Dodge 2006 Sprinter Скачать руководство пользователя страница 1

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TABLE OF CON T EN T S

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1

SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2

SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0

IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0

SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

3.1

AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.1.1

DRIVER AIRBAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3.1.2

CLOCKSPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.1.3

PASSENGER AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.1.4

SEAT BELT TENSIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.1.5

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.1.6

DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.1.6.1

ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.1.6.2

STORED CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.2

COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.2.1

COMMUNICATION K-LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.2.2

CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.3

HEATING & A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.3.1

AUTOMATIC TEMPERATURE CONTROL (ATC) . . . . . . . . . . . . . . . . . .5

3.3.1.1

SYSTEM CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.3.1.2

SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.3.2

CABIN HEATER MODULE (CHM) & HEATER BOOSTER MODULE
(HBM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.3.2.1

SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.3.2.2

VENTING THE HEATER’S EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.3.2.3

SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.4

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.5

POWER DOOR LOCKS/RKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.5.1

CENTRAL LOCKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.5.2

REMOTE KEYLESS ENTRY (RKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.5.3

AUTO DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.5.4

ACCIDENT RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.6

VEHICLE THEFT SECURITY SYSTEM (VTSS) . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.7

USING THE DRBIII

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.8

DRBIII

ERROR MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.9

DRBIII

DOES NOT POWER UP (BLANK SCREEN). . . . . . . . . . . . . . . . . . . . . .11

3.10

DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.0

DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.1

DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.2.1

TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . .11

4.2.2

VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .12

4.2.3

SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.2.4

DRBIII

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3

WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3.1

VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3.2

ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . .12

Содержание 2006 Sprinter

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 22: ...NOTES 14...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 256: ...NOTES 248...

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

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

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

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

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

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

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

Страница 264: ...NOTES 256...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 297: ...10 0 SCHEMATIC DIAGRAMS 10 1 AIRBAG SYSTEM S C H E M A T I C D I A G R A M S 289 SCHEMATIC DIAGRAMS...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 311: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

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

Страница 313: ...DRBIII ERROR MESSAGES 4 3 9 1 DRBIII DOES NOT POWER UP BLANK SCREEN 5 3 9 2 DISPLAY IS NOT VISIBLE 5 4 0 DISCLAIMERS SAFETY WARNINGS 5 4 1 DISCLAIMERS 5 4 2 SAFETY 5 4 2 1 TECHNICIAN SAFETY INFORMATI...

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

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

Страница 316: ...NOTES iv...

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

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

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

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

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

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

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

Страница 324: ...NOTES 8...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 404: ...NOTES 88...

Страница 405: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 418: ...NOTES xii...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 662: ...the DRBIII display any TCM DTCs All Yes Refer to symptom list for problems related to TCM Perform NO START VERIFICATION VER 1 No Go To 11 11 Perform the Checking the ECM Power and Grounds test Were a...

Страница 663: ...open Perform NO START VERIFICATION VER 1 14 Turn the ignition off Disconnect the ECM harness connectors Remove the Starter Motor Relay from the Fuse Relay Block Measure the resistance between ground a...

Страница 664: ...ord and erase all DTCs from ALL modules Start and run the engine for 2 minutes Operate all functions of the system that caused the original concern 15 Turn the ignition off and wait 5 seconds Turn the...

Страница 665: ...lete 4 If the initial or another symptom exists the repair is not complete Check all pertinent Technical Service Bulletins TSBs and return to the Symptom List if necessary 5 For previously read DTCs t...

Страница 666: ...NOTES 248...

Страница 667: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES 8 2 CONTROLS AND SOLENOIDS C O M P O N E N T L O C A T I O N S 249 COMPONENT LOCATIONS...

Страница 668: ...8 3 DA TA LINK CONNECTOR C O M P O N E N T L O C A T I O N S 250 COMPONENT LOCATIONS 8 2 CONTROLS AND SOLENOIDS Continued...

Страница 669: ...8 4 SENSORS C O M P O N E N T L O C A T I O N S 251 COMPONENT LOCATIONS...

Страница 670: ...C O M P O N E N T L O C A T I O N S 252 COMPONENT LOCATIONS 8 4 SENSORS Continued...

Страница 671: ...8 5 SWITCHES C O M P O N E N T L O C A T I O N S 253 COMPONENT LOCATIONS...

Страница 672: ...NOTES 254...

Страница 673: ...NER LINE 1 3 20BL PASSENGER SEAT BELT TENSIONER LINE 2 4 20BR PASSENGER SEAT BELT TENSIONER LINE 1 5 20BK FUSED IGNITION SWITCH OUTPUT RUN START 6 20BR GROUND 7 20YL AIRBAG WARNING INDICATOR DRIVER 8...

Страница 674: ...ESSURE SERVOMOTOR CONTROL 5 CAMSHAFT POSITION SENSOR BLACK CAV CIRCUIT FUNCTION 1 20BR DG CAMSHAFT POSITION SENSOR GROUND 2 20YL GY CAMSHAFT POSITION SENSOR SIGNAL 3 18RD BL EXCEPT OBD CAMSHAFT POSITI...

Страница 675: ...UTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR GROUND 26 20WT GY BRAKE PRESSURE SENSOR SIGNAL 27 18BK BL TCS SWITCH ASR SENSE 28 18BR LEFT FRONT WHEEL SPEED SENSOR 29 20BR LEFT REAR WHEEL SPEED SENSOR 30 2...

Страница 676: ...R GROUND 5 20BR GROUND 6 7 20BL YL K ECM 8 20BK BL DG FUSED IGNITION SWITCH OUTPUT RUN START 9 20BL BK K ABS SHIFTER ASSEMBLY 10 11 20BL K TCM RADIO 12 20GY DG RD K CTM SSM 13 20BK RD K ACM 14 15 20WT...

Страница 677: ...CAMSHAFT POSITION SENSOR SIGNAL 39 20GY O2 1 1 SENSOR CELL SIGNAL 40 20GY WT O2 1 1 VIRTUAL GROUND 49 16BK VT FUEL INJECTOR NO 4 LOW SIDE CONTROL 50 16BK DG FUEL INJECTOR NO 3 LOW SIDE CONTROL 51 16B...

Страница 678: ...ENSOR 5 VOLT SUPPLY 25 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 26 18BR BL ACCEL PEDAL POSITION SENSOR GROUND NO 1 28 18BR DG INTAKE AIR TEMPERATURE SENSOR GROUND 31 20BL YL K ECM 32 20DG ENHAN...

Страница 679: ...TOR NO 1 HIGH SIDE CONTROL FUEL INJECTOR NO 2 BLACK CAV CIRCUIT FUNCTION 1 14BK VT EXCEPT OBD FUEL INJECTOR NO 2 CONTROL 1 16BK BL OBD FUEL INJECTOR NO 2 LOW SIDE CONTROL 2 14BL EXCEPT OBD COMMON INJE...

Страница 680: ...CTOR NO 5 LOW SIDE CONTROL 2 14BL EXCEPT OBD COMMON INJECTOR DRIVER NO 2 2 16BK WT OBD FUEL INJECTOR NO 5 HIGH SIDE CONTROL FUEL PRESSURE SENSOR BLACK CAV CIRCUIT FUNCTION 1 20BR GY FUEL PRESSURE SENS...

Страница 681: ...UEL PUMP RELAY OUTPUT 87A FUEL QUANTITY CONTROL VALVE OBD CAV CIRCUIT FUNCTION 1 20BK WT FUEL QUANTITY SOLENOID CONTROL 2 18RD BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY FUEL TEMPERA TURE SENSOR CAV CIR...

Страница 682: ...C O N N E C T O R P I N O U T S 264 CONNECTOR PINOUTS...

Страница 683: ...FUSED IGNITION SWITCH OUTPUT RUN START 7 15A 16BK YL FUSED IGNITION SWITCH OUTPUT RUN START 8 20A 16RD YL FUSED B 9 15A INTERNAL FUSED B 10 10A 16GY DG RD HEADLAMP SWITCH OUTPUT 11 10A 16GY BK FUSED...

Страница 684: ...C O N N E C T O R P I N O U T S 266 CONNECTOR PINOUTS...

Страница 685: ...25A 16BK YL OPTIONAL EQUIPMENT RELAY OUTPUT 8 10A 16BK RD OPTIONAL EQUIPMENT RELAY OUTPUT 9 15A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 10 7 5A 16RD YL WT FUSED D RELAY NO 1 OUTPUT 11 7 5A 16RD YL WT FU...

Страница 686: ...C O N N E C T O R P I N O U T S 268 CONNECTOR PINOUTS...

Страница 687: ...D FUSED B 9 40A 12RD FUSED B 10 30A 12RD GY FUSED B STARTER MOTOR RELA Y FUSE RELA Y BLOCK CAV CIRCUIT FUNCTION 30 12BK YL STARTER MOTOR RELAY OUTPUT 85 18VT DG STARTER MOTOR RELAY CONTROL 86 18RD BL...

Страница 688: ...OLTAGE 4 14BK VT GLOW PLUG NO 2 SUPPLY VOLTAGE 5 14BK BL GLOW PLUG NO 1 SUPPLY VOLTAGE 6 INTAKE AIR PRESSURE SENSOR OBD CAV CIRCUIT FUNCTION 1 20BR RD INTAKE PRESSURE SENSOR GROUND 2 20VT DG INTAKE PR...

Страница 689: ...0BR YL EXCEPT OBD MASS AIR FLOW SENSOR GROUND 3 20YL BL OBD MASS AIR FLOW SENSOR GROUND 4 20BR BK EXCEPT OBD MASS AIR FLOW SENSOR 5 VOLT SUPPLY 4 20YL DG OBD MASS AIR FLOW SENSOR SIGNAL 5 20YL DG EXCE...

Страница 690: ...C O N N E C T O R P I N O U T S 272 CONNECTOR PINOUTS...

Страница 691: ...SPEED CONTROL SWITCH CAV CIRCUIT FUNCTION 1 18GY OFF SIGNAL 2 18BK VERIFICATION SIGNAL 3 18BL RESUME SIGNAL 4 18YL DECEL SET SIGNAL 5 18DG ACCEL SET SIGNAL 6 18RD S C SWITCH 12 VOLT SUPPLY WA TER IN F...

Страница 692: ...NOTES 274...

Страница 693: ...10 0 SCHEMATIC DIAGRAMS 10 1 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 275 SCHEMATIC DIAGRAMS...

Страница 694: ...10 2 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 276 SCHEMATIC DIAGRAMS...

Страница 695: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 277 CHARTS AND GRAPHS...

Страница 696: ...NOTES 278...

Страница 697: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Страница 698: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Страница 699: ...d Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13...

Страница 700: ......

Страница 701: ...Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official docum...

Страница 702: ...els Van 8 001 to 9 000 lbs class G D7 Sprinter 4042 mm 159 in in connection with 16 wheels Van 8 001 to 9 000 lbs class G 7 8 Engine 41 2 7L 5 cyl Diesel 612 ME9 42 2 7L 5 cyl Diesel 612 MF1 43 2 7L 5...

Страница 703: ...strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts Fig 2 and Fig 3 Fig 1 INTERNATIONAL CONTRO...

Страница 704: ...Fig 2 FASTENER IDENTIFICATION 4 INTRODUCTION VA...

Страница 705: ...Fig 3 FASTENER STRENGTH VA INTRODUCTION 5...

Страница 706: ...ION The metric system is based on quantities of one ten one hundred one thousand and one million The following chart will assist in converting metric units to equivalent English and SAE units or vise...

Страница 707: ...Meter 1 Cubic Foot 0 03 Cubic Meter 1 Yard 0 9 Meter 1 Cubic Yard 0 8 Cubic Meter 1 Mile 1 6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton meters N...

Страница 708: ...Fig 4 METRIC CONVERSION CHART 8 INTRODUCTION VA...

Страница 709: ...CES DESCRIPTION Individual Torque Charts appear within many of the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 5 VA I...

Страница 710: ...Fig 5 TORQUE SPECIFICATIONS 10 INTRODUCTION VA...

Страница 711: ...servicing DaimlerChrysler Corporation vehicles AUTOMA TIC TRANSMISSION FLUID NAG1 NOTE Refer to Service Procedures in this group for fluid level checking procedures Use ATF approved to MB 236 10 MB 2...

Страница 712: ...antin G05 BASF AG MOPAR part number 05066386AA or an equivalent Extended Life Coolant with the HOAT inhibitor system This cool ant offers the best engine cooling without corrosion when mixed with 50 a...

Страница 713: ...s The following engine oils have been determined to meet DaimlerChrysler requirements DaimlerChrysler Approved En gine Oil SAE Rating MB Sheet Number 76 Pure Syn thetic Motor Oil 5W 40 229 3 76 Royal...

Страница 714: ...10W 30 228 3 Ursa Premium TDX 15W 40 228 3 Valvoline Syn Power MXL 0W 30 229 3 1 Engine oil also meets API classification CI 4 Other oils may meet requirements see oil label to determine Use of the a...

Страница 715: ...iate 21 TRANSMISSION AUTO MATIC FLUID STANDARD PROCEDURE REAR AXLE 03L 1 oz 8 1 2 1 8 L 4 0 pts FUEL TANK Primary 100 L 26 4 gal Reserve 10 5 L 2 8 gal Nominal refill capacities are shown A variation...

Страница 716: ...E BEING USED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION When using another vehicle as a booster do not allow vehicles to touch Electrical systems can be damaged on eith...

Страница 717: ...ansmission is Damaged Remove the propeller shafts leading to the drive axles The vehicle can be towed without restriction If the Front Axle is Damaged Raise the front axle Observe the same towing rest...

Страница 718: ...e number of days a clock symbol will also appear in the multi function display You should have the maintenance performed within the stated period distance The service indicator will be reset after an...

Страница 719: ...filter renewal Every oil service Air cleaner with maintenance indicator Check degree of contamination Air cleaner filter element renewed as necessary Chassis and body Trailer coupling Check operation...

Страница 720: ......

Страница 721: ...ARM REMOVAL 6 INSTALLATION 7 SPRING REMOVAL 7 INSTALLATION 8 SPRING CLAMP PLATES REMOVAL 8 INSTALLATION 9 SPRING STOP PLATES REMOVAL 9 INSTALLATION 9 STABILIZER BAR DESCRIPTION 9 OPERATION 9 REMOVAL...

Страница 722: ...44 Outer Tie Rod End Nut 130 96 Outer Tie Rod End Nut Jam Nut 50 37 SPECIAL TOOLS FRONT SUSPENSION SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 9288 LEAF SPRING WEDGE BLOCK...

Страница 723: ...bushing into the control arm using special tool C 4212F and 9302 1 Driver with 9302 2 Sizer cup and 9302 4 Receiver Fig 2 3 Press the bushing in all the way until the lip is seated properly into the...

Страница 724: ...heels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the wheel flange ring if equipp...

Страница 725: ...icle 2 Remove the front wheels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the hu...

Страница 726: ...all joint using special tool 9294 1 Driver with 9294 2 Reciever and C 4212 F Fig 7 INSTALLA TION 1 Install the ball joint into the lower control arm using special tool 9294 3 Installer ring inserted i...

Страница 727: ...N 9 Lower the vehicle 10 Remove the spring blocks between the spring and the spring clamp plates While the vehicles wheels are on the ground 11 Roll the vehicle approximately 1 mm forwards and the bac...

Страница 728: ...knuckle on the lower ball joint 4 Raise the lower control arm approximately 10 mm with a jack 5 Install both stop plate bolts to the lower control arm 6 Install the strut bolts to the steering knuckl...

Страница 729: ...lts retaining the spring stop plate from the lower control arm INSTALLA TION 1 Install the spring stop plate to the lower con trol arm Tighten the bolts to 60 N m 44 ft lbs 2 Install the stabilizer li...

Страница 730: ...ver for the upper strut mounting Fig 12 4 Remove the nut on the upper strut mounting Fig 12 5 Raise and support the vehicle 6 Remove the front wheels 7 Raise the lower control arm approximately 10 mm...

Страница 731: ...ehicle ride comfort could be affected and premature bush ing wear may occur DIAGNOSIS AND TESTING SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between...

Страница 732: ...shock 3 Leaking shock 3 Replace shock SPECIFICA TIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Sway Bar Link 95 60 Sway Bar Clamp To Axle SRW 25 18 Sway Bar Clamp To Axle DRW 7...

Страница 733: ...e action throughout each stroke should be smooth and even The shock absorber bushings do not require any type of lubrication Do not attempt to stop bushing noise by lubricating them Grease and mineral...

Страница 734: ...t the vehicle 2 Support the rear axle 3 Remove the U bolt and spring plate Fig 3 4 Remove the spring from the front spring bracket Fig 3 5 Remove the rear spring with the spring shackle from the sprin...

Страница 735: ...ing Tighten to 90 N m 66 ft lbs 2 Raise the rear axle while installing the spring shackle to the spring bracket Tighten to 85 N m 63 ft lbs 3 Lower the vehicle STABILIZER BAR REMOVAL 1 Raise and suppo...

Страница 736: ...ION 1 Install the stabilizer bar to the stabilizer links and tighten to 95 N m 60 ft lbs Fig 4 2 Lower the vehicle 3 Install the stabilizer link to the frame Tighten to 95 N m 60 ft lbs Fig 5 SWAY BAR...

Страница 737: ...ents An alignment is considered essential for efficient steering good directional stabil ity and to minimize tire wear The most important measurements of an alignment are caster camber and toe Fig 1 C...

Страница 738: ...sure 4 Alignment 4 Align vehicle to specifications EXCESSIVE STEERING EFFORT 1 Loose or worn steering gear 1 Replace steering gear 2 Column coupler binding 2 Replace coupler 3 Tire pressure 3 Adjust t...

Страница 739: ...erence Max 1 33 Caster 0 0 5 Steering Knuckle Inclina tion 0 0 5 Steering Knuckle Inclina tion Left to Right Difference Max 1 REAR SPECIFICATIONS DESCRIPTION REAR SPECIFICATION Toe In Max 0 0 25 Cambe...

Страница 740: ......

Страница 741: ...ON 10 PROPELLER SHAFT DIAGNOSIS AND TESTING PROPELLER SHAFT PROPELLER SHAFT VIBRA TION Out of round tires or wheels that are out of bal ance will cause a low frequency vibration Driveline vibration ca...

Страница 742: ...rsal Joint Noise 1 Loose U joint clamp screws 1 Install new clamps and screws and tighten to proper torque 2 Lack of lubrication 2 Replace as U joints as neces sary PROPELLER SHAFT BALANCE NOTE Removi...

Страница 743: ...LER SHAFT RUNOUT 1 Clean the propeller shaft surface where the dial indicator will contact the shaft 2 The dial indicator must be installed perpendic ular to the shaft surface 3 Measure runout at the...

Страница 744: ...ubble in sight glass and record measurement This measurement w ill give you the transmis sion yoke Output Angle A 6 Rotate propeller shaft 90 degrees and place inclinometer on yoke bearing parallel to...

Страница 745: ...propeller shaft angles involved with a two three piece Fig 5 propel ler shaft is the same as those for a one piece propel ler shaft Fig 4 UNIVERSAL JOINT ANGLE EXAMPLE 1 4 9 Angle C 2 3 2 Angle B 3 I...

Страница 746: ...rame floor bolt 100 74 Center Bearing support to frame floor bolt 95 70 Center Bearing to support nut 105 77 SPECIAL TOOLS SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 938 BR...

Страница 747: ...n at the flange 5 Remove propeller shaft intermediate bearing nuts from retaining bracket and bracket for brake cable NOTE The brake cable bracket is only installed in vehicles with wheelbase 3550 mm...

Страница 748: ...Fig 8 2 PIECE PROPELLER SHAFT 1 FLANGE BOLT 6 NUT 2 BEARING 7 BRACKET 3 PROPELLER SHAFT 8 RETAINING BRACKET 4 REAR AXLE 9 COLLARED BOLT 5 CABLE BRACKET 10 TRANSMISSION 3 8 PROPELLER SHAFT VA...

Страница 749: ...e 3550 mm 4 Install propeller shaft to rear axle and trans mission flange with installation marks are aligned Tighten bolts to 70 N m 66 ft lbs 5 Install retaining bracket and tighten bolts to 100 N m...

Страница 750: ...ring splitter must be positioned behind the thrust washer of the bearing INSTALLA TION 1 Press center bearing on propeller shaft with protective caps and washer with Installer 9275 Fig 14 Fig 11 BOOT...

Страница 751: ...2 Install snap ring 3 Coat propeller shaft spline with universal grease 4 Push rubber boot onto propeller shaft 5 Push together propeller shaft Pay attention to alignment markings for installation pos...

Страница 752: ...and then acceler ate the vehicle to the speed range where the noise is the greatest Shift out of gear and coast through the peak noise range If the noise stops or changes greatly Check for insufficie...

Страница 753: ...he vehicle is shifted into gear or the clutch engaged can be caused by High engine idle speed Transmission shift operation Loose engine transmission transfer case mounts Worn U joints Loose spring mou...

Страница 754: ...TOR CONNECTOR 2 U BRACKET 13 BRAKE HOSE 3 PLATE 14 WHEEL BOLT 4 NUT 15 BOLT 5 BRAKE CABLE 16 NUT 6 REAR AXLE 17 PROPELLER SHAFT 7 ABL LEVER 18 BOLT 8 NUT 19 ABS SENSOR 9 SHOCK ABSORBER 20 SENSOR BUSHI...

Страница 755: ...move brake cables 9 Remove hand brake cable at relay unit 10 Remove bracket for brake cables at rear axle tube 11 Remove stabilizer bar from axle brackets 12 Remove shock absorber bolts from rear axle...

Страница 756: ...ICATOR CONNECTOR 2 U BRACKET 13 BRAKE HOSE 3 PLATE 14 WHEEL BOLT 4 NUT 15 BOLT 5 BRAKE CABLE 16 NUT 6 REAR AXLE 17 PROPELLER SHAFT 7 ABL LEVER 18 BOLT 8 NUT 19 ABS SENSOR 9 SHOCK ABSORBER 20 SENSOR BU...

Страница 757: ...wn clips 9 Install and adjust park brake cables 10 Install connection cable of brake pad wear indicator and ABS sensor cable up to the relay unit of the parking brake 11 Install cable ties to the park...

Страница 758: ...in SRW Differential Torque to Rotate 20 40 N m 15 30 ft lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Drain Plug 100 74 Fill Plug 100 74 Differential Cover Bolts 65 48 Ring Gear Bolts 180 1...

Страница 759: ...N A 8992 FLANGE PULL ER N A 9084 REMOVER N A 9275 INSTALLER 460 589 15 15 00 9276 INSTALLER 741 589 00 35 00 9277 PLATE 741 589 01 15 00 9278 INSTALLER 460 589 01 07 00 9279 WRENCH 309 589 01 07 00 9...

Страница 760: ...REMOVER D 103 SCOOTER BLOCK D 115 2A INSTALLER 6448A INSTALLER 8617 FLANGE PULLER 8992 REMOVER 9084 INSTALLER 9275 INSTALLER 9276 3 20 REAR AXLE VA...

Страница 761: ...PLATE 9277 INSTALLER 9278 WRENCH 9279 WRENCH 9290 INSTALLER 9291 SPREADER ADAPTERS 9317 INSTALLER 9523 VA REAR AXLE 3 21...

Страница 762: ...DIAL INDICATOR 9524 INSTALLER 9548 ARBOR DISC 9571 PINION BLOCK 9572 DUMMY BEARING 9573 3 22 REAR AXLE VA...

Страница 763: ...l house 5 Remove brake shoes 2 of parking brake 6 Remove brake control cable lock 7 Remove bearing cap bolts 17 and pull axle shaft out of axle tube 1 Fig 6 8 Remove seal gasket Fig 6 AXLE SHAFT 1 REA...

Страница 764: ...pedal several times until brake pads contact brake discs brake pressure built up 10 Install wheels BEARING SEAL AXLE REMOVAL 1 Remove rear axle shaft 2 With a punch 2 and hammer straighten bear ing 4...

Страница 765: ...ng cover and tapered roller bearings 2 Fig 13 8 Remove tapered roller bearings 6 sealing ring 7 dust shield 5 and bearing cover 2 from axle shaft 1 Fig 14 9 Remove shaft seal 3 from bearing cover 2 wi...

Страница 766: ...de of the locking ring must point towards the nut Fig 17 The locking ring is fitted to ensure the pressing is done over the inner bear ing race only The flat on the locking ring must be aligned with t...

Страница 767: ...nch at both grooves in the bearing nut Fig 19 NOTE The grooved nut must be locked in both directions of rotation 11 Install sealing ring 4 onto roller bearing race Fig 19 12 Install rear axle shaft SH...

Страница 768: ...VAL 1 Remove brake caliper with support 2 Remove axle shaft 3 Back off parking brakes 4 Remove outer hub nut 1 with Wrench 9290 Fig 22 5 Remove locking plate 2 inner hub nut 1 and thrust washer 3 Fig...

Страница 769: ...ar SQ 32 M sealant CAUTION Do not coat seals rubberized sealing sur faces with sealant 5 Install seal 2 into hub with an appropriate installer NOTE Seal ring should be flush with wheel hub or max 3mm...

Страница 770: ...el hub constantly Turn back inner nut and then tighten until it touches the thrust washer without play Then tighten 1 8 turn 13 Install locking plate 2 Fig 29 14 Install outer hub nut and tighten with...

Страница 771: ...spread CAUTION Never spread over 0 3 mm 0 011 in If the housing is over spread it could be distorted or damaged 8 Remove differential 2 with bearings cups 3 and differential shims Fig 32 9 Mark bearin...

Страница 772: ...f differential pinion gears 1 spherical washers and mate shaft 2 Fig 35 4 Remove second set of differential pinion gears 2 spherical washers and mate shaft 1 Fig 36 Fig 33 DIFFERENTIAL COVER 1 BOLTS 2...

Страница 773: ...per differential side gear 1 and shim 2 Fig 39 3 Remove differential cross shaft 1 with pinion gears 2 and spherical washers 3 Fig 40 Fig 37 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENTIAL CASE Fig 38 DIFF...

Страница 774: ...ntial pinions gears 1 with spherical washers and mate shaft 2 Fig 43 3 Install second pinion gears 2 with spherical washers and mate shaft 1 Fig 44 Fig 41 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENTIAL CA...

Страница 775: ...o 45 N m 33 ft lbs Fig 47 7 Check torque to rotate the differential gears with Torque Tool 9744 and a torque wrench Torque should be 20 40 N m 15 30 ft lbs NOTE Shims are available in 0 05 mm 0 002 in...

Страница 776: ...49 3 Install upper differential side gear 1 and shim 2 Fig 50 4 Install differential cover with location numbers 1 on differential case 2 aligned Fig 51 Fig 48 LOWER SIDE GEAR 1 SIDE GEAR 2 DIFFERENT...

Страница 777: ...ngs cups 3 and shims Fig 53 3 Loosely install differential bearing cap bolts 4 Remove spreader 2 and adapters 1 from housing Fig 54 5 Tighten bearing cap bolts to 70 N m 52 ft lbs 6 Install axle shaft...

Страница 778: ...37 3 Fig 55 INSTALLA TION 1 Set differential on Plug C 293 3 2 Install differential 2 bearings 3 with Installer 9523 4 and Handle C 4171 1 Fig 56 3 Install differential case in axle Fig 55 CASE BEARIN...

Страница 779: ...icles shavings in the drained oil replace gear assembly 6 Measure and record torque to rotate the pinion 7 Mark pinion position to pinion flange 1 Fig 57 8 Unlock collared nut 9 Hold pinion flange 1 w...

Страница 780: ...ion flange NOTE Should bearing not be free of play tighten in increases of 10 N m 88 in lbs to maximun of 130 N m 95 ft lbs If bearing is not free from play at 130 N m 95 ft lbs collapsible spacer mus...

Страница 781: ...jaw 3 Remove ring gear bolts from the differential case 4 Drive ring gear off the differential case with a dead blow hammer Fig 64 5 Unlock collared nut 6 Hold pinion flange with Flange Wrench C 3281...

Страница 782: ...him in rear pinion bear ing cup bore 3 Install rear pinion bearing cup with Installer C 4310 and Driver Handle C 4171 4 Install front pinion bearing cup with Installer 8617 and Handle C 4171 5 Install...

Страница 783: ...al with Installer 9276 Fig 72 10 Hold pinion flange with Flange Wrench C 3281 11 Screw on the new collared nut 12 Tighten collar nut carefully to a torque to rotate of 2 5 3 N m 22 27 in lbs 13 Cut th...

Страница 784: ...l new ring gear bolts and alternately tighten to 180 N m 133 ft lbs Fig 75 CAUTION Do not reuse ring gear bolts the bolts can fracture causing extensive damage Failure to heed caution may result in da...

Страница 785: ...6 WHEELS SRW 11 INSTALLATION REAR 16 WHEELS SRW 11 INSTALLATION REAR DRW 11 DISC BRAKE CALIPERS REMOVAL REMOVAL FRONT SRW 11 REMOVAL FRONT DRW 12 REMOVAL REAR SRW 12 REMOVAL REAR DRW 13 INSTALLATION I...

Страница 786: ...ise when braking check suspension components J ounce front and rear of vehicle and listen for noise that might be caused by loose worn or damaged suspension or steering components 3 Inspect brake flui...

Страница 787: ...tant contact with the rotor or drum Drag can occur at one wheel all wheels fronts only or rears only Drag is a product of incomplete brake shoe release Drag can be minor or severe enough to overheat t...

Страница 788: ...ration BRAKE NOISES Some brake noise is common with rear drum brakes and on some disc brakes during the first few stops after a vehicle has been parked overnight or stored This is primarily due to the...

Страница 789: ...Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding Do not pressure bleed without a proper master cyl inder adapter The wrong adapter can lead to leak age o...

Страница 790: ...4 in Rear Disc Brake Rotor Max Axial Runout DRW 02 mm 0 0007 in Front Disc Brake Rotor New DRW 22 mm 0 866 in Front Disc Brake Rotor Wear Limit DRW 19 mm 0 748 in Front Disc Brake Rotor Max Lateral Ru...

Страница 791: ...WD241 WD341 14 mm 0 55 in Rear Disc Brake Rotor Max Lateral Runout Models WD2 YD141 YD241 YD341 YD441 YD541 WD5 WD141 WD241 WD341 1 mm 0 0007 in Rear Disc Brake Rotor Max Axial Runout Models WD2 YD14...

Страница 792: ...gency repair when factory replacement parts are not readily available 1 Cut off damaged tube with Tubing Cutter 2 Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on the...

Страница 793: ...ake caliper Fig 5 7 Remove the brake pads Fig 5 REMOVAL REAR 16 WHEELS SRW 1 Unscrew the cap from the brake fluid reservoir 2 Raise and support the vehicle 3 Remove the rear wheels Refer to 22 TIRES W...

Страница 794: ...ort the vehicle 3 Remove the rear wheels Refer to 22 TIRES WHEELS WHEELS INSTALLATION 4 Remove the wear indicator cable and the wear indicator Fig 8 NOTE Seal off the line ends and connection threads...

Страница 795: ...n the guide pins to 25 N m 221 in lbs for M8 bolt or 30 N m 266 in lbs for M10 bolt 4 Install the retaining spring Fig 6 5 Install the rear wheels Refer to 22 TIRES WHEELS WHEELS INSTALLATION 6 Lower...

