install the trunk pan 3 Install the b...

Page 963: ...Remove the screws attaching the fender to the fascia Fig 28 6 Remove the rivets attaching the fender to the support bracket 7 Remove the nuts where the hinge cover is attached 8 Remove the rear screw...

Page 964: ...VER 1 U NUTS 3 PER SIDE 2 U NUTS 2 PER SIDE 3 SCREW 1 PER SIDE 4 FENDER GRILLE 5 SCREWS 3 PER SIDE 6 HINGE COVER Fig 28 FRONT FENDER 1 RIVETS 2 FENDER SUPPORT 3 WINDSHIELD SURROUND 4 BOLTS 5 SCREWS 6...

Page 965: ...gn with marks made previously 4 Install and tighten the nut to 17 N m 13 ft lbs 5 Install the center screw and tighten to 17 N m 13 ft lbs 6 Install the front screw and tighten to 17 N m 13 ft lbs 7 C...

Page 966: ...Fig 33 4 Remove the rivets attaching the fender to the support bracket 5 Remove the nuts where the hinge cover is attached 6 Remove the rear screws 7 Remove the upper bolts and remove the fender Fig 3...

Page 967: ...clean adhesive residue from frame NOTE Do not apply adhesive close to the inboard edge of the fender support when installed Avoid unsightly squeeze out 2 Using a structural adhesive suitable for bond...

Page 968: ...the sill panel Refer to 23 BODY EX TERIOR ROCKER PANEL COVER INSTALLA TION FRONT STRUT TOWER TO TOWER BRACE REMOVAL 1 Remove air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING...

Page 969: ...LER LOCATIONS FRAME FRONT OF DASH PANEL 3 FRONT OF DASH PANEL 4 FRAME Fig 37 FENDER TIGHTENING SEQUENCE Fig 38 Front Strut Tower to Tower Brace 1 FRONT STRUT TOWER TO TOWER BRACE 2 MOUNTING BOLTS 23 5...

Page 970: ...ecessary Refer to 23 BODY HOOD HOOD ADJUST MENTS HINGE REMOVAL NOTE It is not necessary to remove the hood to replace one or both hinges The hinges can be replaced one at a time 1 Raise and support ho...

Page 971: ...insert shims between hinge and body Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 2 Adjust hood bumper in or out to adjust hood to fender height alignment 3 Adjust the hood latch as ne...

Page 972: ...screws and remove the handle assembly from the bumper beam Fig 6 INSTALLATION 1 Route the cable from the lower fascia opening to the latch 2 Attach the handle to the bumper beam and install the screw...

Page 973: ...8 INSTALLATION 1 Install the silencer pad and install the push pin fasteners 2 Install the ground wires and install the bolts Fig 7 GROUND WIRE ATTACHING POINT 1 WIPER MODULE 2 HOOD ASSEMBLY 3 GROUND...

Page 974: ...TE Lift the clips only enough to release the ball studs Fig 10 3 Remove the support cylinder INSTALLATION 1 Make sure the retaining clips are seated into the ball socket fully 2 Install the support cy...

Page 975: ...L CONSOLE REMOVAL 7 Remove the steering column cover Refer to 23 BODY INSTRUMENT PANEL STEERING COL UMN OPENING COVER REMOVAL 8 Using a trim stick C 4755 or equivalent remove the left speaker cover 9...

Page 976: ...box Refer to 23 BODY IN STRUMENT PANEL GLOVE BOX REMOVAL 7 Remove the glove box striker Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX LATCH STRIKER REMOVAL 8 Remove the two screws to the left of the glo...

Page 977: ...tch electrical connector 2 Position the cover into place and seat the right side clip at the tunnel fully 3 Roll the left side of the cover up and seat the upper clips fully 4 Install the two screws a...

Page 978: ...L PAD ASSEMBLY 5 INSTRUMENT PANEL BRACKET 3 INSTRUMENT PANEL STEERING COLUMN COVER Fig 2 STEERING COLUMN CONNECTORS 1 CLOCK SPRING CONNECTOR 2 WIPER SWITCH CONNECTOR 3 MULTIFUNCTION SWITCH CONNECTOR 4...

Page 979: ...pening Fig 7 19 Remove one screw to left A pillar trim and using a trim stick or equivalent gently pry off and remove trim from vehicle Fig 3 BRAKE LAMP SWITCH MOUNTING 1 ADJUSTABLE PEDALS ASSEMBLY 2...

Page 980: ...radio antenna connector Fig 9 30 Remove four screws and disconnect electrical connectors to radio and remove from vehicle 31 Disconnect the occupant restraint controller ground wires 32 Disconnect the...

Page 981: ...retain ing bolts and tighten to 12 N m 9 ft lbs 15 Connect the three right side electrical connec tors and one ground bolt 16 Reach up underneath the instrument panel and connect the passenger airbag...

Page 982: ...erve capacitor to discharge before beginning any airbag system or instrument panel component service 5 Remove the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 6...

Page 983: ...the trim panel Fig 1 INSTALLATION 1 Position the trim pan and seat the clips fully 2 Install the upper screw and retainer BULKHEAD QUARTER TRIM PANEL REMOVAL 1 Open the top 2 Move the drivers seat for...

Page 984: ...s at the drivers door 9 Install the sill plate 10 Install the screw at the rear of the console 11 Install the sport hoop and install the bolts 12 Tighten the bolts to 28 N m 21 ft lbs 13 Install the s...

Page 985: ...ts 1 Install the carpet 2 For the passenger side carpet install the radio amplifier 3 For the drivers side carpet insert the front of the adjustable footrest into the slot and install the rear bolts T...

Page 986: ...TION 1 Connect the console bezel electrical connectors 2 Install the shift knob and tighten the lock nut to 41 N m 30 ft lbs 3 Position the bezel and seat the spring clips fully Fig 6 TOP STACK CARPET...

Page 987: ...Remove mirror from vehicle INSTALLATION INSTALLATION 1 Position the mirror base at the bracket and slide it downward onto the support bracket 2 Tighten the setscrew 1 N m 15 in lbs torque 3 Connect mi...

Page 988: ...t the mirror support bracket is cor rectly aligned because the adhesive will cure rap idly 7 Allow the adhesive to cure for 8 10 minutes Remove any excess adhesive with an alcohol damp ened cloth 8 Al...

Page 989: ...quarter trim panels Refer to 23 BODY INTERIOR BULKHEAD TRIM PANEL INSTALLATION Sport Hoop 1 Install the sport hoop and install the bolts 2 Tighten the bolts to 28 N m 21 ft lbs 3 Install the sport ho...

Page 990: ...1 Position the console in the vehicle and connect the electrical connectors 2 Install the rear of the console and then the front 3 Install the rear screws 4 Move the seats back and install the four st...

Page 991: ...IMLERCHRYSLER COLOR CODE B BLACK X9 R BLACK RED XR PAINT CODE DESCRIPTION Exterior vehicle body colors are identified on the Body Code plate Refer to VEHICLE DATA VEHI CLE INFORMATION BODY CODE PLATE...

Page 992: ...th color touch up paint Do not overlap touch up color onto the original color coat around the scratch or chip Butt the new color to the original color if possible Do not stroke applicator brush on bod...

Page 993: ...connect and isolate the battery negative cable 4 Move seat as needed to access seat attaching front bolts and rear nuts Fig 1 5 Disconnect electrical connector Fig 2 6 Remove seat from vehicle INSTALL...

Page 994: ...er Fig 6 INSTALLATION NOTE Do not service adjusters separate from cushion assembly 1 Install the seat adjuster onto the seat cushion and install the bolts 2 Tighten the bolts to 28 N m 21 ft lbs 3 Ins...

Page 995: ...r installation by zip ping up the cover 4 Install the seat Refer to 23 BODY SEATS SEAT INSTALLATION SEAT BACK COVER REMOVAL 1 Remove the seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Unzip the seat back...

Page 996: ...ack cover installation by zip ping up the cover 8 Install the seat Refer to 23 BODY SEATS SEAT INSTALLATION SEAT BACK RECLINER REMOVAL 1 Remove the seat Refer to 23 BODY SEATS SEAT REMOVAL 2 Remove th...

Page 997: ...and remove the recliner han dle Fig 12 3 Remove the seat belt buckle bolt and buckle Fig 13 4 Remove the bolts attaching the recliners to the seat cushion 5 Remove the bolts and remove the child restr...

Page 998: ...ALLATION SEAT CUSHION COVER REMOVAL 1 Remove the seat adjuster Refer to 23 BODY SEATS SEAT ADJUSTERS REMOVAL 2 Unclip the recliner cable and remove the seat back assembly Fig 15 3 Disconnect the cushi...

Page 999: ...EFER TO THE URETHANE MANU FACTURER S DIRECTIONS FOR CURING TIME SPECIFICATIONS AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE VAPORS THAT ARE EMITTED FROM THE URE THANE ADHESIVE OR PRIMER COULD CAU...

Page 1000: ...n top and sides of windshield and 25 mm 1 in on bot tom of windshield Allow at least three minutes dry ing time 6 Using a razor knife remove as much original urethane as possible Do not damage paint o...

Page 1001: ...trips and water test windshield to verify repair Fig 3 WINDSHIELD 1 WINDSHIELD GLASS 2 WINDSHIELD SURROUND FRAME 3 WINDSHIELD GLASS SPACERS 4 WINDSHIELD GLASS SHIMS Fig 4 APPLY TAPE TO RETAIN WINDSHIE...

Page 1002: ...nel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION DOOR OPENING PRIMARY SEAL WEATHERSTRIP REMOVAL 1 Using a trim stick C 4755 or equivalent remove the scuff plate 2 Open the convertible top 3 Re...

Page 1003: ...a pillar trim Refer to 23 BODY INTERIOR A PILLAR TRIM REMOVAL 2 Remove the nuts and push pins 3 Remove the weatherstrip Fig 4 INSTALLATION 1 Clean the header with a suitable cleaner 2 Install the weat...

Page 1004: ...at the weatherstrip along the flange fully Fig 4 WINDSHIELD HEADER A PILLAR WEATHERSTRIP 1 WINDSHIELD HEADER A PILLAR WEATHERSTRIP 2 WINDSHIELD SURROUND 3 DOOR OPENING PRIMARY SEAL WEATHERSTRIP 4 DOOR...

Page 1005: ...ECIFICATIONS SEALER LOCATIONS 99 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 102 WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS 103 GAP AND FLUSH SPECIFICATIONS GAP FLUSH...

Page 1006: ...ascia to fender 0 75 1 0 0 0 0 0 1 0 9 Hood to fas cia 4 5 1 0 Parallel within 1 0 1 0 1 5 O F NOTE All measurements are in mm O F Over Flush U F Under Flush RIGHT REAR GAP FLUSH MEASUREMENTS DIMEN SI...

Page 1007: ...OPENING DIMENSIONS OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING DIMENSIONS 3 DOOR OPENING DIMENSIONS 4 CROSS BODY DIMENSIONS 5 TRUNK OPENING DIMENSIONS 6 Fig 3 WINDSHIELD OPENING DI...

Page 1008: ...Fig 4 DOOR OPENING DIMENSIONS Fig 5 CROSS BODY DIMENSIONS ZB BODY STRUCTURE 23 97 OPENING DIMENSIONS Continued...

Page 1009: ...Fig 6 TRUNK OPENING DIMENSIONS 23 98 BODY STRUCTURE ZB OPENING DIMENSIONS Continued...

Page 1010: ...LER LOCATION INDEX DESCRIPTION FIGURE DOOR SURROUND AND DASH ASSEMBLY 7 FRONT OF DASH PANEL AND FRAME 8 REAR CLIP FRAME 9 REAR QUARTER PANEL FRAME 10 WINDSHIELD SURROUND AND DASH ASSEMBLY 11 Fig 7 DOO...

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 1013: ...Fig 10 REAR QUARTER PANEL FRAME Fig 11 WINDSHIELD SURROUND AND DASH ASSEMBLY ZB BODY STRUCTURE 23 101 SEALER LOCATIONS Continued...

Page 1014: ...CTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS STRUCTURAL ADHESIVE LOCATION INDEX DESCRIPTION FIGURE FRONT FENDER SUPPORTS 12 Fig 12 FRONT FENDER SUPPORTS 23 102 BODY STRUCTURE...

Page 1015: ...T FRAME 2 OF 4 14 FRONT FRAME 3 OF 4 15 FRONT FRAME 4 OF 4 16 DESCRIPTION FIGURE FLOOR PAN 1 OF 5 17 FLOOR PAN 2 OF 5 18 FLOOR PAN 3 OF 5 19 FLOOR PAN 4 OF 5 20 FLOOR PAN 5 OF 5 21 REAR FRAME 1 OF 5 2...

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...

Page 1030: ...otor resistor Heater core A C evaporator Blend air door and actuator Mode air doors and actuators Recirculation air door and actuator Based upon the system and mode selected condi tioned air can exit...

Page 1031: ...irculation Mode with the mode con trol This will operate an electrically actuated recir culation air door that closes off the fresh air intake and recirculates the air that is already inside the vehic...

Page 1032: ...a A C Charging Recycling Station 2 Set the A C heater control to the Recirculation mode max A C position the temperature control to the full cool position and the blower motor control to the highest...

Page 1033: ...or clutch relay 4 See A C Compressor Clutch Relay in this group Test the compressor clutch relay and relay circuits Repair the circuits or replace the relay if required 5 Faulty A C pressure transduce...

Page 1034: ...Charge the refrigerant system to the proper level if required 4 Air in the refrigerant sys tem 4 See Refrigerant System Leaks in this group Test the refrigerant system for leaks Repair evacuate and ch...

Page 1035: ...heater hoses should be hot to the touch The coolant return heater hose should be slightly cooler than the coolant supply heater hose If the return hose is much cooler than the supply hose locate and r...

Page 1036: ...clutch relay below 110 kPa 16 psi closes relay above 220 kPa 32 psi High psi Control A C pressure transducer Discharge line mounted input to powertrain control module PCM PCM opens compressor clutch r...

Page 1037: ...scharge Line to A C Condenser Bolt 18 13 Accumulator Mounting Bracket Nuts 5 45 HVAC Housing to Dash Panel Bolts 7 60 HVAC Housing to Dash Panel Nuts 7 60 Liquid Line to A C Con denser Bolt 18 23 Refr...

Page 1038: ...N 24 REMOVAL 25 INSTALLATION 25 A C COMPRESSOR CLUTCH DESCRIPTION The A C compressor clutch assembly consists of a stationary electromagnetic A C clutch field coil a pul ley bearing and pulley assembl...

Page 1039: ...oil lead connector terminals 4 Refer to the A C Clutch Coil Specifications chart for the acceptable A C clutch coil resistance Specifications apply for a work area temperature of 21 C 70 F a If the A...

Page 1040: ...g this procedure set the A C heater controls to the A C Recirculation Mode the blower motor in the highest speed position and the engine speed at 1500 to 2000 rpm This procedure burnishing will seat t...

Page 1041: ...es sor then slide the pulley off of the compressor Fig 5 9 Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing 10 Using sn...

Page 1042: ...e snap ring must face outward 5 Using snap ring pliers Special Tool C 4574 or equivalent install the external snap ring bevel side facing outward that secures the clutch pulley to the front cover of t...

Page 1043: ...rough a receptacle in the power distribution center PDC The inputs and outputs of the A C clutch relay include The common feed terminal 54 receives a bat tery current input from fuse 20 15 amp in the...

Page 1044: ...nates when the rear window defogger EBL system is in operation The A C heater control cannot be repaired and if faulty or damaged it must be replaced The illumi nation lamps are available for service...

Page 1045: ...compressor operation due to the pressure temperature relationship of the refrigerant Before performing diagnosis of the A C low pres sure switch be certain that the switch is properly installed on th...

Page 1046: ...ressure transducer monitors the pres sures in the high side of the refrigerant system through its connection to a fitting on the A C dis charge line The A C pressure transducer will change its interna...

Page 1047: ...er Voltage chart for the possible conditions indicated by the transducer voltage reading A C PRESSURE TRANSDUCER VOLTAGE Voltage Possible Indication 0 0 1 No sensor supply voltage from PCM 2 Shorted s...

Page 1048: ...ter control to monitor the opera tion and relative position of the blend door actuator and the blend air door The A C heater control learns the blend air door stop positions during the calibra tion pr...

Page 1049: ...motor relay is an electromechanical switch that uses a low current input from the ignition switch to control the high current output to the blower motor The movable common feed relay contact is held...

Page 1050: ...NSTALLATION NOTE Refer to the fuse and relay map on the cover of the power distribution center PDC for blower motor relay location 1 Position the blower motor relay into the proper receptacle of the P...

Page 1051: ...r continuity between all of the blower motor resistor terminals In each case there should be continuity If OK repair the wire harness circuits between the blower motor switch and the blower motor resi...

Page 1052: ...or the mode door moves in the opposite direction When the A C heater control makes the voltage to both connections high or both connections low the mode door stops and will not move These connections...

Page 1053: ...to the linkage that drives the recircula tion air door The recirculation door actuator does require mechanical indexing to the recirculation air door as it is electronically calibrated by the A C heat...

Page 1054: ...and isolate the negative battery cable 2 Remove the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Disconnect the wire harness connector from the recirculation...

Page 1055: ...the instrument panel air outlets contain an air outlet barrel that is used to direct or shut off the flow of the conditioned air leaving the instrument panel All of the instrument panel air outlets b...

Page 1056: ...instrument panel component diagnosis or service Disconnect and isolate the negative battery ground cable then wait two minutes for the airbag system capacitor to discharge before performing further di...

Page 1057: ...l from the HVAC housing INSTALLATION 1 Align and install the blower motor into the HVAC housing 2 Install the screws that secure the blower motor to the HVAC housing Tighten the screws to 2 N m 17 in...

Page 1058: ...nto the top of the instrument panel 2 Install the two screws that secure the upper defroster duct to the top of the instrument panel Tighten the screws to 2 N m 17 in lbs 3 Install the defroster grill...

Page 1059: ...mpting any steer ing wheel steering column or instrument panel component diagnosis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the airbag system capac...

Page 1060: ...UTION FLOOR DISTRIBUTION DUCTS REMOVAL 12 Remove the one nut that secures the HVAC housing to the dash panel in the passenger compart ment and remove the housing DISASSEMBLY 1 Remove the HVAC housing...

Page 1061: ...r and lower HVAC housing halves to each other Tighten the screws to 2 N m 17 in lbs 3 Install the foam seals on the heater core and evaporator coil tubes 4 If removed install the blower motor resistor...

Page 1062: ...TIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE 12 Recharge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERAN...

Page 1063: ...MOVAL 49 INSTALLATION 49 HEATER INLET HOSE REMOVAL 50 INSTALLATION 51 HEATER RETURN HOSE REMOVAL 51 INSTALLATION 51 LIQUID LINE DESCRIPTION 52 REMOVAL 52 INSTALLATION 53 REFRIGERANT DESCRIPTION 54 OPE...