Страница 796: ...racks 5 Remove the brake hose at the brake caliper Fig 10 6 Remove the brake caliper guide bolt Fig 10 7 Remove the brake caliper Fig 10 REMOVAL REAR SRW 1 Unscrew the cap from the brake fluid reservo...

Страница 797: ...tor cable and the wear indicator Fig 9 Tighten to 10 N m 89 in lbs 4 Bleed the brake system 5 Check the brake system for any leaks 6 Install the front wheels 7 Lower the vehicle INSTALLA TION FRONT DR...

Страница 798: ...EMOVAL 4 Remove the disc brake caliper from the caliper adapter Refer to 5 BRAKES HYDRAULIC ME CHANICAL DISC BRAKE CALIPERS REMOVAL 5 Remove the disc brake pads Refer to 5 BRAKES HYDRAULIC MECHANICAL...

Страница 799: ...mum dry boiling point ERBP 500 F minimum wet boiling point WERBP 356 F maximum viscosity 1500 mm2 s conforming to FMVSS 116 and ISO 4925 No other type of brake fluid is recommended or approved for usa...

Страница 800: ...d down rod 7 Fill and bleed the brake system Refer to 5 BRAKES STANDARD PROCEDURE 8 Raise the vehicle and adjust the ALB controller Refer to 5 BRAKES HYDRAULIC MECHANICAL ALB CONTROLLER ADJ USTMENTS 9...

Страница 801: ...should fall away slightly under light foot pressure then hold firm If no pedal action is discernible power booster vacuum supply or vacuum check valve is faulty Pro ceed to the POWER BOOSTER VACUUM T...

Страница 802: ...them to return under spring pressure Continue bleeding operations until air bubbles are no longer visible in fluid REMOVAL 1 Using a suction gun remove as much brake fluid from the reservoir as possi...

Страница 803: ...22 Tighten to 23 N m 204 in lbs 2 Reconnect the plug connector for the stop lamp switch Fig 22 3 Install the brake pedal and hook the spring Fig 22 4 Install the retainer and pin for the brake pedal F...

Страница 804: ...ter Tighten to 28 N m 248 in lbs 6 Install the brake lines to the master cylinder Tighten to 14 N m 124 in lbs 7 Install the brake level switch electrical connec tor 8 Bleed the base brake system Refe...

Страница 805: ...caliper adapter Fig 27 5 Apply the parking brake 6 Install two lug studs to secure the disc brake rotor when the locking bolt is removed 7 Remove the wheel flange ring Fig 27 8 Remove the locking bolt...

Страница 806: ...NSTALLA TION FRONT DRW 1 Install the disc brake rotor to the hub and install two lug studs to hold rotor in place 2 Install the locking bolt for the rotor Fig 26 Tighten to 23 N m 204 in lbs 3 Install...

Страница 807: ...INSTALLA TION REAR 1 Press the brake support plate with the axle bearing onto the axle shaft Refer to 3 DIFFEREN TIAL DRIVELINE REAR AXLE AXLE BEARINGS INSTALLATION 2 Install the park brake cable to...

Страница 808: ...N 1 Push the brake control cable lock onto the brake cable Fig 28 2 Insert the safety bolt and snap shut the brake control cable lock Observe the installation posi tion of the brake control cable lock...

Страница 809: ...he brake cable lock for reference on installation 7 Remove the hand brake cable from the anchor plate Fig 31 8 Remove the park brake cable from the vehicle Compress the locking ring on the pulley unit...

Страница 810: ...n the bolts to the mounting bracket Tighten to 25 N m 221 in lbs Fig 33 5 Remove the 6 mm diameter drill bit or allen wrench Fig 33 6 Tighten the hand brake lever one notch Fig 33 7 Clamp the eccentri...

Страница 811: ...special tool 9280 Fig 36 6 Remove the adjuster Fig 36 7 Remove the pressure springs using special tool 9281 Fig 36 8 Remove the rear park brake shoes Fig 36 Pull the park brake shoes apart at the bott...

Страница 812: ...E Preassemble the retracting spring with the short hook eye from the inside together with the adjuster wheel at the bottom Fit the preassembled park brake shoes on the brake carrier 1 Ensure that the...

Страница 813: ...e vehicle and test the park brake sys tem to hold the vehicle Fig 38 STAR WHEEL ADJUSTER 1 LEFT HAND PARK BRAKE SHOES APPLIED 2 RIGHT HAND PARK BRAKE SHOES RELEASED 3 FLAT BLADED TOOL Fig 39 ADJUSTING...

Страница 814: ...port plate OPERA TION The Wheel Speed Sensor consists of a magnet sur rounded by windings from a single strand of wire The sensor sends a small AC signal to the CAB This signal is generated by magneti...

Страница 815: ...h new sensor Fig 2 INSTALLA TION 1 Connect separate wheel speed sensor cables with shrink fit sleeves and shrink fit tubing Fig 2 Only do this step if replacing the sensor 2 Install the clamping bushi...

Страница 816: ...ng and the inside of the tone wheel and pry upwards slightly and work your way around the tone wheel until the wheel is loose Fig 4 3 Remove the tone wheel INSTALLA TION 1 Install the tone wheel to th...

Страница 817: ...ring Refer to 8 ELECTRI CAL RESTRAINTS CLOCKSPRING INSTALLA TION Fig 6 4 Install the upper and lower steering column covers Fig 6 5 Install the front cover Fig 6 6 Install the steering wheel Refer to...

Страница 818: ...connect the yaw rate lateral acceleration sensor electrical connector Fig 11 2 Install the yaw rate lateral acceleration sensor 3 Install the metal cover over top of the sensor 4 Install the screws se...

Страница 819: ...ide to side Lateral motion and vehicle rotational sensing how fast the vehicle is turning This is a 6 wire sensor with all six wires connected to the ESP ABS module REMOVAL 1 Disconnect the battery 2...

Страница 820: ...essure accumulators inlet valves outlet valves and noise attenuators REMOVAL NOTE Store the Hydraulic Control Unit in an upright position only 1 Disconnect the ground cable at the battery The ignition...

Страница 821: ...ulic con trol unit Fig 17 Do not mix up the brake lines Tighten the lines to 16 N m 142 in lbs 3 Reconnect the multiplug to the control module Fig 17 4 Reconnect the ground cable on the battery 5 Blee...

Страница 822: ......

Страница 823: ...SLOW TRAFFIC TRAFFIC J AMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more...

Страница 824: ...ion ing correctly 2 Check gauge Refer to 8 ELECTRICAL INSTRUMENT CLUS TER DIAGNOSIS AND TESTING 3 Air traped in cooling 3 Drain cooling system Refer to 7 COOLING STANDARD PROCE DURE and refill Refer t...

Страница 825: ...2 Radiator neck surface damaged 2 Replace radiator HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum created in cooling sys tem on engine cool down is not being relieved through coolant re servi...

Страница 826: ...tion 2 Obstruction in heater hoses 2 Remove hoses remove obstruc tion 3 Water pump damaged 3 Replace water pump HEAT ODOR 1 Damaged or missing drive line heat shields 1 Repair or replace damaged or mi...

Страница 827: ...the arrow must be within approximately 3 mm 1 8 in of indexing mark Belt is considered new if it has been used 15 minutes or less If this specification cannot be met check for The wrong belt being ins...

Страница 828: ...misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace pulley Inspect...

Страница 829: ...or rumble is heard or felt while drive belt is in operation 1 Incorrect belt tension 1 Inspect Replace tensioner if nec essary 2 Bearing noise 2 Locate and repair 3 Belt misalignment 3 Align belt pull...

Страница 830: ...sen tension adjuster 2 Remove A C compressor drive belt INSTALLATION INSTALLA TION CAUTION When installing the accessory drive belt the belt must be the correct length and routed cor rectly If not eng...

Страница 831: ...Maximum protection against freezing is provided with a 68 percent antifreeze concentration which prevents freezing down to 67 7 C 90 F A higher percentage will freeze at a warmer temperature Also a h...

Страница 832: ...diator upper hose is warm to touch Aim the commercially available black light tool at components to be checked If leaks are present black light will cause additive to glow a bright green color The bla...

Страница 833: ...MOVING TESTER DO NOT TURN TESTER MORE THAN 1 2 TURN IF SYSTEM IS UNDER PRESSURE Operate engine without pressure cap on coolant container until thermostat opens Attach a Pressure Tester to container If...

Страница 834: ...d coolant solution CAUTION Do not use coolant additives that are claimed to improve engine cooling DRAINING COOLING SYSTEM WARNING Do not remove the cylinder block drain plug or loosen the radiator dr...

Страница 835: ...he container w hen the engine is cold Coolant level in a w arm engine w ill be higher due to thermal expansion To purge the cooling system of all air this heat up cool down cycle adding coolant to col...

Страница 836: ...from rotating Fig 5 4 Remove radiator fan shroud and radiator fan Fig 5 NOTE Store the viscous fan clutch in the upright position DO NOT place down flat INSTALLA TION 1 Install fan blade to viscous cl...

Страница 837: ...nd eyes from scalding with hot coolant Risk of poisoning from swallowing coolant Do not open cooling system unless coolant temperature is below 90 C Open cap slowly to release pressure Store coolant i...

Страница 838: ...pull off locking element and pull out coolant temperature sensor 4 Detach air intake hose at charge air distribu tion pipe 5 Detach coolant hoses at thermostat housing 6 Unscrew cap at oil filter hous...

Страница 839: ...CAP SLOWLY TO RELEASE PRESSURE STORE COOL ANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER WEAR PROTECTIVE GLOVES CLOTHES AND EYE WEAR NOTE Capture all residual fluid spillage and store in suitably...

Страница 840: ...ring intercooler to radiator 14 Remove screws and upper radiator trim from radiator 15 Move condenser intercooler power steering cooler assembly forward 16 Lift the radiator assembly up and out of the...

Страница 841: ...6 Install A C condenser 17 Install front bumper 18 Install front end cross member 19 Refill power steering to proper level 20 Refill transmission to proper level 21 Close radiator drain plug and refil...

Страница 842: ...ithin the 124 145 kPa 18 21 psi range for 30 seconds or more If the pointer drops quickly replace the cap CAUTION Radiator pressure testing tools are very sensitive to small air leaks which will not c...

Страница 843: ...1 Disconnect the negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove viscous fan clutch 4 Detach fuel lines from the brackets at the water pump...

Страница 844: ...washer behind the guide pulley to assure proper alignment 3 Install belt guide pulleys Tighten bolts to 35 N m 26 lbs ft Fig 13 4 Attach the coolant hoses to the water pump and tighten clamps Fig 13...

Страница 845: ...rs Refer to 23 BODY INTERI OR HEADLINER REMOVAL 3 Disconnect the antenna and electrical connec tions near the windshield Fig 1 4 Remove the mounting nut 5 Remove the antenna assembly from the roof and...

Страница 846: ...to instrument panel wire harness 5 Install glove box Refer to 23 BODY INSTRU MENT PANEL GLOVE BOX INSTALLATION 6 Install the headliner Refer to 23 BODY IN TERIOR HEADLINER INSTALLATION 7 Install the...

Страница 847: ...ctor and remove speaker INSTALLA TION 1 Install wire harness connector 2 Place speaker into instrument panel 3 Install speaker grille 4 Install the A pillar trim Refer to 23 BODY INTERIOR A PILLAR TRI...

Страница 848: ......

Страница 849: ...l sys tem and to the EMIC through the use of a combina tion of soldered splices splice block connectors and many different types of wire harness terminal con nectors and insulators Refer to the approp...

Страница 850: ...internal programming and hard wired inputs from the front door ajar switches the key in ignition switch the ignition switch the seat belt switch and the turn signal hazard warning multi function switc...

Страница 851: ...vides the optional Remote Keyless Entry RKE system fea tures including support for the RKE Lock with optional horn and park lamps flash Unlock with park lamps flash driver door only unlock and unlock...

Страница 852: ...ent panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before perform ing further diagnosis or s...

Страница 853: ...ower dash panel and consists of an electronic printed circuit board which is designed as a milliliter board assembly fitted on both sides The routing of the wiring harness connector at the ECM connect...

Страница 854: ...electrical appliances Starter control immobilizer cruise control kick down air conditioner Maintenance computer ASSYST optional Glow plug for pre heating post heating and intermittent heating Error c...

Страница 855: ...ccelerator pedal module which is equipped with dual hall sensors Measurement of the intake air mass using new mass air flow MAF sensor with increase precision and extended measuring range O2 sensor fo...

Страница 856: ...the function mentioned above The high precision of the MAF measurement enables the calculation of the actual injection quantity from the measured air mass and from the oxygen sensor signal in order to...

Страница 857: ...ulic prob lems When a problem is sensed the TCM stores a diagnostic trouble code DTC Some of these codes cause the transmission to go into Limp In or default mode Some DTCs cause permanent Limp In and...

Страница 858: ...tes SHIFT SCHEDULES The basic shift schedule includes up and down shifts for all five gears The TCM adapts the shift program according to driving style accelerator pedal position and deviation of vehi...

Страница 859: ...re in order for shift member to apply These return springs have slightly different values This also affects the application pressure and is compen sated for by fill pressure adaptation Fill Time Adapt...

Страница 860: ...C 140 F and less than 70 C 158 F Fail ure to stay within these temperature ranges will void the procedure 2 Drive the vehicle until the transmission tem perature is in the specified range 3 Perform 4...

Страница 861: ...INSTALLATION 16 BATTERY TRAY DESCRIPTION 16 OPERATION 16 REMOVAL 16 INSTALLATION 16 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on this model Some veh...

Страница 862: ...system In order for the engine to start and the battery to maintain its charge properly all of the components that are used in these systems must perform within specifications It is important that th...

Страница 863: ...nal con nections are loose or cor roded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The bat...

Страница 864: ...nosis and testing procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which...

Страница 865: ...with a sodium bicarbonate baking soda and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film Fig 2 Rinse the battery with clean water Ensure that the clea...

Страница 866: ...capacity low maintenance storage batteries are standard factory installed equipment on this model The primary battery is located in the engine compartment on all models A second auxiliary bat tery may...

Страница 867: ...ed period A battery must also be able to accept a charge so that its voltage potential may be restored The battery is vented to release excess hydrogen gas that is created when the battery is being ch...

Страница 868: ...r to evaluate the battery condition Damage to the battery may result from overcharging CAUTION The battery should not be hot to the touch If the battery feels hot to the touch turn off the charger and...

Страница 869: ...very low at first As the battery warms it will accept a higher charging current rate amperage Charger Capacity A battery charger that supplies only five amperes will require a longer charging time A...

Страница 870: ...battery In most cases the battery can be charged and returned to service after the excessive IOD condition has been corrected 1 Verify that all electrical accessories are off Turn off all lamps remov...

Страница 871: ...h a wire brush before test ing If the battery is equipped with side post termi nals install and tighten the supplied lead terminal stud adapters Do not use steel bolts Failure to prop erly install the...

Страница 872: ...e certain that all electrical accessories are turned off 2 Loosen the battery negative cable terminal clamp pinch bolt hex nut 3 Disconnect the battery negative cable terminal clamp from the battery n...

Страница 873: ...ghten the terminal clamp pinch bolt hex nut to 7 9 N m 70 in lbs 5 Apply a thin coating of petroleum jelly or chas sis grease to the exposed surfaces of the battery cable terminal clamps and the batte...

Страница 874: ...he male terminal posts on the top of the battery The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection...

Страница 875: ...terminal clamp Fig 10 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor connection between the battery positive cable terminal cla...

Страница 876: ...battery The battery tray sup port supports the battery tray and provides an anchor point for the inboard battery hold down hard ware The battery tray and the battery hold down hardware combine to sec...

Страница 877: ...LER 20 REMOVAL 20 INSTALLATION 22 VOLTAGE REGULATOR DESCRIPTION 24 REMOVAL 24 INSTALLATION 26 CHARGING SYSTEM SPECIFICATIONS TORQUE 2 7L DIESEL DESCRIPTION N m Ft Lbs In Lbs B Terminal Nut larger of 2...

Страница 878: ...djusted fan drive belt loose mount ing bolts a misaligned drive pulley or a defective sta tor or diode An instrument panel mounted battery charge indi cator lamp is used When the key is in the on posi...

Страница 879: ...hematics in Cooling System 8 Install generator drive belt Refer to Cooling System for procedure 9 Connect negative battery cable 10 Check charging system for proper operation GENERATOR DECOUPLER PULLE...

Страница 880: ...ry cable 2 Remove generator and accessory drive belt Refer to Generator Removal 3 Position Special Tool 8823 VM 1048 into decoupler Fig 5 4 Determine if end of generator shaft is hex shaped Fig 6 or i...

Страница 881: ...UPLER 2 TOOL 8823 VM 1048 Fig 6 END OF GENERATOR SHAFT HEX 1 GENERATOR SHAFT 2 HEX Fig 7 END OF GENERATOR SHAFT SPLINED 1 GENERATOR SHAFT 2 SPLINES Fig 8 DECOUPLER REMOVAL INA HEX 1 DEEP 10 MM SOCKET...

Страница 882: ...ler by hand from generator INSTALLA TION INA Decoupler 1 Thread decoupler pulley onto generator shaft by hand right hand threads 2 Position Special Tool 8823 VM 1048 into decoupler Fig 5 3 Determine i...

Страница 883: ...nd threads 2 Position Special Tool 8433 Fig 10 into decou pler Align tool to hex end of generator shaft 3 Do not use an adjustable ratcheting click type torque w rench Most click type w renches w ill...

Страница 884: ...1 Disconnect and isolate negative battery cable 2 Raise and support vehicle 3 Remove bolt 2 Fig 16 at turbocharger brace 1 Fig 16 4 Loosen bolt 1 Fig 17 at brace 2 Fig 17 Swivel the race 2 to the side...

Страница 885: ...nting or tipping 10 Check condition of commutator rings 1 Fig 20 If rings are worn replace generator assembly 11 Check condition of carbon brushes 1 Fig 21 If brushes are worn replace generator assemb...

Страница 886: ...e to the carbon brushes 1 Fig 22 slow ly install the voltage regulator straight into the generator w ithout slanting or tipping 4 Install screws 1 3 and 4 Fig 24 5 Install plastic cover 1 Fig 25 screw...

Страница 887: ...1 Fig 26 at brace 2 Fig 26 Tighten bolt 1 to 20 N m 15 ft lbs 9 Install bolt 2 Fig 27 at turbocharger brace 1 Fig 27 Tighten bolt 2 to 30 N m 22 ft lbs 10 Lower vehicle 11 Connect negative battery ca...

Страница 888: ...rage feed circuit components include the battery the battery cables the contact disc por tion of the starter solenoid and the starter motor itself The low amperage control circuit components include t...

Страница 889: ...Relay in Diagnosis and Testing Re place starter relay if required 4 Ignition switch faulty 4 Refer to Ignition Switch and Key Lock Cylinder Re place ignition switch if required 5 Clutch pedal positio...

Страница 890: ...n Sw itch and Key Lock Cylinder Park Neutral Position Sw itch Visually inspect park neutral position switch for indications of physical damage and loose or corroded wire harness connections Refer to P...

Страница 891: ...ry cable clamp to terminal post connection and positive battery cable The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing tests be certain that following proc...

Страница 892: ...esistance tests detect no feed circuit problems refer to Starter Motor in the Diagnosis and Testing CONTROL CIRCUIT TESTING The starter control circuit components should be tested in the order in whic...

Страница 893: ...oft jawed bench vise The vise jaws should be clamped on the mounting flange of starter motor Never clamp on starter motor by field frame 3 Connect a suitable volt ampere tester and a 12 volt battery t...

Страница 894: ...position wiring harness trough for access to starter 4 Working from under vehicle hood remove 2 starter solenoid wiring harness nuts Fig 10 5 Remove solenoid wire connector from solenoid stud and bat...

Страница 895: ...rming to ISO specifications have common physical dimensions cur rent capacities terminal patterns and terminal func tions The starter relay cannot be repaired or adjusted and if faulty or damaged it m...

Страница 896: ...he drivers seat See Fuse Relay Block cover for relay identification and location or refer to Fig 12 1 Install relay into Fuse Relay Block 2 Install cover to side of Fuse Relay Block snaps on Fig 13 FU...

Страница 897: ...ended The rear window defogger system also known as the electric backlight EBL consists of a backglass with two vertical bus bars linked by a series of grid lines fired onto the inside surface of the...

Страница 898: ...ld be detected within three to four minutes of operation 2 If a temperature difference is not detected use a 12 volt DC voltmeter and contact the rear glass heating grid terminal B with the negative l...

Страница 899: ...are electromechanical switches that uses a low current input from the rear window defogger module to control the high current output to the rear window defogger grids The movable common feed contact p...

Страница 900: ...block as required INSTALLA TION NOTE Refer to the fuse and relay map located on the inner surface of the fuse relay block cover for the left and right rear window defogger EBL relay locations 1 Posit...

Страница 901: ...rear window defogger system refer to 8W WIRING DIAGRAM INFORMATION 1 Remove the rear window defogger switch from the instrument panel but leave the switch connected Refer to 8 ELECTRICAL HEATED GLASS...

Страница 902: ...ould result in accidental airbag deployment 1 Disconnect and isolate the negative battery cable 2 Remove the cluster bezel from the instrument panel Fig 7 Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZ...

Страница 903: ...o exceed 204 C 400 F 6 Allow the epoxy to cure 24 hours at room tem perature or use a heat gun with a 260 to 371 C 500 to 700 F range for 15 minutes Hold the heat gun approximately 254 mm 10 inches fr...

Страница 904: ...w defogger terminals are pre soldered and fluxed Do not reuse a terminal if it has been previously heated Place the solder gun onto the new terminal s and heat the terminal until the solder flows Remo...

Страница 905: ...ocated behind the glass of each of the outside rear view mirrors is energized when the ignition switch is turned to the Run posi tion The heater grids heat the glass surface of the outside rear view m...

Страница 906: ...seat back cushions Refer to heated seat elements later in this section for additional information Heated Seat Relay One heated seat relay is used per vehicle The relay is located in the fuse block and...

Страница 907: ...to the Heated Seat Relay through separate hard wired circuits Each switch contains two light emitting diodes LED one for each High and Low setting to let the occupant know that the seat heater system...

Страница 908: ...the sensor decreases The heated seat relay uses this temperature sensor input to monitor the temperature of the seat and regulates the cur rent flow to the seat heating elements accordingly DIAGNOSIS...

Страница 909: ...l INSTALLA TION 1 Grasp the heated seat relay firmly and push it straight in the fuse block 2 Reconnect the battery negative cable HEATED SEAT SENSOR DESCRIPTION The heated seat temperature sensor is...

Страница 910: ...st the heated seat system REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the gear selector bezel trim Refer to the Body section for the procedure 3 Remove the storage bin Refer t...

Страница 911: ...3 Connect battery negative cable HORN SWITCH REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the drivers side airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Remo...

Страница 912: ......

Страница 913: ...If a failure in the glow plug system occurs the glow plug indicator lamp will be illuminated only as long as the fault is current If the failure is no longer present the glow plug indicator lamp will...

Страница 914: ...exhaust smoke after cold start Stabilizing of the cold starting speed The glow plug output stage constantly signals the current operating state and faults The following are faults detected and transm...

Страница 915: ...UEL GAUGE DESCRIPTION 17 OPERATION 18 GEAR SELECTOR INDICATOR DESCRIPTION 18 OPERATION 18 HIGH BEAM INDICATOR DESCRIPTION 19 OPERATION 19 LOW FUEL INDICATOR DESCRIPTION 19 OPERATION 19 LOW OIL LEVEL I...

Страница 916: ...k plastic switch bezel that is integral to the cluster lens and located near the lower edge of the cluster directly below the multi function indicator LCD unit The cluster hood serves as a visor and s...

Страница 917: ...CONTROL MODULES COMMUNICATION DESCRIPTION CAN BUS Besides typical instrument cluster gauge and indi cator support the electronic functions and features that the EMIC supports or controls include the f...

Страница 918: ...and insulators Refer to the appropriate wir ing information The wiring information includes wiring diagrams proper wire and connector repair Fig 3 Gauges Indicators 1 AIRBAG INDICATOR 16 SEATBELT INDI...

Страница 919: ...ndication The EMIC circuitry operates on battery current received through a non switched fused B circuit and on a fused ignition switch output circuit The EMIC circuitry is grounded through a ground c...

Страница 920: ...n this service information CLUSTER ILLUMINA TION The EMIC has several general illumination lamps that are illuminated when the exterior lighting is turned on with the multi function switch The illumi...

Страница 921: ...rk is functional that all of the modules are sending and receiving the proper electronic messages over the CAN data bus and that the instrument cluster is receiving the proper hard wired inputs and re...

Страница 922: ...k down the IC until all of the steps are followed and completed or the new IC may be irreversibly damaged This procedure initial izes and configures the IC for certain optional equipment on the vehicl...

Страница 923: ...back of the instru ment cluster rear cover Fig 5 5 Roll the top of the instrument cluster forward to position the instrument cluster into the instru ment panel 6 Install and tighten the two screws th...

Страница 924: ...ired Refer to the appropriate diagnostic infor mation ADR INDICATOR DESCRIPTION A constant engine speed ADR indicator is stan dard equipment on all instrument clusters but is only functional on vehicl...

Страница 925: ...er detects that the ignition switch is in the On position Therefore the LED will always be off when the ignition switch is in any position except On The LED only illuminates when it is provided a path...

Страница 926: ...seconds The ambient temperature sensor located below the front bumper is a Negative Temperature Coefficient NTC thermistor The internal resistance of the sen sor is reduced as the ambient temperature...

Страница 927: ...l between ground and the instrument clus ter The brake fluid level switch and the input circuit to the instrument cluster can be diagnosed using con ventional diagnostic tools and methods For proper d...

Страница 928: ...charging indica tor for the following reasons Bulb Test Each time the ignition switch is turned to the On position with the engine not run ning the charging indicator is illuminated by the instrument...

Страница 929: ...vel switch The cool ant low indicator Light Emitting Diode LED is com pletely controlled by the instrument cluster logic circuit and that logic will only allow this indicator to operate when the instr...

Страница 930: ...gauge scale it may indicate that the engine or the engine cooling system require service For proper diagnosis of the engine coolant temperature sensor the ECM the CAN data bus the electronic message i...

Страница 931: ...ch is in any position except On The LED only illuminates when it is provided a path to ground by the instrument cluster transistor The instrument cluster will turn on the fuel filter clogged indicator...

Страница 932: ...ontrols the fuel gauge a diagnostic scan tool is required Refer to the appropriate diagnostic information GEAR SELECTOR INDICATOR DESCRIPTION An electronic automatic transmission gear selector indicat...

Страница 933: ...put circuit to the instrument cluster can be diagnosed using conventional diagnos tic tools and methods For proper diagnosis of the instrument cluster circuitry that controls the high beam indicator a...

Страница 934: ...any position except On The LED only illuminates when it is provided a path to ground by the instrument cluster transistor The instrument cluster will turn on the low oil level indi cator for the follo...

Страница 935: ...ht of the multi function indicator display The MIL consists of the International Control and Display Symbol icon for Engine imprinted within a rectangular cutout in the opaque layer of the instru ment...

Страница 936: ...engine oil level data gear selector indicator PRNDL certain diagnostic information and on vehicles so equipped an optional Active Service SYS Tem ASSYST engine oil maintenance indicator and an optiona...

Страница 937: ...d This indicator is controlled by the instru ment cluster circuitry based upon cluster program ming and electronic messages received by the cluster from the Controller Anti lock Brake CAB over the Con...

Страница 938: ...pear silhouetted against a red field through the translu cent outer layer of the overlay when the indicator is illuminated from behind by the LED which is sol dered onto the instrument cluster electro...

Страница 939: ...he Off position The instrument cluster circuitry controls the gauge needle position and provides the following features Vehicle Speed Message Each time the clus ter receives a vehicle speed message fr...

Страница 940: ...from behind by the LED which is soldered onto the instrument clus ter electronic circuit board The traction control indi cator is serviced as a unit with the instrument cluster OPERA TION The tractio...

Страница 941: ...ignition switch is turned to the Off position whichever occurs first The CAB continually monitors the traction control ASR system circuits and sensors to decide whether the system is in good operatin...

Страница 942: ...n the fuse block or the instrument clus ter circuitry that controls the turn signal indicators and the contactless relay a diagnostic scan tool is required Refer to the appropriate diagnostic infor ma...

Страница 943: ...s that the ignition switch is in the On position Therefore the indicator will always be off when the ignition switch is in any position except On The indi cator only illuminates when it is switched to...

Страница 944: ...ssage from the ECM indicating that there is excessive water in the fuel filter with the engine running the water in fuel indicator will be illuminated The indi cator remains illuminated until the clus...

Страница 945: ...EMOVAL 10 INSTALLATION 10 FOG LAMP BULB REMOVAL 10 INSTALLATION 11 FOG LAMP RELAY REMOVAL 11 INSTALLATION 12 FOG LAMP SWITCH REMOVAL 12 INSTALLATION 13 FRONT LAMP UNIT REMOVAL 13 INSTALLATION 13 ADJUS...

Страница 946: ...al to the front lamp units the rear turn lamps that are inte gral to the tail lamp units and a repeater lamp mounted to each front fender just above the front wheel opening Other components of the ext...

Страница 947: ...rs turn signals and engine start control module located within the fuse block underneath the steering column the ElectroMechanical Instrument Cluster EMIC the Engine Control Module ECM or the Controll...

Страница 948: ...viding battery current to the selected low or high beam bulbs Each front lamp unit includes two integral adjustment screws to be used for static horizontal and vertical aiming of the headlamp beam ref...

Страница 949: ...al turn signal flasher at one of two rates to coincide with the flashing of the turn signals The slow rate emulates normal turn signal operation while the fast rate emulates bulb out turn signal opera...

Страница 950: ...ng further diagnosis or service This is the only sure way to disable the supplemental restraint sys tem Failure to take the proper precautions could result in accidental airbag deployment 1 Disconnect...

Страница 951: ...tion to automatically adjust the brake lamp switch plunger 7 Reconnect the battery negative cable ADJUSTMENTS ADJUSTMENT WARNING To avoid personal injury or death on vehicles equipped with airbags dis...

Страница 952: ...crews that secure the CHMSL lamp to the vehicle then remove the lens from the lamp housing Fig 8 3 Push straight in on the CHMSL bulb and rotate it counterclockwise about 30 degrees to remove it from...

Страница 953: ...Fig 10 2 Insert the bulb holder into the back of the clearance lamp housing and rotate it clockwise about 30 degrees to lock it into place 3 Reinstall the clearance lamp onto the vehicle Refer to 8 E...

Страница 954: ...ght and a left DRL relay are each located in a dedicated connector of the vehicle wire harness Each connector is snapped into an opening in a stamped sheet metal bracket which is secured with screws w...

Страница 955: ...y is located in a dedicated connector of the vehi cle wire harness This connector is snapped into an opening in a stamped sheet metal bracket which is secured with screws within the driver side front...

Страница 956: ...are fully seated in the relay connector 4 Position the cover panel onto the top of the driver side seat riser Fig 15 5 Install and tighten the two screws that secure the cover panel to the top of the...

Страница 957: ...vehicle Refer to 23 BODY EXTERIOR GRILLE REMOVAL 3 Remove the two screws that secure the cover at the inboard side of the front lamp unit Fig 18 4 Remove the cover from the front lamp unit 5 From the...