Page 1064: ...nt is burned An electronic leak detector is recom mended Severe personal injury or death may result from improper service procedures WARNING If accidental system discharge occurs ventilate the work ar...

Page 1065: ...l will absorb moisture from the atmosphere if left uncapped Do not open a container of refrigerant oil until you are ready to use it Replace the cap on the oil container immedi ately after using Store...

Page 1066: ...R 134a refrigerant recovery recycling charging sta tion that meets SEA Standard J2210 must be used Fig 1 Contact an automotive service equipment supplier for refrigerant recovery recycling charging eq...

Page 1067: ...evacuated before the refriger ant system can be filled Moisture and air mixed with the refrigerant system will raise the compressor head pressure above acceptable operating levels This will reduce th...

Page 1068: ...the refrig erant system is recovered and evacuated Before charging the A C system you MUST replenish any oil lost during the recovery process Refer the equipment manufacturer instructions for more inf...

Page 1069: ...cannot be adjusted or repaired and must not be removed or otherwise disturbed The valve is only serviced as a part of the A C compressor DIAGNOSIS AND TESTING A C COMPRESSOR When investigating an A C...

Page 1070: ...ioned without disconnecting the refrigerant lines or discharging the refrigerant system Dis charging is not necessary if servicing the compres sor clutch clutch coil or the engine 1 Recover the refrig...

Page 1071: ...within the A C con denser gives up its heat The refrigerant then condenses as it leaves the A C condenser and becomes a high pres sure liquid The volume of air flowing over the condenser fins is criti...

Page 1072: ...ten the bolts to 5 N m 45 in lbs 3 Reposition the radiator and tighten the upper isolators securely 4 Remove the tape or plugs from the A C dis charge and liquid line fittings and both condenser ports...

Page 1073: ...me rail 6 Remove the bolt that secures the A C discharge line to the A C condenser Fig 9 7 Disconnect the A C discharge line from the A C condenser and remove and discard the O ring seal 8 Install plu...

Page 1074: ...C evaporator is positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is dis tributed through the heating A C system ducts and outlets Howev...

Page 1075: ...clean and unrestricted and that the evapora tor insulator is properly installed 2 Assemble the HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING ASSEMBLY 3 Install the HVAC...

Page 1076: ...s part of the liquid line ACCUMULATOR DESCRIPTION The accumulator Fig 13 is mounted in the engine compartment between the A C evaporator and the A C compressor An integral mounting bracket is used to...

Page 1077: ...or and remove and discard the O ring seals 8 Install plugs in or tape over the opened suc tion line fittings and the accumulator ports 9 Remove the two nuts that secure the accumu lator to the inner f...

Page 1078: ...tery 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 air bag system Failure to t...

Page 1079: ...16 3 Using spring tension clamp pliers compress and slide the clamps off of each end of the hose being removed CAUTION DO NOT apply excessive pressure on heater tubes or connections when removing hea...

Page 1080: ...ld result in possible personal injury or death NOTE The heater return tube is constructed from formed steel tubing and rubber hoses Depending on application the ends are secured to the heater core eng...

Page 1081: ...eplaced when ever the liquid line is removed and installed If the liquid line is found to be leaking or is dam aged it must be replaced REMOVAL WARNING Refer to the applicable warnings and cautions fo...

Page 1082: ...ft lbs 6 Remove the tape or plugs from the liquid line fitting and condenser port 7 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the liquid line fitting Use only the...

Page 1083: ...ment of the vehicle and on the A C compressor to identify that the A C system is equipped with R 134a refrig erant REFRIGERANT OIL DESCRIPTION The refrigerant oil used in R 134a refrigerant sys tems i...

Page 1084: ...st be drained from the old compressor and measured Drain all of the refrigerant oil from the new A C com pressor then fill the new compressor with the same amount of refrigerant oil that was drained o...

Page 1085: ...to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE NOTE The protective cap helps aid in service port sealing and helps protects the refrigerant system from contamina...

Page 1086: ...the suction line from the A C com pressor and remove and discard the O ring seal 6 Install plugs in or tape over the opened suc tion line fitting and the compressor port 7 Raise and support the vehicl...

Page 1087: ...ove the bolt that secures the rear section of the suction line to the accumulator Fig 25 10 Disconnect the suction line from the accumu lator and remove and discard the O ring seal 11 Install plugs in...

Page 1088: ...tion line into the engine compartment 2 Remove the tape or plugs from the suction line fitting and the accumulator port 3 Lubricate a new rubber O ring seal with clean refrigerant oil and install it o...

Page 1089: ......

Page 1090: ...m monitor any component that could affect emissions levels In many cases these components were being tested under OBD I The OBD I requirements focused mainly on testing emissions related components fo...

Page 1091: ...nges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen To detect a shift in the A F mixture lean or rich the ou...

Page 1092: ...esistance decreases The PCM continues biasing the 5 volt signal to the sen sor Each time the signal is biased the PCM reads a voltage decrease When the PCM detects a voltage decrease of a predetermine...

Page 1093: ...trip When the test fails 6 times the counter increments to 3 a malfunction is entered and a Freeze Frame is stored the code is matured and the MIL is illuminated If the first test passes no further t...

Page 1094: ...e the PCM to store an oxygen sensor or misfire diagnostic trouble code The major non monitored circuits are listed below along with examples of failures modes that do not directly cause the PCM to set...

Page 1095: ...rcuits Response rate is the time required for the sensor to switch from lean to rich once it is exposed to a richer than optimum A F mixture or vice versa As the sen sor starts malfunctioning it could...

Page 1096: ...will be a lack of oxygen downstream of the converter The output of the downstream O2S will indicate limited activity in this condition As the converter loses the ability to store oxygen the condition...

Page 1097: ...e PCM stores a diagnos tic trouble code in memory Other diagnostic trouble code criteria might include engine RPM limits or input voltages from other sensors or switches that must be present before ve...

Page 1098: ...Control Mod ule PCM have two recognized states HIGH and LOW For this reason the PCM cannot recognize the difference between a selected switch position versus an open circuit a short circuit or a defec...

Page 1099: ...certain operating conditions All engines use a duty cycle purge system The PCM controls vapor flow by operating the duty cycle EVAP purge solenoid Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS E...

Page 1100: ...omponents never spray carburetor type cleaner into any of the plastic tubes or the fixed orifice fitting Never attempt to clean the fixed orifice fitting with a metal object as calibration could be af...

Page 1101: ...Disconnect the electrical connector Fig 3 3 Remove the vacuum lines Fig 4 4 Pull solenoid up and off the mounting bracket Fig 5 Fig 2 EVAP PURGE SOLENOID LOCATION Fig 3 ELECTRICAL CONNECTOR Fig 4 VACU...

Page 1102: ...cap con tains pressure vacuum relief valves A malfunction in the system or damage to the fuel lines could cause excessive fuel tank pressure The relief valves pre vent possible excessive pressure or...

Page 1103: ...Before installing hoses to LDP make sure they are not cracked or split If a hose leaks it will cause the Check Engine Lamp to illumi nate Connect lines to the LDP 3 Install electrical connector to pu...

Page 1104: ...owing shut off or by having the fuel level in the tank rise high enough to close the control valve The control valve contains a float that rises to seal the large diameter vent path to the canister At...

Page 1105: ...orative canister is not purged 100 of the time the PCM stores information about the evapora tive canister s vapor content in a memory cell The purge free cells are constructed similar to cer tain purg...

Page 1106: ...P make sure they are not cracked or split If a hose leaks it will cause the Check Engine Lamp to illumi nate Connect lines to the LDP 3 Install electrical connector to pump and push locking tab to loc...

Page 1107: ...f the MIL is illuminated and a fault is stored from another monitor In these situations the Task Manager postpones monitors pending resolu tion of the original fault The Task Manager does not run the...

Page 1108: ...extinguished and the Task Manager automatically switches the trip counter to a warm up cycle counter DTCs are auto matically erased following 40 warm up cycles if the component does not fail again Fo...

Page 1109: ...different Similar conditions Windows Fuel System and Misfire FUEL SYSTEM Fuel System Similar Conditions Window An indicator that Absolute MAP When Fuel Sys Fail and RPM When Fuel Sys Failed are all in...

Page 1110: ...in accessing the Similar Conditions Window Adaptive Memory Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correctio...

Page 1111: ......

Page 1112: ...STENER IDENTIFICATION Intro 2 FASTENER USAGE Intro 4 FINESSE SANDING BUFFING POLISHING 23 81 FLOOR DISTRIBUTION DUCT 24 30 FLUID CAPACITIES 0 4 FLUID COOLER 19 29 FLUID FILL CHECK LOCATIONS 0 4 FLUID...

Page 1113: ...BACK COVER 23 84 SEAT BACK RECLINER 23 85 SEAT BACK 23 84 SEAT BELT RETRACTOR 8O 12 SEAT BELT BUCKLE 8O 13 SEAT BELT SWITCH 8O 14 SEAT BELT TENSIONER 8O 14 SEAT BELT WARNING INDICATOR 8J 7 SEAT CUSHIO...

Page 1114: ..._____________________________________________ ______________________________________________________________________________________ ___________________________________________________________________...

Page 1115: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 8...

Page 1116: ...ES AND BLANK SCREEN 11 3 5 1 DRBIIIT DOES NOT POWER UP 11 3 5 2 DISPLAY IS NOT VISIBLE 11 4 0 DISCLAIMERS SAFETY WARNINGS 11 4 1 DISCLAIMERS 11 4 2 SAFETY 12 4 2 1 TECHNICIAN SAFETY INFORMATION 12 4 2...

Page 1117: ...CIRCUIT VOLTAGE TOO HIGH 59 P0133 O2 SENSOR 1 1 SLOW RESPONSE 63 P0139 O2 SENSOR 1 2 SLOW RESPONSE 63 P0153 O2 SENSOR 2 1 SLOW RESPONSE 63 P0159 O2 SENSOR 2 2 SLOW RESPONSE 63 P0135 O2 SENSOR 1 1 HEA...

Page 1118: ...WITCHING PROPERLY 131 P0645 A C CLUTCH RELAY CIRCUIT 133 P0801 REVERSE GEAR LOCKOUT CIRCUIT OPEN OR SHORTED 135 P1195 O2 SENSOR 1 1 SLOW DURING CATALYST MONITOR 137 P1196 O2 SENSOR 2 1 SLOW DURING CAT...

Page 1119: ...TOR PINOUTS 225 A C COMPRESSOR CLUTCH BLACK 2 WAY 225 A C LOW PRESSURE SWITCH DK GREEN 2 WAY 225 A C PRESSURE TRANSDUCER BLACK 4 WAY 225 BATTERY TEMPERATURE SENSOR 2 WAY 225 BRAKE LAMP SWITCH BLACK 6...

Page 1120: ...N SENSOR 2 2 RIGHT BANK DOWN BLACK 4 WAY 233 FUSES PDC 235 A C COMPRESSOR CLUTCH RELAY 235 AUTO SHUT DOWN RELAY 235 FUEL PUMP RELAY 235 OXYGEN SENSOR HEATER RELAY 236 RUN ACC RELAY 236 STARTER MOTOR R...

Page 1121: ...NOTES vi...

Page 1122: ...IX STEP TROUBLE SHOOTING PROCEDURE Diagnosis of the Powertrain Control Module PCM is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem iso...

Page 1123: ...ot within specifications and other trou ble code criteria arming conditions are met a trouble code will store in the PCM memory The On Board Diagnostics have evolved to the second Generation of Diagno...

Page 1124: ...ltage Oxygen Sensor Response Fuel System Lean Fuel System Rich Inputs Checked For Requires 3 Consecutive Rationality Catalytic Converter Fuel System Good Trips to Efficiency Except EWMA Extinguish The...

Page 1125: ...is possible that the Evaporative Leak Detection Monitor will run during the O2 Sensor Heater Monitor 1 O2 Sensor Heater Monitor This monitor requires a cold start usually an overnight soak or parked...

Page 1126: ...ize of the leak based on how fast long it must pump the LDP as it tries to maintain pressure in the system EVAP LEAK DETECTION SYSTEM COMPONENTS FIGURE 1 Service Port Used with special tools like the...

Page 1127: ...hragm moves up ward when vacuum above the diaphragm exceeds spring force This upward movement closes the vent valve It also causes low pressure below the dia phragm unseating the inlet check valve and...

Page 1128: ...E FOUND P1494 LEAK DETECTION PUMP SW OR MECH FAULT P1495 LEAK DETECTION PUMP SOLENOID CIRCUIT ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST 1 Cold start with ambient temperature obtained from mo...

Page 1129: ...P system between the LDP and the fuel tank This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles If no blockage is present the LDP d...

Page 1130: ...PMENT The Evaporative Emission Leak Detector EELD Miller Special Tool 8404 is capable of visually de tecting leaks in the evaporative system and will take the place of the ultrasonic leak detector 691...

Page 1131: ...e Most intermittent codes are caused by wiring or connector problems Intermittent conditions that come and go like this are the most difficult to diagnose they must be looked for under specific condit...

Page 1132: ...he same time ver 2 29 date 1 Oct 99 file key HND1 CC date Mar 8 2000 line 1297 err 0x1 User Requested COLD Boot Press MORE to switch between this display and the application screen Press F4 when done...

Page 1133: ...NDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS Follow the vehicle manufacturer s service specifi cations at all times Do not use the DRBIIIt if it has been damaged Do not use the test leads if th...

Page 1134: ...wires ohmmeter oscilloscope vacuum gauge voltmeter 12 volt test light minimum 25 ohms resistance with probe 6801 CAUTION A 12 volt test light should not be used for the following circuits damage to th...

Page 1135: ...O2S Oxygen Sensor OBD I On Board Diagnostics 1st Genera tion OBD II On Board Diagnostics 2nd Gener ation ORVR On Board Refueling Vapor Recovery PCI Bus Programmable Communications In terface BUS J1850...

Page 1136: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15...

Page 1137: ...ays a no response message refer to the appropriate symptom in the powertrain diagnostic procedures Turn the ignition off Disconnect the PCM C3 harness connector Use Scope input cable CH7058 Cable to P...

Page 1138: ...this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM C3 harness connector Disconnect th...

Page 1139: ...C Disconnect the PCM harness connectors Measure the resistance between the SCI Transmit circuit and the SCI Receive circuit at the PCM connector Is the resistance below 5 0 ohms All Yes Repair the sho...

Page 1140: ...the DLC Is the resistance below 5 0 ohms All Yes Go To 10 No Repair the SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 10 If there are no possible causes remaining view re...

Page 1141: ...or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspec...

Page 1142: ...Repair the PCI Bus circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the module that when disconnected the short to voltage was eliminated Perform BODY VERIFICATION TEST V...

Page 1143: ...n wires and broken bent pushed out or corroded terminals Inspect and clean all PCM engine and chassis grounds that related to the DTC set If numerous trouble codes were set use a wire schematic to hel...

Page 1144: ...032 O2 SENSOR 1 1 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition Desired state does not equal Actual state P0051 O2 SENSOR 2 1...

Page 1145: ...Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 3 Ignition on engine not running With the DRBIIIt actuate the O2 Heater Test Using a 12 volt test light connected to ground probe the K342 Fused ASD...

Page 1146: ...ematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and progra...

Page 1147: ...NCE IN THE K25 BATTERY TEMP SENSOR SIGNAL CIRCUIT RESISTANCE IN THE K900 SENSOR GROUND CIRCUIT K25 BATTERY TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engi...

Page 1148: ...rity Backprobe the K25 Battery Temp Sensor Signal circuit at the Sensor harness connector and the PCM harness connector with both voltmeter leads Start the engine Allow the engine to idle Is the volta...

Page 1149: ...IFICATION TEST VER 5 No Go To 8 8 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect...

Page 1150: ...RCUIT SHORTED TO GROUND K1 MAP SENSOR SIGNAL CIRCUIT SHORTED TO K900 SENSOR GROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the rela...

Page 1151: ...n the ignition off Disconnect the PCM harness connectors Measure the resistance in the K7 5 volt Supply circuit from the MAP Sensor harness connector to the PCM harness connector Is the resistance bel...

Page 1152: ...RCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Start the engine With the DRBIIIt read the MAP Sensor volt...

Page 1153: ...harness connector Is the resistance below 100 ohms All Yes Repair the short between the K7 5 volt Supply circuit and the K1 MAP Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go...

Page 1154: ...IP EQUAL TO ZERO IAT SENSOR VOLTAGE BELOW 1 0 VOLT RESISTANCE IN THE K21 IAT SENSOR SIGNAL CIRCUIT RESISTANCE IN THE K900 SENSOR GROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 Ignition on engine not r...

Page 1155: ...N VERIFICATION TEST VER 5 5 Turn the ignition off NOTE Ensure the voltmeter leads meet the terminals in the connector and that there is good terminal to wire connection NOTE Ensure the voltmeter leads...

Page 1156: ...the DRBIIIt read the IAT Sensor voltage Is the voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 2...

Page 1157: ...T VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire har...

Page 1158: ...on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt read the IAT voltage Is the voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITT...

Page 1159: ...ERIFICATION TEST VER 5 5 Measure the resistance of the K900 Sensor ground circuit from the IAT Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 6 No...

Page 1160: ...ted Freeze Frame data With the DRBIIIt read the ECT Sensor voltage Is the ECT Sensor voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform...

Page 1161: ...5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire harness a...

Page 1162: ...CABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt read ECT voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer...

Page 1163: ...m POWERTRAIN VERIFICATION TEST VER 5 5 Measure the resistance of the K900 Sensor ground circuit from the ECT Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All...

Page 1164: ...etected when the two conditions are met a DTC will be set after 4 seconds POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO RESISTANCE IN THE K7 5 VOLT SUPPLY CIRCUIT K7 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND...

Page 1165: ...engine not running With the DRBIIIt monitor the TP Sensor voltage while slowly depressing the throttle pedal from the idle position to the wide open throttle position Does voltage start at approximat...

Page 1166: ...R 5 8 Measure the resistance between ground and the K22 TP Sensor 1 Signal circuit at the TP Sensor harness connector Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the short to ground in...

Page 1167: ...ignition off Disconnect the PCM harness connectors Measure the resistance of the K1 MAP Sensor Signal circuit from the MAP Sensor harness connector to the PCM harness connector Is the resistance below...

Page 1168: ...ics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program th...

Page 1169: ...IT PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt read the Throttle Position Sensor voltage Is the...

Page 1170: ...circuit from the TP Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the open in the K7 5 volt Supply circuit Perform POWERTRAIN VERIFIC...

Page 1171: ...to the wide open throttle position Does voltage start at approximately 0 8 of a volt and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Pro...

Page 1172: ...PPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data NOTE Ensure the throttle is fully closed and free from binding or carbon build up Star...

Page 1173: ...the TP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short between the K7 5 volt Supply circuit and the K22 TP Sensor No 1 Signal circuit Perform POWERTRAIN VERIFICATION...