Страница 958: ...ion the vehicle on a level surface 2 Turn On the headlamp low beams or the fog lamps if equipped 3 Open the hood 4 Set up the headlamp adjuster according to the instructions provided by the manufactur...

Страница 959: ...ate the battery negative cable 2 Locate the turn park side marker bulb holder on the rear outboard side of the front lamp unit housing Fig 24 3 Rotate the bulb holder counterclockwise about 30 degrees...

Страница 960: ...ousing and remove the cover Fig 26 3 Disconnect the front lamp unit wire harness connector from the connector receptacle for the head lamp leveling motor Fig 27 4 Rotate the headlamp leveling motor co...

Страница 961: ...SWITCH REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat...

Страница 962: ...cluster bezel onto the instrument panel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL INSTALLATION 4 Reconnect the battery negative cable HIGH BEAM HEADLAMP BULB REMOVAL 1 Disconnect and isolate the...

Страница 963: ...over onto the back of the lamp housing 3 Reinstall the license plate lamp unit to its mounting location Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR LICENSE PLATE LAMP UNIT INSTALLATION 4 Reconnect t...

Страница 964: ...w beam headlamp bulb into the integral bulb holder on the front lamp unit reflector Be certain that the lugs on the bulb base are engaged in the recesses of the bulb holder Fig 36 2 Engage the low bea...

Страница 965: ...ury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner or instrument panel component...

Страница 966: ...d isolate the battery negative cable 2 If the vehicle is so equipped remove the trim from the inside of the right or left rear corner pillar 3 From inside the vehicle use hand pressure to push the two...

Страница 967: ...al lamp bulb into the tail lamp socket plate Fig 42 2 Align the socket plate with the mounting hole in the inner rear pillar 3 Using hand pressure push the socket plate gently and evenly into the inne...

Страница 968: ...aining clip then pull the rear edge of the lamp outward to disengage it from the mounting hole Fig 45 3 Pull the repeater lamp housing slightly to the rear to disengage the front edge of the unit from...

Страница 969: ...unit near the mounting hole on the fender panel Fig 46 2 Reconnect the vehicle wire harness connector to the connector receptacle on the back of the repeater lamp unit 3 Position the repeater lamp len...

Страница 970: ...ld result in accidental airbag deployment 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel from the steering column opening cover below the steering column on the ins...

Страница 971: ...ted in the terminal cavities in the receptacle of the fuse block and both latches are fully engaged 4 Reinstall the fuse access panel onto the steer ing column opening cover below the steering column...

Страница 972: ...e a single incandescent bulb An optional version of these lamps includes an integral three po sition switch that protrudes through the lamp lens Cargo Lamp Sw itch Toggle type remote cargo lamp switch...

Страница 973: ...are provided with battery current at all times by a fuse in the fuse block beneath the steering column The front side and rear door jamb switches control a ground path for each of these lamps except...

Страница 974: ...into the inboard side of the ash receiver bin allows light from the lamp on the halo ring to also illuminate the ash receiver The ash receiver cigar lighter lamp is ser viced only as a unit with the...

Страница 975: ...BEZEL REMOVAL 3 From the back of the accessory switch bezel disconnect the vehicle wire harness connector for the cargo lamp switch from the receptacle on the back of the switch Fig 4 4 From the back...

Страница 976: ...LLA TION REAR PILLAR 1 From the front of the switch bezel align the cargo lamp switch body with the opening in the bezel and push the switch into the bezel until the two latches on the outside of the...

Страница 977: ...kwise about 30 degrees on the circuit board Fig 7 4 Pull the bulb holder and bulb unit straight out from the mounting hole in the circuit board INSTALLA TION 1 Grasp the dome lamp intrusion sensor uni...

Страница 978: ...or jamb switch away from the mounting hole in the pillar far enough to access and disconnect the vehicle wire harness connector from the back of the switch INSTALLA TION 1 Position the door jamb switc...

Страница 979: ...on the edge of the entry exit lamp hous ing opposite from the retainer clip into the mounting hole 4 Push firmly and evenly on the notched edge of the entry exit lamp housing until the retainer clip l...

Страница 980: ...straint sys tem Failure to take the proper precautions could result in accidental airbag deployment 1 Position the time delay relay to its vehicle wire harness connector within the driver side seat ri...

Страница 981: ...r will unlock the drivers door pressing it a second time within 2 5 seconds will unlock all other doors The transmitter has a range of 10 meters A key is inte gral to the transmitter When a transmitte...

Страница 982: ...anel center bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL CENTER BEZEL REMOVAL 3 Remove the central locking switch from the bezel Fig 2 INSTALLA TION 1 Install switch to bezel 2 Install in...

Страница 983: ...MIRROR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove power mirror switch Refer to 8 ELECTRICAL POWER MIRRORS POWER MIRROR SWITCH REMOVAL 3 Using an ohmmeter test for continuity b...

Страница 984: ...remove switch INSTALLA TION 1 Connect electrical harness connector to switch 2 install the mirror switch power window switch trim 3 Install the door handle trim 4 Connect the battery negative cable Fi...

Страница 985: ...motor terminal pins will cause the motor to rotate in one direction Reversing current through the motor terminals will cause the motor to rotate in the opposite direction Refer to the appropriate wiri...

Страница 986: ...nnectors from switches 5 Remove power window switch from trim INSTALLA TION 1 Install switch to trim 2 Connect wire harness connectors to switches 3 Install power window switch trim to door trim panel...

Страница 987: ...OPERATION 17 REMOVAL 18 INSTALLATION 19 FRONT SEAT BELT RETRACTOR REMOVAL 20 INSTALLATION 22 FRONT SEAT BELT BUCKLE REMOVAL 23 INSTALLATION 23 PASSENGER AIRBAG DESCRIPTION 24 OPERATION 24 REMOVAL 25 I...

Страница 988: ...raints for this model include Front Seat Belts Both outboard front seating positions are equipped with three point seat belt sys tems employing a lower B pillar mounted inertia latch type retractors h...

Страница 989: ...t panel in front of the driver Clockspring The clockspring is located near the top of the steering column directly beneath the steering wheel Driver Airbag The driver airbag is located in the center o...

Страница 990: ...ds upon the angle and severity of an impact Deployment is not based upon vehicle speed rather deployment is based upon the rate of deceleration as measured by the forces of gravity G force upon the im...

Страница 991: ...als may produce harmful and irritating gases sodium hydroxide is formed in the presence of moisture or combustible compounds An airbag inflator unit may also contain a gas canister pres surized to ove...

Страница 992: ...deployment must have the deployed restraints replaced In addition if the driver airbag has been deployed the clockspring and the steering wheel must be replaced If the passenger airbag has been deploy...

Страница 993: ...acitor to discharge before performing further diagnosis or service This is the only sure way to disable the supplemental restraint system Failure to take the proper precau tions could result in accide...

Страница 994: ...itry of the ACM which includes a microprocessor an electronic impact sensor an electronic safing sen sor and an energy storage capacitor A stamped metal cover plate is permanently secured to the bot t...

Страница 995: ...ers that sense the rate of vehicle deceleration which provide verifica tion of the direction and severity of an impact On models equipped with optional side curtain airbags the ACM also monitors input...

Страница 996: ...oy the supple mental restraints If an airbag control module is accidentally dropped during service the module must be scrapped and replaced with a new unit Failure to observe this warning could result...

Страница 997: ...nsioner impact sensor or instrument panel com ponent diagnosis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before pe...

Страница 998: ...he seat riser under the driver side front seat Tighten the screws to 2 N m 18 in lbs 10 Move the driver side front seat back to its driving position 11 Do not reconnect the battery negative cable at t...

Страница 999: ...ockspring rotor connects the clockspring to the driver airbag while two single pig tail wires connect to the feed and ground terminals of the horn switch located within the hub cavity of the steering...

Страница 1000: ...two clockspring mounting screws far enough so that they extend into the clearance holes in the upper surface of the clockspring rotor preventing the rotor from changing position relative to the clocks...

Страница 1001: ...ightened into the clockspring case until the clockspring has been installed on the steering column If the screws are tightened into or removed from the case before the clockspring is installed on a st...

Страница 1002: ...r airbag protective trim cover is the most visible part of the driver airbag Fig 18 The driver airbag is located in the center of the steering wheel where it is secured with two screws to the armature...

Страница 1003: ...proper electrical signal to the initiator the electrical energy generates enough heat to initiate a small pyrotechnic charge which in turn ignites chemical pellets within the inflator Once ignited th...

Страница 1004: ...vehicle Refer to 8 ELECTRICAL RESTRAINTS STANDARD PRO CEDURE SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT WARNING To avoid personal injury or death on vehicles equipped with airbags disable the s...

Страница 1005: ...review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle Refer to 8 ELECTRICAL RESTRAINTS STANDARD PRO CEDURE SERVICE AFTER...

Страница 1006: ...has been deployed review the rec ommended procedures for service after a supplemen tal restraint deployment before removing the front seat belt and retractor from the vehicle Refer to 8 ELECTRICAL RE...

Страница 1007: ...sengage the connector from the seat belt tensioner initiator connector receptacle Improper removal of the con nector insulator can result in damage to the seat belt tensioner circuits or the connector...

Страница 1008: ...nd anchors for proper installation oper ation or damage Replace any belt that is cut frayed or torn Straighten any belt that is twisted Tighten any loose fasteners Replace any belt that has a damaged...

Страница 1009: ...gtail wire to the seat frame Fig 26 3 On the driver side only pull the seat belt switch pigtail wire out through the clearance hole in the seat riser cover far enough to access and discon nect the pig...

Страница 1010: ...air bag mounting bracket that is secured with screws to the tubular steel instrument panel structural support above the glove box opening The end plates are secured to each side of the passenger airba...

Страница 1011: ...for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the passenger airbag has been deployed review t...

Страница 1012: ...N Do not pull on the wires to disengage the connector from the passenger airbag inflator connector receptacle Improper removal of the con nector insulator can result in damage to the airbag circuits o...

Страница 1013: ...1 Carefully position the passenger airbag and airbag door unit to the instrument panel Fig 29 2 When installing the passenger airbag recon nect the vehicle wire harness connector to the airbag inflat...

Страница 1014: ...or death during and following any seat belt service carefully inspect all seat belts buckles mounting hardware retractors and anchors for proper installation oper ation or damage Replace any belt tha...

Страница 1015: ...he turning loop trim cover and the turning loop bracket 10 Remove the screw that secures the rear seat belt retractor to the bracket on the rear seat cushion frame Fig 35 11 Remove the rear seat belt...

Страница 1016: ...f the bracket Fig 32 8 From the front of the turning loop bracket insert the pin through both turning loops and the bracket then secure it from behind the bracket with a new push nut 9 Position the tu...

Страница 1017: ...rear seat cushion frame Fig 36 2 Install and tighten the screw that secures either the inboard rear seat belt buckle to the rear seat cushion frame Tighten the screw to 35 N m 26 ft lbs 3 Reinstall t...

Страница 1018: ...t belt switch may de diagnosed using conventional diagnostic tools and methods SEAT BELT TENSIONER DESCRIPTION Front seating position seat belt tensioners supple ment the standard driver and optional...

Страница 1019: ...he potential for occupant injuries The ACM monitors the condition of the seat belt tensioners through circuit resistance The ACM will illuminate the airbag indicator in the ElectroMe chanical Instrume...

Страница 1020: ...Fig 40 5 Remove the nut that secures the front seat belt turning loop to the height adjuster Fig 41 6 Remove the front seat belt turning loop from the height adjuster 7 Remove the two screws that secu...

Страница 1021: ...ster Tighten the nut to 35 N m 26 ft lbs 5 Position the height adjuster trim to the upper B pillar so that the driver on the back of the trim engages the lug of the height adjuster Fig 40 6 Reinstall...

Страница 1022: ...ARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the side curtain airbag has been deployed review the recommended procedures for service after a supplemental restraint deployment before...

Страница 1023: ...r the belt line Fig 47 9 Remove the screw that secures the front of the side curtain airbag to the A pillar Fig 48 10 Remove the screw that secures the rear of the side curtain airbag to the B pillar...

Страница 1024: ...ior surfaces In large doses these depos its may cause irritation to the skin and eyes WARNING To avoid personal injury or death use extreme care to prevent any foreign material from entering the side...

Страница 1025: ...protect the internal electronic circuitry and components The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the vehicle wire harn...

Страница 1026: ...t the vehicle wire harness connector from the side impact sensor connector receptacle Fig 52 4 Remove the two screws that secure the side impact sensor to the forward vertical surface of the step well...

Страница 1027: ...ensor connector receptacle 4 Reinstall the trim paneling to the interior of the front door step well Refer to 23 BODY INTE RIOR STEPWELL SCUFF PADS INSTALLATION 5 Do not reconnect the battery negative...

Страница 1028: ......

Страница 1029: ...the system is accomplished by a 4 position instrument panel mounted switch Fig 1 Sw itch settings Fig 2 are 1 Set Accelerate 2 Resume Set Speed 3 Set Decelerate 4 Off The system is designed to operate...

Страница 1030: ...n extremely high rate Once the speed control has been disengaged depressing the RES ACCEL switch when speed is greater than 30 mph restores the vehicle to the tar get speed that was stored in the ECM...

Страница 1031: ...LA TION The speed control switch is mounted to the back of the multi function switch Fig 3 1 Position speed control switch to back of multi function switch 2 Install switch mounting screw Fig 4 Refer...

Страница 1032: ......

Страница 1033: ...door The key must be held in the locking position for more than two seconds Activation is indicated by the turn sig nal lights flashing once Unlocking the vehicle at one of the other doors will trigge...

Страница 1034: ...ness connector 2 Position module Install and tighten mounting fasteners 3 Install driver seat cushion 4 Connect battery negative cable SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION The Sentry Key Remote...

Страница 1035: ...ronically coded in the SKREEM and in all programmed transponder keys It is used for immobilization and RKE functions for data security In addition each transponder key will have a unique identificatio...

Страница 1036: ...ER CLUS TER INSTALLATION 4 Connect the battery negative cable 5 Verify vehicle and system operation 6 Close hood SENTRY KEY REMOTE ENTRY MODULE TRAN SPONDER RING 1 Maneuver wiring through instrument p...

Страница 1037: ...ithin the range of the SKREEM s transponder ring when it is inserted into the ignition lock cylinder When the ignition switch is turned to the ON position the SKREEM communicates with the Sentry Key v...

Страница 1038: ......

Страница 1039: ...R FLUID LEVEL SWITCH DESCRIPTION 16 OPERATION 16 WASHER HOSES TUBES DESCRIPTION 18 OPERATION 18 WASHER NOZZLE DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATION 19 WASHER PUMP MOTOR DESCRIPTION 19 OP...

Страница 1040: ...of the wind shield in the engine compartment Multi Function Sw itch The multi function switch is secured to the top of the steering column just below the steering wheel Only the left lighting control...

Страница 1041: ...The wiper linkage module includes the two wiper drive links the wiper motor crank arm the two wiper piv ots and the linkage and motor mounting bracket Wiper Motor The wiper motor is secured to the wi...

Страница 1042: ...within the fuse block monitors inputs from the intermittent wipe and washer switch cir cuitry of the multi function switch and the park switch in the wiper motor When the intermittent wipe position is...

Страница 1043: ...he down position at the moment the Off position is selected the park switch is an open cir cuit The control module logic circuit directs battery current to the low speed brush of the wiper motor which...

Страница 1044: ...eering wheel steering column airbag seat belt tensioner or instrument panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the syste...

Страница 1045: ...n the multi function switch and the washer pump as required 3 Faulty washer pump motor 3 Test and replace the washer pump as required 4 Faulty muli function switch 4 Test and replace the multi functio...

Страница 1046: ...TION AND NO PULSE FEATURE 1 Faulty low speed request circuit 1 Test and repair the open low speed re quest circuit between the multi function switch and the rain sensor control module as required 2 Fa...

Страница 1047: ...Periodic cleaning of the squeegees is suggested to remove any deposits of salt or road film The wiper blades arms and windshield glass should only be cleaned using a sponge or soft cloth and windshiel...

Страница 1048: ...er arm if it has comparatively lower spring tension as evi denced by a lower scale reading 4 Inspect the wiper blades and squeegees for any indications of damage contamination or rubber dete rioration...

Страница 1049: ...ently freeze and plug the nozzle while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns In addition the check valve prevents washer fluid from s...

Страница 1050: ...direct IR light beams at the windshield at an angle When the windshield glass is dry most of this IR light is reflected back to the sensor which uses photocell receivers to measure the intensity of th...

Страница 1051: ...the rear view mirror and the rain sen sor from the rain sensor bracket Refer to 8 ELEC TRICAL WIPERS WASHERS RAIN SENSOR REMOVAL 3 Cut diagonally through the nylon mesh fabric from the rear view mirro...

Страница 1052: ...ered unusable 9 Remove the rain sensor from the center of the bracket INSTALLA TION WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint syst...

Страница 1053: ...art circuit so that the RSCM will operate whenever the ignition switch is in the On or Start positions The RSCM receives ground at all times through its connection to the instrument panel wire harness...

Страница 1054: ...TCH DESCRIPTION The optional washer fluid level switch is a single pole single throw switch that is integral to a unique version of the washer pump motor unit located rear ward facing side of the wash...

Страница 1055: ...et terminal connector that is secured under a ground screw located near the right headlamp in the engine compartment The switch is connected in series between ground and the washer fluid switch sense...

Страница 1056: ...g the under side of the wiper arms to the two washer nozzles Washer hose is available for service only as roll stock which must then be cut to length The molded plastic washer hose fittings cannot be...

Страница 1057: ...ator hole on the wiper arm WASHER PUMP MOTOR DESCRIPTION The washer pump motor unit is located in a dedi cated hole on the top of the sump area near the back of the windshield washer reservoir on the...

Страница 1058: ...vent hose from the barbed vent nipple near the top of the washer pump motor unit 4 Using hand pressure firmly grasp and pull the washer pump out of the rubber grommet seal in the reservoir Care must...

Страница 1059: ...grommet seal for the washer pump motor unit and the filler cap are each available for service replacement OPERA TION The washer fluid reservoir provides a secure on vehicle storage location for a larg...

Страница 1060: ...eservoir into the grommet in the dash panel 4 Position the washer reservoir mounting hole over the stud nut on the right inner fender Fig 21 5 Install and tighten the nut and washer that secures the t...

Страница 1061: ...l hook Concealed within the stamped steel channel one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end while the other end of the spring is hooked through th...

Страница 1062: ...er pivot shaft 4 If necessary use a suitable battery terminal puller to disengage the wiper arm from the wiper pivot shaft Fig 25 5 Remove the wiper arm pivot end from the wiper pivot shaft INSTALLA T...

Страница 1063: ...multi function switch to the Off position then check for the correct wiper arm position and readjust as required 5 Engage the pivot cover with the wiper arm hinge pin then push the pivot end of the c...

Страница 1064: ...blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring loaded wiper arm along the length of the element The com bination of the w...

Страница 1065: ...the left driver side of the windshield 1 Lift the wiper arm off of the windshield glass until the wiper arm hinge is in its over center posi tion 2 Position the wiper blade near the hook forma tion o...

Страница 1066: ...Crank Arm The wiper motor crank arm is a stamped steel unit with a round hole on the driven end that is secured to the wiper motor output shaft with a nut and a long ball stud secured to the drive en...

Страница 1067: ...from the wiper pivots Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARM REMOVAL 3 Remove the five nuts that secure the ventila tion housing to the dash panel and the underside of the cowl top panel Fig 2...

Страница 1068: ...s on the top of the engine 5 Disconnect the wiper motor pigtail wire connec tor from the vehicle wire harness connector 6 Remove the nut and washer that secures each wiper pivot housing to the outside...

Страница 1069: ...ehicle wire harness connector 6 Reinstall the ventilation housing onto the dash panel and the underside of the cowl top panel Fig 29 7 Reinstall the wiper arms onto the wiper pivots Refer to 8 ELECTRI...

Страница 1070: ...per motor transmission Two input contacts alternately close the wiper park switch sense output circuit contact to ground or to battery current depending upon the position of the wipers on the glass Th...

Страница 1071: ...N m 105 in lbs 3 If this wiper motor is being reinstalled position the motor crank arm on the wiper motor output shaft so that the index marks made during the removal procedure are aligned If this is...

Страница 1072: ...c field draws the movable relay contact point away from the fixed normally closed contact point and holds it against the fixed normally open contact point When the relay coil is de energized spring pr...

Страница 1073: ...sing the latches and pulling it straight down from the receptacle on the bottom of the fuse block INSTALLA TION WARNING To avoid personal injury or death on vehicles equipped with airbags disable the...

Страница 1074: ......

Страница 1075: ...8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER 8W 41 1 AIR CONDITIONING HEA TER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 CENTRAL TIMER MODULE 8W 45 1 AUDIO SYSTEM 8W 47 1 REAR W...

Страница 1076: ......

Страница 1077: ...s it is important to understand all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of t...

Страница 1078: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMA TION VA...

Страница 1079: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 VA 8W 01 WIRING DIAGRAM INFORMA TION 8W 01 3...

Страница 1080: ...Fig 3 Wiring Diagram Symbols 8W 01 4 8W 01 WIRING DIAGRAM INFORMA TION VA...

Страница 1081: ...0 show the entire splice and provide references to other sections the splices serves Section 8W 70 only contains splice dia grams that are not shown in their entirety some where else in the wiring dia...

Страница 1082: ...CT WITH HOT PARTS SUCH AS THE RADIA TOR EXHAUST MANIFOLD S TAIL PIPE CATA LYTIC CONVERTER AND MUFFLER WARNING DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRESENT IN AND AROUND THE B...

Страница 1083: ...blem area 6 Verify the proper operation For this step check for proper operation of all items on the repaired circuit Refer to the wiring diagrams STANDARD PROCEDURE ELECTROSTA TIC DISCHARGE ESD SENSI...

Страница 1084: ...ring diagrams and disconnect or isolate all items on the suspected fused circuit 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ignition switch or re connecting the battery 4 St...

Страница 1085: ...st all affected systems DIODE REMOVAL 1 Disconnect the battery 2 Locate the diode in the harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current fl...

Страница 1086: ...tant that the cor rect gage be used as shown in the wiring diagrams 1 Remove one half 1 2 inch of insulation from each wire that needs to be spliced 2 Place a piece of adhesive lined heat shrink tub i...

Страница 1087: ...abin Heater Module 8W 42 Clockspring 8W 41 43 Controller Antilock Brake 8W 35 Courtesy Lamps 8W 44 Crankcase Heater 8W 30 Crankshaft Position Sensor 8W 30 Component Page Cylinder Lock Switch Driver 8W...

Страница 1088: ...Fuses 8W 42 Roof A C Blower Stage Relays 8W 42 Roof A C Blowers 8W 42 Roof A C Compressor Fuse 8W 42 Component Page Roof A C Control Module 8W 42 Roof A C Fan Fuse 8W 42 Roof A C Switch 8W 42 Roof A...

Страница 1089: ...W 10 7 12 30 Fuse 21 8W 10 12 13 30 Component Page Fuse Block No 1 8W 10 3 11 12 13 14 15 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 Fuse Block No 2 8W 10 10 17 25 26 Fused Ignition Switch Run St...

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Страница 1123: ...eater Timer Auxiliary 8W 11 20 High Idle Switch 8W 11 27 33 Component Page Instrument Cluster 8W 11 18 25 Instrument Panel Socket 8W 11 25 Interior Light Switch 8W 11 22 27 Interior Light Switch Drive...

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Страница 1163: ...No 4 8W 15 6 Interior Lamp No 5 8W 15 6 Interior Lamp Left 8W 15 6 Interior Lamp Middle Front 8W 15 5 6 Interior Lamp Middle Rear 8W 15 5 6 Interior Lamp Rear No 2 8W 15 5 Interior Lamp Right 8W 15 5...

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Страница 1195: ...3 6 Data Link Connector 8W 18 2 3 4 5 Engine Control Module 8W 18 5 6 Fuse 5 8W 18 2 Fuse 6 8W 18 3 Component Page Fuse Block No 1 8W 18 2 Fuse Block No 2 8W 18 3 G200 8W 18 5 Instrument Cluster 8W 18...

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Страница 1201: ...8W 20 2 5 Fuse 6 8W 20 2 5 Fuse 7 8W 20 4 Fuse 9 8W 20 3 Fuse 19 8W 20 3 Component Page Fuse Block No 1 8W 20 4 5 6 Fuse Block No 2 8W 20 3 Fuse Block No 3 8W 20 3 G200 8W 20 2 G202 8W 20 3 4 Generato...

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Страница 1207: ...SYSTEM Component Page Battery 8W 21 2 Engine Control Module 8W 21 2 Fuel Pump Relay 8W 21 2 Component Page Fuse Block No 1 8W 21 2 Starter Motor 8W 21 2 Starter Motor Relay 8W 21 2 VA 8W 21 STARTING...

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Страница 1209: ...l Pump Relay 8W 30 18 Fuel Quantity Control Valve 8W 30 7 Fuel Shutdown Solenoid 8W 30 7 Fuel Temperature Sensor 8W 30 5 Fuse 5 8W 30 13 19 Fuse 7 8W 30 20 Fuse 12 8W 30 2 Component Page Fuse 16 8W 30...

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Страница 1235: ...1 7 Fuse 12 8W 31 8 Fuse 16 8W 31 3 Fuse 17 8W 31 3 Fuse Block No 1 8W 31 3 7 9 Fuse Block No 2 8W 31 2 7 Component Page Fuse Block No 3 8W 31 8 G100 8W 31 8 G202 8W 31 2 7 G203 8W 31 8 9 Locker Switc...

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Страница 1245: ...ge Brake Lamp Switch 8W 33 2 Controller Antilock Brake 8W 33 2 Engine Control Module 8W 33 3 Fuse 5 8W 33 2 Component Page Fuse Block No 1 8W 33 2 Shifter Assembly 8W 33 2 Speed Control Switch 8W 33 3...

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Страница 1249: ...3 10 Fuse 6 8W 35 5 Fuse 7 8W 35 5 Fuse 9 8W 35 5 Fuse Block No 1 8W 35 3 10 Fuse Relay Block 8W 35 5 G100 8W 35 4 Component Page G200 8W 35 4 7 8 G202 8W 35 7 G203 8W 35 2 G300 8W 35 8 G302 8W 35 4...

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Страница 1259: ...0 14 Interior Lamp Right 8W 39 14 Component Page Intrusion Sensor No 1 8W 39 2 3 Intrusion Sensor No 2 8W 39 2 3 Intrusion Sensor No 3 8W 39 2 3 Optional Equipment Relay 8W 39 13 Panic Alarm Switch 8W...

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Страница 1273: ...Door J amb Switch Passenger 8W 40 6 Engine Coolant Level Switch 8W 40 7 Fuel Level Sensor 8W 40 3 Fuse 1 8W 40 2 Fuse 6 8W 40 3 Fuse 18 8W 40 2 Component Page Fuse Block No 1 8W 40 2 Fuse Block No 2 8...

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Страница 1281: ...8W 41 2 Fuse 7 8W 41 3 Fuse 8 8W 41 2 Fuse Block No 1 8W 41 2 3 Fuse Block No 2 8W 41 2 Fuse Block No 3 8W 41 3 Component Page G200 8W 41 3 G202 8W 41 3 G203 8W 41 2 Horn 8W 41 3 Horn Relay 8W 41 3 Ho...

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Страница 1285: ...23 Fuse Block No 1 8W 42 2 6 7 9 18 Fuse Block No 2 8W 42 3 Fuse Block No 3 8W 42 8 11 14 15 20 22 Component Page Fuse Relay Block 8W 42 2 12 G100 8W 42 11 G102 8W 42 2 G200 8W 42 3 5 9 G202 8W 42 2 8...

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Страница 1311: ...imer Module 8W 43 2 Clockspring 8W 43 3 Data Link Connector 8W 43 2 Engine Control Module 8W 43 2 Fuse 18 8W 43 2 Component Page Fuse Block No 1 8W 43 2 G201 8W 43 2 G202 8W 43 2 Instrument Cluster 8W...

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Страница 1315: ...44 7 8 10 G202 8W 44 5 G203 8W 44 2 11 Interior Lamp No 1 8W 44 6 Component Page Interior Lamp No 2 8W 44 6 Interior Lamp No 3 8W 44 6 Interior Lamp No 4 8W 44 6 Interior Lamp No 5 8W 44 6 Interior La...

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Страница 1327: ...Door Lock Motor Ajar Switch Assembly Passenger 8W 45 7 Door Lock Motor Ajar Switch Assembly Rear 8W 45 4 6 Door Lock Motor Ajar Switch Assembly Right Sliding 8W 45 5 6 Component Page Fuse 5 8W 45 3 Fu...

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Страница 1335: ...47 2 Fuse 15 8W 47 2 Fuse Block No 1 8W 47 2 G203 8W 47 3 Instrument Cluster 8W 47 2 Component Page Radio 8W 47 2 3 4 5 Radio Antenna 8W 47 3 Radio Cellular Antenna 8W 47 3 Speaker Left Front Door As...

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Страница 1341: ...W 48 3 Fuse Block No 2 8W 48 4 Fuse Relay Block 8W 48 2 G202 8W 48 4 Component Page G203 8W 48 3 G300 8W 48 4 Rear Window Defogger Relay 8W 48 2 3 4 Security System Module 8W 48 4 Window Defogger Modu...

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Страница 1345: ...14 15 G203 8W 50 9 Component Page Hazard Warning Switch 8W 50 2 Headlamp Adjust Switch 8W 50 7 8 9 Headlamp Assembly Left 8W 50 3 6 7 9 10 11 13 14 Headlamp Assembly Right 8W 50 3 6 8 9 10 11 13 15 H...

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Страница 1361: ...3 6 7 8 9 Headlamp Switch 8W 51 4 License Plate Lamp No 1 8W 51 3 Component Page License Plate Lamp No 2 8W 51 3 Marker Lamp Connector 8W 51 2 Marker Lamp Left Rear 8W 51 3 Marker Lamp Right Rear 8W...

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Страница 1371: ...ecurity System Module 8W 52 4 6 Component Page Sentry Key Remote Entry Module 8W 52 3 4 Tail Lamp Assembly Left 8W 52 4 Tail Lamp Assembly Right 8W 52 6 Trailer Tow Control Module 8W 52 4 6 Turn Signa...

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Страница 1377: ...6 Multi Function Switch 8W 53 2 3 Rain Sensor 8W 53 6 Component Page Rain Sensor Control Module 8W 53 2 3 4 5 6 Washer On Off Switch 8W 53 3 Washer Pump Motor Front 8W 53 3 5 Wiper Motor Front 8W 53 2...

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Страница 1383: ...8W 54 3 G202 8W 54 2 G300 8W 54 3 Hazard Warning Switch 8W 54 2 Component Page Lamp Relay Right 8W 54 3 Multi Function Switch 8W 54 2 Shifter Assembly 8W 54 3 Trailer Tow Connector 8W 54 3 Trailer Tow...

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Страница 1387: ...55 2 Fuse 13 8W 55 2 Fuse 15 8W 55 4 Fuse Block No 1 8W 55 4 Fuse Block No 3 8W 55 2 Component Page G203 8W 55 2 Microphone Connector 8W 55 2 Optional Equipment Relay 8W 55 2 Radio 8W 55 2 3 4 Radio C...

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Страница 1391: ...0 2 3 G203 8W 60 2 3 Optional Equipment Relay 8W 60 2 3 Component Page Power Window Motor Driver 8W 60 2 4 Power Window Motor Passenger 8W 60 4 Power Window Switch Driver 8W 60 2 4 Power Window Switch...

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Страница 1395: ...g 8W 61 8 Door Lock Motor Ajar Switch Assembly Driver 8W 61 4 Door Lock Motor Ajar Switch Assembly Left Sliding 8W 61 6 Door Lock Motor Ajar Switch Assembly Passenger 8W 61 5 Component Page Door Lock...

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Страница 1403: ...e 8 8W 62 2 Fuse Block No 2 8W 62 2 G203 8W 62 2 3 Optional Equipment Relay 8W 62 2 Component Page Power Mirror Motor Driver 8W 62 2 3 4 Power Mirror Motor Passenger 8W 62 2 4 Power Mirror Switch 8W 6...

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Страница 1407: ...3 Fuse Block No 3 8W 63 3 G202 8W 63 4 G203 8W 63 2 3 Component Page Heated Seat Module Driver 8W 63 4 Heated Seat Module Passenger 8W 63 4 Heated Seat Switch Driver 8W 63 2 3 4 Heated Seat Switch Pa...

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Страница 1411: ...27 S254 8W 44 6 S255 8W 10 16 S256 8W 11 16 S257 8W 18 5 S258 8W 31 7 S259 8W 18 6 S260 8W 18 6 S261 8W 11 18 Component Page S262 8W 10 29 S300 8W 11 32 S301 8W 11 32 S302 8W 11 32 S303 8W 15 23 S304...

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Страница 1413: ...ure Sensor 8W 80 11 Brake Wear Sensor Left Front 8W 80 12 Brake Wear Sensor Left Rear 8W 80 12 Brake Wear Sensor Right Front 8W 80 12 Brake Wear Sensor Right Rear 8W 80 12 C100 8W 80 12 C100 8W 80 13...

Страница 1414: ...le C4 Except OBD 8W 80 43 Component Page Engine Control Module C5 Except OBD 8W 80 44 Engine Coolant Level Switch 8W 80 44 Engine Coolant Temperature Sensor 8W 80 44 Engine Oil Sensor 8W 80 44 Evapora...

Страница 1415: ...ver Switch Assembly 8W 80 71 Roof A C Control Module 8W 80 72 Roof A C Switch 8W 80 72 Component Page Roof A C Temperature Setting Control 8W 80 72 Roof Fan Motor 8W 80 73 Roof Fan Switch 8W 80 73 Roo...

Страница 1416: ...ACCEL PEDAL POSITION SENSOR GROUND NO 1 3 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 4 18BR GY ACCEL PEDAL POSITION SENSOR GROUND NO 2 5 18GY DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 2 ACCELERAT...

Страница 1417: ...AV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 3 16BK BL DG FUSED IGNITION SWITCH OUTPUT 4 16VT YL ADDITIONAL HEAT EXCHANGER SWITCH CAV 4 TO ADDITIONAL HEAT EXCHANGER CAV D 5 16BR GROUND 7 16VT BL ADDIT...

Страница 1418: ...D K ACM 10 20DG DRIVER AIRBAG SQUIB 1 LINE 2 11 20VT DRIVER AIRBAG SQUIB 1 LINE 1 12 13 20BL DG PASSENGER AIRBAG SQUIB 1 LINE 2 14 20BR DG PASSENGER AIRBAG SQUIB 1 LINE 1 15 16 17 18 19 20 20DG ENHANC...

Страница 1419: ...ATER BOOSTER MODE 5 18BR VT WATER CYCLE VALVE CONTROL 6 20RD BL 5 VOLT SUPPLY 7 18BK YL K IC ATC HBM CHM 8 20BL VT D RELAY CONTROL 8 16RD YL WT FUSED D RELAY OUTPUT 9 16GY DG RD LAMP DRIVER 10 16BL CA...

Страница 1420: ...XILIARY HEATER CONTROL CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 16RD YL FUSED B 4 5 6 7 16YL CABIN HEATER CONTROL 8 9 10 16BR GROUND BLOWER MOTOR RESISTOR BLOCK CAV CIRCUIT FUNCTION 1 12YL BK...

Страница 1421: ...OTOR FRONT BLACK CAV CIRCUIT FUNCTION 1 12RD BL BLOWER MOTOR 2 12BK GROUND BODY PLUG CONNECTOR CAV CIRCUIT FUNCTION 1 14BL YL D RELAY NO 2 OUTPUT 2 14RD FUSED B 3 14BK YL FUSED IGNITION SWITCH RUN STA...

Страница 1422: ...FUNCTION 1 16YL BK FUSED ENGINE CONTROL RELAY OUTPUT 2 16YL WT GROUND 3 4 16YL DG BOOST PRESSURE SERVOMOTOR CONTROL 5 BOOST PRESSURE SOLENOID BLACK CAV CIRCUIT FUNCTION 1 20WT BOOST PRESSURE SOLENOID...

Страница 1423: ...P CAV CIRCUIT FUNCTION 1 20WT BRAKE SWITCH OUTPUT 2 16RD BK FUSED IGNITION SWITCH OUTPUT RUN START 3 20BK BL RD BRAKE LAMP SWITCH 4 BRAKE LAMP SWITCH C2 EXCEPT ESP BLACK CAV CIRCUIT FUNCTION 1 16BK BL...

Страница 1424: ...WT BRAKE WEAR SENSOR SIGNAL BRAKE WEAR SENSOR RIGHT FRONT CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BR WT BRAKE WEAR SENSOR SIGNAL BRAKE WEAR SENSOR RIGHT REAR CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16BR W...

Страница 1425: ...6 16BK 7 16BK BL 8 14BK VT 9 10 C101 YELLOW ENGINE SIDE CAV CIRCUIT 1 16WT BL 2 14BK YL 3 16BL DG 4 16BK RD C101 YELLOW MAIN BODY SIDE CAV CIRCUIT 1 20BL 2 12BK YL 3 16BL DG 4 16BK RD C102 EXCEPT OBD...

Страница 1426: ...MAIN BODY CAV CIRCUIT 1 20BL 2 12BK YL 3 4 5 6 16YL RD C200 BLACK DASH SIDE CAV CIRCUIT 1 16GY 2 16GY DG 3 16BK YL 4 16DG BL WT 5 16YL BK 6 16BL RD 7 16BK RD 8 16WT BK 9 16WT DG 10 16WT YL 11 16WT RD...

Страница 1427: ...6WT YL 11 16WT RD 12 16BK RD 13 18VT YL 14 16BR BK 15 16YL 16 16BR WT 17 16GY RD 18 16BK YL DG 19 16BK YL 20 21 22 C201 DASH SIDE CAV CIRCUIT 1 2 16GY DG RD 3 16RD BL 4 20BL VT 4 16RD YL WT 5 16VT WT...

Страница 1428: ...0BL VT 5 16VT WT 6 20BL RD WT 7 16BK RD 8 16RD YL 9 16BK RD 10 18BK BL 11 16YL 12 13 16RD 14 15 18RD BK 16 17 18 19 20 21 22 C202 DASH SIDE CAV CIRCUIT 1 16WT RD 2 16WT BL RD 3 20BK BL RD 4 20BL DG 5...

Страница 1429: ...L DG 5 6 18BK DG 7 20DG WT 8 20DG 9 10 11 20YL 12 C203 DASH SIDE CAV CIRCUIT 1 18GY YL 2 18GY BR 3 18GY WT 4 5 6 7 8 9 10 18VT DG 11 16RD 12 C203 BLACK MAIN BODY SIDE CAV CIRCUIT 1 18GY YL 2 18GY BR 3...

Страница 1430: ...11 20BR RD 12 20RD BL 13 16RD BK 14 14BK VT 15 16RD C204 GRAY MAIN BODY SIDE CAV CIRCUIT 1 18BK RD 2 18BK YL 3 20DG WT 4 20DG 5 18DG RD 6 18BR VT 7 16BL 8 16BL YL 9 16BL DG 10 18BR BL 11 20BR RD 12 20...

Страница 1431: ...VT BK 7 16VT BR 8 16VT 10 16BK RD 11 18BR WT 15 16BK BL WT 18 16VT YL 19 16VT BL 20 18RD BK WT 21 18BK BL C206 MAIN BODY SIDE CAV CIRCUIT 1 16BK BL WT 2 14BK VT 3 16VT DG 4 16VT RD 5 16VT YL 6 16VT BK...

Страница 1432: ...YL C207 MAIN BODY SIDE CAV CIRCUIT 11 16DG 12 16YL 17 16RD YL C208 CABIN SIDE CAV CIRCUIT 3 16WT 4 16BK C208 DASH SIDE CAV CIRCUIT 3 16WT 4 16BK C209 CABIN SIDE CAV CIRCUIT 1 16BR BL 2 16WT BL 3 16BR...

Страница 1433: ...SIDE CAV CIRCUIT 1 14BR 2 16BK YL 3 16BK YL DG 4 16BK WT 5 16BL WT 6 C210 BLACK MAIN BODY SIDE CAV CIRCUIT 1 14BR 2 16BK YL 3 16BK YL DG 4 16BK WT 5 16BL WT 6 C211 POWER MIRROR SWITCH SIDE CAV CIRCUIT...

Страница 1434: ...DG 5 18DG 6 18WT GY C214 LT BLUE CABIN SIDE CAV CIRCUIT 1 16YL 2 16VT 3 16BK 4 16BR 5 6 C214 LT BLUE DASH SIDE CAV CIRCUIT 1 16YL 2 16VT 3 16BK 4 16BR 5 6 C215 BLACK CABIN SIDE CAV CIRCUIT 1 16RD YL 2...

Страница 1435: ...BR WT 6 14BR C216 BLACK CABIN SIDE CAV CIRCUIT 1 12RD 2 C216 BLACK MAIN BODY SIDE CAV CIRCUIT 1 12RD 2 C217 CABIN SIDE CAV CIRCUIT 1 16RD YL 2 16YL 3 16DG 4 16YL C217 MAIN BODY SIDE CAV CIRCUIT 1 16RD...

Страница 1436: ...6BR WT 2 16BR YL 3 16RD DG 4 16DG YL 5 20DG BK 6 20GY BK 7 20DG WT BL C219 MAIN BODY SIDE CAV CIRCUIT 5 16BK RD 6 16BL RD 7 16YL WT 8 16DG BK 9 16BK RD 10 16BL RD 11 16YL RD 12 16DG YL C219 BLACK CABI...

Страница 1437: ...AV CIRCUIT 1 16RD YL 2 16BR 3 16GY DG RD C221 MAIN BODY SIDE CAV CIRCUIT 1 16BL WT 2 16BK YL DG 3 16BK WT C221 PASSENGER DOOR SIDE CAV CIRCUIT 1 16BL WT 2 16BK YL DG 3 16BK WT C224 BLOWER MOTOR SOLENO...

Страница 1438: ...OLENOID SIDE CAV CIRCUIT 1 12RD 2 12RD BL 3 16RD C225 DASH SIDE CAV CIRCUIT 1 12RD BL 2 12BL 3 16RD C226 CABIN SIDE CAV CIRCUIT 1 16GY 2 3 16RD DG 4 16RD BL 5 16BK 6 16BR C300 BODY SIDE CAV CIRCUIT 1...

Страница 1439: ...RCUIT 1 20DG 2 20BR 3 20BK DG 4 16RD YL C301 BODY SIDE CAV CIRCUIT 1 20RD 2 20YL 3 20WT 4 5 6 7 8 C301 CABIN SIDE CAV CIRCUIT 1 20RD 2 20YL 3 20WT 4 5 6 7 8 C306 ROOF SIDE CAV CIRCUIT 2 14BR VA 8W 80...

Страница 1440: ...L YL REST SYSTEM HEATER BOOSTER MODE CABIN HEATER MODULE CHM CAV CIRCUIT FUNCTION 1 14RD FUSED B 2 14BR GROUND 3 16BL YL F AN STAGE 1 RELAY HIGH SIDE CONTROL 4 16DG DOSING PUMP CONTROL 5 16BL RD K IC...

Страница 1441: ...K DRIVER DOOR UNLOCK SENSE 2 16BL RD DRIVER DOOR LOCK DRIVER 3 16BK RD DRIVER DOOR UNLOCK DRIVER 4 16YL BK DRIVER DOOR LOCK SENSE 5 16DG BL WT PASSENGER FRONT DOOR UNLOCK SENSE 6 16YL BL PASSENGER FRO...

Страница 1442: ...OCK SENSE 11 16YL WT LEFT SLIDING DOOR LOCK SENSE 12 16YL BK REAR DOOR LOCK SENSE 13 16YL RD RIGHT SLIDING DOOR LOCK SENSE 14 16DG YL RIGHT SLIDING DOOR UNLOCK SENSE 15 16 17 16BK RD PASSENGER DOORS U...

Страница 1443: ...P DIODE CAV CIRCUIT FUNCTION 3 18DG RD CIRCULATION PUMP RELAY OUTPUT 4 18DG BK CABIN HEATER MODULE CIRCULATION PUMP RELAY OUTPUT 4 18BK EXCEPT PROGRAM TIMER FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CLOCK...

Страница 1444: ...EED SENSOR 17 18 19 20 20WT BRAKE SWITCH OUTPUT 21 20BR GROUND 22 23 18BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 24 20DG WT CAN C BUS 25 20BR SENSOR GROUND 26 20WT GY BRAKE PRESSURE SENSOR SIGNAL 27...

Страница 1445: ...NG DOOR CAV CIRCUIT FUNCTION 1 16RD YL FUSED B 2 16BR WT DOOR AJAR SWITCH SENSE COURTESY LAMP PASSENGER DOOR CAV CIRCUIT FUNCTION 1 16RD YL FUSED B 2 16BR WT FRONT COURTESY LAMPS CONTROL COURTESY LAMP...

Страница 1446: ...ANKSHAFT POSITION SENSOR SIGNAL NO 1 2 20DG OBD CRANKSHAFT POSITION SENSOR SIGNAL NO 2 CTEL ANTENNA CONNECTOR CAV CIRCUIT FUNCTION 1 16BK CELLULAR ANTENNA W SHIELD 2 SHIELD CTEL CONNECTOR CAV CIRCUIT...

Страница 1447: ...YL K ECM 8 20BK BL DG FUSED IGNITION SWITCH OUTPUT RUN START 9 20BL BK K ABS SHIFTER ASSEMBLY 10 11 20BL K TCM RADIO 12 20GY DG RD K CTM SSM 13 20BK RD K ACM 14 15 20WT GY K IC ATC HBM CHM 16 20RD YL...

Страница 1448: ...R AJAR SWITCH ASSEMBLY LEFT SLIDING C1 CAV CIRCUIT FUNCTION 1 16BK RD PASSENGER DOORS UNLOCK DRIVER 2 16BL RD PASSENGER DOORS LOCK DRIVER DOOR LOCK MOTOR AJAR SWITCH ASSEMBLY LEFT SLIDING C2 CAV CIRCU...

Страница 1449: ...CIRCUIT FUNCTION 3 16YL BK CARGO VAN REAR DOOR LOCK SENSE 4 16DG RD CARGO VAN REAR DOOR UNLOCK SENSE 4 16YL BK PASSENGER VAN REAR DOOR LOCK SENSE 5 16DG RD PASSENGER VAN REAR DOOR UNLOCK SENSE DOOR L...

Страница 1450: ...GY MODULATION PRESSURE SOLENOID CONTROL 3 20BL GY N2 INPUT SPEED SENSOR 4 20GY BL TEMPERATURE SENSOR P N SWITCH 5 6 16BK SOLENOID SUPPLY VOLTAGE 7 20BK BL SENSOR SUPPLY VOLTAGE 8 16WT BL 2 3 SOLENOID...

Страница 1451: ...20YL GY CAMSHAFT POSITION SENSOR SIGNAL 39 20GY O2 1 1 SENSOR CELL SIGNAL 40 20GY WT O2 1 1 VIRTUAL GROUND 49 16BK VT FUEL INJECTOR NO 4 LOW SIDE CONTROL 50 16BK DG FUEL INJECTOR NO 3 LOW SIDE CONTRO...

Страница 1452: ...SENSOR GROUND 10 11 20DG WT CAN C BUS 12 20DG CAN C BUS 13 18BK FUSED IGNITION SWITCH OUTPUT RUN START 14 18DG ACCEL SET SIGNAL 15 16 18YL DECEL SET SIGNAL 17 20DG ENHANCED ACCIDENT REPORT DRIVER 18 1...

Страница 1453: ...NGINE RPM 19 18BK FUSED IGNITION SWITCH OUTPUT RUN START 24 18BL RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY 25 18BL DG ACCEL PEDAL POSITION SENSOR SIGNAL NO 1 26 18BR BL ACCEL PEDAL POSITION SENSOR...

Страница 1454: ...PRESSURE SENSOR 5 VOLT SUPPLY 18 20YL DG MASS AIR FLOW SENSOR SIGNAL 19 20BR BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY 20 18VT IGNITION SWITCH OUTPUT START 21 22 18BR WT BOOST PRESSURE SENSOR GROUND 23 18...

Страница 1455: ...L SENSOR SIGNAL 16 17 20BR BK SENSOR GROUND 18 20RD YL ENGINE OIL SENSOR 5 VOLT SUPPLY 19 20 21 20BK WT FUEL PRESSURE SOLENOID CONTROL 22 18RD BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY 23 24 25 26 20DG...

Страница 1456: ...L FUEL INJECTOR NO 1 CONTROL ENGINE COOLANT LEVEL SWITCH BLACK CAV CIRCUIT FUNCTION 1 20DG WT BL ENGINE COOLANT LEVEL SWITCH SIGNAL 2 16BR GROUND ENGINE COOLANT TEMPERATURE SENSOR BLACK CAV CIRCUIT FU...

Страница 1457: ...V CIRCUIT FUNCTION 1 14BK BL EXCEPT OBD FUEL INJECTOR NO 1 CONTROL 1 16BK RD OBD FUEL INJECTOR NO 1 LOW SIDE CONTROL 2 14BK EXCEPT OBD COMMON INJECTOR DRIVER NO 1 2 16BL OBD FUEL INJECTOR NO 1 HIGH SI...

Страница 1458: ...6BK VT OBD FUEL INJECTOR NO 4 LOW SIDE CONTROL 2 14BK EXCEPT OBD COMMON INJECTOR DRIVER NO 1 2 16BL WT OBD FUEL INJECTOR NO 4 HIGH SIDE CONTROL FUEL INJECTOR NO 5 BLACK CAV CIRCUIT FUNCTION 1 14BK DG...

Страница 1459: ...L PRESSURE SOLENOID 12 VOLT SUPPLY FUEL PUMP OBD CAV CIRCUIT FUNCTION 1 14BK FUEL PUMP RELAY OUTPUT 2 14BR GROUND FUEL PUMP RELAY OBD CAV CIRCUIT FUNCTION 30 14RD BK FUSED B 85 18BR RD FUEL PUMP RELAY...

Страница 1460: ...TPUT 3 INTERNAL HIGH BEAM SWITCH OUTPUT 4 16RD BL FUSED RIGHT LAMP RELAY OUTPUT 5 INTERNAL HIGH BEAM SELECT 6 INTERNAL FUSED LEFT RELAY OUTPUT 8 INTERNAL LAMP DRIVER 9 INTERNAL FUSED IGNITION SWITCH O...

Страница 1461: ...BK YL FUSED IGNITION SWITCH OUTPUT RUN START 8 16BK YL WT FOG LAMP RELAY SIGNAL 9 10 16WT FUSED HIGH BEAM SWITCH OUTPUT 11 16RD YL FUSED IGNITION SWITCH OUTPUT RUN START 12 16BR BK WIPER MOTOR CONTROL...

Страница 1462: ...LOW PLUG NO 5 SUPPLY VOLTAGE 2 14BK YL GLOW PLUG NO 4 SUPPLY VOLTAGE 3 14BK RD GLOW PLUG NO 3 SUPPLY VOLTAGE 4 14BK VT GLOW PLUG NO 2 SUPPLY VOLTAGE 5 14BK BL GLOW PLUG NO 1 SUPPLY VOLTAGE 6 HEADLAMP...

Страница 1463: ...LAMP ASSEMBLY RIGHT BLACK CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 16YL WT FOG LAMP RELAY OUTPUT 3 16BR GROUND 4 16BR GROUND 5 16VT WT HEADLAMP ADJUST SWITCH OUTPUT 6 16BK DG RIGHT TURN SIGNAL...

Страница 1464: ...LAY OUTPUT 4 16VT RD S366 COMMON CIRCUIT 5 16BR GROUND 6 7 16VT DG HEATED SEAT SWITCH DRIVER LOW OUTPUT 8 16VT YL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 9 10 16BR GROUND HEATED SEAT SWITCH PASSENGER CA...

Страница 1465: ...WT HEATER TIMER 10 16BK BL DG FUSED IGNITION SWITCH OUTPUT 11 16RD FUSED B 12 16BR GROUND HIGH IDLE SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 18BR WT HIGH IDLE ON SIGNAL 4 18BR WT HIGH...

Страница 1466: ...RUMENT CLUSTER C1 CAV CIRCUIT FUNCTION 1 20BR FUEL LEVEL SENSOR SIGNAL RETURN 2 20BR DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN 4 20WT GY K IC ATC HBM CHM 5 20BR BK PARK BRAKE INDICATOR SIGNAL 7 20BK...

Страница 1467: ...L 12 13 20BK WT LEFT TURN SIGNAL 14 20BR YL BRAKE FLUID LEVEL INDICATOR SIGNAL 15 20BL GENERATOR MONITOR SIGNAL 16 20YL AIRBAG WARNING INDICATOR DRIVER 17 18 20BL VT D RELAY NO 1 CONTROL 18 20BL VT D...

Страница 1468: ...LAMP NO 1 CAV CIRCUIT FUNCTION 1 16DG INTERIOR LAMPS DRIVER 2 16BR GROUND INTERIOR LAMP NO 2 CAV CIRCUIT FUNCTION 1 16DG INTERIOR LAMPS DRIVER 2 16BR GROUND INTERIOR LAMP NO 3 CAV CIRCUIT FUNCTION 1 1...

Страница 1469: ...1 16BR GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP MIDDLE FRONT CAV CIRCUIT FUNCTION 1 16BR GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP MIDDLE...

Страница 1470: ...AR SWITCH SENSE 3 INTERIOR LAMP REAR NO 2 BLACK CAV CIRCUIT FUNCTION 1 16BR WT GROUND 2 16RD YL FUSED B 3 16BR WT DOOR AJAR SWITCH SENSE INTERIOR LAMP RIGHT BLACK CAV CIRCUIT FUNCTION 1 16BR GROUND 2...

Страница 1471: ...8 9 16DG INTERIOR LAMPS DRIVER 10 16BR GROUND INTERIOR LIGHT SWITCH DRIVER CAV CIRCUIT FUNCTION 1 2 3 16RD YL FUSED B 4 5 6 7 16YL INTERIOR LIGHT SWITCH OUTPUT 8 9 10 INTERIOR LIGHT SWITCH PASSENGER...

Страница 1472: ...S DRIVER 3 16BR GROUND 4 16YL INTERIOR LIGHT SWITCH OUTPUT INTRUSION SENSOR NO 1 BLACK CAV CIRCUIT FUNCTION 1 20BR GROUND 2 20DG BK INTRUSION SENSOR 1 SIGNAL 3 20DG YL INTRUSION SENSOR INTERF ACE 4 20...

Страница 1473: ...2 18BR EXCEPT OBD SENSOR GROUND 2 18BR OBD GROUND LATERAL ACCELERATION SENSOR CAV CIRCUIT FUNCTION 1 20YL RD SENSOR SIGNAL 2 20YL WT SENSOR SIGNAL 3 20RD BL POWER INPUT 4 20DG YL SENSOR SIGNAL 5 20BK...

Страница 1474: ...16BR BK LOCKER SWITCH NO 2 OUTPUT 2 16BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT LOW FUEL PRESSURE SENSOR BLACK CAV CIRCUIT FUNCTION 1 18GY DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY 2 18GY YL LOW FU...

Страница 1475: ...LAMP NO 1 LEFT FRONT CAV CIRCUIT FUNCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP NO 1 RIGHT FRONT CAV CIRCUIT FUNCTION 1 16GY RD LAMP DRIVER 2 16BR GROUND MARKER LAMP NO 2 LEFT FRONT CAV CIRC...

Страница 1476: ...NCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP LEFT REAR CAV CIRCUIT FUNCTION 1 16GY BK LAMP DRIVER 2 16BR GROUND MARKER LAMP RIGHT CENTER CAV CIRCUIT FUNCTION 1 16GY RD LAMP DRIVER 2 16BR GRO...

Страница 1477: ...EXCEPT OBD MASS AIR FLOW SENSOR SIGNAL MASTER DOOR LOCK SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 16WT DG PASSENGER DOOR AJAR INDICATOR DRIVER 3 16WT YL MASTER DOOR LOCK SWITCH SENSE ALL...

Страница 1478: ...ELAY OUTPUT 5 20DG YL O2 1 1 PUMP CELL CONTROL 6 20GY O2 1 1 SENSOR CELL SIGNAL PANIC ALARM SWITCH BLACK CAV CIRCUIT FUNCTION 1 18GY DG RD LAMP DRIVER 2 3 18BR GROUND 4 5 6 7 18GY WT PANIC SWITCH SENS...

Страница 1479: ...4 18DG PASSENGER MIRROR VERTICAL MOTOR DRIVER 5 18BL DG PASSENGER MIRROR COMMON DRIVER POWER MIRROR SWITCH CAV CIRCUIT FUNCTION 1 18WT GY PASSENGER MIRROR HORIZONTAL MOTOR DRIVER 2 18WT DG DRIVER MIR...

Страница 1480: ...R WINDOW SWITCH MASTER CAV CIRCUIT FUNCTION 1 16BL WT MASTER PASSENGER WINDOW DRIVER DOWN 2 16BK WT MASTER PASSENGER WINDOW DRIVER UP 3 16BR GROUND 4 16BK YL DG FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 5...

Страница 1481: ...TART A8 16BR GROUND B1 16BR GY SPEAKER RIGHT REAR B2 16WT GY SPEAKER RIGHT REAR B3 18BR RD SPEAKER RIGHT FRONT B4 18BK SPEAKER RIGHT FRONT B5 18BR DG SPEAKER LEFT FRONT B6 18BR SPEAKER LEFT FRONT B7 1...

Страница 1482: ...8BK WIPER STAGE 1 INPUT A4 16BK VT RD WASHER PUMP OUTPUT A5 A6 A7 A8 14BK DG FRONT WIPER MOTOR STAGE 2 OUTPUT B1 B2 18BK GY RD FRONT WIPER MOTOR STAGE 2 INPUT B3 18WT VT NO FUNCTION DEFINED B4 18BK VT...

Страница 1483: ...CIRCUIT FUNCTION 1 18BR BL SENSOR GROUND 2 20BR RD REFRIGERANT PRESSURE SENSOR FEEDBACK 3 20RD BL 5 VOLT SUPPLY REMOTE KEYLESS ENTRY ANTENNA CAV CIRCUIT FUNCTION 1 20BR RKE ANTENNA 3 GROUND ROLLOVER...

Страница 1484: ...OF A C SWITCH CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 16RD BK FUSED D RELAY NO 1 OUTPUT 4 16VT A C F AN MOTOR CONTROL HIGH SPEED 5 6 7 16YL A C F AN MOTOR CONTROL LOW SPEED 8 16RD BK FUSED D...

Страница 1485: ...NAL EQUIPMENT RELAY OUTPUT 9 10 16BR GROUND ROOF THERMOTRONIC CONTROL MODULE CAV CIRCUIT FUNCTION 1 16DG TEMPERATURE SWITCH SENSE 2 3 16VT ROOF A C F AN RELAY CONTROL 4 16DG ROOF A C TEMPERATURE SETTI...

Страница 1486: ...TENSIONER DRIVER YELLOW CAV CIRCUIT FUNCTION 1 20BL DRIVER SEAT BELT TENSIONER LINE 2 2 20BR YL DRIVER SEAT BELT TENSIONER LINE 1 SEAT BELT TENSIONER PASSENGER YELLOW CAV CIRCUIT FUNCTION 1 20BL PASSE...

Страница 1487: ...PANIC SWITCH SENSE 16 16BR GROUND 17 18GY BR TOWING SENSOR SWITCH SENSE 18 18GY YL INTRUSION SENSOR SWITCH SENSE 19 20 16BK DRIVER CYLINDER UNLOCK SENSE 21 16RD DRIVER CYLINDER LOCK SENSE SECURITY SYS...

Страница 1488: ...YL TURN SIGNAL ANTI THEFT ALARM RELAY LEFT RIGHT CONTROL 11 20BR TRANSPONDER COIL 12 TRANSPONDER COIL SHIFTER ASSEMBLY BLACK CAV CIRCUIT FUNCTION 1 2 20GY DG RD LAMP DRIVER 3 20BL DG K ABS SHIFTER AS...

Страница 1489: ...8BL DG SPEAKER LEFT FRONT CTEL SPEAKER LEFT FRONT DOOR ASSEMBLY C2 CAV CIRCUIT FUNCTION 1 18BR DG SPEAKER LEFT FRONT 2 18BR SPEAKER LEFT FRONT SPEAKER LEFT REAR CAV CIRCUIT FUNCTION 1 16BR BL SPEAKER...

Страница 1490: ...AL 5 18DG ACCEL SET SIGNAL 6 18RD S C SWITCH 12 VOLT SUPPLY STEERING ANGLE SENSOR CAV CIRCUIT FUNCTION 1 20DG WT CAN C BUS 2 3 20DG CAN C BUS 4 5 20BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 6 20BR G...

Страница 1491: ...FUNCTION 1 16GY DG RD LAMP DRIVER 2 3 18BK BL TCS SWITCH ASR SENSE 4 5 6 7 16BK BL DG FUSED IGNITION SWITCH OUTPUT 8 9 10 16BR GROUND TOWING INTRUSION SENSOR ON OFF SWITCH CAV CIRCUIT FUNCTION 1 18GY...

Страница 1492: ...NTROL MODULE C1 EXCEPT RETROFIT BLACK CAV CIRCUIT FUNCTION A B C 16BK RD WT STOP TURN SIGNAL LEFT D 16BK DG GY STOP TURN SIGNAL RIGHT E F 14RD BK ELECTRIC BRAKES TRAILER TOW CONTROL MODULE C1 RETROFIT...

Страница 1493: ...R GROUND TRANSMISSION CONTROL MODULE C2 BLACK CAV CIRCUIT FUNCTION 12 20BL GY N2 INPUT SPEED SENSOR 13 20BK BL SENSOR SUPPLY VOLTAGE 14 16WT 1 2 4 5 SOLENOID CONTROL 15 16YL 3 4 SOLENOID CONTROL 16 16...

Страница 1494: ...L NO 1 RIGHT FRONT BLACK CAV CIRCUIT FUNCTION 1 16BK DG RIGHT TURN SIGNAL 2 16BR GROUND TURN SIGNAL NO 2 LEFT FRONT CAV CIRCUIT FUNCTION 1 16BK WT LEFT TURN SIGNAL 2 16BR GROUND TURN SIGNAL NO 2 RIGHT...