Page 1174: ...tle position Does voltage start at approximately 0 8 of a volt and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTR...

Page 1175: ...rm POWERTRAIN VERIFICATION TEST VER 5 2 NOTE If a ECT DTC set along with this code diagnose the ECT DTC first NOTE Inspect the ECT terminals and related PCM terminals Ensure the terminals are free fro...

Page 1176: ...the thermostat Did the thermostat open at the proper temperature All Yes Go To 4 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 4 Note For this test to be valid the thermostat mu...

Page 1177: ...within 27 F and Engine Coolant Temperature above 170 F on the previous key off Set Condition The Oxygen Sensor signal voltage is below 0 156 of a volt for 28 seconds after starting engine P0151 O2 SEN...

Page 1178: ...With the DRBIIIt monitor the O2 Sensor voltage Is the O2 Sensor voltage above 0 16 of a volt All Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3 3 Turn the ignition of...

Page 1179: ...r being tested Is the resistance below 100 ohms All Yes Repair the short between the O2 Sensor Signal circuit and the Heater ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE...

Page 1180: ...an 10 4 volts engine running for more than 4 minutes and coolant temperature above 180 F Set Condition The oxygen sensor voltage is above 1 5 volts P0152 O2 SENSOR 2 1 CIRCUIT VOLTAGE TOO HIGH When Mo...

Page 1181: ...DRBIIIt monitor the O2 Sensor voltage Is the O2 Sensor voltage below 1 5 volts All Yes Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3 3 Turn the ignition off Disconnect t...

Page 1182: ...ess connectors Ignition on engine not running With the DRBIIIt actuate the O2 Heater Test Measure the voltage on the O2 Heater Supply circuit Is the voltage above 11 0 volts All No Repair the Open in...

Page 1183: ...tics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program t...

Page 1184: ...b batt temp 44 F Baro 22 139 H2O battery 10 5 volts MAP 11 79 18 159 H2O RPM 1350 2200 and vss 50 and 65 Set Condition The oxygen sensor signal voltage is switching from below 0 39 of a volt to above...

Page 1185: ...t the exhaust for leaks between the engine and the related O2 Sensor Are there any exhaust leaks All Yes Repair or replace the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST V...

Page 1186: ...Ensure the voltmeter leads are connected for positive polarity Start the engine Allow the engine to idle Is the voltage below 0 10 of a volt All Yes Go To 5 No Repair the excessive resistance in the...

Page 1187: ...ECT less than 147 F battery temperature sensor equal to or less than 27 F and engine at idle for at least 12 seconds Set Condition O2 sensor voltage greater than 3 volts for 60 to 240 seconds P0155 O2...

Page 1188: ...temperatures On a four O2 Sensor system the resistance value for 1 1 and 2 1 O2 Heater elements is between 3 3 and 4 1 ohms and the 1 2 and 2 2 O2 Heater elements is between 4 0 and 5 0 ohms at 70 F 2...

Page 1189: ...nce between ground and the K512 O2 Heater Relay Control circuit at the PCM harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the O2 Heater Control circuit Perfor...

Page 1190: ...o zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Remove the Heater Relay from the PDC Meas...

Page 1191: ...e resistance below 100 ohms All Yes Repair the short to ground in the K512 O2 Sensor Heater Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuing check t...

Page 1192: ...EL SYSTEM LEAN When Monitored With the engine running in closed loop mode the ambient battery temperature above 20 F and altitude below 8000 ft Set Condition If the PCM multiplies short term compensat...

Page 1193: ...elow Specification Go To 3 Within Specification Go To 6 Above Specification Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 CAUTION Stop All Actuations 3 Turn the...

Page 1194: ...All Yes Go To 7 No Go To 13 7 Turn the ignition off NOTE Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test Ignition on engine not running With the DRBIIIt act...

Page 1195: ...mperature value The temp value change should be a smooth transition from start up to normal operating temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Coolant Temperature incr...

Page 1196: ...nal circuit at the PCM harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 15 15 N...

Page 1197: ...ode is stored P0175 2 1 FUEL SYSTEM RICH When Monitored With the engine running in closed loop mode the ambient battery temperature above 20 F and altitude below 8000 ft Set Condition If the PCM multi...

Page 1198: ...ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 379 KPa 14 KPa 55 psi 2 psi Choose a conclusion that best matches your fuel pressure reading All Within Sp...

Page 1199: ...e must be against the stop Is the voltage 0 92 of a volt or less with the Throttle closed All Yes Go To 7 No Check for a binding throttle condition If OK replace the Throttle Position Sensor Perform P...

Page 1200: ...es in neutral ENGINE VALVE TIMING must be within specifications ENGINE COMPRESSION must be within specifications ENGINE EXHAUST SYSTEM must be free of any restrictions or leaks ENGINE PCV SYSTEM must...

Page 1201: ...Go To 14 NOTE Turn the ignition off before continuing 14 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schema...

Page 1202: ...ine Oil Temp Sensor voltage Is the ECT Sensor voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 2 T...

Page 1203: ...TION TEST VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the...

Page 1204: ...RBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt read Engine Oil Temp Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Sym...

Page 1205: ...or Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Measure the resistance of the K900 Sensor ground circuit from the Sensor harness connector to the PCM harness connector Is the resistance...

Page 1206: ...ECTOR 2 CONTROL CIRCUIT When Monitored With battery voltage greater than 10 4 volts the auto shutdown relay energized injector pulse width less than 10ms and engine speed less than 3000 rpm Set Condit...

Page 1207: ...ctors on P0208 INJECTOR 8 CONTROL CIRCUIT When Monitored With battery voltage greater than 10 4 volts the auto shutdown relay energized injector pulse width less than 10ms and engine speed less than 3...

Page 1208: ...Fuel Injector harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the open or short to ground in the K342 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST...

Page 1209: ...Repair the open in the Fuel Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push...

Page 1210: ...is measured during two trips or with a 6 to 30 misfire rate during one trip P0301 CYLINDER 1 MISFIRE When Monitored Any time the engine is running and the adaptive numerator has been successfully upd...

Page 1211: ...ne is running and the adaptive numerator has been successfully updated Set Condition When more than a 1 misfire rate is measured during two trips or with a 6 to 30 misfire rate during one trip P0308 C...

Page 1212: ...history for any misfire condition repairs that have been performed Read and record the FREEZE FRAME DATA Select OBD II MONITORS Read and record the MIS FIRE SIMILAR CONDITIONS WINDOW DATA With these s...

Page 1213: ...ness connectors Disconnect the Fuel Injector harness connectors Ignition on engine not running With the DRBIIIt actuate the ASD Relay Using a 12 volt test light connected to ground probe the K342 ASD...

Page 1214: ...Above Specification Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 7 NOTE Before continuing visually and physically inspect the fuel delivery system for externa...

Page 1215: ...e within specifications ENGINE COMPRESSION must be within specifications ENGINE EXHAUST SYSTEM must be free of any restrictions or leaks ENGINE PCV SYSTEM must flow freely TORQUE CONVERTER STALL SPEED...

Page 1216: ...pecification is 379 KPa 14 KPa 55 psi 2 psi Is the fuel pressure within specification All Yes Repair or replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 13 13...

Page 1217: ...ectors Check the Coil Control circuit for an open short to ground and short to voltage Was a problem found with the Coil Control circuit All Yes Repair the Coil Control circuit Perform POWERTRAIN VERI...

Page 1218: ...R SIGNAL CIRCUIT OPEN K24 CKP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND K24 CKP SENSOR SIGNAL SHORTED TO K7 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN CRANKSHAFT POSITION SENSOR PCM TEST ACTI...

Page 1219: ...ignition off Disconnect the PCM harness connector Ignition on engine not running Measure the voltage of the K24 CKP Sensor Signal circuit at the CKP Sensor harness connector Is the voltage above 5 3 v...

Page 1220: ...KP Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 12 No Repair the open in the K7 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5...

Page 1221: ...replace the Crank Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 15 15 NOTE An intermittent failure with the Cam Position Sensor may cause the P0320 code to set Turn the ignition...

Page 1222: ...K44 CMP SENSOR SIGNAL CIRCUIT OPEN K44 CMP SENSOR SIGNAL CIRCUIT SHORTED GROUND K44 CMP SENSOR SIGNAL SHORTED TO K7 5 VOLT SUPPLY CIRCUIT K900 SENSOR GROUND CIRCUIT OPEN CAMSHAFT POSITION SENSOR PCM T...

Page 1223: ...6 Turn the ignition off Disconnect the PCM harness connectors Ignition on engine not running Measure the voltage on the K44 CMP Sensor Signal circuit at the CMP Sensor harness connector Is the voltage...

Page 1224: ...MP Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 12 No Repair the open in the K7 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5...

Page 1225: ...sary if ok replace the Cam Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 15 15 NOTE An intermittent Crank Position Sensor failure may cause the P0340 code to set Ignition on engi...

Page 1226: ...with engine running engine rpm less than 2016 and none of the coils in dwell when checked Set Condition Peak current is not achieved with battery based dwell plus 1 5 msec of diagnostic offset It tak...

Page 1227: ...Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CON...

Page 1228: ...t and ground Is the resistance below 100 ohms All Yes Repair the short to ground in the Ignition Coil Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 7 6 Turn the ignition off Disc...

Page 1229: ...ONVERTER EFFICIENCY When Monitored After engine warm up to 147 F 180 seconds of open throttle operation at a speed greater than 20 mph with the engine at 1200 1700 rpm and MAP vacuum between 15 0 and...

Page 1230: ...r or replace leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Check the exhaust for excessive smoke from internal oil or coolant leaks Is there an oil or cool...

Page 1231: ...O CANISTER EVAP PURGE HOSE CANISTER TO FUEL TANK EVAP PURGE SOLENOID VACUUM SUPPLY EVAP PURGE SOLENOID LEAKS STUCK OPEN EVAP PURGE SOLENOID TEST ACTION APPLICABILITY 1 Ignition on engine not running W...

Page 1232: ...epair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 6 Note After disconnecting the Evap Purge Solenoid vacuum connections inspect the lines and solenoid for any s...

Page 1233: ...start with battery ambient temperature between 40 F and 90 F and coolant temperature within 10 F of battery ambient Set Condition There is a leak larger than 0 0809 in the evaporative system POSSIBLE...

Page 1234: ...TE See Charts and Graph support material EELD Calibration Setup for an example Connect shop air to the 8404 EELD Set the smoke air control switch to AIR Insert the tester s AIR supply tip clear hose i...

Page 1235: ...indicated by exiting smoke If a leak is concealed from view i e top of fuel tank release the remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404...

Page 1236: ...IT OPEN EVAP PURGE SOLENOID K52 EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN K52 EVAP PURGE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With t...

Page 1237: ...ms All Yes Go To 5 No Repair the open in the K52 Evap Purge Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Measure the resistance between ground and the K52 Evap Purge Solenoid...

Page 1238: ...ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released In...

Page 1239: ...uel Level Sensor voltage Is the Fuel Level Sensor voltage below 0 2 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDTION Symptom Diagnostic Procedure Perform POWERTRAIN VERIFICATION TEST VE...

Page 1240: ...To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire harness and conne...

Page 1241: ...related Freeze Frame data With the DRBIIIt read the Fuel Level Sensor voltage Is the Fuel Level Sensor voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos ti...

Page 1242: ...nal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 5 Measure the resistance of the Z2 Sensor ground circuit from the PCM harness connector to the Fuel Pump Module harness connector Is the resistan...

Page 1243: ...It check for any related DTCs that may be present in the ABS RWAL Module or TCM diagnose any ABS RWAL Module DTC s before continuing With the DRBIIIt read DTCs and record the related Freeze Frame data...

Page 1244: ...istance below 100 ohms All Yes Repair the short to ground in the G7 Vehicle Speed Signal circuit between the CAB and PCM Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 NOTE Before continuing...

Page 1245: ...TO GROUND IAC MOTOR OPERATION IAC MOTOR TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displaye...

Page 1246: ...er circuits Is the voltage above 1 0 volt at any IAC Driver circuit All Yes Repair the short to voltage on the appropriate IAC Driver circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 NOTE...

Page 1247: ...Sensors read the Oil Pressure Sensor voltage Is the Oil Pressure Sensor voltage below 0 1 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERT...

Page 1248: ...m the Sensor harness connector to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the open in the K7 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER...

Page 1249: ...With the DRBIIIt in Sensors read the Oil Pressure Sensor voltage Is the Oil Pressure Sensor voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure...

Page 1250: ...circuit Perform POWERTRAIN VERIFICATION TEST VER 2 5 Measure the resistance of the K900 Sensor ground circuit from the Oil Pressure Sensor harness connector to the PCM harness connector Is the resist...

Page 1251: ...Bus communication failure between processors POSSIBLE CAUSES POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 NOTE This DTC indicates an internal PCM problem If there are no possible causes rema...

Page 1252: ...Frame data Using a 12 volt test light connected to ground backprobe the K20 Gen Field Control circuit at the back of the Generator With the DRBIIIt actuate the Generator Field Driver Does the test li...

Page 1253: ...Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 No Go To 5 5 Measure resistance across the Generator Field Terminals at the Generator Is the resistance between 0 5 of and ohm and 15...

Page 1254: ...IIt actuate the A C Clutch Relay Is the A C Clutch Relay clicking All Yes Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 2 2 Turn...

Page 1255: ...low 100 ohms All Yes Repair the short to ground in the C13 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 6 6 NOTE Before continuing check the PCM harness connect...

Page 1256: ...LOCKOUT SOLENOID PCM TEST ACTION APPLICABILITY 1 With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to t...

Page 1257: ...WERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 Measure the resistance across both terminals of the Reverse Lockout solenoid NOTE The resistance should be about 13 5 ohms at 25 C 77 F Is the resistance...

Page 1258: ...quired P1196 O2 SENSOR 2 1 SLOW DURING CATALYST MONITOR When Monitored With the engine running coolant greater than 170 F open throttle steady to slightly increasing vehicle speed greater than 18 mph...

Page 1259: ...o To 4 No Repair the excessive resistance on the O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 4 Turn the ignition off Backprobe the K900 Sensor ground circuit at the O2 Sensor h...

Page 1260: ...DEG value during the warm up cycle Make sure the transition of temperature change is smooth Did the engine temperature reach a minimum of 80 C 176 F All Yes Go To 2 No Refer to the Service Information...

Page 1261: ...HORTED TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt actuate the Fuel Pump Relay Is the...

Page 1262: ...ir the open in the K31 Fuel Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 5 Measure the resistance between ground and the K31 Fuel Pump Relay Control circuit at the PDC Is the...

Page 1263: ...TTLE LINKAGE IAC DRIVER CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running NOTE All MAP Sensor IAC and or TPS codes present must be diagnosed first before proceeding With the...

Page 1264: ...VERIFICATION TEST VER 2 No Go To 5 5 Turn the ignition off Disconnect IAC Motor harness connector Disconnect the PCM harness connectors Measure the resistance of each of the IAC Driver circuit from t...

Page 1265: ...on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data With the DRBIIIt in Sensors read the MAP Sensor voltage Is the voltage below 2 35 volts All Yes Go To 2 No Re...

Page 1266: ...sive resistance in the K7 5 volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 Measure the resistance between ground and the K7 5 volt Supply circuit in the MAP Sensor harness connector...

Page 1267: ...AL CIRCUIT SHORTED TO GROUND K1 MAP SENSOR SIGNAL CIRCUIT SHORTED TO K900 SENSOR GROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 NOTE If a MAP high or Low DTC set along with P1297 diagnose the High or...

Page 1268: ...s connectors Measure the resistance between ground and the K1 MAP Sensor Signal circuit at the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K...

Page 1269: ...re continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire harness and connectors Pay partic...

Page 1270: ...he Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 2 2 Turn the ignition off...

Page 1271: ...ms All Yes Repair the short to ground in the K51 ASD Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for...

Page 1272: ...RBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perf...

Page 1273: ...ss connectors Measure the resistance of the A342 ASD Relay Output circuit from the ASD Relay cavity in the PDC to the PCM harness connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair t...

Page 1274: ...NSOR CRANKSHAFT POSITION SENSOR TEST ACTION APPLICABILITY 1 Ignition on engine not running WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR TH...

Page 1275: ...ny of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Turn the ignition off Remove the Camshaft Position Sensor Inspect the Tone Wheel...

Page 1276: ...causes remaining view repair All Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 10 NOTE The conditions that set this DTC are not present at this time The foll...

Page 1277: ...y apply to this symptom Read and record the Freeze Frame Data Use this information to help you duplicate the conditions that set the DTC Pay particular attention to the DTC set conditions such as VSS...

Page 1278: ...es Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Disconnect and remove the Crankshaft Position Sensor Inspect the tone wheel flexplate slots for damage foreign material o...

Page 1279: ...atics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program...

Page 1280: ...E OBSTRUCTED LEAK DETECTION PUMP TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and e...

Page 1281: ...s Go To 4 No Repair or replace hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 6 4 Disconnect and remove the LDP pressure hose The LDP pressure hose is the hose that connects the EVAP...

Page 1282: ...eze Frame data With the DRBIIIt monitor the Battery Temperature Sensor voltage Is the voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perfo...

Page 1283: ...Perform POWERTRAIN VERIFICATION TEST VER 5 5 Measure the resistance in the K900 Sensor ground circuit from the PCM harness connector to the Sensor connector Is the resistance below 5 0 ohms All Yes G...

Page 1284: ...r voltage Is the voltage below 0 5 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VERIFICATION TEST VER 5 2 Ignition on engine not ru...

Page 1285: ...VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Using the schematics as a guide inspect the wire harne...

Page 1286: ...CIRCUIT SHORTED TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equa...

Page 1287: ...resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K107 Leak Detection Pump Switch Sense circuit Perform POWERTRAIN VERIFICATION TEST VER 6 5 Measure the resistance between ground an...

Page 1288: ...ILITY 1 Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMIT...

Page 1289: ...l Yes Go To 6 No Repair the open in the K106 Leak Detection Pump Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 6 6 Measure the resistance between ground and the K106 LDP Solenoid C...

Page 1290: ...aulic Fan Solenoid Test found under Engine Test and Systems Test Does the Radiator Fan operate properly All Yes Refer to the INTERMITTENT CONDITION Symptom Diagnos tic Procedure Perform POWERTRAIN VER...

Page 1291: ...used B circuit to keep the ASD Output circuit powered up for this step Connect another jumper wire to the C240 Hydraulic Fan Solenoid Control circuit in the PCM harness connector Momentarily connect t...

Page 1292: ...DTCs and the related Freeze Frame data then clear the DTCs With DRBIIIt actuate the Generator Field Driver With a 12 volt test light connected to ground backprobe the K20 Gen Field Control circuit in...

Page 1293: ...rature near Battery tray Is the temperature within 10 deg of Battery temperature All Yes Go To 5 No Replace the Battery Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 3 5 NOTE Before cont...

Page 1294: ...e Service Information Ignition on engine not running With the DRBIIIt read DTCs and record the related Freeze Frame data Start the engine With the DRBIIIt read the A C Pressure Sensor voltage Is the v...