Страница 1495: ...TIMER 7 16WT RD WARM AIR AUXILIARY HEATER CONTROL WARM AIR AUXILIARY HEATER ASSEMBLY C2 CAV CIRCUIT FUNCTION 1 16DG RD METERING PUMP DRIVER 2 16BR GROUND WASHER PUMP MOTOR FRONT CAV CIRCUIT FUNCTION...

Страница 1496: ...OR 2 18BR LEFT FRONT WHEEL SPEED SENSOR WHEEL SPEED SENSOR LEFT REAR CAV CIRCUIT FUNCTION 1 18WT LEFT REAR WHEEL SPEED SENSOR 2 18BR LEFT REAR WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT FRONT CAV CIR...

Страница 1497: ...L 11 12 13 16GY WINDOW DEFOGGER SWITCH REAR OUTPUT 14 15 16GY DG DEFOGGER RELAYS WINDOW DEFOGGER RELAY LEFT REAR CONTROL 15 16GY BL EXCEPT DEFOGGER RE LAYS WINDOW DEFOGGER LEFT REAR OUTPUT 16 16GY DG...

Страница 1498: ...EAR CAV CIRCUIT FUNCTION 1 16GY DEFOGGER RELAYS WINDOW DEFOGGER RELAY RIGHT REAR OUTPUT 1 16GY EXCEPT DEFOGGER RELAYS WINDOW DEFOGGER RIGHT REAR SIGNAL 2 16BR GROUND WIPER MOTOR FRONT BLACK CAV CIRCUI...

Страница 1499: ...l Heat Exchanger BK NS Additional Heat Exchanger Switch BK NS Air Outlet Temperature Sensor BK Engine Compartment Right Rear 11 33 Airbag Control Module YL Under Driver Seat 17 34 36 Airbag Squib Driv...

Страница 1500: ...Wheel 49 Brake Wear Sensor Right Rear On Right Rear Wheel 49 C100 BK Under Driver Seat 36 C101 YL Under Instrument Panel Left 31 C102 Except OBD BK NS C103 BK Lower Left Instrument Panel 29 C200 BK U...

Страница 1501: ...eat 29 Circulation Pump Relay Relay Block Under Driver Seat N S Clockspring C1 Steering Wheel 17 Clockspring C2 YL Steering Wheel 17 31 Contact Plate Left Rear License Plate Rear Of Vehicle On Left N...

Страница 1502: ...oor Lock Motor Ajar Switch Assembly Rear C2 Right Sliding Door 52 Door Lock Motor Ajar Switch Assembly Right Sliding C1 Cargo Door 45 Door Lock Motor Ajar Switch Assembly Right Sliding C2 Cargo Door 4...

Страница 1503: ...o 1 C5 BK Under Fuse Block No 1 31 Fuses Fuse Block No 1 Steering Column 28 Fuses Fuse Block No 2 Under Driver Seat 35 Fuses Fuse Block No 3 Under Driver Seat N S Fuses Fuse Relay Block Under Driver S...

Страница 1504: ...Front 48 Interior Lamp No 5 Headliner Front 48 Interior Lamp Left BK Left Upper Side 42 Interior Lamp Middle Front BK Headliner Front 42 Interior Lamp Middle Rear BK Headliner Middle Rear 42 Interior...

Страница 1505: ...ock Switch BK Center Of Instrument Panel 20 Metering Pump BK Instrument Panel 27 Microphone Connector Instrument Panel N S Multi Function Switch Steering Wheel 24 Optional Equipment Relay Relay Block...

Страница 1506: ...le BK Center Roof A C Unit 40 Seat Belt Switch BK Driver Seat Belt Lock 26 Seat Belt Tensioner Driver YL Driver Seat Back 34 Seat Belt Tensioner Passenger YL Passenger Seat Back 34 36 Security System...

Страница 1507: ...hicle On The Right Side 45 Turn Signal Relay Fuse Block No 1 In Fuse Block No 1 N S Turn Signal Anti Theft Alarm Relay Left Re lay Block BK Under Driver Seat N S Turn Signal Anti Theft Alarm Relay Rig...

Страница 1508: ...nel 5 G304 Front Center Headliner 5 SPLICES SPLICE NUMBER LOCATION FIG S100 Under Drivers Seat 18 S101 Instrument Panel 18 S102 Under Drivers Seat 18 S103 Under Drivers Seat 18 S104 Near Headlamp Asse...

Страница 1509: ...S230 Center Instrument Panel 23 25 S231 Left Plenum 27 S232 Left Plenum 27 S250 Near Turn Signal Anti Theft Alarm Relay Left 18 S251 Near Trailer Tow Control Module 9 S252 Near Trailer Tow Control Mo...

Страница 1510: ...r Map Reading Lamp Switch 21 S326 Top Body Front Center 42 S327 Near Security System Module 18 S328 Near Central Timer Module 18 S329 Near Central Timer Module 18 S330 Near Security System Module 18 S...

Страница 1511: ...FIG S365 Near A C Fan Switch 21 S366 Near Heated Seat Module Driver 18 S375 Under Driver Seat 23 S376 Above pedals 24 S377 Front Center Headliner 24 S378 Left Plenum 27 VA 8W 91 CONNECTOR GROUND SPLI...

Страница 1512: ...Fig 1 ENGINE COMPARTMENT LEFT FRONT 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1513: ...Fig 2 ENGINE COMPARTMENT AND WHEEL SPEED SENSORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 15...

Страница 1514: ...Fig 3 FRONT COMPONENTS 1 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1515: ...Fig 4 FRONT COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 17...

Страница 1516: ...Fig 5 FRONT COMPONENTS 3 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1517: ...Fig 6 FRONT COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 19...

Страница 1518: ...Fig 7 ENGINE COMPARTMENT LEFT 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1519: ...Fig 8 ENGINE COMPARTMENT REAR VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 21...

Страница 1520: ...Fig 9 INTERIOR LAMP SPLICES 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1521: ...Fig 10 ENGINE COMPARTMENT OVERVIEW VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 23...

Страница 1522: ...Fig 11 FUEL AND AIR COMPONENTS 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1523: ...Fig 12 ENGINE AND INJECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 25...

Страница 1524: ...Fig 13 ENGINE SENSORS AND INJECTORS 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1525: ...Fig 14 ENGINE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 27...

Страница 1526: ...Fig 15 GLOW PLUGS AND FRONT ENGINE 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1527: ...Fig 16 TRANSMISSION VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 29...

Страница 1528: ...Fig 17 FRONT CABIN 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1529: ...Fig 18 BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 31...

Страница 1530: ...Fig 19 INSTRUMENT PANEL 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1531: ...Fig 20 CENTER STACK SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 33...

Страница 1532: ...Fig 21 INSTRUMENT PANEL SPLICES 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1533: ...Fig 22 INSTRUMENT PANEL AND SHIFTER VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 35...

Страница 1534: ...Fig 23 INTERIOR COMPONENTS 1 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1535: ...Fig 24 INTERIOR COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 37...

Страница 1536: ...Fig 25 INTERIOR COMPONENTS 3 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1537: ...Fig 26 INTERIOR COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 39...

Страница 1538: ...Fig 27 MIRRORS AND INTERIOR 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1539: ...Fig 28 FUSE BLOCK NO 1 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 41...

Страница 1540: ...Fig 29 DASH INLINE CONNECTORS 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1541: ...Fig 30 AJAR SWITHES LIGHTER ROOF FAN VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 43...

Страница 1542: ...Fig 31 STEERING COLUMN AND PEDALS 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1543: ...Fig 32 STEERING SYSTEM VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 45...

Страница 1544: ...Fig 33 HVAC ASSEMBLY 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1545: ...Fig 34 RESTRAINTS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 47...

Страница 1546: ...Fig 35 FUSE AND RELAY BLOCKS 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1547: ...Fig 36 UNDER DRIVER SEAT VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 49...

Страница 1548: ...Fig 37 INTRUSION SENSORS 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1549: ...Fig 38 ROOF INLINE CONNECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 51...

Страница 1550: ...Fig 39 ROOF A C UNIT 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1551: ...Fig 40 ROOF A C RELAYS AND MODULE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 53...

Страница 1552: ...Fig 41 ROOF A C FUSES 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1553: ...Fig 42 INTERIOR LAMPS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 55...

Страница 1554: ...Fig 43 POWER DOOR LOCKS 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1555: ...Fig 44 WINDOW MOTORS AND SPEAKERS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 57...

Страница 1556: ...Fig 45 DOORS AND TURN SIGNALS 8W 91 58 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1557: ...Fig 46 DOOR LOCK MOTOR AJAR SWITCH VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 59...

Страница 1558: ...Fig 47 UNDERBODY SPLICES 8W 91 60 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1559: ...Fig 48 INTERIOR LAMPS ANTENNA VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 61...

Страница 1560: ...Fig 49 BRAKE SENSORS 8W 91 62 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1561: ...Fig 50 INTERIOR BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 63...

Страница 1562: ...Fig 51 UNDERBODY 8W 91 64 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1563: ...Fig 52 BODY GROUNDS AND AJAR SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 65...

Страница 1564: ...Fig 53 REAR LIGHTING 8W 91 66 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...

Страница 1565: ...ses Cartridge fuses Relays Following are general descriptions and theory of operation for the major components in the power dis tribution system Refer to Wiring for the location of complete circuit di...

Страница 1566: ...ltage supply circuits These circuit breakers can protect the systems from a short circuit or from an overload condition caused by an obstructed or stuck power window regulator or switch The circuit br...

Страница 1567: ...integral to the body wire harness If any internal circuit or the fuse block housing is faulty or damaged the entire fuse block and body wire harness unit must be replaced OPERA TION All of the circuit...

Страница 1568: ...secures the receptacle base to the instrument panel 4 Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the reta...

Страница 1569: ...he fuse block fuse as required 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally...

Страница 1570: ......

Страница 1571: ...TANDARD PROCEDURE CHECKING CAMSHAFT POSITION 28 STANDARD PROCEDURE INSPECTING TAPPET CLEARANCE 30 REMOVAL 30 INSTALLATION 32 CYLINDER HEAD COVER S REMOVAL 33 INSTALLATION 34 VALVE STEM SEALS DESCRIPTI...

Страница 1572: ...INSTALLATION 69 TIMING CHAIN COVER REMOVAL 70 INSTALLATION 71 TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL TENSIONING AND SLIDE RAILS 72 REMOVAL INTERMEDIATE GEAR 73 REMOVAL TIMING CHAIN TENSIONING RAI...

Страница 1573: ...ster and adapter from cylinder head 11 Install glow plugs Refer to 8 ELECTRICAL IGNITION CONTROL GLOW PLUG INSTALLA TION 12 Install engine cover Refer to 9 ENGINE INSTALLATION COMPRESSION SPECIFICATIO...

Страница 1574: ...der Head Gasket AIR LOSS THROUGH AIR INTAKE AREA 1 Sealing Sur faces 1 Remove Cyl inder Head for Further Inspec tion CONDITION POSSIBLE CAUSES CORRECTION 2 Intake Valves and Seats 2 Replace Valves Gui...

Страница 1575: ...LEASE PRESSURE STORE COOL ANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER WEAR PROTECTIVE GLOVES CLOTHES AND EYE WEAR 1 Disconnect the negative battery cable NOTE REPLACE THE AIR CONDITIONING DRIER...

Страница 1576: ...er 17 Remove the change air cooler A C conderser and fan as an assembly 18 Disconnect the charge air hose at the intake manifold Fig 3 19 Remove the radiator assembly 20 Disconnect the high pressure a...

Страница 1577: ...the vehicle 28 Disconnect the front exhaust at the turbo charger Fig 4 29 Disconnect the electrical connector at the transmission Fig 4 TURBOCHARGER INLET 1 CCV BREATHER 5 MAF SENSOR 2 OIL LEVEL INDI...

Страница 1578: ...smission jack 39 Place a wood block between the transmission housing and the front frame cross over 40 Remove the transmission jack 41 Remove the exhaust bracket right side 42 Remove the engine ground...

Страница 1579: ...is opened to the atmo sphere 1 Install the engine lifting fixture special tool 9308 to the engine lifting eyelets 2 Attach the engine hoist 3 Install the engine assembly into the vehicle engine compar...

Страница 1580: ...nnect the fuel lines at the filter assembly Fig 9 25 Connect the power steering hoses 26 Install the radiator charge air cooler and hose s assemblies Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 27...

Страница 1581: ...ming Case Cover 20 15 Bolt Front Cover to Cylin der Head 14 124 12m Bolt Cylinder Head to Crankcase 3 stages torque torque angle torque angle 60 90 90 44 90 90 Crankcase Timing Case Cover End Cover Bo...

Страница 1582: ...ss Fly wheel to Crankshaft 2 stage 1 torque 1 torque angle 45 90 33 90 Turbo Charger Bolt Oil Feed Line to Cyl inder Head 9 22 80 194 Bolt Oil Feed Line to Tur bo Charger 30 22 Bolt Turbo Charger Sup...

Страница 1583: ...to Cylinder Head Cover 11 97 Nut Bolt Crankshaft Posi tion Sensor to Engine Block 8 70 Pre Glow System Cylinder Head to Glow Plug 12 106 Starter Bolt Starter to Crankcase 42 31 Nut Connection of Circu...

Страница 1584: ...10 15 Bolt Thremostat Housing to Cylinder Head 9 80 Coolant Drain Plug to Crankcase 30 22 Engine Suspension Engine Mount Engine Bracket Bolt Engine Bracket to Crankcase 2 stage torque torque angle 20...

Страница 1585: ...0 5 Nut Exhaust Bracket to Threaded Plate of Center Exhaust Pipe 20 177 Support Exhaust Bracket on Transmission 20 177 Refrigerant Compressor Bolt Refrigerant Compres sor to Timing Case Cover 20 177 B...

Страница 1586: ...ine to Rail Injector New Reused 22 25 16 18 5 Nut Pressure Line to High Pressure Pump Rail 22 16 Screw Tensioning Claw to Injector 2 stage 1 torque 1 torque angle 7 90 62 90 Rail Pressure Sensor to Ra...

Страница 1587: ...00 8940 VIBRATION DAMPER RE MOVER N A 8941 SLIDE HAMMER 611 589 00 15 00 8942 OIL JET INSTALLER 611 589 01 14 00 8944 REAR MAIN SEAL IN STALLER N A 9312 1 CHAIN SEPARATOR RIV ETING TOOL 9312 4 THRUST...

Страница 1588: ...8932 CRANKSHAFT LOCK 8936 FRONT CRANKSHAFT SEAL INSTALLER 8938A EXTRACTION CLAW 8940 VIBRATION DAMPER REMOVER 9 18 ENGINE VA...

Страница 1589: ...8941 SLIDE HAMMER 8942 OIL JET INSTALLER 8944 REAR MAIN SEAL INSTALLER 9307 VALVE SERVICE TOOLS VA ENGINE 9 19...

Страница 1590: ...8951 ASSEMBLY LINKS 9285 FUEL LINE WRENCH 9286 GLOW PLUG PLIERS 9295 COMPRESSION HOSE ADAPTOR 9525 TIMING CHAIN GUIDE 9539 FUEL LINE PLIERS 9 20 ENGINE VA...

Страница 1591: ...the negative battery cable 2 Remove the heat shield 3 Remove the air flow sensor Refer to 14 FUEL SYSTEM FUEL INJ ECTION MANIFOLD AIR FLOW MAF SENSOR REMOVAL 4 Disconnect the air intake pressure sens...

Страница 1592: ...ow plugs arranged slant wise The intake and exhaust valves have solid valve stems and conical valve springs The cylinder head is not ser viceable and must be replaced should a repair become necessary...

Страница 1593: ...y cable 2 Position piston of cylinder 1 to ignition TDC 3 Raise and support vehicle 4 Install retaining lock 8932 for crankshaft starter ring gear WARNING RISK OF INJURY TO SKIN AND EYES FROM SCALDING...

Страница 1594: ...engine harness con nected 18 Remove the turbocharger oil supply line at the cylinder head and turbocharger Fig 14 19 Disconnect the turbocharger at the exhaust manifold Fig 14 20 Unbolt the transmiss...

Страница 1595: ...BELT CHAIN TENSIONER PULLEY REMOVAL WARNING NO FIRE OPEN FLAMES OR SMOKING SERVICE VEHICLE IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES RISK OF POISON ING FROM INHALING AND SWALLOWING FUEL RIS...

Страница 1596: ...driver of inlet camshaft sprocket 8 Remove top guide rail INSTALLATION INSTALLA TION CYLINDER HEAD WARNING Refer to 14 FUEL SYSTEM WARN ING NOTE Thoroughly clean all mating surfaces with appropriate s...

Страница 1597: ...housing with tappets to cylinder head Fig 14 14 Install camshafts Refer to 9 ENGINE CYL INDER HEAD CAMSHAFT S INSTALLATION 15 Install top guide rail Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN A...

Страница 1598: ...USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHES 7 Start the engine and inspec...

Страница 1599: ...hole in the left inlet camshaft sprocket Fig 19 NOTE The two markings in the inlet camshaft sprockets must be positioned opposite and mark ings of camshaft and camshaft bearing cap must be aligned If...

Страница 1600: ...s 5 Use a pressing tool and apply pressure to the tappet by hand Fig 20 6 If the tappet drops faster in comparison to the other tappets remove the camshaft and replace the tappet REMOVAL NOTE Tappets...

Страница 1601: ...aring caps 13 Paint mark or scribe each camshaft bearing cap identifying which camshaft and which position 14 Remove the camshaft bearing caps at exhaust camshaft bearing cap 1 3 4 and 6 in sequence 1...

Страница 1602: ...fts at axial bearing Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S STANDARD PROCEDURE NOTE Pay attention to markings on camshaft bear ing caps CAUTION Do not rotate engine counter clockwise 3 Position th...

Страница 1603: ...recesses 15 Clean and install injectors Refer to 14 FUEL SYSTEM FUEL INJ ECTION FUEL INJ EC TOR STANDARD PROCEDURE Refer to 14 FUEL SYSTEM FUEL INJ ECTION FUEL INJ EC TOR INSTALLATION 16 Reconnect neg...

Страница 1604: ...tive battery cable WARNING Refer to 14 FUEL SYSTEM WARN ING WARNING USE EXTREME CAUTION WHEN ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH FAN DO NOT PUT YOUR HANDS NEAR PUL LEYS BELTS OR FAN...

Страница 1605: ...for each cylinder being serviced Failure to do so may result in damage to the vehicle or personal injury 9 Install crankshaft lock special tool 8932 10 Seal injector hole with adaptor 9534 and retain...

Страница 1606: ...ig 27 7 Remove valve stem seals Fig 28 8 Repeat steps 5 through 9 for each valve as nec essary 9 Remove cylinder head from assembly board WARNING Valves springs and retainers must be kept in order of...

Страница 1607: ...G 21 Install engine cover Refer to 9 ENGINE COVER INSTALLATION INSTALLA TION VALVES WARNING Valves must be kept in their original positions in cylinder head Failure to do so will result in engine dama...

Страница 1608: ...de the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system can be refilled and the vehicle placed in service immediately STANDARD PROCEDURE MEASURING CYLIN DER BOR...

Страница 1609: ...fter any bearing damage occurred remove all debris which is present in the main oil gallery connecting rod bores and in the crankshaft and oil galleries Include removal of the inserting steel ball of...

Страница 1610: ...AL REAR REMOVAL 4 Remove pistons Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECTING ROD REMOVAL CAUTION The crankshaft bearing caps are num bered consecutively beginning with the first crank shaft beari...

Страница 1611: ...manual for specifications 8 Fill the cooling system with the proper coolant to the proper level Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 9 Connect the negative battery cable WARNING USE E...

Страница 1612: ...tall the fly wheel and tighten bolts in two stages Fig 33 45N m 33 lbs ft then 90 5 Install the oil pan drain plug and tighten to 25N m 18 lbs ft 6 Lower the vehicle 7 Fill the crankcase with the corr...

Страница 1613: ...ation damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 3 Remove the retaining lock for the crankshaft ring gear 4 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE...

Страница 1614: ...CAUTION WHEN THE ENGINE IS IN OPERATION DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHES 5 Start the vehicle INSTALLA TION CRANK...

Страница 1615: ...ction pressures Oil jets in the engine block lubricate and cool the pis ton and pin assembly The connecting rods have a pressed in place wrist pin bushing featuring specially adjusted lubrication groo...

Страница 1616: ...bore repair as necessary Fig 38 NOTE If excessive wear is present press in new connecting rod bushings 4 Measure connecting rod bushing inner diame ter Fig 38 5 Inspect wristpin bushing 6 Measure pist...

Страница 1617: ...urface it is then necessary to measure the piston protrusion Measure protrusion between piston crown and cyl inder head contact surface without the head gasket installed The measurment must be carried...

Страница 1618: ...osits The carbon deposits on the pistons must be removed NOTE If the arrows indicating the driving direction on the piston are no longer visible they must be marked again 9 Remove the connecting rod t...

Страница 1619: ...bushing CAUTION Assemble the piston and connecting rod so that the arrow is pointing in the direction of travel in the opposite direction of power flow The marking on the connecting rod is pointing t...

Страница 1620: ...otate the crankshaft sufficiently so that the connecting rod does not touch the connecting rod journal when the piston is pushed onto the cyl inder bore 8 Install piston with arrow pointing in the dir...

Страница 1621: ...ENGINE LU BRICATION OIL PUMP INSTALLATION 14 Install engine oil pan and oil pan drain plug Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION CAUTION Install a cylinder head gasket of standard thickne...

Страница 1622: ...ate the ring in the groove It must move freely around circumference of the groove RING SIDE CLEARANCE CHART ITEM SPECIFICATION Top Compression Ring 0 012 0 016 mm 0 0047 0 0063 in Second Compression R...

Страница 1623: ...able 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Install retaining lock for crankshaft ring gear Fig 47 4 Remove crankshaft center bolt and washer Fig 47 NOT...

Страница 1624: ...D IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 8 Start vehicle and inspect for leaks VACUUM PUMP DESCRIPTION The vacuum pump is operated...

Страница 1625: ...ixture 8534 with adap tors 8534 16 and raise the engine slightly 2 Raise and support the vehicle 3 Remove the engine mount bolts Fig 49 4 Lower the vehicle 5 Using the engine support fixture 8934 rais...

Страница 1626: ...ine mount and tighten bolt to 83 N m 61 lbs ft Fig 50 7 Remove the engine support fixture and adap tors OIL REMOVAL OIL SEPARA TOR 1 Disconnect breather hose 2 Remove the separator retaining bolts 3 T...

Страница 1627: ...clean and inspect cap gasket replace as necessary 3 Remove oil filter Fig 52 INSTALLA TION 1 Inspect oil filter cap gasket if all right lubri cate with clean engine oil 2 Install oil filter 3 Screw oi...

Страница 1628: ...ully seated into engine block Fig 55 4 Reassemble engine 5 Install engine into vehicle OIL PAN REMOVAL 1 Drain engine oil 2 Remove the sway bar retaining bolts and swing sway bar down and out of the w...

Страница 1629: ...Disconnect the oil level sensor 8 Remove the transmission cooler lines from the oil pan bolts and carefully position the lines aside 9 Remove the oil pan bolts 10 Remove oil pan and gasket Fig 57 Fig...

Страница 1630: ...ting surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly 1 Slide the oil pan into position 2 Slide the gasket into position 3 Add sealant to the joints...

Страница 1631: ...LOOSE CLOTHES 16 Start the engine and inspect for leaks OIL PUMP REMOVAL REMOVAL 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 Remove the oil pump bolts Fig 57 3 Press the chai...

Страница 1632: ...engine oil Refer to LUBRICATION MAINTENANCE FLUID TYPES SPECIFICA TIONS WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE C...

Страница 1633: ...stall insert on riveting tool Fig 64 NOTE The outer plate is held in place magnetically by riveting tool 10 Insert new outer plate into the moving assem bly insert 11 Position riveting tool so that sp...

Страница 1634: ...tes on the capacitance principle features an integrated electronic circuit which analyzes the three signals the signals are con stantly relayed to the ECM and over the CAN bus to the instrument cluste...

Страница 1635: ...ig 67 4 Rotate front stabilizer bar upward and secure to axle beam Tighten to 22 lbs ft 30 N m 5 Lower the vehicle 6 Lower the engine into the mounts 7 Remove engine support fixture 8 Raise and suppor...

Страница 1636: ...block between cyl inders 1 and 2 Fig 68 7 Disconnect the charge air hose at the intake manifold Fig 69 Fig 68 FUEL INJECTORS AND HIGH PRESSURE FUEL LINES 1 FUEL RAIL 2 HIGH PRESSURE FUEL INJECTOR LIN...

Страница 1637: ...th fuel lines at the fuel filter Fig 69 12 Remove the lower intake manifold support bracket Fig 70 13 Raise and support the vehicle 14 Remove the rear intake manifold mounting bolts while accessible f...

Страница 1638: ...ON 7 Connect the coolant hose at the EGR valve Fig 69 8 Secure the engine wiring harness and cable duct to the intake manifold tighten fastener to 9N m 80 in lbs 9 Connect the EGR wiring harness conne...

Страница 1639: ...raight edge 2 Inspect exhaust manifold for cracks or distor tion 3 Install new exhaust manifold gasket over the studs 4 Position the exhaust manifold over to studs and tighten retaining nuts to 30 N m...

Страница 1640: ...o 9 ENGINE REMOVAL 9 Remove front cover at cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 10 Remove accessory drive belt 11 Remove the high pressure fuel pump Refer to 14 FUEL SYSTEM FUEL DELIV...

Страница 1641: ...olt in two stages 200N m 147 lbs ft then 90 M10 9 bolt 325N m 240 lbs ft then 90 10 Remove the engine support fixture 11 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 12 Inst...

Страница 1642: ...arm they are always replaced together 1 Disconnect negative battery cable 2 Remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL NOTE Remove timing case cover carefully Care must be taken not...

Страница 1643: ...ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 6 Insert locking pin through first camshaft bear ing cap into hole in inlet camshaft sprocket to lock inlet camshaft 7 Remove timing chain tensioner...

Страница 1644: ...m bearing pin Fig 77 REMOVAL TIMING CHAIN 1 Remove cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL NOTE Cover the timing chain area Care must be taken not to drop any...

Страница 1645: ...ensure that the thrust pin is positioned at the left timing chain pin of a chain link 4 Install special tool 9312 onto timing chain link Fig 79 NOTE Cover the timing chain area Care must be taken not...

Страница 1646: ...re that no grease or oil is present during reassembly CAUTION ENSURE THAT THE SPRING IS COR RECTLY INSTALLED ON THE TENSIONING CLAMP AND SLIDE RAIL 1 Install rail on bearing pin Fig 75 2 Install timin...

Страница 1647: ...OVER S INSTALLATION WARNING NO FIRE FLAMES OR SMOKING SER VICE VEHICLE IN WELL VENTILATED AREA RISK OF INJURY FROM INHALING OR SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL WE...

Страница 1648: ...of old timing chain evenly as it becomes free to the same extent that new tim ing chain is drawn in 2 Draw in new timing chain with the oil holes facing up by rotating the crankshaft slowly in direc...

Страница 1649: ...ing tool by inserting pieces 9312 7 and 9312 10 Fig 86 NOTE Ensure that the riveted link and riveting tool are aligned 7 Press in new riveted link as far as the stop Fig 87 8 Remove guide link and riv...

Страница 1650: ...ly insert 9312 11 to 9312 1 17 Position riveting tool exactly over middle of pin 18 Tighten riveting tool spindle to end of travel Fig 89 19 Repeat procedure for both riveting pins Fig 89 20 Inspect r...

Страница 1651: ...timing chain tensioner Fig 91 INSTALLA TION NOTE Carefully clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly 1 Install timing chain tens...

Страница 1652: ......

Страница 1653: ...EXHAUST SYSTEM DESCRIPTION 2 7L DIESEL CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edge...

Страница 1654: ...Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten replace exhaust manifold to cyli...

Страница 1655: ...tab is inserted into the alignment slot 2 Install mounting bracket and nuts Fig 1 3 Install clamp 4 Lower the vehicle 5 Start the vehicle and inspect for exhaust leaks Repair exhaust leaks as necessar...

Страница 1656: ...low speeds the flow cross section is reduced by closing the guide vanes Fig 2 Consequently the speed at which the exhaust gas impacts on the tur bine wheel is increased as a result of which the speed...

Страница 1657: ...py water check the air inlet ducts rubber sleeves charge air cooler and intake manifold for leaks REMOVAL 1 Remove front bumper 2 Remove headlamp assemblies 3 Remove front cross member together with f...

Страница 1658: ...for turbo charger boost pressure It generates a control vacuum in response to a PWM signal from the ECM Vacuum is achieved by mixing the system vacuum from the vacuum pump with atmospheric pressure to...

Страница 1659: ...arger Fig 6 5 Remove the vacuum line from the turbocharger vacuum unit Fig 6 6 Separate the oil supply at the cylinder head and turbocharger Fig 6 7 Separate the oil return flow line at the turbo char...

Страница 1660: ...22 lbs ft 30 N m at turbocharger Fig 6 4 Replace gaskets and install oil return line at turbocharger Tighten bolt to 80 lbs in 9 N m Fig 6 NOTE Counterhold the connection at the turbo charger when ti...

Страница 1661: ...stall the retaining bolts Tighten bolts to 70 lbs in 8 N m 2 Connect vacuum hoses 3 Connect electrical connector 4 Install air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING I...

Страница 1662: ......

Страница 1663: ...CATIONS FRAME DIMENSIONS 3 SPECIFICATIONS TORQUE 8 ENGINE CRADLE CROSSMEMBER REMOVAL 8 INSTALLATION 10 REAR CROSSMEMBER TRANSMISSION REMOVAL 11 INSTALLATION 11 TRAILER HITCH REMOVAL 11 INSTALLATION 12...

Страница 1664: ...ets 5 Disconnect electrical connector INSTALLA TION 1 Connect outside temperature sensor electrical connector 2 Slide fascia onto the support brackets 3 Install fascia screws and tighten to 23 N m 17...

Страница 1665: ...fascia INSTALLA TION 1 Install fascia and seat the corners over the sup port brackets 2 Seat bumper support brackets clips below end panel firmly 3 Install the four plastic rivets to the bumper step i...

Страница 1666: ...INDEX DESCRIPTION FIGURE 05 FRAME DIMEN SIONS 1 5 05 FRAME DIMEN SIONS 2 6 FRAME DIMENSIONS 7 13 4 FRAME BUMPERS VA...

Страница 1667: ...Fig 5 05 FRAME DIMENSIONS 1 VA FRAME BUMPERS 13 5...

Страница 1668: ...Fig 6 05 FRAME DIMENSIONS 2 13 6 FRAME BUMPERS VA...

Страница 1669: ...Fig 7 FRAME DIMENSIONS VA FRAME BUMPERS 13 7...

Страница 1670: ...mount bolts nuts 45 33 WARNING Microencapsulated bolts and self lock ing nuts may only be used once If you use microencapsulated bolt or self locking nuts more than once the self locking function is...