Page 1295: ...ssure Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the short between the F888 5 volt Supply circuit and the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION...

Page 1296: ...ROUND CIRCUIT PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the A C refrigerant System is properly charged per the Service Information Ignition on engine not running With the DRBIIIt read DTCs and recor...

Page 1297: ...the ignition off Disconnect the PCM harness connectors Measure the resistance of the F888 5 volt Supply circuit between the A C Pressure Sensor harness connector and the PCM harness connector Is the...

Page 1298: ...UIT OPEN RESISTANCE IN THE GENERATOR FIELD COIL PCM TEST ACTION APPLICABILITY 1 Turn the ignition off NOTE Battery must be fully charged and capable of passing a battery load test Note Generator Belt...

Page 1299: ...e Generator and Battery Perform POWERTRAIN VERIFICATION TEST VER 3 No Go To 4 4 Start the engine WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS N...

Page 1300: ...ir the open in the K20 Generator Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 8 Measure resistance across the Generator Field Terminals at the Generator Is the resistance above 15...

Page 1301: ...Procedure Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIIIt attempt to communicate with the Instrument cluster Can communication be established with the Inst...

Page 1302: ...TEST VER 1 2 With the DRBIIIt attempt to communicate with the BCM Can communication be established with the BCM All Yes Go To 3 No Refer to the Communication Category and perform the appropri ate symp...

Page 1303: ...rite Failure All Yes Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt perform the SRI Memory Test Does...

Page 1304: ...trument Panel Odometer Is the mileage within the specified range displayed on the DRBIIIt All Yes Test Complete No Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER...

Page 1305: ...RCUIT K33 SKIP SHIFT SOLENOID CONTROL CIRCUIT OPEN K33 SKIP SHIFT SOLENOID CONTROL CIRCUIT SHORT TO GROUND SKIP SHIFT SOLENOID PCM TEST ACTION APPLICABILITY 1 With the DRBIIIt read DTCs and record the...

Page 1306: ...rcuit Perform POWERTRAIN VERIFICATION TEST VER 2 No Go To 5 5 Measure the resistance across both terminals of the Skip Shift solenoid NOTE The resistance should be about 13 5 ohms at 25 C 77 F Is the...

Page 1307: ...Lamp Switch harness connector Using a 12 volt test light connected to ground probe the A103 Fused B circuit at the Brake Lamp Switch harness connector Does the test light illuminate brightly All Yes G...

Page 1308: ...ed in the next step Ignition on engine not running Using a 12 volt test light connected to ground probe the K29 Brake Lamp Switch Signal circuit at the Brake Lamp Switch harness connector Is the test...

Page 1309: ...KIP SHIFT SOLENOID STUCK Repair Instructions SKIP SHIFT SOLENOID STUCK Check for a mechanically stuck Skip Shift Solenoid This will not set a DTC in the PCM but will prevent 2nd 3rd gear engagement Pe...

Page 1310: ...T SOLENOID STUCK Repair Instructions REVERSE LOCKOUT SOLENOID STUCK Check for a mechanically stuck Reverse Lockout Solenoid This will not set a DTC in the PCM but will prevent reverse gear engagement...

Page 1311: ...available over the BUS With the DRBIIIt check for DTCs in the PCM and HVAC module Are any A C DTC s or communication failures present All Yes Diagnose the related DTC s or BUS failure before continui...

Page 1312: ...RBIIIt actuate the A C Clutch Relay Does the test light illuminate brightly on and off with the relay actuation All Yes Replace the A C Clutch Coil Perform BODY VERIFICATION TEST VER 1 No Go To 8 8 Tu...

Page 1313: ...C Clutch Relay Perform BODY VERIFICATION TEST VER 1 12 Ignition on engine not running With the DRBIIIt in the HVAC under the Monitors screen read the A C Select Switch state While monitoring the DRBII...

Page 1314: ...8 2 Ignition on engine not running Measure the voltage between the Generator B Terminal and the Battery Post Caution Ensure all wires are clear of the engine s moving parts Start the engine Is the vo...

Page 1315: ...o To 7 No Repair the open in the K20 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 7 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or ter...

Page 1316: ...ht should blink On and Off every 1 4 seconds While monitoring the 12 volt test light wiggle the Field Terminals back to the PCM and ASD Relay Was there any interruption in the normal cycle of the test...

Page 1317: ...to see if the fan wire harness is properly connected at the fan solenoid on the fan motor Check the harness for continuity from the Hydraulic Fan Relay to the solenoid Inspect connector terminals for...

Page 1318: ...ssary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running Using a 12 volt test light connected to ground probe the F202 PCM Fused Ignition Switch Output circuit in the PCM harn...

Page 1319: ...Yes Go To 2 No Go To 5 CAUTION Stop All Actuations 2 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fuel system hos...

Page 1320: ...hose fitting or line the fuel system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet S...

Page 1321: ...in either the Fused B circuit or the Ignition Switch Output circuit Inspect the related fuses and repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 9 Turn the ignition off Remove the Fue...

Page 1322: ...g All Below Specification Go To 2 Within Specification Go To 4 2 Turn the ignition off WARNING The fuel system is under a constant pressure even with the engine off Before testing or servicing any fue...

Page 1323: ...ition off NOTE Fuel specification is 379 KPa 14 KPa 55 psi 2 psi Using special tool C4390 Hose Clamp Pliers pinch the rubber fuel line between the fuel pressure gauge and the engine Monitor the fuel p...

Page 1324: ...RBIIIt If any DTCs are present they must be repaired before continuing with any other No Start diagnostic tests Refer to the Symptom list for the related P code that is reported by the PCM Ensure that...

Page 1325: ...VER 1 No Go To 5 5 Turn the ignition off Remove the ASD relay from the PDC Disconnect the PCM harness connectors Verify the ASD Relay is getting voltage on the Fused B circuits before continuing Measu...

Page 1326: ...the engine Monitor the fuel pressure gauge for a minimum of 5 minutes NOTE The pressure should not fall below 276 KPa 40 psi Does the fuel pressure drop All Yes Replace Fuel Pump Module Perform POWERT...

Page 1327: ...k the related circuit s for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 2 2 NOTE Verify the battery is fully charged and capable of passing a load test before continuing WARN...

Page 1328: ...Button Starter Switch harness connector and properly install the Switch Disconnect the Clutch Interlock Switch harness connector Ignition on engine not running Using a 12 volt test light connected to...

Page 1329: ...ine All Yes Go To 10 No Go To 11 10 Turn the ignition off Disconnect the PCM harness connectors Measure the resistance in the K90 Starter Relay Control circuit from the Relay terminal and the PCM harn...

Page 1330: ...T ACTION APPLICABILITY 13 If there are no other possible causes remaining review repair All Repair Replace the Starter Perform POWERTRAIN VERIFICATION TEST VER 1 209 STARTING NO CRANK CONDITION Contin...

Page 1331: ...light illuminate brightly All Yes Go To 2 No Repair the open or short to ground in the A14 Fused B circuit Inspect and replace fuses as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition...

Page 1332: ...sensors that use the K7 5 volt Supply circuit Did the voltage return to 4 5 to 5 2 volts when disconnecting any of the sensors All Yes Replace the sensor that is pulling down the K7 5 volt supply Per...

Page 1333: ...ematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there is no possible causes remaining view repair All Repair Replace and program...

Page 1334: ...riate symptom With the DRBIIIt read the SKIM codes Are there any SKIM DTCs All Yes Refer to the Sentry Key Immobilizer category and perform the appropriate symptom diagnostics Perform POWERTRAIN VERIF...

Page 1335: ...rform POWERTRAIN VERIFICATION TEST VER 1 6 The following additional items should be checked as a possible cause for a start and stall condition Refer to any Technical Service Bulletins TSBs that may a...

Page 1336: ...ill present All Yes Repair is not complete refer to the appropriate symptom No Repair is complete POWERTRAIN VERIFICATION TEST VER 1 APPLICABILITY 1 Inspect the vehicle to ensure that all engine compo...

Page 1337: ...s at 64 Km h 40 mph Ensure the transmission shifts properly through all gears At some point stop the vehicle and turn off the engine for at least 10 seconds 13 With the DRBIIIt read DTCs Are any DTCs...

Page 1338: ...release the CANCEL switch The speed control should disengage 17 Bring the vehicle speed back up above 35 mph and engage speed control 18 Depress the OFF switch to turn OFF Cruise light will be off Th...

Page 1339: ...nd Mileage in PCM Erase codes in ABS and Air Bag modules 9 If the Catalyst was replaced with the DRBIIIt go to the miscellaneous Menu Option 9Catalyst Replaced9 and press enter 10 If a Comprehensive C...

Page 1340: ...rify any type of LDP system repair 9 Software program makes temporary changes to operating mode of PCM For this reason it is critical that test not be interrupted PCM s left in this mode as result of...

Page 1341: ...NOTES 220...

Page 1342: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES AND PDC 8 2 DATA LINK CONNECTOR 8 3 SENSORS AND SOLENOIDS C O M P O N E N T L O C A T I O N S 221 COMPONENT LOCATIONS...

Page 1343: ...C O M P O N E N T L O C A T I O N S 222 COMPONENT LOCATIONS 8 3 SENSORS AND SOLENOIDS Continued...

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 1346: ...FUNCTION 1 C20 18BR A C SWITCH SENSE 2 Z1 20BK GROUND A C PRESSURE TRANSDUCER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 F888 20BR PK 5V SUPPLY 3 C18 20DB A C PRESSURE SIGNAL 4 BA...

Page 1347: ...ER SQUIB 1 LINE 2 2 R43 20BK LB DRIVER SQUIB 1 LINE 1 3 R63 20TN LB DRIVER SQUIB 2 LINE 2 4 R61 20OR LB DRIVER SQUIB 2 LINE 1 5 6 X920 20GY OR RADIO CONTROL MUX RETURN 7 X20 20GY WT RADIO CONTROL MUX...

Page 1348: ...M ENABLE 10 D24 20WT DG FLASH ABS 11 12 13 14 15 16 A105 18DB RD FUSED B ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K2 18TN BK ECT SIGNAL 2 K900 20DB DG SENSOR GROUND ENGINE...

Page 1349: ...START FUEL INJECTOR NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K11 18WT DB FUEL INJECTOR NO 1 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1...

Page 1350: ...UT FUEL INJECTOR NO 6 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K58 18BR DB FUEL INJECTOR NO 6 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 7 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K26...

Page 1351: ...TANK MODULE GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 Z2 20BK LG GROUND 3 G4 20DB FUEL LEVEL SENSOR SIGNAL 4 A141 16DG WT FUEL PUMP RELAY OUTPUT GENERATOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K...

Page 1352: ...RIVER 4 K43 18DG GY IGNITION COIL NO 5 DRIVER IGNITION COIL PACK RIGHT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K17 18DB TN IGNITION COIL NO 2 DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K18 18...

Page 1353: ...UIT FUNCTION 1 2 L61 20LG LEFT TURN SIGNAL 3 F71 20RD IGNITION FEED 4 L63 20DG RD LEFT REAR TURN SIGNAL DRIVER 5 L62 20BR RD RIGHT REAR TURN SIGNAL DRIVER 6 L60 20TN RIGHT TURN SIGNAL 7 G900 20VT OR S...

Page 1354: ...1 20BK GROUND 3 K900 20DB DG SENSOR GROUND 4 K141 18TN WT O2 1 2 SIGNAL OXYGEN SENSOR 2 1 RIGHT BANK UP BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K80 18BK LG O...

Page 1355: ...C O N N E C T O R P I N O U T S 234 CONNECTOR PINOUTS...

Page 1356: ...UN START 62 63 15A G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 64 65 10A F12 18DB RD FUSED IGNITION SWITCH OUTPUT RUN START 66 67 20A F13 18DB FUSED RUN ACC RELAY OUTPUT 68 69 20A L43 18VT FUSED...

Page 1357: ...2 18DG PK FUSED B RUN ACC RELAY CAV CIRCUIT FUNCTION 72 F89 20RD WT RUN ACC RELAY CONTROL 73 A5 14RD FUSED B 74 75 F1 14DB RUN ACC RELAY OUTPUT 76 Z1 20BK GROUND STARTER MOTOR RELAY CAV CIRCUIT FUNCTI...

Page 1358: ...NO 2 DRIVER 10 K39 18GY RD IAC MOTOR NO 3 DRIVER 11 K60 18YL BK IAC MOTOR NO 2 DRIVER 12 13 14 15 K21 18BK RD IAT SIGNAL 16 K2 18TN BK ECT SIGNAL 17 K7 18OR 5V SUPPLY 18 K44 18TN YL CMP SIGNAL 19 K59...

Page 1359: ...NO 6 DRIVER 13 K28 18GY LB FUEL INJECTOR NO 8 DRIVER 14 K8 18BK LG FUEL INJECTOR NO 10 DRIVER 15 K12 18TN FUEL INJECTOR NO 2 DRIVER 16 K14 18LB BR FUEL INJECTOR NO 4 DRIVER 17 C240 18OR RD HYDRAULIC C...

Page 1360: ...UMP SWITCH SENSE 15 K25 18VT LG BATTERY TEMPERATURE SENSOR SIGNAL 16 K80 18BK LG O2 2 1 HEATER CONTROL 17 K90 18TN STARTER MOTOR RELAY CONTROL 18 19 K31 18BR FUEL PUMP RELAY CONTROL 20 K52 18PK BK EVA...

Page 1361: ...SOLENOID CONTROL THROTTLE POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K900 20DB DG SENSOR GROUND 2 K22 18OR DB TP SIGNAL 3 K7 20OR 5V SUPPLY TIRE PRESSURE MONITOR MODULE BLUE 6 WAY CAV CIRCUIT...

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 1366: ...11 0 CHARTS AND GRAPHS 11 1 O2 SENSOR CONFIGURATION C H A R T S A N D G R A P H S 245 CHARTS AND GRAPHS...

Page 1367: ...11 2 VACUUM READINGS 11 3 CAM AND CRANK SENSORS PATTERNS C H A R T S A N D G R A P H S 246 CHARTS AND GRAPHS...

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 1370: ...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 1371: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Page 1372: ...3 1 1 CUSTOMER NORMAL OPERATING MODE 8 3 3 1 2 SHIPPING OPERATING MODE 8 3 4 CHIME WARNING SYSTEM 8 3 4 1 CHIME PRIORITY 9 3 4 2 CHIME ON CONDITIONS 9 3 4 3 WARNING LAMP ANNOUNCEMENT 9 3 4 4 OTHER CHI...

Page 1373: ...3 4 2 1 TECHNICIAN SAFETY INFORMATION 23 4 2 2 VEHICLE PREPARATION FOR TESTING 23 4 2 3 SERVICING SUB ASSEMBLIES 23 4 2 4 DRBIIIT SAFETY INFORMATION 23 4 3 WARNINGS 24 4 3 1 VEHICLE DAMAGE WARNINGS 24...

Page 1374: ...IRCUIT SHORT 106 PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY 108 PASSENGER SEAT BELT TENSIONER SHORT TO GROUND 110 PASSENGER SQUIB 1 CIRCUIT OPEN 112 PASSENGER SQUIB 1 CIRCUIT SHORT 115 PASSENGER S...

Page 1375: ...8 NO RESPONSE FROM HVAC 160 NO RESPONSE FROM INSTRUMENT CLUSTER 162 NO RESPONSE FROM PCM PCI BUS 165 NO RESPONSE FROM PCM SCI ONLY 166 NO RESPONSE FROM RADIO 169 NO RESPONSE FROM TIRE PRESSURE MONITOR...

Page 1376: ...208 BLEND CIRCUIT SHORTED TO GROUND 208 BLEND CIRCUIT SHORTED TO IGN OR BATT 208 COMMON DRIVER SHORTED TO GROUND 208 COMMON DRIVER SHORTED TO IGN OR BATT 208 MODE 1 CIRCUIT SHORTED TO GROUND 208 MODE...

Page 1377: ...CH STUCK 265 HORNS INOPERATIVE 267 INSTRUMENT CLUSTER ABS LAMP CIRCUIT OPEN 270 ABS LAMP CIRCUIT SHORTED 270 AIRBAG LAMP CIRCUIT OPEN 270 AIRBAG LAMP CIRCUIT SHORTED 270 ABS MESSAGES NOT RECEIVED 272...

Page 1378: ...CK DOWN 345 DRIVER WINDOW SWITCH STUCK UP 346 DRIVER WINDOW UP OUTPUT SHORT TO GROUND 347 PASSENGER WINDOW DOWN RELAY COIL OPEN SHORT TO GROUND 349 PASSENGER WINDOW DOWN RELAY COIL SHORT TO BATTERY 35...

Page 1379: ...RUMENT PANEL 411 8 5 POWER WINDOW MOTOR 411 8 6 POWER DOOR LOCKS 411 8 6 1 DRIVER CYLINDER UNLOCK SWITCH 411 8 6 2 DOOR LATCH ASSEMBLY 412 8 6 3 RKE MODULE 412 8 7 TIRE PRESSURE MONITOR MODULE TPM 412...

Page 1380: ...DEFOGGER SYSTEM 425 10 7 EXTERIOR LIGHTING 426 10 7 1 FRONT LAMPS 426 10 7 2 REAR FOG LAMPS EXPORT ONLY 427 10 8 HEATING A C SYSTEM 428 10 9 IGNITION POWER ACCESSORY 429 10 9 1 HORN SYSTEM 429 10 9 2...

Page 1381: ...NOTES x...

Page 1382: ...book if you have any comments or suggestions 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 2005 ZB SRT 10 v...

Page 1383: ...or high When the pro grammed conditions are met the ACM sends an electrical signal to deploy the appropriate airbag system components WARNING THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANI...

Page 1384: ...IONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH DRIVER AIRBAG SQUIB STATUS 1 Using a DRBIIIt read Airbag DTC s If the following active codes are present ACTIVE DTC CONDI...

Page 1385: ...7236 89 Kpa 2500 PSI DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR DO NOT PUNCTURE INCINER ATE OR BRING INTO CONTACT WITH ELECTRICITY DO NOT STORE AT TEMPERA TURE EXCEEDING...

Page 1386: ...plunger and rotate to the desired switch position The spring loaded locking plunger pre vents the user from leaving the key in the switch The key will be automatically ejected when force is not applie...

Page 1387: ...irect you to the specific test s that must be performed In certain test procedures within this manual diagnostic trouble codes are used as a diagnostic tool 3 1 8 1 ACTIVE CODES The code becomes activ...

Page 1388: ...sage This circuit is fairly simple to troubleshoot The circuit must be complete from the switches in the steering wheel to the BCM The ground must be complete so that the switches can cause the voltag...

Page 1389: ...ss 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 cust...

Page 1390: ...me will sound if the door or decklid is still open and the vehicle speed is greater than 4mph 6kph 3 4 3 WARNING LAMP ANNOUNCEMENT The cluster may request a single multiple chimes or a continuous chim...

Page 1391: ...to use the DRBIIIt lab scope The 12v square wave selection on the 20 volt scale provides a good view of the bus activity Voltage on the bus should pulse between zero and about seven and a half volts...

Page 1392: ...ircuit 3 7 2 HEADLAMP SWITCH The Headlamp Switch uses four separate circuits inputs to the Body Control Module BCM plus one circuit as a sense ground return The Headlamp Switch controls the Fog lamps...

Page 1393: ...er relay The BCM powers the blower relay in ignition RUN The PDC powers the blower motor through the closed relay contacts To govern Low M1 M2 blower speeds current flows from the blower motor through...

Page 1394: ...r all Short Too Complex messages first all common door driver circuit related messages second and all other door driver circuit related messages last CAUTION The DRBIIIT can display up to three Actuat...

Page 1395: ...eives the following informa tion via hardwire from the ACM Passenger Airbag Off Instrument Cluster controlled warning indicators based on gauge pointer position Low Engine Oil Pressure Warning indicat...

Page 1396: ...l levels the cluster will maintain the pointer at the Temperature High pointer position When the cluster receives a bus message indicat ing the oil temperature has reached or exceeded the Temperature...

Page 1397: ...and Gauge Cluster learned and standard indica tors Warning Indicators and LCD warnings for approximately 5 seconds Toggle between the Skip shift Amber LED and the Redline Red LED with a pause in betwe...

Page 1398: ...Cluster 3 12 1 TIRE PRESSURE MONITOR MODULE The TPM module is a microprocessor controller that monitors the transmissions from the transmit ters at all times with the ignition on The TPM module will...

Page 1399: ...is enabled This roll switch is open when the vehicle is stopped or below 33 km h 20 mph When the vehicle is moving above 33 km h 20 mph centrifugal force will close the roll switch NOTE The transmitte...

Page 1400: ...ault has set since the last ignition on cycle cycling the ignition switch will not clear the fault Tire Pressure Low and Critical Tire Pressure When the TPM module senses that pressure is below one of...

Page 1401: ...on ID and tire pressure to the module After the module has learned that particular tire pressure sensor transmitter ID the magnet should be moved to each of the other wheels as directed by the DRBIIIt...

Page 1402: ...in the center con sole and the power window motors mounted to the window regulator in each door The BCM controls logic for the driver and passenger door power win dows The BCM receives a muxed hard w...

Page 1403: ...or is closed Disarming Active and Passive Active disarming occurs when the RKE transmit ter is used to unlock the vehicle doors This disarm ing will also halt the alarm once it has been acti vated Acc...

Page 1404: ...system problem it is important to follow approved procedures where applicable These procedures can be found in this General Information Section or in the service man ual procedures Following these pro...

Page 1405: ...gh the insulation this will damage it and eventually cause it to fail because of corrosion Be careful when performing electrical tests so as to prevent acciden tal shorting of terminals Such mistakes...

Page 1406: ...assenger airbag PASS passenger PCI Programmable Communication In terface vehicle communication bus PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyl...

Page 1407: ...NOTES 26...

Page 1408: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 27...

Page 1409: ...Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 1 When Monitored With the ignition on the module on board diagnostics continuously performs internal...

Page 1410: ...he purpose of this test the AECM and ORC modules will be referred to as an ACM From the list below select the appropriate module reporting this diagnostic trouble code SELECT ONE All ACM ACTIVE or STO...

Page 1411: ...tored With ignition on the ACM monitors the PCI Bus for a message from the MIC containing the airbag warning indicator status The MIC transmits the message one time at ignition on upon lamp state chan...

Page 1412: ...ATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a...

Page 1413: ...DES CLUSTER MESSAGE MISMATCH STORED CODE OR INTERMITTENT CONDITION ACM CLUSTER MESSAGE MISMATCH ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged...

Page 1414: ...l modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as y...

Page 1415: ...e that the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2...

Page 1416: ...Cs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active...

Page 1417: ...ODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modu...

Page 1418: ...lved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE If equi...

Page 1419: ...VER SEAT BELT SWITCH SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Turn the ignition on NOTE For t...

Page 1420: ...and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIII...

Page 1421: ...AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be tu...

Page 1422: ...information Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagn...

Page 1423: ...AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be tu...

Page 1424: ...ST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe dis...

Page 1425: ...AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be tu...

Page 1426: ...Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuit shorted to battery Perform AIRBAG VERIFICATION TEST VER 1 No Go To 4 NOTE When reconnecting airbag system components the Ignition must b...

Page 1427: ...NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in iden...

Page 1428: ...test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition...

Page 1429: ...LE IS DROPPED AT ANY TIME IT MUST BE REPLACED Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active c...

Page 1430: ...UIB CIRCUITS OPEN DRIVER SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM DRIVER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition o...

Page 1431: ...DING Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH T...

Page 1432: ...active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate air...

Page 1433: ...SQUIB 1 CIRCUIT SHORT DRIVER SQUIB 1 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on...

Page 1434: ...NUTES BE FORE PROCEEDING Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSON...

Page 1435: ...active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate air...

Page 1436: ...UIT SHORT TO BATTERY DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 1 CIRCUITS SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1...

Page 1437: ...NING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag DTCs Does the DRBIIIt show DRIVER SQUIB 1 SHORT TO BATTERY All Yes Go To...

Page 1438: ...ctive codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airba...

Page 1439: ...CIRCUIT SHORT TO GROUND DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER SQUIB 1 CIRCUITS SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILI...

Page 1440: ...he Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION...

Page 1441: ...o stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you...

Page 1442: ...DRIVER SQUIB 2 CIRCUIT OPEN DRIVER SQUIB 2 LINE 1 OR LINE 2 CIRCUIT OPEN ACM DRIVER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the...

Page 1443: ...pring connector WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY With the DRB read the active Airbag DTCs Does the DRB show DRIVER SQUIB 2 CIRCUIT OPEN All Yes Go To 4 No Replace the Clocksprin...

Page 1444: ...to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you...

Page 1445: ...SQUIB 2 CIRCUIT SHORT DRIVER SQUIB 2 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB 2 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on...

Page 1446: ...ol to the Clockspring connector WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag DTCs Does the DRB show DRIVER SQUIB 2 CIRCUIT SHORT All Yes Go To 4 No R...

Page 1447: ...to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you...

Page 1448: ...IRCUIT SHORT TO BATTERY DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 2 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY...

Page 1449: ...nnector WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag DTCs Does the DRB show DRIVER SQUIB 2 SHORT TO BATTERY All Yes Go To 4 No Replace the Clocksprin...

Page 1450: ...stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you i...

Page 1451: ...2 CIRCUIT SHORT TO GROUND DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO GROUND ACM DRIVER SQUIB 2 CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILIT...

Page 1452: ...Clockspring connector WARNING TURN THE IGNITION ON THEN RECONNECT THE BATTERY With the DRBIIIt read the active Airbag DTCs Does the DRB show DRIVER SQUIB 2 SHORT TO GROUND All Yes Go To 4 No Replace t...

Page 1453: ...o stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you...

Page 1454: ...RT CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT RUN START CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure th...

Page 1455: ...ag Run Start Fuse Perform AIRBAG VERIFICATION TEST VER 1 4 Turn the ignition on Measure the voltage of the Ignition Switch Output circuit between the Airbag Run Start Fuse and ground Is the voltage ab...

Page 1456: ...ctive codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions Wiggle the wiring harness and connectors of the appropriate airba...

Page 1457: ...ED RUN CIRCUIT FUSED IGNITION SWITCH OUTPUT RUN CIRCUIT SHORT TO GROUND ACM FUSED IGNITION RUN CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILI...

Page 1458: ...used Ignition Switch Output Run circuit for a short to ground and replace Airbag Run Fuse Perform AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OF...

Page 1459: ...tructions Perform AIRBAG VERIFICATION TEST VER 1 9 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnos...

Page 1460: ...NDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM Turn the...

Page 1461: ...s while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s in all switch positions...

Page 1462: ...MODULE ACM STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged IF THE MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED...

Page 1463: ...top to stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist...

Page 1464: ...n the ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When recon...

Page 1465: ...Instructions Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before dia...

Page 1466: ...D CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC m...

Page 1467: ...voltage on the PAB MUX Switch Sense and PAB MUX Switch Return circuits at the PAB On Off Switch connector Is there any voltage on either circuit All Yes Repair the Passenger Airbag MUX Switch circuits...

Page 1468: ...TE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identi...

Page 1469: ...ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred to as an...

Page 1470: ...10K ohms All Yes Repair the Passenger Airbag MUX Switch Sense circuit shorted to ground Perform AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Measure the resistance between the PAB MUX Switch Sense cir...

Page 1471: ...OTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in ident...

Page 1472: ...rn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go T...

Page 1473: ...harged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the f...

Page 1474: ...IT OPEN OPEN GAUGE PACK ACM PASSENGER OFF INDICATOR CIRCUITS SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the batte...

Page 1475: ...Cluster connector and ground Is the resistance below 10K ohms All Yes Repair the Passenger Off Indicator Driver circuit shorted to ground Perform AIRBAG VERIFICATION TEST VER 1 No Test Complete 5 WARN...

Page 1476: ...M Adapter and the Gauge Cluster connector Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the open Passenger Airbag Indicator Driver circuit Perform AIRBAG VERIFICATION TEST VER 1 7 WARNING...

Page 1477: ...TE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in identi...

Page 1478: ...y is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC G...

Page 1479: ...nosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE If equipped with Passen...

Page 1480: ...For the purpose of this test the AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system c...

Page 1481: ...distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE If equipped with Passenger Airbag On Off switch read the DTC s...

Page 1482: ...ERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Ensure the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules will be referred...

Page 1483: ...AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored co...

Page 1484: ...AUSES PASSENGER SEAT BELT TENSIONER OPEN PASSENGER SEAT BELT TENSIONER LINE 1 OR LINE 2 CIRCUIT OPEN ACM PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PR...

Page 1485: ...t the Airbag control Module connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool adaptor to the ACM connector Disconnect the Load Tool jumper from the Passen...

Page 1486: ...NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in iden...

Page 1487: ...ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off...

Page 1488: ...rmation Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosin...

Page 1489: ...e AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be...

Page 1490: ...Module in accordance with the Service information Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All act...

Page 1491: ...he AECM and ORC modules will be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be...

Page 1492: ...rmation Perform AIRBAG VERIFICATION TEST VER 1 5 NOTE Ensure the battery is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosin...

Page 1493: ...AIRBAG OPEN PASSENGER SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACM PASSENGER SQUIB 1 CIRCUIT OPEN ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure the bat...

Page 1494: ...accordance with the Service Information Perform AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PR...

Page 1495: ...stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you i...

Page 1496: ...T SHORT PASSENGER SQUIB 1 LINE 1 SHORT TO LINE 2 ACM PASSENGER SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the battery...

Page 1497: ...form AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Airbag Control Modu...

Page 1498: ...stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you i...

Page 1499: ...RY PASSENGER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PASSENGER SQUIB 1 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure...

Page 1500: ...e Passenger Airbag in accordance with the Service Infor mation Perform AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT...

Page 1501: ...top NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in...

Page 1502: ...IRCUIT SHORT TO GROUND PASSENGER SQUIB 1 LINE 1 AND LINE 2 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACM PASSENGER SQUIB 1 CIRCUIT SHORT TO GROUND ACTIVE CODE PRESENT TEST ACTION APPLICABI...

Page 1503: ...MINUTES BE FORE PROCEEDING Disconnect the Airbag Control Module connector NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool adaptor to the Airbag Control Module connect...

Page 1504: ...stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you in...

Page 1505: ...RBAG OPEN PASSENGER SQUIB 2 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PASSENGER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 NOTE Ensure that the...

Page 1506: ...VERIFICATION TEST VER 1 3 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Control Module connector NOTE Check connectors Clean and re...

Page 1507: ...stop NOTE Check connectors Clean and repair as necessary You have just attempted to simulate the condition that initially set the trouble code message The following additional checks may assist you i...

Page 1508: ...D DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TURN THE IGNITION...

Page 1509: ...be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as you work through the system NOTE...

Page 1510: ...TORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TURN THE IGNI...

Page 1511: ...All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while performing the following steps With the DRBIIIt monitor active codes as you work th...

Page 1512: ...CTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TUR...

Page 1513: ...ry is fully charged With the DRBIIIt record and erase all DTCs from all modules All active codes must be resolved before diagnosing any stored codes Maintain a safe distance from all airbags while per...

Page 1514: ...STATUS and read the PASSIVE RESTRAINTS AIRBAG MONITOR DISPLAY WARNING LAMP STATES With no active DTCs Does the LAMP REQ by ACM monitor show ON All Yes WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED A...

Page 1515: ...ion switch from off to on and wait 10 seconds With the DRBIIIt read the audio DTC s Does the DRBIIIt display ALL OUTPUTS SHORT All Yes Go To 2 No Refer to the wiring diagrams located in the service in...

Page 1516: ...ound and any speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Dis...

Page 1517: ...RATIVE TUNE SWITCH INOPERATIVE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be CD MECHANICAL FAILURE When Monitored and Set Condition CD MECHANIC...

Page 1518: ...t is not formatted as a music CD or is scratched dirty so the radio can not play the CD POSSIBLE CAUSES CD PLAY FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched...

Page 1519: ...a CD that is not formatted as a music CD is installed in the radio CD player POSSIBLE CAUSES CD READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD...

Page 1520: ...APPLICABILITY 1 With the DRBIIIt erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the...

Page 1521: ...orm BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio harness connector Start the engine Measure the voltage of each Fused B circuit and the Fused Ignition Switch Output circui...

Page 1522: ...2 No Repair Antenna connection as needed Perform BODY VERIFICATION TEST VER 1 2 Refer to the Audio System in the service information and test the Antenna in accordance with the service procedure Is t...

Page 1523: ...t attempt to communicate with the BCM Was the DRBIIIt able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION...

Page 1524: ...nstrument Cluster harness connector s Disconnect the BCM C4 harness connector Using a 12 volt test light connected to 12 volts check the chime driver circuit for a short to ground Does the test light...

Page 1525: ...F All Yes Replace the Instrument Cluster Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Instrument Cluster harness connectors Disconnect the BCM harness connect...

Page 1526: ...perly before continuing with this test With the DRBIIIt actuate the CHIME BCM actuator Does chime sound a warning All Yes Go To 3 No Refer to symptom Chime Inoperative in the Chime category Perform BO...

Page 1527: ...rn the ignition on With the DRB attempt to communicate with the Airbag Control Module Was the DRB able to I D or communicate with the Airbag Control Module All Yes Go To 2 No Refer to the Communicatio...

Page 1528: ...k the radio IOD fuse for an open before continuing With the DRB attempt to communicate with the Radio Was the DRB able to I D or communicate with the Radio All Yes Go To 2 No Refer to the Communicatio...

Page 1529: ...T CORRECT COUNTRY CODE TEST ACTION APPLICABILITY 1 With the DRB enter Body Computer Miscellaneous then Change Country Code Select the correct country code for the vehicle With the DRB erase BCM DTC s...

Page 1530: ...S INTERNAL BCM FAILURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase BCM DTC s Turn the ignition off then turn the ignition on With the...

Page 1531: ...nition on With the DRB attempt to communicate with the Instrument Cluster MIC Was the DRB able to I D or communicate with the Instrument Cluster MIC All Yes Go To 2 No Refer to the Communication categ...

Page 1532: ...hicle except the PCM NOTE Clear the code If this code continues to set and the DRB can still communicate with the module it will be necessary to replace the module NOTE The conditions that set the DTC...

Page 1533: ...OSSIBLE CAUSES PCI INTERNAL FAULT TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase BCM DTC s Turn the ignition off then turn the ignition...

Page 1534: ...ody Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt attempt to communicate with the PCM Was the DRBIII...

Page 1535: ...All Yes Go To 2 No Repair the Fused Ignition Switch Output Run and Fused Ignition Switch Output Run Start circuits for an open Perform AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting airbag sys...

Page 1536: ...e to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to...

Page 1537: ...off Disconnect the BCM C1 C2 C3 and C4 harness connectors Using a 12 volt test light connected to ground probe the Fused B circuits in the BCM C1 harness connector and the IOD B circuit in the other B...

Page 1538: ...cope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis...

Page 1539: ...To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector Usin...

Page 1540: ...lect Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground...

Page 1541: ...rm BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the A C Heater Control C2 harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignit...

Page 1542: ...ab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chas...

Page 1543: ...ate with the BCM All Yes Go To 2 No Refer to the symptom list for problems related to no communica tion with the BCM Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Instrum...

Page 1544: ...ck lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Instrument Cluster C1 connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage...

Page 1545: ...Instrument Cluster C1 connector Open and close a door This is done to ensure the BCM is awake Is the resistance below 50 0 ohms All Yes Replace the Instrument Cluster in accordance with the service in...

Page 1546: ...It displays a no response message refer to the appropriate symptom in the powertrain diagnostic procedures Turn the ignition off Disconnect the PCM C3 harness connector Use Scope input cable CH7058 Ca...

Page 1547: ...his step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM C3 harness connector Disconnect the...

Page 1548: ...Disconnect the PCM harness connectors Measure the resistance between the SCI Transmit circuit and the SCI Receive circuit at the PCM connector Is the resistance below 5 0 ohms All Yes Repair the shor...

Page 1549: ...the DLC Is the resistance below 5 0 ohms All Yes Go To 10 No Repair the SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 10 If there are no possible causes remaining view re...

Page 1550: ...munication Failure Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the RUN...

Page 1551: ...channel one connector on the DRB Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIIIt select Pep Module Tools Select lab scope Select Live Data Sele...

Page 1552: ...VERIFICA TION TEST 2 Turn the ignition off Disconnect the Tire Pressure Monitor Module harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition S...

Page 1553: ...ssure Monitor Module connector and the DLC Is the resistance below 5 0 ohms All Yes Replace and program the Tire Pressure Monitor Module in accordance with the Service Information Perform TIRE PRESSUR...

Page 1554: ...or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspec...

Page 1555: ...epair the PCI Bus circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Replace the module that when disconnected the short to voltage was eliminated Perform BODY VERIFICATION TEST VE...

Page 1556: ...Connect a jumper wire between the Sense circuit and the Ground circuit With the DRBIIIt in Inputs Outputs read the DECKLID AJAR SW state Does the DRBIIIt display CLOSED All Yes Replace the Decklid Aja...

Page 1557: ...LOSED to OPEN All Yes Replace the Decklid Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Decklid Ajar Switch connector Disconnect the BCM C3 harness connector Using a 12...

Page 1558: ...onnect a jumper wire between the Sense circuit and the Ground circuit With the DRBIIIt in Inputs Outputs read the DRVR DOOR AJAR SW state Does the DRBIIIt display CLOSED All Yes Replace the Driver Doo...