Страница 1671: ...ect brake lines from body side at the couplings Fig 12 13 Support engine cradle with suitable lifting device 14 Remove four cradle support bolts from each side of the cradle Fig 13 Fig 9 FRONT DISC BR...

Страница 1672: ...r Refer to 2 SUSPEN SION FRONT STABILIZER BAR INSTALLATION 5 Install heat shield and nuts 6 Install jounce bumpers and install nuts 7 Install support clips and brake lines 8 Raise engine cradle into p...

Страница 1673: ...mount cover Fig 16 4 Remove crossmember nuts and crossmember INSTALLA TION 1 Install crossmember and install nuts 2 Tighten crossmember nut to 45 N m 33 ft lbs 3 Remove transmission support 4 Install...

Страница 1674: ...the bolts and nuts are greased the trailer hitch may become detached from the vehicle possibly resulting in a serious risk of injury and or damage to property including damage to the vehicle 1 Raise...

Страница 1675: ...detached from the vehicle possibly resulting in a serious risk of injury and or damage to property including dam age to the vehicle 3 Install the angle bracket microencapsulated bolts nuts and hand t...

Страница 1676: ......

Страница 1677: ...ULD GASOLINE BE MIXED WITH DIESEL FUEL NOT EVEN DURING WINTER THE HIGH PRESSURE PUMP IS LUBRICATED BY DIESEL FUEL IMMEDI ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS ING REPLACEMENT AND FLUSHING OF THE COMPL...

Страница 1678: ...al Fuel Pres sure Start the engine and observe the Fuel Pressure Set Point and the Actual Fuel Pressure If the Actual Fuel Pressure Oscillates above and below the Fuel Pressure Set Point in a regular...

Страница 1679: ...onds a maximum of five gradua tion lines 40 ml of the large test vial may be reached If the level has exceeded the five graduation line replace that affected cylinder s injector clear the memory using...

Страница 1680: ...d fuel filter If no problem is found with the fuel sys tem replace the low pressure fuel pump 1 Disconnect the negative battery cable 2 Connect a fuel gauge to the low pressure fuel supply to the high...

Страница 1681: ...till below specification replace the fuel pump If the fuel pressure is within the specification replace the fuel filter and retest at the high pressure pump to verify system function Fig 6 FUEL PRESSU...

Страница 1682: ...7 INSTALLATION HIGH PRESSURE PUMP 17 FUEL PUMP MODULE DESCRIPTION 18 REMOVAL 18 INSTALLATION 20 FUEL QUANTITY CONTROL VALVE DESCRIPTION 21 OPERATION 21 REMOVAL 21 INSTALLATION 21 FUEL RAIL DESCRIPTION...

Страница 1683: ...rail pressure Engine is switched off Calculating Pre injection Quantity The pre injec tion quantity is calculated on the basis of Engine speed Atmospheric pressure Coolant temperature Boost air tempe...

Страница 1684: ...ng Maximum Engine Speed The ECM determines the engine speed based on the signal supplied by the crankshaft sensor and lim its this by interrupting the operation of the fuel injectors Fuel Quantity Con...

Страница 1685: ...ing Unstable fuel rail pressure This can manifest itself as instability of idle speeds excessive under shoot overshoot at engine start up or excessive undershoot overshoot when the engine operating co...

Страница 1686: ...ptied The water drain plug and water in fuel WIF sensor are located on the top of the filter Water is drained by using the in tank electric fuel pump to generate flow attach a hose to the drain plug T...

Страница 1687: ...rimp clamps using special tool 9539 Fig 2 5 Connect the WIF wiring harness connector Fig 2 6 Connect negative battery cable 7 Cycle ignition several times to build pressure 8 Start engine and inspect...

Страница 1688: ...driveability concern 5 Start engine run for a few minutes turn engine off and inspect for leaks Refer to 14 FUEL SYSTEM WARNING Refer to 14 FUEL SYS TEM DIAGNOSIS AND TESTING FUEL RAIL PRESSURE SEN SO...

Страница 1689: ...pressure pump is mounted to the front of the cylinder head and must be replaced as an assem bly should a failure occur Fig 5 DESCRIPTION LOW PRESSURE PUMP The electric fuel pump is located in the fue...

Страница 1690: ...s the fuel pressure which exists at the fuel quantity control valve 11 to approximately 5 bar 72 5 psi If the pressure is exceeded the pressure relief valve opens and passes the fuel to the return flo...

Страница 1691: ...eccentric shaft 9 and the fuel is compressed The valve 2 disk shuts off the delivery volume to the fuel supply Once the fuel pressure in the cylinder rises beyond the pressure which exists in the hig...

Страница 1692: ...e pump will begin running immediately supplying fuel through fuel filter and onto the high pressure pump The lift pump and low pressure fuel circuit operate at a pressure between 3 8 5 5 bar 55 80 psi...

Страница 1693: ...p and remove pump Fig 8 INSTALLA TION HIGH PRESSURE PUMP Refer to 14 FUEL SYSTEM WARNING CAUTION Clean sealing surfaces with appropriate solvents and replace all seals NOTE Inspect then attach high pr...

Страница 1694: ...he following components Electric fuel pump transfer or lift pump Fuel reservoir Fuel gauge sending unit fuel level sensor Fuel supply line connection Fuel return line connection Fuel is supplied to th...

Страница 1695: ...float assembly to fall into fuel tank 8 While holding float rod remove fuel pump module from fuel tank 9 Remove float assembly from fuel tank 10 Remove and discard rubber gasket seal from pump module...

Страница 1696: ...l pump module into opening in fuel tank 8 Position locknut over top of fuel pump module Install locknut finger tight 9 The fuel line fittings should be pointed to the right side of the vehicle Rotate...

Страница 1697: ...f the sensors In order to adapt the quantity injected either the rail pressure can be adjusted by way of the pressure regulator valve and the quantity control valve or the actuation time of the soleno...

Страница 1698: ...the fuel rail 6 Remove injector high pressure lines Fig 19 7 Remove fuel rail retaining bolts Fig 19 CAUTION When slackening and tightening fuel injection line union nuts counter hold with wrench at t...

Страница 1699: ...nspect for leaks Refer to 14 FUEL SYSTEM WARNING FUEL TANK DESCRIPTION The plastic fuel tank Fig 20 is mounted to the frame rails under the left center side of the vehicle The fuel tank contains a ser...

Страница 1700: ...el Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Filler Tube 10 Vent Hose 11 Hose 12 Clamps 13 Cushioning Material 14 Two Way Valve Fig 21 FUEL COOLER LINES 1 Expansion Tank 2 Top of Tank...

Страница 1701: ...odule 7 Disconnect fuel supply line at tank 8 Disconnect fuel return line at tank 9 Continue to carefully lower tank for removal 10 If fuel pump module is to be removed thor oughly clean area at top o...

Страница 1702: ...k 4 Raise tank until positioned near body Fig 23 FUEL TANK ASSEMBLY 1 Strap Bolts 2 2 Hose not with all engines 3 Fuel Outlet Line 4 Fuel Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Fill...

Страница 1703: ...d snug to body 8 Install and position both fuel tank support straps 7 Fig 26 to mounting bolts 1 9 Install 2 fuel tank strap nuts 8 Refer to Torque Specifications 10 Remove hydraulic jack 11 Connect f...

Страница 1704: ...TANK ASSEMBLY 1 Strap Bolts 2 2 Hose not with all engines 3 Fuel Outlet Line 4 Fuel Return Line 5 Plug 6 Fuel Tank 7 Tank Straps 2 8 Nuts 2 9 Filler Tube 10 Vent Hose 11 Hose 12 Clamps 13 Cushioning M...

Страница 1705: ...umbers 5 To remove sending unit from pump module press on plastic locking tabs 1 Fig 30 while slid ing sending unit 4 on its tracks INSTALLA TION 1 Noting their previous positions connect wires from 2...

Страница 1706: ...s probes to close the electronic circuit when water is present in the system When diesel fuel is present in the system it s dielectric does not conduct electricity well properties do not allow any ele...

Страница 1707: ...JECTOR CLASSIFICATION 37 CLEANING FUEL INJECTORS 38 REMOVAL 38 INSTALLATION 39 FUEL PRESSURE SENSOR DESCRIPTION 39 OPERATION 39 REMOVAL 39 INSTALLATION 40 FUEL PRESSURE SOLENOID DESCRIPTION 40 OPERATI...

Страница 1708: ...is injected into the engine The accelerator pedal position sensor is serviced as an assembly with the accelerator pedal assembly REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the APP se...

Страница 1709: ...Refer to On Board Diagnostics in Emissions Con trol System for a list of Diagnostic Trouble Codes DTC s for certain fuel system components REMOVAL 1 Disconnect the negative battery cable 2 Unplug the...

Страница 1710: ...y the camshaft position sensor the vehicle will not start because cylinder order can not be detected REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover 3 Disconnect camshaft position se...

Страница 1711: ...can occur at exactly the right moment The engine speed signal is also processed by the ECM from the crankshaft sen sor This signal is then transferred to other control modules over the CAN bus If the...

Страница 1712: ...bleed orifice seat The rail s high pressure build up in the valve control chamber and the same pressure is also present in the nozzle s chamber volume The rail pressure applied at the control plunger...

Страница 1713: ...its downward movement it can overspring with the return spring so that it exerts no downwards acting forces on the armature and the ball The closing of the bleed orifice lead to pressure build up in t...

Страница 1714: ...MOVAL WARNING NO SPARKS OPEN FLAMES OR SMOK ING RISK OF POISONING FROM INHALING AND SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL POUR FUELS ONLY INTO SUITABLE AND APPROPRI AT...

Страница 1715: ...en injectors are removed re enter all injector six digit codes 8 Program all injector codes into the ECM using the scan tool 9 Start engine allow to run turn engine off and inspect for leaks Refer to...

Страница 1716: ...sent in the fuel rail flows to the ball seat of the pressure solenoid Fig 16 The specified pressure required by the system is built up in the rail by the fuel pressure solenoid building up a magnetic...

Страница 1717: ...pair Refer to 14 FUEL SYSTEM WARNING WARNING NO SPARKS OPEN FLAMES OR SMOK ING RISK OF POISONING FROM INHALING AND SWALLOWING FUEL RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL POUR FUELS ONL...

Страница 1718: ...e controller quantity of the pressure regulat ing valve is reduced and the fuel temperature is lowered REMOVAL NOTE Capture and properly store all fluid seepage in appropriately marked containers 1 Di...

Страница 1719: ...ocking tabs seat the sensor to the pipe and release tabs Fig 21 3 Connect negative battery cable INTAKE AIR PRESSURE SEN SOR DESCRIPTION An absolute pressure sensor is mounted to the air cleaner housi...

Страница 1720: ...ng resistor in the rear so that it is 320 F 160 C higher than the temperature of the intake air The temperature at the heating resistor is mea sured by a sensor resistor in between Because the incomin...

Страница 1721: ...r is a planar zirconium dioxide ZrO2 dual cell limiting current probe with a integral heater The term wide ban refers to the ability of the O2 sensor to generate a clear signal over a wide air fuel ra...

Страница 1722: ...hen the oxygen level on the supply side reaches zero the current stops The ECM activates the integral heater element to raise the temperature of the sensor to 700C 192 F for the ZrO2 to become conduct...

Страница 1723: ...ration in the gas sample chamber is high The sensor cell measures the differ ence between the oxygen concentrations in the sam pler chamber and the reference air channel A voltage lower than 450mV is...

Страница 1724: ...TION 1 Install the oxygen sensor Fig 28 2 Install the heatshield and tighen fasteners to 9N m 80 lbs in Fig 27 3 Properly position the oxygen sensor wiring har ness and connect the electrical connect...

Страница 1725: ...e rotation of the pinion moves the gear rack from side to side This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels Fig 1 Power assist is provided...

Страница 1726: ...nternal pump noise 3 Replace pump 4 Air in fluid 4 Check for lekas Evacuate air from P S system SUCKING AIR SOUND 1 Loose return line clamp 1 Replace clamp 2 O ring missing or damaged on hose fitting...

Страница 1727: ...bricate suspension compnents 4 High friction in steering gear 4 Replace gear LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING WHEEL 1 Worn or loose suspen...

Страница 1728: ...g wheel and lock the steering wheel in the straight ahead position The position of the steering gear must not be altered again for the entire duration of the w ork procedure 4 Remove the electrical ce...

Страница 1729: ...spring for the brake pedal to the steering column 6 Reconnect the electrical connector to the igni tion lock 7 Install the combination switch 8 Install the clockspring 9 Install the steering wheel 10...

Страница 1730: ...ound cable on the battery 2 Remove the air bag module from the steering wheel 3 Turn the steering wheel and lock the steering wheel in the straight ahead position Fig 7 4 Remove the steering wheel bol...

Страница 1731: ...ION FRONT SPRING CLAMP PLATES REMOVAL 8 Remove both the high pressure and return hoses from the steering gear Refer to 19 STEER ING PUMP HOSES REMOVAL Fig 2 9 Remove the steering shaft clamping bolt f...

Страница 1732: ...er tie rod ends to the steer ing knuckle Fig 2 Tighten to 130 N m 96 ft lbs 8 Install the upper stabilizer bar link to the sta bilizer bar 9 Install the front wheels 10 Fill and bleed the power steeri...

Страница 1733: ...front tires 3 Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator 4 Position indicator plunger on the topside of the outer tie rod end NOTE The dial indicat...

Страница 1734: ...LLA TION 1 Install the outer tie rod end by screwing it onto thew inner tie rod end Fig 1 2 Install the outer tie rod end into the steering knuckle Fig 1 3 Tighten the outer tie rod end nut Fig 1 Tigh...

Страница 1735: ...uid cooler NOTE Power steering pumps are not interchange able with pumps installed on other vehicles OPERA TION Hydraulic pressure is provided for the power steer ing gear by the belt driven power ste...

Страница 1736: ...ack and forth NOTE Do not contact or hold the wheel against the steering stops 7 Run a quart of fluid through the system then stop the engine and install the return line lines 8 Fill the system with f...

Страница 1737: ...ll power steering cap tightly 7 Test the system for leaks and proper operation FLUID COOLER TUBE REMOVAL 1 Siphon as much power steering fluid as possi ble out of the reservoir 2 Remove the grille Ref...

Страница 1738: ...onnect the return hose from the gear 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 4 Remove the left headlight assembly 5 Disconnect the return line at the cooler tube 6 Remove the ret...

Страница 1739: ...2 DISASSEMBLY 97 ASSEMBLY 99 INPUT CLUTCH K3 DISASSEMBLY 102 ASSEMBLY 103 ELECTROHYDRAULIC UNIT DESCRIPTION 105 OPERATION 112 REMOVAL 120 DISASSEMBLY 121 ASSEMBLY 125 INSTALLATION 129 FLUID AND FILTER...

Страница 1740: ...SHIFT MECHANISM DESCRIPTION 168 OPERATION 168 REMOVAL 169 INSTALLATION 170 SOLENOID DESCRIPTION 171 OPERATION 174 TEMPERATURE SENSOR PARK NEUTRAL CONTACT DESCRIPTION PARK NEUTRAL CONTACT 176 TRANSMISS...

Страница 1741: ...three multi disc holding clutches three multi disc driving clutches and two freewheel ing clutches Electronic transmission control enables precise adaptation of pressures to the respective operating...

Страница 1742: ...ic control unit comprises the shift plate made from light alloy for the hydraulic control and an electrical control unit The electrical control unit comprises of a supporting body made of plastic into...

Страница 1743: ...e extent the hydraulic control can be used to engage 2nd gear or reverse using the following pro cedure Stop the vehicle Move selector lever to P Switch off engine Wait at least 10 seconds Start engin...

Страница 1744: ...AR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETARY...

Страница 1745: ...rn on the fixed sun gear 23 and increase the torque from the annulus gear 11 to the planetary carrier 15 The planetary carrier 15 moves at a reduced speed in the running direction of the engine Center...

Страница 1746: ...lanetary pinion gears 18 turn on the fixed sun gear 22 and increase the torque from the annulus gear 10 to the planetary carrier 14 The output shaft 26 connected to the planetary carrier 14 turns at a...

Страница 1747: ...CH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER...

Страница 1748: ...g direction of the engine Center Planetary Gear Set The annulus gear 10 is driven at the same speed as the rear planetary carrier 15 as a result of a mechanical connection The sun gear 22 is held agai...

Страница 1749: ...gear 10 to the planetary carrier 14 The output shaft 5 connected to the planetary carrier 14 turns at a reduced speed in the running direction of the engine VA AUTOMA TIC TRANSMISSION NAG1 SERVICE IN...

Страница 1750: ...ING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 1...

Страница 1751: ...held against the housing by the multiple disc holding clutch B2 6 The planetary pinion gears 18 turn on the fixed sun gear 22 and increase the torque from the annulus gear 10 to the planetary carrier...

Страница 1752: ...INION GEARS 6 HOLDING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PL...

Страница 1753: ...rns at the input speed as a result of the engaged multiple disc clutch K2 9 The multiple disc clutch K3 12 connects the sun gears 22 and 23 of the rear and center planetary gearset The planetary gears...

Страница 1754: ...AR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETARY...

Страница 1755: ...lus gear 11 and the sun gear 23 The sun gear 23 moves at an increased speed in the running direction of the engine Center Planetary Gear Set The annulus gear 10 turns at the input speed as a result of...

Страница 1756: ...s 18 turn between the annulus gear 10 and the sun gear 22 The speed of the planetary carrier 14 and the output shaft connected to the planetary carrier 5 lies between that of the annulus gear 10 and t...

Страница 1757: ...REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETAR...

Страница 1758: ...planetary car rier 15 so that the sun gear 23 turns in the oppo site direction to the running direction of the engine Center Planetary Gear Set The annulus gear 10 is held against the housing by the...

Страница 1759: ...r 10 and increase the torque from the sun gear 22 to the planetary carrier 14 The output shaft 26 con nected to the planetary carrier 14 turns at a reduced speed in the opposite direction to the run n...

Страница 1760: ...RS 6 HOLDING CLUTCH B2 19 REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY S...

Страница 1761: ...to the planetary carrier 15 The sun gear 22 turns backwards due to the engaged multiple disc clutch K3 12 The planetary gears 18 turn on the fixed annulus gear 10 and increase the torque from the sun...

Страница 1762: ...1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING CLUTCH K1 3 1 2 4 5 SHIFT PRESSURE SHIFT VALVE 7 HOLDING CLUTCH B1 4 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 8 SHIFT PR...

Страница 1763: ...zed via the solenoid valve for 1 2 and 4 5 shift 1 Because of the holding pressure shift valve 4 the working pressure p A is present at the multiple disc holding clutch B1 7 Clutch K1 6 is unpressuriz...

Страница 1764: ...moved and the shift pressure p S coming from the shift pressure shift valve 3 is Fig 17 Shift Phase 1 2 Shift Phase 1 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING...

Страница 1765: ...utch pressure the shift pressure in clutch K1 The controlled pressure in clutch B1 7 is inversely proportional to the capacity of the clutch being engaged The rising shift pressure p S at clutch K1 6...

Страница 1766: ...ng valve 4 and the holding valve downshifts The line pressure is then routed to the command valve 5 Fig 18 Shift Phase 1 2 Shift Phase 2 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVER...

Страница 1767: ...ts basic position Via the holding pressure shift valve 4 the working pressure p A now passes via the Fig 19 Second Gear Engaged 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE...

Страница 1768: ...h K1 6 The multiple disc holding clutch B1 7 is deactivated unpressurized The spring of the shift pressure shift valve 3 pushes the valve back to its basic position 21 30 AUTOMA TIC TRANSMISSION NAG1...

Страница 1769: ...e coming from the 1 2 4 5 shift valve 3 is routed to the holding clutch B1 7 via the command valve Fig 20 Shift Phase 2 1 Shift Phase 1 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERL...

Страница 1770: ...it disen gages is controlled during the shift phase depending on engine load via the modulating pressure p MOD and the shift pressure in clutch B1 7 The increasing shift pressure in clutch B1 which a...

Страница 1771: ...allows line pressure p A to pass through the com mand valve 5 Fig 21 Shift Phase 2 1 Shift Phase 2 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OVERLAP VALVE 6 DRIVING CLUTCH K1 3 1 2 4...

Страница 1772: ...ownshifts the valve to its initial position The line pressure p A is switched to the holding clutch B1 7 and the Fig 22 First Gear Engaged 1 1 2 4 5 SHIFT SOLENOID 5 1 2 4 5 COMMAND VALVE 2 1 2 4 5 OV...

Страница 1773: ...e of the holding valve by the downshifted com mand valve The upshifted holding valve also allows the remaining pressure in clutch K1 6 to be vented VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION...

Страница 1774: ...CH B1 11 PRESSURE HOLDING VALVE 2 DRIVING CLUTCH K1 12 3 4 HOLDING PRESSURE SHIFT VALVE 3 HOLDING CLUTCH B3 13 3 4 COMMAND VALVE 4 DRIVING CLUTCH K3 14 3 4 SHIFT PRESSURE SHIFT VALVE 5 HOLDING CLUTCH...

Страница 1775: ...tivation of the multiple disc hold ing clutch B2 Fig 24 Activation Sequence 1 HOLDING CLUTCH B1 11 PRESSURE HOLDING VALVE 2 DRIVING CLUTCH K1 12 3 4 HOLDING PRESSURE SHIFT VALVE 3 HOLDING CLUTCH B3 13...

Страница 1776: ...0 is ener gized This allows shift valve pressure p SV to enter the spring chamber of the shift valve B2 9 and to reach the end face of the 3 4 command valve 13 The shift valve B2 9 is held in the uppe...

Страница 1777: ...note following a If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and che...

Страница 1778: ...Filter 2 Oil Pump 2 Replace Oil Pump WHINING SINGING 1 Gear Set Noises in 1st 2nd 5th Gear 1 Replace Transmission 2 Intermediate Bearing Of The Drive Shaft At 0 km h Only When Cold 2 Replace Intermedi...

Страница 1779: ...er Not Installed 2 Install Oil Filter 3 Free Wheeling Clutch F2 Defec tive 3 Replace Free Wheeling Clutch F2 Hollow Shaft and Rear Sun Gear Inner Disc Car rier K3 GRABBING 2 3 COAST ING UPSHIFT AND OR...

Страница 1780: ...eal Ring Installed 2 Install Drain Plug Correctly 3 Weld Seam Of Torque Converter Leaky 3 Replace Torque Converter 4 Radial Sealing Ring Oil Pump Defective 4 Replace Sealing Ring 5 O Ring Oil Pump Def...

Страница 1781: ...ion a Remove bracket for the oil cooler feed and return lines 1 Fig 29 from engine oil pan flange Detail shows right side of motor Position is mirrored for the left side of engine b Detach bracket of...

Страница 1782: ...er bracket When pulling out cable press together hooks of shift cable retainer at the points shown arrows c Pull shift cable out of ball socket Ball socket can remain on transmission lever Fig 29 Cool...

Страница 1783: ...driving plate 13 Remove torque converter drain plug and drain automatic transmission oil into a clean container Re install the drain plug and torque the plug to 14 N m 130 in lbs 14 Support engine Ins...

Страница 1784: ...transmission 21 Remove the transmission towards the rear and lower Ensure that the converter remains in the transmission housing when the transmission is removed 22 Remove the torque converter DISASS...

Страница 1785: ...output shaft nut 9 Remove the nut holding the propeller shaft flange to the output shaft and remove the flange 10 Remove the transmission rear oil seal with a suitable slide hammer and screw 11 Remov...

Страница 1786: ...16 Remove the geartrain end play shim from the output shaft Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged Fig 43 Slide Remover 9082 Col...

Страница 1787: ...Remove the transmission housing from the converter housing 21 Remove output shaft with center and rear gear set and clutch K3 3 Fig 45 22 Remove thrust needle bearing 4 and thrust washer 5 Fig 45 23 R...

Страница 1788: ...crew Torx socket bolts 1 Fig 46 and remove multiple disc holding clutch B1 5 from con verter housing Screw two opposed bolts into the multiple disc holding clutch B1 5 and separate from the converter...

Страница 1789: ...ginal position on top of the spring washer 30 Unscrew Torx socket bolts 7 Fig 47 31 Remove multiple disc holding clutch B2 4 Fig 47 from transmission housing The externally toothed disc carrier for mu...

Страница 1790: ...stall B2 B3 and Parking Gear 1 SNAP RING 5 PARK GEAR 2 HOLDING CLUTCH B3 DISCS 6 TRANSMISSION HOUSING 3 SPRING WASHER 7 BOLTS M8X60 4 HOLDING CLUTCH B2 Fig 49 Measure B3 Clutch Clearance 1 OUTER DISC...

Страница 1791: ...Apply only light pressure less than 10 N 3 lbs of force to the clutch pack when measuring the clutch clearance with the feeler gauge Applying excessive force to the clutch will give an incorrect readi...

Страница 1792: ...he bolts to hold clutch B1 5 Fig 51 to the converter housing 9 Securely tighten multiple disc holding clutch B1 5 on converter housing 2 to 10 N m 88 5 in lbs 10 Install new torque converter hub seal...

Страница 1793: ...12 Install oil pump 6 and securely tighten Tighten the oil pump bolts to 20 N m 177 in lbs VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 55...

Страница 1794: ...tput shaft with center and rear gear set and clutch K3 3 Fig 53 Fig 53 Install K1 K2 and K3 Clutches 1 DRIVING CLUTCH K1 5 THRUST WASHER 2 SUN GEAR OF FRONT PLANETARY GEAR SET 6 FRONT PLANETARY GEAR S...

Страница 1795: ...0 in 25 Install the selected end play shim 26 Screw in Torx socket bolts through the con verter housing into the transmission housing Tighten the bolts to 20 N m 177 in lbs 27 Install output shaft bea...

Страница 1796: ...t shaft in and out and record read ing End play should be 0 3 0 5 mm 0 012 0 020 in Adjust as necessary 33 Install the output shaft washer onto the out put shaft 34 Install a new transmission rear sea...

Страница 1797: ...71 in lbs 42 Install oil filter 4 Fig 62 43 Install oil pan 5 Fig 62 Tighten the bolts to 8 N m 71 in lbs 44 Install guide bushing 12 Fig 62 Fig 61 Stake Output Shaft Nut 1 STAKING TOOL 9078 2 PROPEL...

Страница 1798: ...aulic transmis sion jack and raise the transmission into position Secure transmission on hydraulic jack with a strap or ask an assistant to hold it 7 Move the transmission into position on the dowel p...

Страница 1799: ...of bolts 2 are in front of opening Rotate engine for wards at crankshaft Install and torque the bolts to 50 N m 37 ft lbs e Rotate engine by hand and tighten the first two bolt pairs to 50 N m 37 ft l...

Страница 1800: ...ine oil pan flange Detail shows right side of motor Position is mirrored for the left side of engine b Attach the bracket for the cable retainer 4 Fig 74 to the threaded shank of a engine oil pan bolt...

Страница 1801: ...nto position b Push lower connection of oil filler pipe 1 Fig 77 into the fill hole in the side of the trans mission housing c Install bolts 2 Fig 77 to cylinder head Tighten the bolts to 8 N m 71 in...

Страница 1802: ...h cor rect automatic transmission fluid Refer to 21 TRANSMISSION AUTOMATIC NAG1 FLUID AND FILTER STANDARD PROCEDURE 23 Road test the vehicle and verify the repair Fig 77 Fill Tube 1 FILL TUBE 2 BOLTS...

Страница 1803: ...SCHEMA TICS AND DIAGRAMS HYDRAULIC FLOW IN PARK VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 65...

Страница 1804: ...HYDRAULIC FLOW IN REVERSE FAILSAFE 21 66 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1805: ...HYDRAULIC FLOW IN REVERSE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 67...

Страница 1806: ...HYDRAULIC FLOW IN NEUTRAL DEFAULT 21 68 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1807: ...HYDRAULIC FLOW IN NEUTRAL VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 69...

Страница 1808: ...HYDRAULIC FLOW IN NEUTRAL TO DRIVE TRANSITION 21 70 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1809: ...HYDRAULIC FLOW IN DRIVE FAILSAFE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 71...

Страница 1810: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 72 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1811: ...HYDRAULIC FLOW IN DRIVE FIRST TO SECOND GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 73...

Страница 1812: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 74 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1813: ...HYDRAULIC FLOW IN DRIVE SECOND TO THIRD GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 75...

Страница 1814: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR 21 76 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1815: ...HYDRAULIC FLOW IN DRIVE THIRD TO FOURTH GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 77...

Страница 1816: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR 21 78 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1817: ...HYDRAULIC FLOW IN DRIVE FOURTH TO FIFTH GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 79...

Страница 1818: ...HYDRAULIC FLOW IN DRIVE FIFTH GEAR 21 80 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1819: ...HYDRAULIC FLOW IN DRIVE FIFTH GEAR EMCC VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 81...

Страница 1820: ...HYDRAULIC FLOW IN DRIVE FIFTH TO FOURTH GEAR TRANSITION 21 82 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1821: ...HYDRAULIC FLOW IN DRIVE FOURTH TO THIRD GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 83...

Страница 1822: ...HYDRAULIC FLOW IN DRIVE THIRD TO SECOND GEAR TRANSITION 21 84 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...

Страница 1823: ...HYDRAULIC FLOW IN DRIVE SECOND TO FIRST GEAR TRANSITION VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 85...

Страница 1824: ...5 B3 Clutch Snap rings 3 2 3 5 3 8 4 1 4 4 and 4 7 0 126 0 138 0 150 0 162 0 173 0 185 COMPONENT METRIC mm INCH in K1 Clutch Clearance Double Sid ed Friction Discs 3 Disc 2 7 3 1 0 106 0 122 4 Disc 3...

Страница 1825: ...alve Body Hous ing Side Cover 4 35 Bolt Shift Plate 8 71 Bolt Solenoid Leaf Spring 8 71 Plug Oil Pan Drain 20 177 Nut Shifter Mechanism to Floor Pan 7 65 SPECIAL TOOLS AUTOMA TIC TRANSMIS SION NAG1 SP...

Страница 1826: ...iversal C 4171 Bar Gauge 6311 End Play Set 8266 Adapter Geartrain End play 8266 18 Dipstick 8863B Compressor Multi use Spring 8900 Tool Pressing 8901 21 88 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA...

Страница 1827: ...Installer Seal 8902A Tool Staking 9078 Remover Bearing 9082 Installer Bearing 9287 VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 89...

Страница 1828: ...LUTCH 13 K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 3 EXTERNALLY TOOTHED DISC 14 K2 CLUTCH PISTON 4 INTERNALLY TOOTHED DISC 15 FRONT PLANETARY GEARSET PLANETARY CARRIER 5 K3 CLUTCH 16 FRONT PLANETARY G...

Страница 1829: ...nnulus gear 11 turn at the same speed as the input shaft 21 If the multi plate clutch K3 5 is actuated via the piston 7 the piston compresses the disc set The sun gear 12 of the center planetary gear...

Страница 1830: ...scs are re used this disc must be returned to its original position on top of the spring plate Fig 81 Input Clutch K1 Components 1 K1 OUTER DISC CARRIER 7 DISC SPRING 2 FREEWHEELING CLUTCH F1 8 SPRING...

Страница 1831: ...carefully blowing compressed air into the drilled oil feed passage 6 Remove snap ring 3 and take out front free wheeling clutch F1 2 Take care when removing the F1 clutch to prevent the clutch sprags...