Page 1559: ...rom CLOSED to OPEN All Yes Replace the Driver Door Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Driver Door Ajar Switch connector Disconnect the BCM C3 harness connecto...

Page 1560: ...nd circuit for continuity Does the light illuminate All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Hood Ajar Switch connector With the D...

Page 1561: ...ch State change from CLOSED to OPEN All Yes Replace the Hood Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 connector Disconnect the Hood Ajar Swit...

Page 1562: ...nector Connect a jumper wire between the Sense circuit and the Ground circuit With the DRBIIIt in Inputs Outputs read the PASS DOOR AJAR SW state Does the DRBIIIt display CLOSED All Yes Replace the Pa...

Page 1563: ...e from CLOSED to OPEN All Yes Replace the Passenger Door Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Passenger Door Ajar Switch connector Disconnect the BCM C3 harness...

Page 1564: ...Module With the DRBIIIt read the active DTC s Does the DRBIIIt display DEFOG RELAY CONTROL CKT SHORTED TO BATT All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and c...

Page 1565: ...ontrol circuit at the A C Heater Control Module connector with the Ignition off and on Is there any voltage present All Yes Repair the Rear Window Defogger Relay Control circuit for a short to battery...

Page 1566: ...DTC information Does the DRBIIIt read Left Fog Lamp Output Open All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a possible intermittent...

Page 1567: ...ttent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and install a known good Fog Lamp in place of the Left...

Page 1568: ...ng for 5 seconds in each position With the DRB read DTC s Does the DRBIIIt read Left High Beam Output Open All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the...

Page 1569: ...sconnect the Left Headlamp harness connector Using a 12 volt test light connected to ground check the Left High Beam Output circuit in the Left Headlamp harness connector Turn the high beam headlamps...

Page 1570: ...BIIIt read the DTC information Does the DRBIIIt read Left High Beam Output Short All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a poss...

Page 1571: ...on Using a 12 volt test light connected to ground check the Left High Beam Output circuit Does the test light illuminate brightly All Yes Replace the High Beam Headlamp Perform BODY VERIFICATION TEST...

Page 1572: ...present Inspect the related wiring harness for a possible intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Check fuse 6 in the PDC Is the fuse open All Yes Replace...

Page 1573: ...ODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Remove the Headlamp Relay from the Power Distribution Center Disconnect the Body Control Module C2 connector Measure the resistance of th...

Page 1574: ...ribution Center Substitute the original Headlamp Relay with a known good relay Turn the ignition on With the DRBIIIt clear the current Body Control Module DTCs Turn the ignition off wait 10 seconds th...

Page 1575: ...e intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Park Lamp harness connector Disconnec...

Page 1576: ...d erase DTC s With the DRBIIIt read DTC s Attempt to operate the Rear Fog Lamps while monitoring the DRBIIIt Does the DRBIIIt display REAR FOG LAMP RELAY OPEN SHORT TO GROUND All Yes Go To 2 No The co...

Page 1577: ...ce between 85 0 and 106 0 ohms All Yes Go To 6 No Replace the Rear Fog Lamp Relay Perform BODY VERIFICATION TEST VER 1 6 With the ignition OFF With the Rear Fog Lamp Relay disconnected Disconnect the...

Page 1578: ...this DTC to set is currently not present Using the wiring diagram schematic as a guide inspect the related wiring harness and connectors for a possible intermittent condition Perform BODY VERIFICATION...

Page 1579: ...ymptom is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Tu...

Page 1580: ...tent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and install a known good Fog Lamp in place of the Right...

Page 1581: ...ing for 5 seconds in each position With the DRB read DTC s Does the DRBIIIt read Right High Beam Output Open All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect t...

Page 1582: ...sconnect the Right Headlamp harness connector Using a 12 volt test light connected to ground check the Left High Beam Output circuit in the Right Headlamp harness connector Turn the high beam headlamp...

Page 1583: ...DRBIIIt read the DTC information Does the DRBIIIt read Right High Beam Output Short All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a...

Page 1584: ...on Using a 12 volt test light connected to ground check the Right High Beam Output circuit Does the test light illuminate brightly All Yes Replace the High Beam Headlamp Perform BODY VERIFICATION TES...

Page 1585: ...losed for 10 minutes CHECKSUM FAILURE ACTIVE When Monitored At every power up five seconds after ignition is on Set Condition This DTC will set if the calculated check sum does not match the stored va...

Page 1586: ...nition on Set Condition If the A C Heater Control Module does not receive the dimming function message from the Body Control Module for more than 5 seconds then the A C Heater Control Module backlight...

Page 1587: ...er circuits while attempting to drive this actuator Only one overcurrent DTC can set per ignition cycle RECIRC OVERCURRENT STORED When Monitored When actuator movement is requested Set Condition This...

Page 1588: ...l cold position Monitor the DRBIIIt for active HVAC DTCs during the following test steps Press the A C switch on wait 30 seconds and then press it off Press the EBL switch on wait 30 seconds and then...

Page 1589: ...Set Condition If two or more drivelines shorted together BLEND CIRCUIT SHORTED TO GROUND When Monitored When the Actuator Circuit Test is executed Set Condition This message will set if the A C Heate...

Page 1590: ...short high on the Mode Door 2 Driver circuit RECIRC CIRCUIT SHORTED TO GROUND When Monitored When the Actuator Circuit Test is executed Set Condition This message will set if the A C Heater Control de...

Page 1591: ...then rerun the Actuator Circuit Test to ensure no new messages exist CAUTION If Overcurrent DTCs are active and the DRBIIIt displays Actu ator Circuit Test Passed proceed to Act Ckt Test Pass Overcurr...

Page 1592: ...ion on With the DRBIIIt in HVAC System Tests actuate the Actuator Circuit Test What message does the DRBIIIt display All Same msg as from start of test Replace the A C Heater Control Module in accorda...

Page 1593: ...Mode Door 2 Driver ckt Is the resistance below 10K ohms on any of the circuits All Yes Repair the door driver circuits with a resistance below 10K ohms for a short together Perform BODY VERIFICATION T...

Page 1594: ...est Replace the A C Heater Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Different msg than from start of test Using the wiring diagram as a guide insp...

Page 1595: ...not in set in Funeral Mode Turn the ignition on Turn the Blower control to low speed Press the A C switch on Press the EBL switch on Watch the A C and EBL status indicators on the A C Heater Control M...

Page 1596: ...r door actuator electrical circuits shorted to voltage door actuator electrical circuits shorted to ground A short to voltage or ground on the door actuator electrical circuits will also set door actu...

Page 1597: ...ult messages Turn the ignition on With the DRBIIIt read HVAC DTCs Does the DRBIIIt display any HVAC DTCs All Yes Return to the symptom list and choose the symptom s Perform BODY VERIFICATION TEST VER...

Page 1598: ...VER 1 6 Turn the ignition off Remove the applicable door actuator from the A C Heater Housing Assembly Disconnect the door actuator harness connector By hand attempt to rotate the door actuator in bot...

Page 1599: ...DTC will set if the A C Heater Control Module detects an excessive current draw on any of the door driver circuits while attempting to drive this actuator Only one overcurrent DTC can set per ignitio...

Page 1600: ...he symptom list and choose the symptom s If two or more drivelines are shorted together when running the Actuator Ckt Test the DRBIIIt may display Actuator Ckt Test Passed even though Overcurrent DTCs...

Page 1601: ...on This DTC will set when the A C Heater Control Module senses excessive current draw on the Rear Window Defogger Relay Control Circuit POSSIBLE CAUSES DEFOG RELAY CONTROL CKT SHORTED TO BATT TEST ACT...

Page 1602: ...nal loopback test is executed If the internal loopback test fails the DTC will set POSSIBLE CAUSES CHECK FOR ADDITIONAL HVAC DTCS A C HEATER CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignitio...

Page 1603: ...gnition on Set Condition This DTC will set if the A C Heater Control Module does not receive the VIN message from the PCM for more than 5 seconds POSSIBLE CAUSES CHECK FOR ADDITIONAL HVAC DTCS CHECK F...

Page 1604: ...9 9VIN Msg Pres YES9 Does the DRB display NO RESPONSE after the message All Yes Refer to symptom No Response From PCM PCI Bus in the Communication category Perform BODY VERIFICATION TEST VER 1 No Rep...

Page 1605: ...the DRBIIIt able to I D or communicate with the HVAC Module All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition o...

Page 1606: ...C s Did this DTC reset All Yes Replace the A C Heater Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Using the wiring diagram schematic as a guide in...

Page 1607: ...N The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground back probe the Panel Lamps Driver circuit...

Page 1608: ...t between the A C Heater Control C2 harness connector and the Body Control Module C2 harness connector Is the resistance below 5 0 ohms All Yes Replace the Body Control Module in accordance with the S...

Page 1609: ...ON TEST VER 1 No Go To 2 2 NOTE All Actuator Circuit Test fault messages and Overcurrent DTCs must be repaired before diagnosing Calibration fault messages Turn the ignition on With the DRBIIIt read a...

Page 1610: ...sition in 25 increments while checking for a change in airflow air temperature coming from the panel vents Does the airflow air temperature change with respect to the position of the blend control All...

Page 1611: ...he Power Distribution Center Fuse 1 Turn the ignition on Turn the blower on and operate it in all speeds and modes Does the blower motor operate properly without blowing the fuse All Yes Check the Blo...

Page 1612: ...connector Turn the ignition on NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground back pro...

Page 1613: ...Driver circuit between the Blower Motor harness connector and the A C Heater Control Module C1 harness connector Is the resistance below 5 ohms All Yes Replace the Blower Motor in accordance with the...

Page 1614: ...und and each of the Blower Motor Driver circuits Is the resistance below 10K ohms on any of the circuits All Yes Repair all Blower Motor Driver circuits with a resistance below 10K ohms for a short to...

Page 1615: ...ver circuit and the Blower Motor High Driver circuit Is the resistance below 10K ohms between any of the circuits All Yes Repair the Blower Motor Driver circuits with a resistance below 10K ohms for a...

Page 1616: ...s NOTE When the EBL status indicator is flashing it will not indicate EBL operating status However the EBL switch will continue to function nor mally NOTE When the EBL status indicator is flashing the...

Page 1617: ...ault message is displayed proceed to the conclusion question Turn the ignition on Turn the mode select control to the panel position Verify that the blower motor operates correctly in all speeds Diagn...

Page 1618: ...Refer to the Powertrain Diagnostic Procedures Manual for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Recheck the climate control system performance Refer to Service Information for a...

Page 1619: ...BILITY 1 With the DRBIIIt erase DTCs Cycle the ignition switch from OFF to ON Turn the radio on With the DRBIIIt read DTCs Does the DRBIIIt display ACCESSORY RELAY CONTROL CIRCUIT OPEN All Yes Go To 2...

Page 1620: ...n the BCM C4 connector and the Relay connector Is the resistance below 5 0 ohms All Yes Go To 4 No Repair the Accessory Relay Control circuit for an open Perform BODY VERIFICATION TEST VER 1 4 If ther...

Page 1621: ...MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt erase DTCs Cycle the ignition switch from OFF to ON Turn the radio on With the DRBIIIt read DTCs Does the DRBIIIt display ACCESSORY RELAY CONTROL CI...

Page 1622: ...tor Remove the Accessory Relay from the PDC Disconnect the Body Control Module C4 connector Measure the resistance between ground and the Accessory Relay Control circuit Is the resistance below 1000 0...

Page 1623: ...CH RUN START OUTPUT OPEN BCM TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the BCM C2 harness connector Measure the voltage between the Fused Ignition Switch Output Run Start circuit an...

Page 1624: ...Unlock 1472 1764 ohms Run 539 767 ohms Did the Ignition Switch resistance measure within specifications for each position All Yes Replace and program the Body Control Module in accordance with the Ser...

Page 1625: ...r the Ignition Switch Sense circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Ignition Switch harness connector Disconnect the BCM C...

Page 1626: ...hms Unlock 1472 1764 ohms Run 539 767 ohms Did the Ignition Switch measure the correct resistance in each position All Yes Replace and program the Body Control Module in accordance with the Service In...

Page 1627: ...IGNITION SW voltage Does the DRBIIIt display IGNITION SW 0 0 volts All Yes Go To 2 No Replace the Ignition Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn...

Page 1628: ...sed Ignition Switch Output Run circuit Airbag Control Module ACM NOTE ACM fuse does not protect circuit BCM C3 harness connector pin 33 Fused Ignition Switch Output Run circuit Multi Function Switch B...

Page 1629: ...d C4 harness connectors Using the wiring diagram schematic as a guide measure the resistance between ground and the appropriate circuit in the BCM harness connectors Is the resistance below 10k ohms o...

Page 1630: ...Switch Output Run circuit to any of the following Blower Motor Relay In PDC Rear Window Defogger Relay In PDC Back Up Lamp Switch Right and Left Back Up Lamps Back Up Lamp Switch Output circuit NOTE...

Page 1631: ...d Ignition Switch Output Run circuits in the BCM C2 harness connector Using the wiring diagram schematic as a guide disconnect the appropriate compo nent harness connector Is the resistance below 10k...

Page 1632: ...ondition that caused this DTC is currently not present Use the wiring diagram schematic as a guide and inspect the related wiring harness for a possible intermittent condition Perform BODY VERIFICATIO...

Page 1633: ...and C4 harness connectors Measure the resistance between ground and the IOD B circuit in the BCM C3 and C4 harness connectors Is the resistance below 1000 0 ohms All Yes Repair the IOD B circuit for a...

Page 1634: ...onnect the BCM C4 harness connector Disconnect the Instrument Cluster C1 harness connector Measure the resistance of the Wake Up circuit between the BCM C4 connector and the MIC C1 connector NOTE If s...

Page 1635: ...RBIIIt select Body Control Module then Actuators Observe the DVOM while using the DRBIIIt to actuate the Cluster Wake Up 9On9 Did the DVOM indicate a brief approximately 2 seconds continuity to ground...

Page 1636: ...connector Measure the voltage between the Instrument Cluster Wake Up Signal circuit and ground Is there any voltage present All Yes Repair the Instrument Cluster Wake Up Signal circuit for a short to...

Page 1637: ...st Turn the ignition off Disconnect the Ignition Switch harness connector Measure the voltage between the Fused B circuit and ground Is the voltage above 10 0 volts All Yes Go To 2 No Repair the Fused...

Page 1638: ...the Ignition Switch connector Is the resistance above 5 0 ohms All Yes Repair the Fused Ignition Switch Output Run Start circuit for an open If the fuse is open make sure to check for a short to groun...

Page 1639: ...With the DRBIIIt read DTC s Attempt to operate the Exhaust Relay while monitoring the DRBIIIt Does the DRBIIIt display EXHAUST RELAY OPEN SHORT TO GROUND All Yes Go To 2 No The condition that caused...

Page 1640: ...Is the resistance between 85 0 and 106 0 ohms All Yes Go To 6 No Replace the Exhaust Relay Perform BODY VERIFICATION TEST VER 1 6 With the ignition OFF Disconnect the Body Control Module C4 connector...

Page 1641: ...this DTC to set is currently not present Using the wiring diagram schematic as a guide inspect the related wiring harness and connectors for a possible intermittent condition Perform BODY VERIFICATIO...

Page 1642: ...rol Module DTC s Turn the ignition off wait 10 seconds then turn the ignition on With the DRBIIIt read the current Body Control Module DTC s Attempt to operate the horn Does the DRBIIIt display HORN R...

Page 1643: ...on Center Disconnect the Body Control Module C2 connector Measure the resistance of the Horn Relay Control circuit at the Horn Relay connector to ground Is the resistance below 5 0 ohms All Yes Repair...

Page 1644: ...IIt display HORN RELAY COIL SHORT TO BATTERY All Yes Go To 2 No The condition that caused this symptom is currently not present Inspect the related wiring harness for a possible intermittent condition...

Page 1645: ...e ignition On Measure the voltage of the Horn Relay Control circuit at the relay Is the voltage above 10 0 volts All Yes Repair the Horn Relay Control circuit for a short to voltage Perform BODY VERIF...

Page 1646: ...f wait 10 seconds then turn the ignition on With the DRBIIIt read the current Body Control Module DTC s Does the DRBIIIt display HORN SWITCH STUCK All Yes Go To 2 No The condition that caused this sym...

Page 1647: ...rn switch as necessary Perform BODY VERIFICATION TEST VER 1 4 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED AIRB...

Page 1648: ...BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIIIt actuate the Horn Relay Do the horns operate All Yes Go To 3 No Go To 7 3 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MI...

Page 1649: ...nect the Body Control Module C4 connector NOTE Check connectors Clean repair as necessary Measure the resistance of the Horn Switch Sense circuit between the clockspring C1 connector and the Body Cont...

Page 1650: ...lts check the Ground circuits in the horn connectors Does the test light illuminate brightly All Yes Replace the Horns as necessary Perform BODY VERIFICATION TEST VER 1 No Repair the Ground circuit fo...

Page 1651: ...ster performs an indicator check each time the CAB commands the indicator On or Off Set Condition The Instrument Cluster detects a short in the ABS lamp driver circuit cluster internal AIRBAG LAMP CIR...

Page 1652: ...This is an internal Instrument Cluster failure All View repair Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 271 INSTRUMENT CLUSTER ABS...

Page 1653: ...mptom NO RESPONSE FROM CAB CONTROLLER in the Communication category Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase the DTC from the Instrument Cluster Cycle the ignition and wait approx...

Page 1654: ...TENT CONDITION BODY CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition off then on Leave the ignition on for at least 15 seconds With the DR...

Page 1655: ...l Sensor measure less than 50 ohms or more than 1050 ohms All Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ig...

Page 1656: ...PLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition off then on Leave the ignition on for at least 15 seconds With the DRBIIIt in Body Computer read DTCs Did this DTC res...

Page 1657: ...d the Fuel Level Sensor Signal circuit Is the resistance below 5 0 ohms All Yes Repair the Fuel Level Sensor Signal circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Bo...

Page 1658: ...HVAC Control Turn the ignition on With the DRBIIIt erase BCM DTCs Turn the ignition off Disconnect the HVAC Control harness connector Actuate the Park Lamps Turn the ignition on With the DRBIIIt read...

Page 1659: ...FICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the BCM C4 harness connector Disconnect the Radio harness connector Measure the resistance between ground and the Panel Lamps Driver c...

Page 1660: ...to symptom BUS SIGNALS OPEN FROM BCM in the Communication category Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTCs Cycle the ignition and wait approximately 1 minute With the DRBII...

Page 1661: ...f check POSSIBLE CAUSES INSTRUMENT CLUSTER TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt record and erase DTC s Turn the ignition off wait 15 seconds then turn the ignition on With...

Page 1662: ...1 2 With the DRBIIIt erase the DTC from the Instrument Cluster Cycle the ignition and wait approximately 1 minute With the DRBIIIt read DTCs Did this DTC reset All Yes Replace the Instrument Cluster...

Page 1663: ...2 No Refer to symptom NO RESPONSE FROM PCM PCI BUS in the communication category Perform BODY VERIFICATION TEST VER 1 2 With the DRBIIIt erase DTCs Cycle the ignition and wait approximately 1 minute W...

Page 1664: ...luster Self Test this will also initiate the Gauge Cluster Self Test Turn the ignition off Press and hold the Trip Reset button while turning the ignition on Gauge Cluster Self Test sequence performed...

Page 1665: ...4 Turn the ignition off Disconnect the Instrument Cluster C2 harness connector Disconnect the Gauge Cluster C2 harness connector Using the wiring diagram schematic as a guide measure the resistance o...

Page 1666: ...e Fused Ignition Switch Output Run Start circuit and ground Is the voltage below 10 5 volts All Yes Repair the Fused Ignition Switch Output Run Start circuit for an open Perform BODY VERIFICATION TEST...

Page 1667: ...re 140 F 60 C 200 F 90 C 260 F 120 C Temp Critical Volts 10V 12V 14V Oil Pressure 40 PSI 280 kPa 60 PSI 415 kPa 80 PSI 560 kPa Oil Temperature 180 F 120 C 240 F 160 C 300 F Temp Critical Illuminate al...

Page 1668: ...ossible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Rearview Mirror harness connect...

Page 1669: ...possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Body Control Module C2 harnes...

Page 1670: ...ssible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Multifunction Switch harness con...

Page 1671: ...play Reading Lamp Output Short All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pi...

Page 1672: ...ION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Try to operate the Decklid Release several times With the DRBIIIt read DTCs Does the DRBI...

Page 1673: ...e Solenoid Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Decklid Release Solenoid connector Disconnect the BCM C2 harness connector Measure the resistance of t...

Page 1674: ...on switch from Off to Run Try to operate the Decklid Release several times With the DRBIIIt read DTCs Does the DRBIIIt display DECKLID RELEASE OUTPUT SHORT TO GROUND All Yes Go To 2 No The condition t...

Page 1675: ...sistance between ground and the Decklid Release Driver circuit Is the resistance below 1000 0 ohms All Yes Repair the Decklid Release Driver circuit for a short to ground Perform BODY VERIFICATION TES...

Page 1676: ...ndicator will illuminate solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Remove the key and operate t...

Page 1677: ...1 Above 5 3 volts Go To 4 4 Disconnect the Driver Cylinder Unlock Switch connector Disconnect the Body Control Module C3 connector NOTE Check connectors Clean repair as necessary Turn the ignition on...

Page 1678: ...n solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Remove the key and operate the Driver Cylinder Unlo...

Page 1679: ...0 ohms All Yes Repair the Driver Cylinder Unlock Switch Mux circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 If there are no possible causes remaining view repair All Re...

Page 1680: ...to OFF to ON With the DRBIIIt read DTC s Remove the key and operate the Driver Cylinder Unlock Switch several times while monitoring the DRBIIIt Wait 10 seconds Does the DRBIIIt display DRIVER CYLINDE...

Page 1681: ...itch Mux circuit and ground Is the voltage above 4 9 volts All Yes Replace the Driver Cylinder Unlock Switch Perform BODY VERIFICATION TEST VER 1 No Repair the Driver Cylinder Unlock Switch Mux circui...

Page 1682: ...TSS indicator will stay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door wind...

Page 1683: ...BODY VERIFICATION TEST VER 1 5 Disconnect the Body Control Module C2 and C3 connectors Disconnect the Driver Interior Door Handle Switch connector Measure the resistance between the Driver Door Switc...

Page 1684: ...olid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door window Remove the key and operat...

Page 1685: ...EST VER 1 No Go To 4 4 Turn the ignition off Disconnect the Body Control Module C2 and C3 connectors Measure the resistance between Driver Door Switch Mux circuit and the Driver Door Switch Return cir...

Page 1686: ...RBIIIt Does the DRBIIIt display DRIVER DOOR UNLATCH CIRCUIT SHORTED TO GROUND All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent con...

Page 1687: ...n solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door window Remove the key and ope...

Page 1688: ...Driver Exterior Door Handle Switch Sense circuit in the BCM C4 connector Is the resistance below 10000 0 10K ohms All Yes Repair the Driver External Door Handle Switch Sense circuit for a short to gr...

Page 1689: ...stay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door window Remove the key a...

Page 1690: ...Go To 4 4 Disconnect the Body Control Module C2 and C3 connectors Measure the resistance between the Driver Door Switch Mux circuit and the Driver Door Switch Return circuits in the BCM C2 and C3 con...

Page 1691: ...When this code is present the VTSS indicator will stay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read...

Page 1692: ...tch Mux circuit and the Passenger Door Switch Return circuit in the BCM C3 and C5 connectors Is the resistance below 200 ohms All Yes Go To 6 No Replace the Passenger Interior Door Handle Switch Perfo...

Page 1693: ...ay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door window Remove the key and...

Page 1694: ...o Go To 4 4 Turn the ignition off Disconnect the Body Control Module C3 and C4 connectors Measure the resistance between the Passenger Door Switch Mux circuit and the Passenger Door Switch Return circ...

Page 1695: ...DRBIIIt Does the DRBIIIt display PASSENGER DOOR UNLATCH CIRCUIT SHORTED TO GROUND All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermitten...

Page 1696: ...ill stay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the passenger door window Remove th...

Page 1697: ...To 4 4 Disconnect the Body Control Module C3 and C4 connectors Measure the resistance between the Passenger Door Switch Mux circuit and the Passenger Door Switch Return circuits in the BCM C3 and C5 c...

Page 1698: ...will stay on solid during the arming process With the DRBIIIt record and erase DTC s Cycle the ignition switch from ON to OFF to ON With the DRBIIIt read DTC s Lower the driver door window Remove the...

Page 1699: ...To 4 4 Disconnect the Body Control Module C3 and C4 connectors Measure the resistance between the Passenger Door Switch Mux circuit and the Passenger Door Switch Return circuits in the BCM C3 and C5 c...

Page 1700: ...LATCH MOTOR SHORT TO GROUND PASSENGER DOOR LATCH MOTOR SHORT TO GROUND TEST ACTION APPLICABILITY 1 With the DRBIIIt record and erase DTC s With the DRBIIIt read DTC s Try to open and close the driver...

Page 1701: ...ER 1 No Replace the Door Latch Motor Perform BODY VERIFICATION TEST VER 1 4 Disconnect the Body Control Module C2 connector Disconnect the Driver Door Latch Motor connector Measure the resistance betw...

Page 1702: ...urn the ignition on With the DRBIIIt record and erase DTC s With the DRBIIIt read DTCs Operate the RKE transmitter while monitoring the DRBIII Does the DRBIIIt display RKE PROGRAM LINE OUTPUT OPEN All...

Page 1703: ...ICATION TEST VER 1 4 Turn the ignition off Disconnect the Remote Keyless Entry Module connector Disconnect the Body Control Module C4 connector Measure the resistance of the RKE Module Program Enable...

Page 1704: ...l Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for an intermittent condition Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Remote Keyless Entr...

Page 1705: ...ve caused that fuse to blow Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Disconnect the Body Control Module C1 connector Measure the voltage between Fused B circuit and ground Is the voltage abov...

Page 1706: ...TCH BODY CONTROL MODULE TEST ACTION APPLICABILITY 1 With the DRBIIIt read DTC s Does the DRBIIIt display any Driver Door Switch related trouble codes All Yes Refer to symptom list for problems related...

Page 1707: ...3 connector and the Switch connector Is the resistance below 5 0 ohms All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Repair the Driver Door Switch Mux circuit for an o...

Page 1708: ...ing a 12 volt test light connected to 12 volts check the Driver Door Switch Return circuit Does the test light illuminate brightly All Yes Go To 12 No Repair the Driver Door Switch Return circuit for...

Page 1709: ...e test light illuminate brightly when the door was actuated All Yes Replace the Latch Motor Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Disconnect the Body Control Module C2 connector Disconnect...

Page 1710: ...PLICABILITY 5 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 329 POWER DOOR LOCKS RKE DRIVER DOOR UNLATCH INOPERA...

Page 1711: ...With the DRBIIIt read DTC s Does the DRBIIIt display any Passenger Door Switch related trouble codes All Yes Refer to symptom list for problems related to POWER DOOR LOCKS RKE No Go To 2 2 Select the...

Page 1712: ...Switch Return circuit between the BCM C4 connector and the Switch connector Is the resistance below 5 0 ohms All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Repair the...

Page 1713: ...RIFICATION TEST VER 1 12 Disconnect the Passenger Door Lock Switch connectors Measure the voltage of the Passenger Door Switch Mux circuit Is the voltage above 4 5 volts All Yes Go To 13 No Repair the...

Page 1714: ...he test light illuminate brightly when the door was actuated All Yes Replace the Latch Motor Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Disconnect the Body Control Module C2 connector Disconnec...

Page 1715: ...ICABILITY 5 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 334 POWER DOOR LOCKS RKE PASSENGER DOOR UNLATCH INOPER...

Page 1716: ...iginal transmitter battery is ap proximately 3 2 volts If not replace the battery Secure a known good ZB or RS transmitter With the DRBIIIt enter BODY BODY COMPUTER MISCELLANEOUS then PROGRAM RKE and...

Page 1717: ...access to the RKE module Turn the ignition off and disconnect the RKE module connector Disconnect the Body Control Module C3 connector Measure the resistance of the Remote Keyless Entry Interface wir...

Page 1718: ...s Cycle the ignition switch from Off to Run Try to operate the Driver Window Motor several times With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER WINDOW DOWN CIRCUIT SHORT TO GROUND All Yes...

Page 1719: ...tance between ground and the Driver Window Down Driver circuit Is the resistance below 1000 0 ohms All Yes Repair the Driver Window Down Driver circuit for a short to ground Perform BODY VERIFICATION...

Page 1720: ...WINDOW UP DRIVER OPEN WINDOW HALL EFFECT GROUND OPEN DRIVER WINDOW DOWN DRIVER OPEN BODY CONTROL MODULE WINDOW DRIVER OPEN BODY CONTROL MODULE DRIVER WINDOW HALL EFFECT OPEN TEST ACTION APPLICABILITY...

Page 1721: ...ICATION TEST VER 1 5 Disconnect the Window Motor connector Turn the ignition on With the DRBIIIt in Inputs Outputs read the DRV WINDOW HALL state While observing the DRBIIIt momentarily connect and di...

Page 1722: ...minate brightly when the switch is in either position All Yes Replace the Driver Power Window Motor Perform BODY VERIFICATION TEST VER 1 No Go To 10 10 Turn the ignition off Disconnect the Window Moto...

Page 1723: ...DOW SWITCH MUX CIRCUIT SHORT TO VOLTAGE BODY CONTROL MODULE DRIVER WINDOW SWITCH RETURN OPEN TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from...

Page 1724: ...4 7 volts Go To 5 Above 5 3 volts Go To 6 5 Turn the ignition off Disconnect the Window Switch connector Disconnect the BCM C3 harness connector Measure the resistance of the Driver Switch Mux circuit...

Page 1725: ...DRIVER WINDOW SWITCH SHORTED TO GROUND All Yes Go To 2 No The condition that caused the code to set is not present at this time Using the wiring diagram schematic as a guide inspect the wiring and con...

Page 1726: ...TION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER WINDOW SWITCH STUCK DOWN All...

Page 1727: ...ION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER WINDOW SWITCH STUCK UP All Yes...

Page 1728: ...ignition switch from Off to Run Try to operate the Driver Window Motor by using the Driver Window Switch With the DRBIIIt read DTCs Does the DRBIIIt display DRIVER WINDOW UP OUTPUT SHORT TO GROUND All...

Page 1729: ...sistance between ground and the Driver Window Up Driver circuit Is the resistance below 1000 0 ohms All Yes Repair the Driver Window Up Driver circuit for a short to ground Perform BODY VERIFICATION T...

Page 1730: ...W DOWN RELAY CONTROL WIRE OPEN PASSENGER WINDOW DOWN RELAY CONTROL WIRE SHORT TO GROUND BODY CONTROL MODULE PASSENGER WINDOW DOWN RELAY CONTROL OPEN SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn th...

Page 1731: ...4 Turn the ignition off NOTE The Passenger Window Down Relay is located left of the steering column and taped to the harness Remove the Passenger Window Down Relay Disconnect the BCM C3 harness connec...

Page 1732: ...to Run Try to operate the Passenger Window Motor several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER WINDOW DOWN SHORTED TO BAT TERY All Yes Go To 2 No The condition that caus...

Page 1733: ...C3 harness connector Measure the Voltage between ground and the Passenger Window Down Relay Control circuit Is there any voltage present All Yes Repair the Passenger Window Down Relay Control circuit...

Page 1734: ...RELAY OUTPUT WIRE OPEN PASSENGER WINDOW DOWN RELAY GROUND CIRCUIT OPEN PASSENGER WINDOW UP RELAY OUTPUT WIRE OPEN PASSENGER WINDOW DOWN RELAY OPEN PASSENGER WINDOW UP RELAY OPEN BODY CONTROL MODULE PA...

Page 1735: ...Motor Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Window Motor connector Disconnect the BCM C3 harness connector Measure the resistance of the Passenger Wind...

Page 1736: ...put circuit Does the test light illuminate brightly All Yes Go To 10 No Check the Window Up Relay Ground and repair as necessary If the ground is good replace the relay Perform BODY VERIFICATION TEST...

Page 1737: ...own Relay Output circuit between the Relay connector and the Window Motor connector Is the resistance below 5 0 ohms All Yes Replace the Passenger Window Down Relay Perform BODY VERIFICATION TEST VER...

Page 1738: ...ITCH MUX CIRCUIT SHORT TO VOLT AGE BODY CONTROL MODULE PASSENGER WINDOW SWITCH RETURN OPEN TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from O...

Page 1739: ...olts Go To 5 Above 5 3 volts Go To 6 5 Turn the ignition off Disconnect the Window Switch connector Disconnect the BCM C3 harness connector Measure the resistance of the Passenger Switch Mux circuit b...

Page 1740: ...PLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Operate the Passenger Window Motor With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGE...

Page 1741: ...ance between ground and the Passenger Switch Mux circuit Is the resistance below 10000 0 ohms All Yes Repair the Passenger Window Switch Mux circuit for a short to ground Perform BODY VERIFICATION TES...

Page 1742: ...CTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER WINDOW SWITCH STUCK DOWN...

Page 1743: ...TION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER WINDOW SWITCH STUCK UP All...

Page 1744: ...ition on With the DRBIIIt erase DTCs Cycle the ignition switch from Off to Run Try to operate the Passenger Window Motor several times With the DRBIIIt read DTCs Does the DRBIIIt display PASSENGER WIN...

Page 1745: ...ween ground and the Passenger Window Up Relay Control circuit Is the resistance below 1000 0 ohms All Yes Repair the Passenger Window Up Relay Control circuit for a short to ground Perform BODY VERIFI...

Page 1746: ...ccess to and disconnect the Driver Power Window Motor connector Turn the ignition on Using a 12 volt test light connect one end to the Driver Window Down Driver and the other end to the Driver Window...

Page 1747: ...r circuit between the BCM C2 connector and the Window Motor connector Is the resistance below 5 0 ohms All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Repair the Driver...

Page 1748: ...SSENGER WINDOW DOWN OPEN RELAY PASSENGER WINDOW UP OPEN RELAY FUSED B OPEN RELAY FUSED B OPEN TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt erase DTCs Cycle the ignition switch fro...

Page 1749: ...ght illuminate brightly when the PASS WINDOW UP circuit is actuated All Yes Go To 5 No Go To 12 5 Gain access to and disconnect the Passenger Power Window Motor connector Using a 12 volt test light co...

Page 1750: ...d B circuit in the Passenger Window Down Relay connector Is the voltage above 10 0 volts All Yes Replace the Relay Perform BODY VERIFICATION TEST VER 1 No Repair the Fused B circuit for an open Perfor...

Page 1751: ...y Using a 12 volt test light connected to 12 volts check both of the Passenger Window Up Relay Ground circuits Does the test light illuminate brightly when connected to both the Ground circuits All Ye...

Page 1752: ...e DRBIIIt display CRITICAL TIRE PRESSURE All Yes Check and adjust tire pressure Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST No Go To 2 2 Turn the ignition off Visually inspect the relat...

Page 1753: ...Condition When the TPM Module does not receive a transmission from the Tire Pressure Sensor Transmitter within the last 32 transmissions A BCM 9Tire Module Diagnostic9 fault will be set The 9LO TIRE9...

Page 1754: ...d connector terminals Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST 2 Turn the ignition on With the DRBIIIt read TPM Module DTCs Does the DRBIIIt display TIRE PRESSURE SENSOR TRANSMITTER...

Page 1755: ...e and program the Tire Pressure Sensor Transmitter in accordance with the Service Information Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST 5 Turn the ignition off Visually inspect the re...

Page 1756: ...and long enough for the TPM Module to receive a transmission from each transmitter LEFT REAR TIRE PRESSURE SENSOR TRANSMITTER LOW BATTERY TPM When Monitored Ignition ON Vehicles speed over 33 Km h 20...

Page 1757: ...ough for the TPM Module to receive a transmission from each transmitter POSSIBLE CAUSES TIRE PRESSURE SENSOR TRANSMITTER LOW BATTERY CONDITION TEST ACTION APPLICABILITY 1 Turn the ignition on With the...

Page 1758: ...splay TIRE PRESSURE LOW All Yes Check and adjust tire pressure Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST No Go To 2 2 Turn the ignition off Visually inspect the related wiring harness...

Page 1759: ...RF detector Do all wheels have Tire Pressure Sensor Transmitters transmitting All Yes Go To 2 No Replace and program the Tire Pressure Sensor Transmitter in accordance with the Service Information Pe...

Page 1760: ...W TIRE PRESSURE SIGNAL CIRCUIT OPEN TPM MODULE INTERNAL FAILURE BCM INTERNAL FAILURE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read BCM and TPM Module DTCs Does the DRBIIIt dis...

Page 1761: ...EM VERIFICA TION TEST No Go To 5 5 Turn the ignition off Disconnect the BCM harness connector Disconnect the TPM Module harness connector Using a 12 volt test light connected to 12 volts check the Low...

Page 1762: ...Module in accordance with the Service Information Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST 8 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pi...

Page 1763: ...GROUND LOW TIRE PRESSURE SIGNAL CIRCUIT OPEN TPM MODULE INTERNAL FAILURE BCM INTERNAL FAILURE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read BCM and TPM Module DTCs Does the DR...

Page 1764: ...VERIFICA TION TEST No Go To 5 5 Turn the ignition off Disconnect the BCM harness connector Disconnect the TPM Module harness connector Using a 12 volt test light connected to 12 volts check the Low Ti...

Page 1765: ...ule in accordance with the Service Information Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA TION TEST 8 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierce...