Страница 1832: ...spring plate 8 Insert spring plate with the curvature towards the sun gear Check sealing ring 9 replace if necessary Fig 83 Input Clutch K1 Components 1 K1 OUTER DISC CARRIER 7 DISC SPRING 2 FREEWHEEL...

Страница 1833: ...e outer mul tiple disc carrier 7 Insert snap ring 11 8 Measure the K1 clutch pack clearance by mounting Pressing Tool 8901 1 Fig 85 on outer multiple disc 9 Using a lever press compress pressing tool...

Страница 1834: ...the groove in the outer multiple disc carrier 3 17 The correct clutch clearance for transmissions with single sided friction discs is 2 4 2 8 mm 0 095 0 110 in for six friction disc versions 2 6 3 0 m...

Страница 1835: ...used this disc must be returned to its original position on top of the disc spring 6 Take out disc spring 14 Fig 88 Fig 88 Input Clutch K2 Components 1 NEEDLE ROLLER BEARING 11 SPRING RETAINER SEALIN...

Страница 1836: ...ess until snap ring 2 is released 8 Remove snap ring 2 Fig 88 9 Take out disc spring 10 and pull piston 9 out of outer multiple disc carrier Fig 89 Compress K2 Clutch Spring 1 MULTI USE SPRING COMPRES...

Страница 1837: ...if necessary Fig 90 Input Clutch K2 Components 1 NEEDLE ROLLER BEARING 11 SPRING RETAINER SEALING O RING 2 K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR SET 12 SPRING RETAINER 3 THRUST BEARING 13 S...

Страница 1838: ...1 1 Fig 92 on outer multiple disc 9 Using a lever press compress pressing tool as far as the stop then the marking ring is still visible see small arrow 10 Using a feeler gauge determine the play L Fi...

Страница 1839: ...13 Adjust with snap ring 6 if necessary Snap rings are available in thicknesses of 2 3 mm 0 091 in 2 6 mm 0 102 in 2 9 mm 0 114 in 3 2 mm 0 126 in 3 5 mm 0 138 in and 3 8 mm 0 150 in 14 Insert axial...

Страница 1840: ...to its original position on top of the spring plate 3 Place Multi use Spring Compressor 8900 9 Fig 94 on disc spring 5 and compress the spring until the snap ring 4 is exposed 4 Remove snap ring 4 5 R...

Страница 1841: ...h single sided friction discs an externally lugged disc is installed first followed by an inter nally lugged disc and continuing on until all the required discs are installed All single sided discs ar...

Страница 1842: ...a feeler gauge to determine the play L Fig 98 at three points between the snap ring 7 and outer multiple disc 2 14 During the measurement the snap ring 7 must contact the upper bearing surface of the...

Страница 1843: ...nnection 2 establishes the connection to the vehicle side cable harness and to the transmission control module TCM With the exception of the solenoid valves all other electric components are fixed to...

Страница 1844: ...regulated at the regulating valve pressure regulating valve in relation to the working pressure p A up to a maximum pres sure of 8 bar 116 psi It supplies the modulating pressure regulating solenoid v...

Страница 1845: ...the torque converter lockup clutch and distribution of the lubri cating oil Fig 102 Torque Converter Lockup Clutch Regulating Valve 1 TORQUE CONVERTER LOCK UP CLUTCH 2 TORQUE CONVERTER OUTPUT 3 TORQU...

Страница 1846: ...e shift valve housing the 2 3 and 3 4 overlap regulating valves are installed in the valve housing The overlap regulating valve regulates the pressure reduction during a shift phase Fig 103 Overlap Re...

Страница 1847: ...shift valve housing the 3 4 command valve is installed in the valve housing The command valve switches the shift group from the stationary phase to the shift phase and back again Fig 104 Command Valve...

Страница 1848: ...valves are installed in the shift valve housing the 3 4 holding pressure shift valve is installed in the valve housing The holding pressure shift valve allocates the working pressure to one actuator o...

Страница 1849: ...the valve housing of the electrohy draulic control module The valve controls the fluid to lubricate and cool the mechanical part of the transmission and limits the pressure in the torque converter Shi...

Страница 1850: ...12 starter interlock contact 9 and transmission oil temperature sensor 8 of the electric valve control unit 7 supply the TCM with input sig nals The solenoid valves are controlled by the TCM and trigg...

Страница 1851: ...4 Fig 112 in relation to load modulating pressure p Mod and gear K1 or K2 pressure 1 The spring in the work ing pressure regulating valve sets a minimum pres sure level basic pressure Fig 112 Working...

Страница 1852: ...surized In its regulating position slipping torque converter lockup clutch pressurized a reduced volume of lubricating oil flows through the annular passage 7 bypassing the torque converter and passin...

Страница 1853: ...ing pressure p Mod and the pressure in the activating actuator The reg ulated pressure is inversely proportional to the trans fer capacity of the activating shift actuator regulated overlap Fig 114 Ov...

Страница 1854: ...m mand valve Fig 115 is subjected to the shift valve pressure p SV shift phase then the shift pressure p S is switched to the activating element and the overlap pressure p is switched to the deactivat...

Страница 1855: ...igher pres sure taking into account the spring force and the effective surface area The other element of the shift group is then unpressurized The valve switches over only during the shift phase and o...

Страница 1856: ...during the stationary and shift phases so the shift state is maintained during the shift phase in this case too Lubrication Pressure Regulating Valve At the working pressure regulating valve surplus...

Страница 1857: ...to the working pressure p A as far as the maximum pressure Shift Valve Pressure Regulating Valve The non constant regulating valve pressure p RV is regulated to a constant shift valve pressure p SV at...

Страница 1858: ...13 pin plug connector 1 Fig 124 Turn bayonet lock of guide bushing 2 anti clock wise 6 Loosen guide bushing 2 and remove from transmission housing Fig 122 Remove Electrohydraulic Unit 1 HEAT SHIELD 2...

Страница 1859: ...end away retaining lug on stiffening rib on transmission oil temperature sensor 7 Remove electrohydraulic control module 12 from the shift plate 13 Fig 125 Remove Electrohydraulic Unit 1 HEAT SHIELD 2...

Страница 1860: ...and blown out with compressed air noting that parts may be blown away 9 Unbolt leaf spring 5 Fig 128 10 Unscrew Torx bolts 1 Fig 128 11 Remove valve housing 2 from valve body 4 Fig 128 12 Remove seal...

Страница 1861: ...e from plastic 4 and eight from steel 1 3 15 Note the location of all check balls 1 3 4 Fig 131 and the central strainer 2 for re installa tion Remove all check balls 1 3 4 and the central strainer 2...

Страница 1862: ...ALVE BODY 8 SHIFT VALVE PRESSURE REGULATING VALVE 2 1 2 4 5 COMMAND VALVE 9 B2 SHIFT VALVE 3 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 10 2 3 HOLDING PRESSURE SHIFT VALVE 4 1 2 4 5 SHIFT PRESSURE SHIFT VAL...

Страница 1863: ...noting that parts may be blown away 1 Install the pressure supply valve 1 Fig 135 into the valve body Fig 133 Valve Housing Components 1 2 3 OVERLAP REGULATING VALVE SLEEVE AND PISTON 6 3 4 SHIFT PRE...

Страница 1864: ...nents 1 VALVE BODY 8 SHIFT VALVE PRESSURE REGULATING VALVE 2 1 2 4 5 COMMAND VALVE 9 B2 SHIFT VALVE 3 1 2 4 5 HOLDING PRESSURE SHIFT VALVE 10 2 3 HOLDING PRESSURE SHIFT VALVE 4 1 2 4 5 SHIFT PRESSURE...

Страница 1865: ...Fig 137 Valve Housing Components 1 2 3 OVERLAP REGULATING VALVE SLEEVE AND PISTON 6 3 4 SHIFT PRESSURE SHIFT VALVE 2 VALVE HOUSING 7 3 4 OVERLAP REGULATING VALVE SLEEVE AND PISTON 3 SELECTOR VALVE 8...

Страница 1866: ...Fig 140 Tighten the bolts to 8 N m 71 in lbs 11 Install leaf spring 5 Fig 140 12 Install the strainers 1 2 for the modulating pressure and shift pressure control solenoid valves Fig 141 into the valv...

Страница 1867: ...cle INSTALLA TION 1 Position the electrohydraulic unit in the trans mission housing 2 Insert selector valve 1 Fig 143 in driver of detent plate 2 When installing the electrohydraulic control module in...

Страница 1868: ...ise to connect plug connector 1 10 Position the heat shield 2 Fig 146 onto the transmission housing and install the screw 1 and bolt 3 to hold the shield in place 11 Fill the transmission with the cor...

Страница 1869: ...d by the rotating parts and flows back into the oil gallery 2 through the upper opening arrow DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air al...

Страница 1870: ...if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only...

Страница 1871: ...mine the height of the oil level on the dipstick and using the height the transmission temperature and the Transmission Fluid Graph Fig 150 determine if the transmission oil level is correct 9 Add or...

Страница 1872: ...lug 8 Fig 153 is aligned with the access hole NOTE Clean the area around the drain plug to pre vent dirt from entering the torque converter 5 Using a suitable drain pan to catch the fluid remove the t...

Страница 1873: ...ing elements 3 and a cage 6 for these locking elements OPERA TION The freewheeling clutch Fig 155 optimizes indi vidual gearshifts They lock individual elements of a planetary gear set together or aga...

Страница 1874: ...F2 3 3 Remove snap ring 2 Fig 156 for freewheel 4 Press freewheeling clutch 3 out of sun gear 5 Check O rings 6 replace if necessary Fig 156 Freewheeling Clutch F2 1 HOLLOW SHAFT 4 K3 INNER DISC CARR...

Страница 1875: ...etary sun gear for damage Replace as necessary Fig 157 Freewheeling Clutch F2 Anti Friction Bearing 1 K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR 2 ANTI FRICTION BEARING 3 FREEWHEELING CLUTCH F2...

Страница 1876: ...clutch F2 When the assembly is held with the F2 clutch snap ring upward it should be possible to rotate the hollow shaft counter clockwise 6 Install retaining ring 5 onto hollow shaft 1 GEARSHIFT CAB...

Страница 1877: ...Remove bottom 2 Fig 160 of the center sec tion of instrument panel 4 Pry ball socket of transmission shift cable off ball knob at the shift lever assembly SLA Use a suitable slotted screwdriver 5 Rais...

Страница 1878: ...cket 3 Lower vehicle 4 Install the transmission shift cable onto the ball knob at the SLA 5 Install the bottom section 2 Fig 163 of the center section of instrument panel 6 Install the top section 3 F...

Страница 1879: ...he transmission housing Fig 165 Holding Clutches 1 B1 CLUTCH 10 CENTER PLANETARY GEARSET ANNULUS GEAR 2 EXTERNALLY TOOTHED DISC 11 CENTER PLANETARY GEARSET PINION GEARS 3 INTERNALLY TOOTHED DISC 12 CE...

Страница 1880: ...e planetary pin ion gears 11 turn on the sun gear 12 If the multiple disc holding clutch B3 4 is actu ated via the piston 6 the planetary carrier 9 and the annulus gear 10 are locked When the multiple...

Страница 1881: ...H B1 DISASSEMBL Y 1 Remove the teflon rings 1 Fig 167 from the B1 plate carrier hub 2 Fig 167 Remove the Teflon Rings 1 TEFLON RINGS 2 PLATE CARRIER HUB VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA...

Страница 1882: ...ring 4 Place the Multi use Spring Compressor 8900 8 Fig 168 on disc spring 3 and compress the spring until the snap ring 4 is exposed 5 Remove snap ring 4 6 Remove piston 2 from the outer multiple dis...

Страница 1883: ...ck snap ring for correct seat 3 Insert snap ring 4 Fig 169 4 Insert disc spring 2 Fig 170 in the outer multiple disc carrier Observe the disc spring 2 installation position The lugs of the disc spring...

Страница 1884: ...uter multiple disc 7 Using a lever press Fig 171 compress press ing tool as far as the stop then the marking ring is still visible see small arrow 8 For transmissions using double sided friction discs...

Страница 1885: ...c versions 11 Adjust with snap ring 5 if necessary Snap rings are available in thicknesses of 2 6 mm 0 102 in 2 9 mm 0 114 in 3 2 mm 0 126 in 3 5 mm 0 138 in 3 8 mm 0 150 in and 4 1 mm 0 162 in 12 Ins...

Страница 1886: ...p of the disc spring 3 Place the Multi use Spring Compressor 8900 on the spring disc 14 and compress the spring until the groove for the snap ring is exposed 4 Remove snap ring 16 Fig 175 5 Remove spr...

Страница 1887: ...Press piston guide ring 13 out of the B2 pis ton 10 8 Separate piston guide 4 from the B3 piston 8 by blowing compressed air into the bore A Fig 176 Fig 176 B2 Clutch Oil Supply Locations A B3 PISTON...

Страница 1888: ...aling rings 2 4 6 must point outwards Fig 177 Holding Clutch B2 B3 Seals 1 PISTON GUIDE RING 4 B2 PISTON SEALING RING 2 PISTON GUIDE RING SEALING RING 5 B3 PISTON B2 OUTER DISC CARRIER 3 PISTON GUIDE...

Страница 1889: ...Fig 178 in B3 piston 8 Fig 178 Holding Clutch B2 1 SNAP RING 9 B2 PISTON SEALING RING 2 MULTIPLE DISC PACK 10 B2 PISTON 3 DISC SPRING 11 PISTON GUIDE SEALING RING 4 B2 AND B3 PISTON GUIDE 12 PISTON G...

Страница 1890: ...friction multiple discs in ATF fluid for one hour before installing 8 Insert disc spring 3 and multiple disc pack 2 in the B2 outer multiple disc carrier 9 Insert snap ring 1 NOTE During the measureme...

Страница 1891: ...The speed sensors are pressed against the transmission housing 2 by a spring 7 which is held against the valve housing of the shift plate 5 This ensures a defined distance between the speed sensors an...

Страница 1892: ...g behind the torque con verter and is driven by the drive flange of the torque converter The pump creates the oil pressure required for the hydraulic procedures OPERA TION When the engine is running t...

Страница 1893: ...ng a flat plate across the mounting face of the pump housing and measuring the distance between the plate and the gears Acceptable side clearance Inner gear 0 064 mm 0 0025 in max Outer gear 0 069 mm...

Страница 1894: ...shaft nut 4 Remove the nut holding the propeller shaft flange to the output shaft and remove the flange 5 Remove the transmission rear oil seal with a suitable slide hammer and screw 6 Remove the tran...

Страница 1895: ...aring inner race Retrieve the shim from the bearing and install over the output shaft and against the park gear 10 Remove the output shaft bearing 3 Fig 194 Fig 192 Position Remover 9082 On Bearing 1...

Страница 1896: ...er ring must be installed Retaining rings are available in thick nesses of 2 0 mm 0 079 in 2 1 mm 0 083 in and 2 2 mm 0 087 in 5 Install the output shaft washer onto the output shaft 6 Install a new t...

Страница 1897: ...ft flange to the output shaft and remove the flange 4 Remove the output shaft seal with suitable screw and slide hammer INSTALLA TION 1 Position the new output shaft seal over the out put shaft and ag...

Страница 1898: ...lever to position D 3 Remove top section 3 Fig 203 of the center section of instrument panel 4 Remove bottom section 2 Fig 204 of the cen ter section of instrument panel Fig 202 Stake Output Shaft Nut...

Страница 1899: ...u ment panel between the steering column and the shift lever assembly SLA 2 Install the park lock cable 2 Fig 208 to the ignition switch 3 Tighten the park lock cable 2 Fig 209 to the ignition switch...

Страница 1900: ...onnect battery Fig 209 Tighten Park Lock Cable to Ignition Switch 1 IGNITION SWITCH 2 PARK LOCK CABLE Fig 210 Engage Park Lock Cable to SLA 1 PARK LOCK CABLE COUPLING 2 LOCK TAB 3 BOLT 4 SHIFT LEVER A...

Страница 1901: ...n Several kinds of seals are used to accomplish this within a transmission These include but are not limited to O rings D rings lip seals sealing rings or extremely close tolerances between the piston...

Страница 1902: ...smaller piston moves ten inches This principle is true in other instances also A common garage floor jack is a good example To raise a car weighing 2000 lbs an effort of only 100 lbs may be required F...

Страница 1903: ...r moving gear wheels or shift collars When two components of the planetary gear set are locked together the planetary gear set is locked and turns as a closed unit The torque and engine speed are conv...

Страница 1904: ...move rear gear set 5 with integrated tubu lar shaft of center gear set from output shaft 6 Remove thrust washer 4 Fig 219 Output Shaft with Center and Rear Planetary Geartrain 1 TEFLON RINGS 7 DRIVING...

Страница 1905: ...h K3 7 6 Mount retaining ring shim thrust needle bear ing and thrust washer 8 11 Fig 220 7 Using grease insert the upper two Teflon rings 1 in the groove so that the joint remains together Fig 220 Out...

Страница 1906: ...ion can be overriden see operator s manual Reverse inhibitor As soon as the vehicle speed exceeds approx 4 mph it is no longer possible to move the selector lever from position N to posi tion R OPERA...

Страница 1907: ...her The shift range is increased by one gear each time and the increased shift range is displayed in the instrument cluster possibly the transmission upshifts to a faster gear Tipping the selector lev...

Страница 1908: ...ON 1 Position the shift lever assembly SLA onto the vehicle 2 Install the bolts to hold the SLA to the vehicle Tighten the bolts to 6 N m 53 in lbs 3 Connect the park lock cable coupling 1 Fig 226 to...

Страница 1909: ...otion The solenoids used in transmission applications are attached to valves which can be classified as nor mally open or normally closed The normally open solenoid valve is defined as a valve which a...

Страница 1910: ...ibilities include variable force pulse width modulated con stant ON or duty cycle The variable force and pulse width modulated versions utilize similar methods to control the current flow through the...

Страница 1911: ...the shell of the elec tric valve control unit and pressed against the shift plate by a spring The PWM solenoid valve 1 for the torque con verter lockup controls the pressure for the torque converter...

Страница 1912: ...l the attraction is removed and the plunger will return to its original position due to spring pressure The plunger is made of a conductive material and accomplishes this movement by providing a path...

Страница 1913: ...ontrolled by the TCM into the appropriate hydraulic control pressure p S TCC Fig 234 Modulating Pressure Control Solenoid Valve 1 MODULATING PRESSURE CONTROL SOLENOID VALVE 2 CONTACT SPRING 3 CONDUCTO...

Страница 1914: ...ze selector valve and selec tor lever positions P and N The park neutral con tact consists of the plunger 2 the permanent magnet 3 the dry reed contact 4 TRANSMISSION TEMPERA TURE SENSOR Fig 236 Shift...

Страница 1915: ...cuit to the starter in the selector lever positions P and N is closed TRANSMISSION TEMPERA TURE SENSOR The temperature of the transmission oil has a con siderable effect on the shifting time and there...

Страница 1916: ...elec tronically applied converter clutch The converter clutch provides reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatur...

Страница 1917: ...of the converter As the converter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 243 Impeller 1 ENGINE FLEXPLATE 4...

Страница 1918: ...ted through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 244 T...

Страница 1919: ...zero slippage condition could be obtained A hydraulic piston with friction material was added to the turbine assembly to provide this mechanical lock up In order to reduce heat build up in the transmi...

Страница 1920: ...over running clutch to its shaft Fig 249 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter...

Страница 1921: ...ed for and actuated During Partial EMCC some slip does occur Partial EMCC will usually occur at low speeds low load and light throttle situations FULL EMCC During Full EMCC operation the TCM increases...

Страница 1922: ...converter is fully seated 7 If necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recomme...

Страница 1923: ...DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 9 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 9 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 10 STANDARD PROCEDURE REPAIRING LEAKS 12 CLEANING 12 SPECIFICATIONS TI...

Страница 1924: ...oceed to Method 2 METHOD 2 RELOCA TE TIRE ON WHEEL NOTE Rotating the tire on wheel is particularly effective when there is runout in both tire and wheel 1 Remove tire from wheel and mount wheel on ser...

Страница 1925: ...he high spot Place a mark on the tire at the valve stem location Fig 4 3 Break down the tire and remount it 180 degrees on the rim Fig 5 4 Measure the total indicator runout again Mark the tire to ind...

Страница 1926: ...eel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balan...

Страница 1927: ...Fig 7 Static Unbalance Balance 1 HEAVY SPOT 2 CENTER LINE OF SPINDLE 3 ADD BALANCE WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP VA TIRES WHEELS 22 5...

Страница 1928: ...n be used but may not provide the same tire longevity benefits CAUTION 3500 Dual rear tires have a new tire rota tion pattern This is to accommodate the asymmet rical design of the ON OFF road tires a...

Страница 1929: ...tire rotation inter val shown in the section on Tire Rotation Refer to 22 TIRES WHEELS STANDARD PROCEDURE This will help to achieve a greater tread life TIRE IDENTIFICA TION Tire type size aspect rat...

Страница 1930: ...e driven at continuous speeds above 75 mph 120 km h For emergency vehicles that are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct in...

Страница 1931: ...re gauge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight DIAGNOSIS AND TESTING TIRE NOISE OR VIBRA TION Radial ply tires are sensitive to force imp...

Страница 1932: ...IS AND TESTING TIRE VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Cor rection Chart to diagnose and correct a vehicle lead or drift problem Fig 16 Fig 15 Tire Wear Patterns 22 10 TIRES WHE...

Страница 1933: ...Fig 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART VA TIRES WHEELS 22 11...

Страница 1934: ...deteri oration of the tires To remove the protective coating apply warm water and let it soak for a few minutes Afterwards scrub the coating away with a soft bristle brush Steam cleaning may also be u...

Страница 1935: ...THE RIM COULD FAIL WITH OUT WARNING STANDARD PROCEDURE STANDARD PROCEDURE WHEEL REPLACE MENT The wheel stud lugs are designed for specific appli cations They must be replaced with equivalent parts Do...

Страница 1936: ...ame number sequence Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS Tighten lug nuts in same numbered sequence a second time to the specified torque This will ensure that the wheels are thoroughly mate...

Страница 1937: ...riations 3 Install the hub cap to the wheel then install snugly the lug nuts to hold the hub cap to the wheel DRW Fig 23 4 Install the wheel lug nuts DRW and tighten to specification Refer to 22 TIRES...

Страница 1938: ......

Страница 1939: ...when the ignition is OFF Damage to electrical system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol...

Страница 1940: ...cted use a suitable mirror to gain visual access A mirror can also be used to deflect light to a limited access area to assist in locating a leak point BRIGHT LIGHT LEAK TEST METHOD Some water leaks i...

Страница 1941: ...e The one difference is the material used for the repair The materials must be specific for each substrate rigid repair material for rigid plastic repair semi rigid repair material for semi rigid plas...

Страница 1942: ...CARBONATE LEXAN MERLON CALIBRE MAKROLON PC TAIL LIGHT LENSES IP TRIM VALANCE PANELS PC ABS PC ABS ALLOY GERMAX BAY BLENDS PULSE DOORS INSTRUMENT PAN ELS PPO POLYPHENYLENE OXIDE AZDEL HOSTALEN MAR LEX...

Страница 1943: ...BODY TRIMS TPE THERMO POLYETHYLENE TPE HYTREL BEXLOY V FASCIAS BUMPERS CLAD DINGS TPO THERMOPOLYOLEFIN POLYTROPE RENFLEX SANTOPRENE VISAFLEX ETA APEX TPO SHIELDS CLADDINGS BUMPERS END CAPS TEL CAR RUB...

Страница 1944: ...trate through and make a good bond between the panel and the adhesive Structurally the more dry wall tape used the stronger the repair Another kind of repair that can be done to repair large cracks an...

Страница 1945: ...l that has extensive puncture type damage can be repaired by cutting out the damaged material Fig 7 Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is dam age...

Страница 1946: ...y panel with adhesive sandwiched between the panel and squares Fig 9 12 Position patch in cutout against support squares and adjust patch until the gap is equal along all sides Fig 10 13 Drill 3 mm 0...

Страница 1947: ...CUTOUT AND ALIGN 1 CUTOUT 2 SUPPORT SQUARES Fig 11 APPLY ADHESIVE TO SUPPORT SQUARES 1 APPLICATOR 2 SUPPORT SQUARES 3 ADHESIVE Fig 12 INSTALL SCREWS 1 PATCH 2 GAP Fig 13 GRIND SURFACE 1 PATCH 2 GAP 3...

Страница 1948: ...ed to eliminate noises caused by metal plastic and vinyl components Long life lubricants and greases can also be used on a vari ety of components Refer to the Buzz Squeak Rat tle Kit table for materia...

Страница 1949: ...rubber When access is not possible oil will migrate to condition Vinyl rubber plastic metal Examples Convertible top bushings pull cups trim panel inserts 30 to 400 Fahr enheit 34 to 205 Cel sius Kry...

Страница 1950: ...crews 10 89 Sliding door center roller arm bolt 45 33 Sliding door center track bolts nuts 10 89 Sliding door inside handle screw 10 89 Sliding door latch screws 10 89 Sliding door latch lock control...

Страница 1951: ...LLATION 21 WINDOW REGULATOR MANUAL REMOVAL 21 INSTALLATION 22 CHECK REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Rem...

Страница 1952: ...s Fig 3 4 Remove the bolts and disconnect the door check from the a pillar Fig 4 5 Support door with a suitable device 6 Loosen the hinge set screws Fig 5 7 Remove door by lifting off hinge pins INSTA...

Страница 1953: ...ODY DOOR FRONT LATCH STRIKER REMOVAL 3 Remove side view mirror Refer to 23 BODY EXTERIOR SIDE VIEW MIRROR REMOVAL 4 Loosen hinge bolts and adjust door gap and align ridge pattern as necessary 5 Tighte...

Страница 1954: ...TALLA TION 1 Position front of handle into front slot in door Fig 10 2 Position rear of handle into latch opening and engage lock and latch actuation levers with the latch levers Fig 11 3 Slide exteri...

Страница 1955: ...and remove hinge Fig 14 INSTALLA TION 1 Install hinge and install bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Tighten hinge set bolts 4 Install side view mirror Refer to 23 BODY EXTERIOR SIDE VIEW MIR...

Страница 1956: ...remove the striker Fig 16 INSTALLA TION 1 Install striker and install bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Check door for flush and adjust the striker hor izontally if necessary Refer to 23 BOD...

Страница 1957: ...pped 6 Open pocket door Fig 19 7 Using a trim stick C 4755 or equivalent sepa rate window frame molding from door Fig 20 Fig 17 TRIM PANEL HANDLE 1 SWITCH BEZEL 2 HANDLE COVER Fig 18 TRIM PANEL FASTEN...

Страница 1958: ...REGULATOR POWER REMOVAL 1 Lower front window approximately 2 cm 3 4 in 2 Disconnect and isolate battery negative cable 3 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 4 Discon...

Страница 1959: ...5 Remove glass support 6 Connect the electrical connector 7 Connect battery negative cable 8 Verify correct window operation 9 Install trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION W...

Страница 1960: ...10 N m 89 in lbs 4 Remove glass support 5 Connect battery negative cable 6 Verify correct window operation 7 Install trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION Fig 26 GLASS SUPPORT...

Страница 1961: ...llar trim if equipped Refer to 23 BODY INTERIOR D PILLAR TRIM REMOVAL 4 Remove the rivets and remove the receiver INSTALLA TION 1 Install the receiver and replace the rivets 2 Install d pillar trim if...

Страница 1962: ...Fig 2 CHECK STRAP 1 RECEIVER 2 DOOR CHECK Fig 3 DOOR HINGES 1 DOOR 2 TORX BOLTS 2 PER HINGE 3 ALLEN BOLTS 1 PER HINGE 23 24 DOORS REAR VA...

Страница 1963: ...move bolts 2 and remove top closing wedge 1 8 Remove bolts 9 and remove door check 10 Refer to 23 BODY DOORS REAR CHECK REMOVAL 9 Remove the bolts 3 and remove the door hinges 4 Refer to 23 BODY DOORS...

Страница 1964: ...m closing wedge 21 10 Remove rear door seal 8 11 Remove the four screws 9 14 from the lock rod actuator 12 Using locking pliers hold upper lock rod 2 and remove lock rod actuator 13 Remove clips 15 14...

Страница 1965: ...RIOR HANDLE INSTALLATION 6 Install the latch assembly 14 Refer to 23 BODY DOORS REAR LATCH INSTALLATION 7 Install trim panel 20 Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 8 Install door Refer...

Страница 1966: ...or and install switches 17 12 Connect electrical connectors and install license plate lighting 18 19 13 Install trim panel 20 Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 14 Install door Refer...

Страница 1967: ...ach door individually 3 Close the door and check gap measurement 4 Loosen allen screw through hole in hinge Fig 9 NOTE Adjust so that bottom closing wedges make contact and door gaps are uniform all t...

Страница 1968: ...w 2 at top hinge turn in adjustment screw 2 at bottom hinge Retaining magnet strikes too hard against mat ing plate Turn in adjustment screw 1 at top and bottom hinge Retaining magnet does not make co...

Страница 1969: ...t of door Fig 14 NOTE Front door shown rear door similar 3 Pull rear of handle out away from door and dis engage the latch levers 4 Slide handle towards the rear of door and remove INSTALLA TION 1 Pos...

Страница 1970: ...MOVAL NOTE It is not necessary to remove the door to replace the hinges if they are replaced one at a time 1 Using a grease pencil or equivalent mark the position of the hinge on the door 2 Remove the...

Страница 1971: ...latch cable 2 Install handle and screws 3 Install trim cover LATCH REMOVAL 1 Disconnect and isolate battery negative cable 2 Remove right side trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVA...

Страница 1972: ...pin fasteners if equipped 3 Using a trim stick C 4755 or equivalent remove the lower trim panel 4 Remove rivets and remove upper trim panel if equipped INSTALLA TION 1 Install upper trim panel and re...

Страница 1973: ...CK CONTROL REMOVAL 38 INSTALLATION 39 REAR LATCH REMOVAL 40 INSTALLATION 40 REAR LATCH STRIKER REMOVAL 40 INSTALLATION 40 SLIDING DOOR REMOVAL 40 DISASSEMBLY 42 ASSEMBLY 43 INSTALLATION 44 ADJUSTMENTS...

Страница 1974: ...rear of vehicle and remove from back of track INSTALLA TION 1 Install roller arm into upper track from back 2 Position roller arm on door and install the bolts 3 Tighten bolts to 25 N m 18 ft lbs 4 A...

Страница 1975: ...l scuff pad Fig 5 2 Remove the door screws and remove the roller arm Fig 6 INSTALLA TION 1 Install roller arm and install door screws 2 Tighten screws to 25 N m 18 ft lbs 3 Install stepwell scuff pad...

Страница 1976: ...w center track and apply pressure of approximately 40 p s i over the entire surface of the track 5 Install the front bolts and tighten to 10 N m 89 in lbs 6 Install the interior nuts and tighten to 10...

Страница 1977: ...bolts to 10 N m 89 in lbs 4 Connect electrical connectors 5 Install trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL INSTALLATION 6 Connect battery negative cable Fig 9 ELECTRICAL CONNECTORS 1 CO...