Page 1766: ...er air inflation Are the tire s at the recommended air inflation pressure All Yes Go To 3 No Adjust the tire s air pressure to the recommended pressure Perform TIRE PRESSURE MONITORING SYSTEM VERIFICA...

Page 1767: ...ignition on With the DRBIIIt erase DTCs Cycle the ignition Off then On With the DRBIIIt in Body Computer read DTCs Did this DTC reset All Yes Go To 2 No The condition is not present at this time Monit...

Page 1768: ...n Perform VTSS VERIFICATION TEST 1A 4 Turn the ignition off Disconnect the VTSS Indicator harness connector Disconnect the BCM C4 harness connector Measure the resistance of the VTSS Indicator Driver...

Page 1769: ...en turn the ignition on With the DRBIIIt in Body Computer read DTCs Did this DTC reset All Yes Go To 2 No The condition is not present at this time Monitor DRBIIIt parameters while wiggling the relate...

Page 1770: ...ween ground and the VTSS Indicator Driver circuit Is the resistance below 100 ohms All Yes Repair the VTSS Indicator Driver circuit for a short to ground Perform VTSS VERIFICATION TEST 1A No Replace t...

Page 1771: ...must be disarmed prior to turning the ignition on Inspect wiring for intermittent problems or after market add on that may cause this condition Repair or replace as necessary Perform VTSS VERIFICATIO...

Page 1772: ...he vehicle theft security system must arm and flash the VTSS indicator properly With the DRBIIIt read the Decklid Ajar Sw status Open the Decklid Does the DRBIIIt display CLOSED All Yes Replace the Bo...

Page 1773: ...the vehicle theft security system must arm and flash the VTSS indicator properly With the DRBIIIt read the Drv Dr Ajar Sw status Open the driver door Does the DRBIIIt display CLOSED All Yes Replace t...

Page 1774: ...before continuing with this test Attempt to operate the Fog and Parking lamps With the DRBIIIt read BCM DTCs Were there any problems found All Yes Refer to symptom list for problems related to Exterio...

Page 1775: ...alid the vehicle theft security system must arm and flash the VTSS indicator properly With the DRBIIIt read the Hood Ajar Sw status Open the hood Does the DRBIIIt display CLOSED All Yes Replace the Bo...

Page 1776: ...IIt display a HORN RELAY CONTROL CIRCUIT DTC active All Yes Refer to Ignition Power Accessory for the related symptom s Perform VTSS VERIFICATION TEST 1A No Go To 2 2 Does the horn operate from the ho...

Page 1777: ...the vehicle theft security system must arm and flash the VTSS indicator properly With the DRBIIIt read the Pass Dr Ajar Sw status Open the passenger door Does the DRBIIIt display CLOSED All Yes Replac...

Page 1778: ...cylinder switch DTC s In Inputs Outputs check that the hood ajar and trunk ajar switch states display open with the hood and decklid closed Were there any problems found All Yes Refer to the Symptom...

Page 1779: ...s Check that the driver and passenger door ajar switch states display open with the doors closed Check that the Ignition Status displays Lock with the ignition key in the Lock position Were there any...

Page 1780: ...DRBIIIt record and erase DTC s With the DRBIIIt read DTC s Attempt to operate the Headlamp Washers while monitoring the DRBIIIt Does the DRBIIIt display HEADLAMP WASHER RELAY OPEN SHORT TO GROUND All...

Page 1781: ...d 106 0 ohms All Yes Go To 6 No Replace the Headlamp Washer Pump Relay Perform BODY VERIFICATION TEST VER 1 6 With the ignition OFF With the Headlamp Washer Pump Relay disconnected Disconnect the Body...

Page 1782: ...lamp Washers while monitoring the DRBIIIt Does the DRBIIIt display HEADLAMP WASHER RELAY SHORT TO BATTERY All Yes Go To 2 No The condition that caused this DTC to set is currently not present Using th...

Page 1783: ...r Pump Relay Is the resistance between 85 0 and 106 0 ohms All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Replace the Headlamp Washer Pump Relay Perform BODY VERIFICAT...

Page 1784: ...BIIIt Does the DRBIIIt display Wiper Pump Switch Stuck All Yes Go To 2 No The condition that caused this DTC to set is currently not present Using the wiring diagram schematic as a guide inspect the r...

Page 1785: ...odes DTC s present and the customer s concern can no longer be duplicated the repair is complete Are any DTC s present or is the original concern still present All Yes Repair is not complete refer to...

Page 1786: ...ir is not complete refer to the appropriate symptom No Repair is complete POWERTRAIN VERIFICATION TEST VER 1 APPLICABILITY 1 Inspect the vehicle to ensure that all engine components are properly insta...

Page 1787: ...r is complete TIRE PRESSURE MONITORING SYSTEM VERIFICATION TEST APPLICABILITY 1 Ensure the air pressure is properly set in ALL tires 2 Ensure using the DRBIIIt that the TPM Module is programmed with A...

Page 1788: ...6 The VTSS Indicator will flash rapidly for approximately 15 seconds and then begin to flash slowly If the VTSS Indicator is not performing as described this indicates a system fault Refer to symptom...

Page 1789: ...NOTES 408...

Page 1790: ...8 0 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM C O M P O N E N T L O C A T I O N S 409 COMPONENT LOCATIONS...

Page 1791: ...8 2 BODY CONTROL MODULE 8 3 HEATING A C SYSTEM C O M P O N E N T L O C A T I O N S 410 COMPONENT LOCATIONS...

Page 1792: ...8 4 INSTRUMENT PANEL 8 5 POWER WINDOW MOTOR 8 6 POWER DOOR LOCKS 8 6 1 DRIVER CYLINDER UNLOCK SWITCH C O M P O N E N T L O C A T I O N S 411 COMPONENT LOCATIONS...

Page 1793: ...8 6 2 DOOR LATCH ASSEMBLY 8 6 3 RKE MODULE 8 7 TIRE PRESSURE MONITOR MODULE TPM C O M P O N E N T L O C A T I O N S 412 COMPONENT LOCATIONS 8 6 POWER DOOR LOCKS Continued...

Page 1794: ...8 8 VEHICLE THEFT SECURITY SYSTEM VTSS 8 8 1 DRIVER CYLINDER UNLOCK SWITCH 8 8 2 VEHICLE THEFT SECURITY SYSTEM INDICATOR C O M P O N E N T L O C A T I O N S 413 COMPONENT LOCATIONS...

Page 1795: ...NOTES 414...

Page 1796: ...DER UNLOCK SWITCH MUX 15 Q3 20OR TN PASSENGER WINDOW SWITCH MUX 16 G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE 17 M1 20YL VT IOD B 18 19 20 G4 20LB VT FUEL LEVEL SENSOR SIGNAL 21 P97 20LG YL DRIVER D...

Page 1797: ...8VT WT EXPORT REAR FOG LAMP RELAY CONTROL 18 F921 20PK YL FUSED IGNITION SWITCH OUTPUT RUN 19 20 G20 20BR VT IGNITION SWITCH SENSE 21 L107 20WT BK PARK LAMP SWITCH SENSE 22 Q901 20OR VT PASSENGER WIND...

Page 1798: ...GY 8 C304 EXPORT BLACK BODY SIDE CAV CIRCUIT 1 J1 16WT DB 2 Z1 16BK DG C304 EXPORT BLACK REAR FOG LAMP SIDE CAV CIRCUIT 1 J1 18WT 2 Z1 18BK EXHAUST SOLENOID EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 J...

Page 1799: ...OID RELAY OUTPUT EXPORT ACCESSORY FUSE CAV CIRCUIT FUNCTION A A1 10RD B B A104 10RD FUSED B FOG LAMP LEFT REAR EXPORT 2 WAY CAV CIRCUIT FUNCTION 1 J1 20WT REAR FOG LAMP RELAY OUTPUT 2 Z1 20BK GROUND F...

Page 1800: ...URN SIGNAL 3 F71 20PK TN IGNITION FEED 4 L63 20WT DG LEFT REAR TURN SIGNAL DRIVER 5 L62 20WT RD RIGHT REAR TURN SIGNAL DRIVER 6 L60 20TN RIGHT TURN SIGNAL 7 G900 20VT OR SENSE RETURN 8 E19 20OR VT PAN...

Page 1801: ...20WT REAR FOG LAMP RELAY OUTPUT SIDE REPEATER LAMP LEFT EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L61 20LG LEFT FRONT TURN SIGNAL CONTROL 2 Z1 18BK GROUND SIDE REPEATER LAMP RIGHT EXPORT BLACK 2 WAY...

Page 1802: ...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 421 SCHEMATIC DIAGRAMS...

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 1806: ...10 5 DOOR AJAR SYSTEM 10 6 ELECTRICALLY HEATED SYSTEMS 10 6 1 REAR WINDOW DEFOGGER SYSTEM S C H E M A T I C D I A G R A M S 425 SCHEMATIC DIAGRAMS...

Page 1807: ...10 7 EXTERIOR LIGHTING 10 7 1 FRONT LAMPS S C H E M A T I C D I A G R A M S 426 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 1810: ...10 9 IGNITION POWER ACCESSORY 10 9 1 HORN SYSTEM S C H E M A T I C D I A G R A M S 429 SCHEMATIC DIAGRAMS...

Page 1811: ...10 9 2 EXHAUST CONTROL SYSTEM EXPORT ONLY S C H E M A T I C D I A G R A M S 430 SCHEMATIC DIAGRAMS 10 9 IGNITION POWER ACCESSORY Continued...

Page 1812: ...10 10 INSTRUMENT CLUSTER GAUGE CLUSTER S C H E M A T I C D I A G R A M S 431 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 1816: ...10 14 TIRE PRESSURE MONITOR MODULE TPM S C H E M A T I C D I A G R A M S 435 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 1818: ...10 16 WIPER SYSTEM 10 16 1 HEADLAMP WASHERS EXPORT ONLY S C H E M A T I C D I A G R A M S 437 SCHEMATIC DIAGRAMS...

Page 1819: ...NOTES 438...

Page 1820: ...5 DRBIIIT ERROR MESSAGES 4 3 5 1 DRBIIIT DOES NOT POWER UP BLANK SCREEN 4 3 5 2 DISPLAY IS NOT VISIBLE 5 4 0 DISCLAIMERS SAFETY WARNINGS 5 4 1 DISCLAIMERS 5 4 2 SAFETY 5 4 2 1 TECHNICIAN SAFETY INFOR...

Page 1821: ...41 8 2 DATA LINK CONNECTOR 41 8 3 HYDRAULIC CONTROL UNIT HCU 41 8 4 POWER DISTRIBUTION CENTER 42 8 5 MESSAGE CENTERS 42 8 6 WHEEL SPEED SENSORS 42 8 7 WHEEL SPEED SENSOR CONNECTORS 43 8 8 BRAKE LAMP...

Page 1822: ...isolation repair of isolated problem verification of proper operation 2 0 IDENTIFICATION OF SYSTEM Vehicles equipped with the Teves Mark 20e an tilock brake system can be identified by the pres ence...

Page 1823: ...sor pole tips excessive runout of the tone wheel or excessive air gap 3 1 2 SYSTEM COMPONENTS ANTILOCK BRAKE SYSTEM controller antilock brake CAB vacuum booster master cylinder hydraulic control unit...

Page 1824: ...s opened during an antilock stop The pump is also used to drain the accumulator circuits after the antilock stop is complete The pump is operated by an integral electric motor This motor is con trolle...

Page 1825: ...lic system leaks regular brake system problems non ABS related If no obvious problems are found erase diagnostic trouble codes and with the key on wiggle the wire harness and connectors Recheck for co...

Page 1826: ...ON FOR TESTING Make sure the vehicle being tested has a fully charged battery If it does not false diagnostic codes or error messages may occur 4 2 3 SERVICING SUB ASSEMBLIES Some components of the an...

Page 1827: ...continuing 2 Connect the DRBIIIt to the data link connector located under the dash If the DRBIIIt does not power up check the power and ground supplies to the connector 3 Select the system in questio...

Page 1828: ...r DRB diagnostic read out box DTC diagnostic test code EVBP Electronic Variable Brake Propor tioning HCU hydraulic control unit HZ Hertz JBLK junction block JTEC Jeep and Truck Engine Controller LF le...

Page 1829: ...NOTES 8...

Page 1830: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...

Page 1831: ...TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt read Freeze Frame information With the DRBIIIt erase DTCs Turn the ignition off Turn the ignition on With...

Page 1832: ...ake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Bus circuit for an open Perform ABS VERIFICATION TEST VER 1 4 Turn the ignition off Visually inspect th...

Page 1833: ...OUND CIRCUIT OPEN ABS VALVE FUSED B CIRCUIT OPEN ABS PUMP FUSED B CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs With the DRBIIIt erase DTC...

Page 1834: ...a 12 volt test light connected to ground probe the ABS Pump Fused B circuit at the CAB harness connector Did the test light illuminate All Yes Replace the Controller Antilock Brake in accordance with...

Page 1835: ...CK SIGNAL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTCs Are there any Instrument Cluster or ABS DTCs present All Yes Refer to the appropriate category for the related sym...

Page 1836: ...R 1 4 NOTE The following steps will initiate the Instrument Cluster self test Turn the ignition off Press and hold the odometer reset button Turn the ignition to RUN Observe the Instrument Cluster ind...

Page 1837: ...HEEL ON VEHICLE TEST ACTION APPLICABILITY 1 Inspect the tire sizes on the vehicle Is a smaller than production tire mini spare or two mini spares installed on both front wheels All Yes Replace the inc...

Page 1838: ...detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set RIGHT FRONT SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit c...

Page 1839: ...or Is the affected Wheel Speed Sensor or any of the connectors damaged All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the affected Wheel...

Page 1840: ...el Speed Sensor Signal circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Se...

Page 1841: ...1 11 Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors Disconnect the affected Wheel Speed Sensor connector Turn the ignition on Measure the voltage of the affected Wh...

Page 1842: ...wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were any pro...

Page 1843: ...reafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is...

Page 1844: ...ptom s Perform ABS VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIIIt in Sensors monitor ALL the Wheel Speed Sensor Signals while an assistant drives the vehicle Slowly acceler...

Page 1845: ...o Repair as necessary Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Inspect the wheel bearings for excessive runout or clearance NOTE Refer to the appropriate service information if nece...

Page 1846: ...RUNNING CONTINUOUSLY ABS PUMP FUSE ABS PUMP MOTOR INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR ABS PUMP FUSED B CIRCUIT INTERMITTENT SHORT TO GROUND ABS PUMP FUSED B CIRCUIT SHORT TO GROUND CAB...

Page 1847: ...Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 4 Turn the ignition off Remove and inspect the ABS Pump fuse Is the ABS Pump fuse open All Yes Go To 5 No Go To 8 5 Turn the ig...

Page 1848: ...ecessary Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Fused B terminal in the CAB harness connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wir...

Page 1849: ...ess connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground Did the ABS Pump Motor operate All...

Page 1850: ...IGNITION SWITCH OUTPUT RUN CIRCUIT HIGH DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s With...

Page 1851: ...oken bent pushed out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the CAB connector Note Check connector C...

Page 1852: ...roded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Ensure the battery is fully charged Inspect the vehicle for aftermarket accessories that may exceed the Gener...

Page 1853: ...NITION SWITCH OUTPUT RUN CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIIIt read DTC s With the DRBIIIt erase DTC s Turn the ignition off Turn the igniti...

Page 1854: ...Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Fused Ignition Switch Output RUN circuit for an open Perform ABS...

Page 1855: ...OPEN ABS VALVE FUSED B CIRCUIT INTERMITTENT SHORT TO GROUND ABS VALVE FUSED B CIRCUIT SHORT TO GROUND DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT TEST ACTION APPLICABI...

Page 1856: ...ults of this test to be valid Using a test light connected to 12 volts probe the ABS Valve Fused B circuit fuse terminal Did the test light illuminate All Yes Replace the Controller Antilock Brake in...

Page 1857: ...t illuminate All Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAB Ground circuit for an open Perform ABS VERIF...

Page 1858: ...for an open Perform ABS VERIFICATION TEST VER 1 3 Disconnect the Brake Lamp Switch harness connector Connect a jumper wire between the Brake Lamp Switch B and Brake Lamp Switch Output circuits With th...

Page 1859: ...Go To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the CAB harness connector U...

Page 1860: ...e Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Press F2 again when complete Connect the Black lead to the chassi...

Page 1861: ...to Symptom list and troubleshoot new or recurring symptom 7 NOTE For Sensor Signal and Pump Motor faults the CAB must sense all 4 wheels at 25 km h 15 mph before it will extinguish the ABS Indicator 8...

Page 1862: ...8 0 COMPONENT LOCATIONS 8 1 CONTROLLER ANTILOCK BRAKE CAB 8 2 DATA LINK CONNECTOR 8 3 HYDRAULIC CONTROL UNIT HCU C O M P O N E N T L O C A T I O N S 41 COMPONENT LOCATIONS...

Page 1863: ...8 4 POWER DISTRIBUTION CENTER 8 5 MESSAGE CENTERS 8 6 WHEEL SPEED SENSORS LEFT FRONT RIGHT FRONT C O M P O N E N T L O C A T I O N S 42 COMPONENT LOCATIONS...

Page 1864: ...LEFT REAR RIGHT REAR 8 7 WHEEL SPEED SENSOR CONNECTORS LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR C O M P O N E N T L O C A T I O N S 43 COMPONENT LOCATIONS...

Page 1865: ...8 8 BRAKE LAMP SWITCH 8 9 ABS PUMP MOTOR C O M P O N E N T L O C A T I O N S 44 COMPONENT LOCATIONS...

Page 1866: ...EED SENSOR 12V SUPPLY 4 5 D25 20VT YL PCI BUS 6 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 7 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12V SUPPLY 8 D24 20WT DG FLASH ABS 9 A10 12RD DG FUSED B 10 F5...

Page 1867: ...20VT YL PCI BUS 3 4 Z2 20BK LG GROUND 5 Z40 18BK VT GROUND 6 D20 20LG SCI RECEIVE 7 D21 20PK SCI TRANSMIT 8 9 D23 20WT BR FLASH PROGRAM ENABLE 10 D24 20WT DG FLASH ABS 11 12 13 14 15 16 A105 18DB RD...

Page 1868: ...C O N N E C T O R P I N O U T S 47 CONNECTOR PINOUTS...

Page 1869: ...15A A64 16DG WT FUSED B 23 24 10A F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN 60 61 15A F202 20PK GY FUSED IGNITION SWITCH OUTPUT RUN START 62 63 15A G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START...

Page 1870: ...L SPEED SENSOR 12V SUPPLY 2 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR RIGHT REAR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12V SUPPLY 2 B1 18YL...

Page 1871: ...NOTES 50...

Page 1872: ...10 0 SCHEMATIC DIAGRAMS 10 1 TEVES MARK 20e CONTROLLER ANTILOCK BRAKE ABS S C H E M A T I C D I A G R A M S 51 SCHEMATIC DIAGRAMS...

Page 1873: ...NOTES 52...

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