Страница 1978: ...R LATCH STRIKER REMOVAL 1 Open door 2 Remove bolts and remove striker Fig 14 INSTALLA TION 1 Install striker and bolts 2 Tighten bolts to 25 N m 18 ft lbs 3 Adjust striker if necessary Refer to 23 BOD...

Страница 1979: ...Fig 15 SLIDING DOOR 1 STOP BUMPER 2 SCREWS 2 3 SCREWS 2 4 LOWER ROLLER ARM 5 END PIECE 6 SCREWS 2 VA DOORS SLIDING 23 41...

Страница 1980: ...NG EXTERIOR HANDLE REMOVAL 10 Remove center roller arm 20 Refer to 23 BODY DOORS SLIDING LOWER ROLLER ARM REMOVAL 11 Remove stabilizer wedges 6 Refer to 23 BODY DOORS SLIDING STABILIZER REMOVAL 12 Rem...

Страница 1981: ...Y DOORS SLIDING REAR LATCH INSTALLA TION 9 Install lock rod 25 and connect to latch lock control 10 Install the lock knob 27 11 Install the trim panel 24 Refer to 23 BODY DOORS SLIDING TRIM PANEL INST...

Страница 1982: ...body sealant should be used when removing or moving the hinges 1 Remove bolts and remove striker Fig 18 2 Check gaps and ridge pattern on door all the way around Refer to 23 BODY BODY STRUC TURE GAP...

Страница 1983: ...zer closing wedge screws Fig 22 9 Close sliding door to adjust closing wedge 10 Open door and tighten screws to 10 N m 89 in lbs Door Stop Bumper Adjust 1 Loosen door stop bumper bolts 2 Open sliding...

Страница 1984: ...o receive the glass and weatherstrip seal 2 Start at an inside upper corner Separate the seal from the window opening Push the glass and seal outward from the window opening Remove the glass and seal...

Страница 1985: ...rify that the seal is seated in the window opening Fig 25 7 Test the window for water leaks Refer to 23 BODY DIAGNOSIS AND TESTING WATER LEAKS Fig 25 Glass Weatherstrip Seal Installation 1 BODY PANEL...

Страница 1986: ...connect the filler cap tether 4 Remove two bolts and remove filler door INSTALLA TION 1 Install the door and bolts 2 Connect filler cap tether 3 Close doors GRILLE REMOVAL 1 Remove screw rivets Fig 1...

Страница 1987: ...river s Side 1 Disconnect and isolate battery negative cable 2 Remove trim plug Fig 3 NOTE If the vehicle is not equipped with power mirrors skip to step 5 3 Remove trim panel Refer to 23 BODY DOOR FR...

Страница 1988: ...with power mir rors skip to step 6 4 Connect the electrical connector 5 Connect dust boot to a pillar 6 Install trim plug 7 Connect battery negative cable SIDE VIEW MIRROR GLASS REMOVAL 1 Disconnect...

Страница 1989: ...eference marks 2 Install cowl bolts and tighten to 23 N m 17 ft lbs 3 Install hood nuts and tighten to 23 N m 17 ft lbs 4 Check and adjust hood if necessary Refer to 23 BODY HOOD HOOD ADJ USTMENTS HOO...

Страница 1990: ...am bumpers up or down if nec essary LATCH REMOVAL 1 Remove bolts and remove latch Fig 3 2 Disconnect latch cable INSTALLA TION 1 Connect latch cable and install latch 2 Install the bolts and tighten L...

Страница 1991: ...nd install the nut and washer 3 Connect spring and prop onto hood and install the retaining spring SAFETY LATCH REMOVAL 1 Open hood 2 Using a grease pencil or equivalent mark the position of the safet...

Страница 1992: ...INSTALLA TION 1 Install the latch and install the bolts 2 Adjust the latch if necessary Refer to 23 BODY HOOD HOOD ADJ USTMENTS Fig 6 SAFETY LATCH 1 SAFETY LATCH 2 BOLTS 23 54 HOOD VA...

Страница 1993: ...BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIV...

Страница 1994: ...HIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Move selector lever to position...

Страница 1995: ...TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Install the bezel and install the screws 2 Install the...

Страница 1996: ...THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Install bottom section and ins...

Страница 1997: ...SSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN...

Страница 1998: ...cover Fig 13 Fig 9 STEERING COLUMN SHROUD 1 SHROUD 2 SCREWS 2 3 NUT Fig 10 POWER DISTRIBUTION CENTER 1 BOLT 2 POWER DISTRIBUTION CENTER 3 GROUND NUT 4 WASHER 5 NUT 6 GROUND WIRE Fig 11 POWER DISTRIBUT...

Страница 1999: ...move brake pedal spring Fig 17 Fig 13 SIDE COVERS NOZZLES 1 LEFT SIDE COVER 2 RIGHT SIDE COVER 3 BRACKET 4 OUTER AIR NOZZLE 5 INNER AIR NOZZLE 6 INNER AIR NOZZLE 7 OUTER AIR NOZZLE Fig 14 PROTECTIVE M...

Страница 2000: ...position 25 Remove steering column support bolts Fig 19 26 Remove the screws and remove instrument panel Fig 20 Fig 17 BRAKE PEDAL SPRING 1 STEERING COLUMN 2 SPRING Fig 18 IGNITION TRANSPONDER 1 COLUM...

Страница 2001: ...OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERVICED WITH DOORS IN THE ORIGINAL COL...

Страница 2002: ...NSTRUMENT PANEL GLOVE BOX INSTALLATION 28 Install radio Refer to 8 ELECTRICAL AU DIO RADIO INSTALLATION 29 Connect battery negative cable TOP COVER CLUSTER REMOVAL WARNING ON VEHICLES EQUIPPED WITH AI...

Страница 2003: ...NECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABL...

Страница 2004: ...IT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS...

Страница 2005: ...E PASSENGER AIRBAG DOOR FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAGS ARE SERV...

Страница 2006: ...ARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT 1 Position top cover and slide toward front of vehicle NOTE Observe cable routing for radio The leads should not be located above the a...

Страница 2007: ...ATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO T...

Страница 2008: ...ACKET 75 STEPWELL SCUFF PADS REMOVAL 75 INSTALLATION 76 SUN VISOR REMOVAL 76 INSTALLATION 76 INTERIOR CAUTION CAUTION Do not attempt to remove interior trim panels moldings without first removing the...

Страница 2009: ...1 Install the handle and install the screws B PILLAR TRIM REMOVAL 1 Remove the lower seat belt anchor bolt Fig 4 2 Pull door opening weatherstrip away from flange along the b pillar Fig 5 3 Using a tr...

Страница 2010: ...TS REMOVAL Cargo Passenger Van Front 1 Remove the stepwell scuff pads Refer to 23 BODY INTERIOR STEPWELL SCUFF PADS REMOVAL 2 Remove the three bolts and tray behind drivers seat 3 Remove cup holder Re...

Страница 2011: ...2 Remove the sun visors Refer to 23 BODY INTERIOR SUN VISOR REMOVAL 3 Remove the b pillar trim Refer to 23 BODY INTERIOR B PILLAR TRIM REMOVAL 4 Remove the assist handle Refer to 23 BODY INTERIOR ASSI...

Страница 2012: ...trical connector and install the front duct work cover 7 Install the push pin fasteners 8 Install the second and third row seats Refer to 23 BODY SEATS SEAT INSTALLATION 9 Connect battery negative cab...

Страница 2013: ...vial to saturate the felt applicator b Remove the paper sleeve c Apply accelerator to the contact surface on the bracket d Allow the accelerator to dry for five minutes e Do not touch the bracket con...

Страница 2014: ...racket if necessary SUN VISOR REMOVAL 1 Remove the support screws and remove the visor Fig 10 INSTALLA TION 1 Position visor and support on header 2 Install the screws Fig 9 SLIDING DOOR SCUFF PAD 1 T...

Страница 2015: ...or color can result PAINT TOUCH UP DESCRIPTION When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use MOPAR Scr...

Страница 2016: ...PTION CAUTION Do not remove more than 5 mils of clearcoat finish if equipped Basecoat paint must retain clearcoat for durability Use a Paint Thickness Gauge PR ETG 2X or equiv alent to determine film...

Страница 2017: ...T CUSHION COVER REAR REMOVAL 83 INSTALLATION 83 ARMREST REMOVAL 1 Remove the screws and remove the armrest cover 2 Remove the three bolts and remove the arm rest from the seat back INSTALLA TION 1 Ins...

Страница 2018: ...uring installation operate the seat back release lever once 3 Install the spline side seat back bolt 4 Install remaining seat back side NOTE It may be necessary to press the guide tabs apart slightly...

Страница 2019: ...Remove the seat cushion Refer to 23 BODY SEATS SEAT CUSHION FRONT REMOVAL 4 Remove the four bolts attaching adjust to seat track INSTALLA TION 1 Install the adjuster onto the seat track and install t...

Страница 2020: ...fer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT RETRACTOR REMOVAL 4 Remove seat belt buckles as necessary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT BUCKLE REMOVAL 5 Remove the headrests Refer to 2...

Страница 2021: ...the lower seat belt anchors as neces sary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT RETRACTOR REMOVAL 4 Remove seat belt buckles as necessary Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT BUC...

Страница 2022: ...dow opening 3 Position the glass and seal in the trim panel opening 4 Pull the installation cord outward and force the seal lip over the panel flange around the edge of the opening Fig 1 5 Seat the se...

Страница 2023: ...NI CAL DATA SHEETS AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212 TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBL...

Страница 2024: ...e is cured Water leaks can result The windshield fence should be cleaned of most of its old urethane bonding material A small amount of old urethane approximately 1 mm in height should remain on the f...

Страница 2025: ...ss to be re glued with a suitable glass preparation solvent and rag 8 Using a flash light verify that glass primer is without damage 9 Re prime any damaged area If old adhesive has been exposed for mo...

Страница 2026: ...ening 2 Level old bead of windshield opening adhesive to a thickness of approximately 1 mm 0 04 in and remove loose adhesive Fig 10 3 Clean and dry area of windshield opening to be re glued with a sui...

Страница 2027: ...neously on both sides CAUTION Roll down the left and right front door glass and open the rear glass slider if available before installing windshield to avoid pressurizing the passenger compartment if...

Страница 2028: ...move channel 3 Remove outer belt weatherstrip INSTALLA TION 1 Install outer belt weatherstrip 2 Install glass run channel and install the screws 3 Install the door glass Refer to 23 BODY DOOR FRONT DO...

Страница 2029: ...NT DOORS 1 SLIDING DOORS 2 REAR DOORS 3 NOTE All measurements are in mm LOCATION GAP FLUSH 1 Door at top 7 0 5 FLUSH 2 Door at upper b pil lar 7 0 5 Up to max 1 mm recessed at rear with 1 mm overlap w...

Страница 2030: ...FLUSH 3 Door ridge at b pillar and side panel FLUSH without offset NOTE All measurements are in mm LOCATION GAP FLUSH 1 Rear doors at top 13 0 5 FLUSH 2 Right rear door to left rear door 8 0 5 FLUSH...

Страница 2031: ...OPENING DIMENSIONS SPECIFICA TIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 4 Fig 4 WINDSHIELD OPENING VA BODY STRUCTURE 23 93...

Страница 2032: ......

Страница 2033: ...obstructions in front of the radiator or A C condenser will reduce the performance of the A C and engine cooling systems The engine cooling system includes the radiator thermostat radiator hoses and...

Страница 2034: ...air The automatic temperature control ATC system controls interior temperature by taking actual values from the temperature sensors and the CAN bus and comparing them to the nominal value of the tempe...

Страница 2035: ...he amount of moisture in the air is not wasted Wring ing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers Although an owner may expect too much from their...

Страница 2036: ...se 2 Check the fuses in the Power distribution block and junction block Repair the shorted circuit or component and replace the fuses if required Refer to Group 8 3 Faulty A C compressor clutch coil 3...

Страница 2037: ...t system if required 6 Engine overheating 6 Test the engine cooling system and repair if required Refer to Group 7 Cooling The low side pressure is too high and the high side pres sure is too low 1 Ac...

Страница 2038: ...ing system connections Inoperative or stuck heater water valve Plugged heater core If proper coolant flow is verified and heater floor outlet air temperature is insufficient a mechanical problem may e...

Страница 2039: ...Compres sor Denso 10S17 ND 8 PAG oil Freeze up Con trol Evaporator Tem perature Sensor Input to rear A C control module evaporator fin mounted cycles clutch off below 1 6 C 35 F cycles clutch back on...

Страница 2040: ...18 REMOVAL 18 INSTALLATION 18 BLOWER MOTOR SWITCH DESCRIPTION 19 OPERATION 19 DIAGNOSIS AND TESTING BLOWER MOTOR SWITCH 19 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 19 OPERATION 19 REMOVAL 20 INSTALL...

Страница 2041: ...t Check the air gap in four or more places on the clutch plate to verify that the air gap is still correct Spin the clutch pulley before making the final air gap check A C COMPRESSOR CLUTCH BREAK IN A...

Страница 2042: ...pulley to the front of the compressor then slide the pulley off of the com pressor Fig 4 8 Remove the screw that secures the clutch coil wire harness connector bracket and ground clip to the top of th...

Страница 2043: ...uch coil wire harness leads are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil NOTE A new snap ring must be used to secure the clutch...

Страница 2044: ...BIII scan tool PRELIMINARY CHECKS 1 If no diagnostic trouble codes DTCs are found in the A C heater control or the powertrain control module PCM go to Step 2 If any DTCs are found repair as required 2...

Страница 2045: ...o discharge before performing further diagnosis or service This is the only sure way to disable the supplemental restraint system Failure to take the proper precau tions could result in accidental air...

Страница 2046: ...essor clutch and the auxiliary radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage The A C pressure transducer input to the ATC m...

Страница 2047: ...stem Refer to 24 HEATING AIR CONDITION ING PLUMBING STANDARD PROCEDURE 2 Disconnect and isolate the battery negative cable 3 Disconnect the wire harness connector from the A C pressure transducer Fig...

Страница 2048: ...trol module makes adjust ments to maintain the requested interior temperature by cycling both the A C compressor and solenoid heater valve on and off The air outlet temperature sensor is diagnosed by...

Страница 2049: ...ged it must be replaced REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the front license plate bracket Refer to 23 BODY EXTERIOR LICENSE PLATE BRACKET REMOVAL 3 Disconnect the wi...

Страница 2050: ...ation views for the various wire harness connectors splices and grounds 1 Disconnect and isolate the negative battery cable 2 Disconnect the wire harness connector from the blower motor resistor 3 Che...

Страница 2051: ...onditioned air downstream of the A C evaporator Fig 18 The evaporator temperature sensor is an electrical thermistor within a molded plastic case that is inserted into the HVAC housing near the coldes...

Страница 2052: ...e harness connector from evaporator temperature sensor Fig 19 15 Remove evaporator temperature sensor from HVAC housing INSTALLA TION 1 Install the probe of the evaporator temperature sensor between t...

Страница 2053: ...stic Procedures For circuit descriptions and diagrams refer to the appro priate wiring information MODE DOOR CABLES REMOVAL The air distribution control cables mode door cables can be removed and inst...

Страница 2054: ...l solenoid The electrical solenoid is connected to the A C heater control through the vehicle electrical sys tem by a dedicated two wire lead and connector The output shaft of the recirculation door a...

Страница 2055: ...le INSTALLA TION 1 Connect the actuator shaft to the recirculation door pivot lever 2 Install the two screws that secure the recircu lation door actuator to the ventilation housing Tighten the screws...

Страница 2056: ...ESTING REAR A C TEMPERATURE CONTROL 39 REMOVAL 39 INSTALLATION 40 TEMPERATURE SENSOR DESCRIPTION 40 OPERATION 40 DIAGNOSIS AND TESTING REAR TEMPERATURE SENSOR 40 REMOVAL 40 INSTALLATION 41 SUPPRESSOR...

Страница 2057: ...arallel with the relay coil and helps to dissipate voltage spikes and electromag netic interference that can be generated as the elec tromagnetic field of the relay coil collapses The rear A C clutch...

Страница 2058: ...r A C condenser fan relay is an electrome chanical device that uses a low current input to con trol the high current output to the A C condenser fan for the rear heating A C system The rear A C conden...

Страница 2059: ...d of the relay coil collapses The rear A C condenser fan relay terminals are connected to the vehicle electrical system through a receptacle in the relay block located in the rear A C evaporator housi...

Страница 2060: ...A C temperature control and the temperature sensor The rear A C control module is located in the upper left side of the rear A C evaporator housing OPERA TION The rear A C control module is supplied f...

Страница 2061: ...diagrams REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo rator housing Refer to 24 HEATING AIR CON DITIONING DISTRIBUTION REAR AIR FILTER R...

Страница 2062: ...disengagement and control rear A C condenser cooling fan operation Fig 7 The rear A C control module will disengage the rear A C clutch if the rear refrigerant system pres sure exceeds approximately...

Страница 2063: ...ver the refrigerant from the rear refriger ant system Refer to 24 HEATING AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refe...

Страница 2064: ...ar suction line pressure rises to approximately 234 to 262 kPa 34 to 38 psi or above Lower ambient temperatures below approximately 1 C 30 F will also cause the rear A C low pressure switch contacts t...

Страница 2065: ...l dimensions current capacities terminal functions and patterns The rear blower motor relays are elec tromechanical devices that switches fused battery current directly to the rear blower motors The r...

Страница 2066: ...e rear blower motor relays cannot be repaired and if faulty or damaged they must be replaced Refer to the appropriate wiring information for diag nosis and testing of the ISO standard relay and for co...

Страница 2067: ...3 The rear A C blower motor switch allows the selection of one of two blower motor speeds and an Off position OPERA TION With the front A C switch activated the rear blower motor speed can be selected...

Страница 2068: ...of the ohmmeter to terminal 10 and the positive ohmmeter lead to terminals 1 7 and 4 To check the switch s integral light emitting diodes reverse the ohmmeter leads 4 Check for continuity between the...

Страница 2069: ...e sensor is located in the rear A C evaporator housing OPERA TION The rear evaporator temperature sensor signals the rear A C control module to cycle the rear A C clutch off if the rear evaporator tem...

Страница 2070: ...ol for the optional rear A C system is a thumbwheel type control mounted in the switch panel on the instrument panel Fig 17 The rear A C temperature control allows the selection of four temperature se...

Страница 2071: ...rol 3 Check for continuity between terminal 9 and terminals 3 and 5 of the A C temperature control In all instances there should be continuity NOTE To check the switch s internal circuits con nect the...

Страница 2072: ...f faulty or damaged it must be replaced DIAGNOSIS AND TESTING REAR TEMPERA TURE SENSOR 1 Disconnect and isolate the negative battery cable 2 Disconnect the wire harness connector from the rear tempera...

Страница 2073: ...or the three rear blower motor relays The suppression filters also impede the prop agation of RF interference into the vehicles electrical system by the rear blower motors to ensure interfer ence free...

Страница 2074: ...HVAC wiring diagrams REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the cover from the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVA...

Страница 2075: ...terference suppression filter Fig 23 for the rear A C condenser fan protects the rear A C control circuits and the vehicles electrical system from volt age spikes which may be generated by the rear co...

Страница 2076: ...uts that secure the rear condenser fan suppression filter to the rear A C condenser housing and remove the sup pression filter INSTALLA TION 1 Position the rear condenser fan suppression fil ter to th...

Страница 2077: ...y 4 Install the insulation blanket onto the ventila tion housing AIR OUTLETS REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint sys...

Страница 2078: ...ide air outlets install the air outlet retaining bracket to the right side of the instrument panel Tighten the screw to 2 N m 17 in lbs 4 If servicing the passenger side air outlets install the passen...

Страница 2079: ...23 BODY INSTRUMENT PANEL REMOVAL 2 Remove the screw that secures the left and or right side defroster duct to the heater housing depending on the duct being removed Fig 5 3 Remove the defroster duct...

Страница 2080: ...IONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The HVAC housing...

Страница 2081: ...LECTRICAL RESTRAINTS PASSENGER AIRBAG REMOVAL 20 Disconnect the wire harness connector from the evaporator temperature sensor and air outlet temperature sensor Fig 8 21 Remove the wire harness from th...

Страница 2082: ...TALLA TION NOTE High pressures are produced in the refriger ant system when the A C compressor is operating Extreme care must be exercised to make sure that each of the refrigerant system connections...

Страница 2083: ...E 26 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE INSTRUMENT PANEL DUCTS REMOVAL 1 Remove the instrument panel Refer to 23...

Страница 2084: ...IONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo...

Страница 2085: ...reservoir ports 11 Remove the eight nuts and washers that secure the rear A C condenser housing to the roof panel 12 Carefully separate the body sealer between the rear A C condenser housing and the r...

Страница 2086: ...gerant oil of the type recommended for the rear A C compressor in the vehicle 7 Connect the rear liquid line to the rear refrig erant reservoir outlet Tighten the liquid line nut to 35 N m 26 ft lbs 8...

Страница 2087: ...secure the rear A C evaporator cover to the rear of the evaporator housing and remove the cover INSTALLA TION 1 Position the rear A C evaporator cover to the rear A C evaporator housing 2 Install the...

Страница 2088: ...f the way 9 Remove the nut that secures the positive wire lead to the rear A C system terminal block and posi tion the wire lead out of the way 10 Remove the insulating tape from around the rear evapo...

Страница 2089: ...vap orator housing and install the four bolts and washers and four damping washers that secure the evapora tor housing to the roof panel Tighten the bolts to 25 N m 18 ft lbs 5 Install the nine screws...

Страница 2090: ...tor housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 22 Install the cover onto the rear A C condenser housing Refer to 24 HEATING AIR CONDI TIONI...

Страница 2091: ...connect the wiring harness connectors to the suppression filter and to the rear blower motor being serviced 5 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONI...

Страница 2092: ...VALVE DESCRIPTION 73 OPERATION 73 DIAGNOSIS AND TESTING A C EXPANSION VALVE 74 REMOVAL 74 INSTALLATION 74 ELECTRIC COOLANT PUMP DESCRIPTION 75 OPERATION 75 REMOVAL 75 INSTALLATION 76 HEATER CORE DESC...

Страница 2093: ...ed by qualified service personnel Severe per sonal injury or death may result from improper service procedures WARNING Avoid breathing the refrigerant and refrigerant oil vapor or mist Exposure may ir...

Страница 2094: ...open the refrigerant system or uncap a replacement component until you are ready to ser vice the system Immediately after disconnecting a component from the refrigerant system seal the open fittings w...

Страница 2095: ...erant dye STANDARD PROCEDURE REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING Eye protection must be worn when ser vicing an A C refrigerant system Turn off rotate clockwise all valves on the equipment be...

Страница 2096: ...the proper care and use of this equipment REFRIGERANT SYSTEM EVACUA TE WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEAT...

Страница 2097: ...make contact with the bottom surfaces of the evaporator inlet and outlet tubes 3 Open all of the windows or doors of the passen ger compartment 4 Set the A C button on the A C Heater controls to the o...

Страница 2098: ...The A C compressor is driven by the engine through an electric clutch drive pulley and belt arrangement The A C compressor is lubricated by refrigerant oil that is circulated throughout the refrigeran...

Страница 2099: ...ONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE If the high pressure relief valve still does not seat properly replace the a c compressor Refer to 24 HEATING AIR CONDITIONING PLUMBI...

Страница 2100: ...or Fig 5 6 Remove the bolts that secure the underbody suction and discharge lines to the A C compressor 7 Disconnect the underbody suction and dis charge lines from the A C compressor and remove and d...

Страница 2101: ...engine com partment and loosely install the three compressor retaining bolts Tighten the bolts using the following sequence to 20 N m 14 ft lbs The upper bolt at the front of the compressor The lower...

Страница 2102: ...ver the opened liquid line fitting and the condenser ports 9 Disconnect the wire harness connector from the auxiliary fan 10 Remove the auxiliary fan and upper bracket assembly 11 Remove the auxiliary...

Страница 2103: ...e line fitting and discard 7 Install plug in or tape over the opened dis charge line fitting and the condenser inlet port 8 Remove the bolt that secures the discharge line fitting to the top of the co...

Страница 2104: ...g refrigerant through the A C evaporator The A C evaporator tubes are connected and sealed to the A C expansion valve by use of rubber O rings and a tapping block The A C evaporator is serviced by rem...

Страница 2105: ...TIONING DISTRIBUTION HVAC HOUSING INSTALLATION A C EXPANSION VALVE DESCRIPTION The A C expansion valve controls the amount of refrigerant entering the A C evaporator and is of a thermostatic expansion...

Страница 2106: ...e performing the fol lowing operation Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions cou...

Страница 2107: ...t near the battery and is controlled by the A C heater control The electric coolant pump housing contains two coolant hose connections and an electric motor which drives the vane type pump using a mag...

Страница 2108: ...engine is transferred to the heater core fins and tubes Air directed through the heater core picks up the heat from the heater core fins The heater water valve controls the heater output air temperat...

Страница 2109: ...G ASSEMBLY NOTE If the heater core is being replaced flush the cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM CLEANING RE VERSE FLUSHING 5 Install the HVAC housing Refer to 24 HEA...

Страница 2110: ...BING REFRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM RECOV ERY 2 Disconnect and isolate the negative battery cable 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 4 Remove the nut that...

Страница 2111: ...he liquid and suction line fittings the receiver drier outlet port and both expansion valve ports 3 Lubricate new rubber O ring seals with clean refrigerant oil and install them onto the suction and l...

Страница 2112: ...ts 4 Lubricate new rubber O ring seals with clean refrigerant oil and install them on the liquid line fit tings 5 Connect the front and rear sections of the liq uid line to the receiver drier 6 Instal...

Страница 2113: ...ant system This ensures proper lubrica tion of the A C compressor Too little oil will result in damage to the A C compressor Too much oil will reduce the cooling capacity of the A C system It will not...

Страница 2114: ...com pressor 5 Install the bolt that secures the A C suction line to the A C compressor Tighten the bolt to 23 N m 17 ft lbs 6 Remove the tape or plugs from the liquid and suction line fittings and bo...

Страница 2115: ...nd remove the water valve from the rubber mounts 9 If necessary remove the rubber mounts from the bracket or water valve INSTALLA TION 1 If removed install the rubber mounts to the heater water valve...

Страница 2116: ...personal injury or death 1 Remove the rear A C evaporator housing and place it on a workbench Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION REAR REAR A C EVAPORATOR HOUSING REMOVAL 2 Remove the f...

Страница 2117: ...ION The rear A C expansion valve controls the amount of refrigerant entering the rear A C evaporator Fig 24 The rear A C expansion valve is of an externally equalized thermostatic expansion valve TXV...

Страница 2118: ...nt system Refer to 24 HEATING AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the insulating tape from around the area of the rear A C expansion valve Fig 25 5 Disconnect t...

Страница 2119: ...to the rear A C expansion valve Tighten the nut to 35 N m 26 ft lbs 6 Connect the equalizer tube to the rear evapora tor outlet tube Tighten the nut to 10 N m 88 in lbs 7 Position the rear expansion v...

Страница 2120: ...ve the cover from the rear A C evaporator housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system...

Страница 2121: ...underneath of the vehicle 13 Disconnect the rear A C discharge line from the underbody discharge line and remove and discard the O ring seal 14 Remove the foam rubber seal from the open ing in the flo...

Страница 2122: ...ee foam insulators to the right inner quarter panel 9 Install the right quarter trim panel Refer to 23 BODY INTERIOR QUARTER TRIM PANEL INSTALLATION 10 Connect the rear discharge line to the rear A C...

Страница 2123: ...warnings and cau tions could result in possible personal injury or death CONDENSER TO RECEIVER DRIER 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo...

Страница 2124: ...to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER REMOVAL 5 Disconnect the rear liquid line from the reser voir and remove and discard the O ring seal Fig 32 6 Disconnect the rear...

Страница 2125: ...R CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 10 Install the cover onto the rear A C condenser housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLAT...

Страница 2126: ...bracket that secures the rear receiver drier to the rear A C con denser housing and remove the receiver drier 8 Install plugs into or tape over the opened rear liquid line fitting and reservoir and re...

Страница 2127: ...he air filter from the rear A C evapo rator housing Refer to 24 HEATING AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 H...

Страница 2128: ...ser housing Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION REAR SUCTION LINE DESCRIPTION The rear A Csuction line is the refrigerant line that carries refrig...

Страница 2129: ...ft quarter trim panel Refer to 23 BODY INTERIOR QUARTER TRIM PANEL REMOVAL 8 Remove the three foam insulators from the left inner quarter panel 9 Remove the foam rubber seal from the opening in the fl...

Страница 2130: ...NG STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the rear refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 12 Install the cove...

Страница 2131: ...Push the A C line disconnect tool into the open side of the coupler cage to expand the garter spring Once the garter spring is expanded and while still pushing the disconnect tool into the open side o...

Страница 2132: ...cted the A C compres sor Two sections of the underbody suction line low side are connected together by a tapping block with an O ring seal The underbody A C dis charge line uses a spring lock type ref...

Страница 2133: ...derbody suction line 6 Disconnect the front section of the underbody suction line from the rear section and remove and discard the O ring seal 7 Install plug in or tape over all of the opened suction...

Страница 2134: ...w rubber O ring seal with clean refrig erant oil install it onto the discharge line fitting and install the bolt that secures the discharge line to the compressor Tighten the bolt to 21 N m 15 ft lbs...

Страница 2135: ...on line to the rear section of the suction line and install the retaining bolt Tighten the bolt to 25 N m 18 ft lbs 8 Lower the vehicle 9 Evacuate the rear refrigerant system Refer to 24 HEATING AIR C...

Страница 2136: ...tional heat depending on engine coolant temperature OPERA TION The supplemental cabin heater is activated by using the temperature control on the A C heater con trol The supplemental cabin heater is a...

Страница 2137: ...ntrol module using the DRBIII scan tool and the procedures listed in Vehicle Performance under Cabin Heater Diagnosis in Group 18 Loss of coolant Leakage or heater develops smoke during combustion ope...

Страница 2138: ...6 Lower the vehicle FUEL DOSING PUMP DESCRIPTION The dosing pump is a combined delivery dosing and shut off system for the fuel supply to the supple mental cabin heater from the vehicle fuel tank OPE...

Страница 2139: ...the fuel pump by depressing the integral spring and pushing the connector towards the dosing pump Pull the con nector towards the cabin heater to verify the instal lation 5 Verify function of the supp...

Страница 2140: ...AL 1 Raise and support the vehicle Take note of the location of the flexible section of the cabin heater exhaust tube NOTE Have an approved fuel holding device ready to capture any diesel fuel that dr...

Страница 2141: ...el tank and tighten the connection securely 3 Install the fuel line at the dosing pump and tighten the connection securely 4 Lower the vehicle NOTE Failure to prime the dosing pump after drain ing the...

Страница 2142: ...open port NOTE Utilize an approved fuel storage container to catch any residual fuel 9 Loosen the two fasteners at the rail Take care to notice that the exhaust tube bracket tab is on top of the heate...

Страница 2143: ...r wire harness from the left side between the heater unit and the heater shield 2 Install the two wiring harness retainers to the cabin heater shield 3 Route the wiring harness along the underside of...

Страница 2144: ...all and tighten the retaining clamp securely 4 Install the cabin heater tubes to the lower heater connection and the lower EGR cooler connec tion and tighten the retaining clamps 5 Lower the vehicle 6...

Страница 2145: ...ield 3 Disconnect the CCV heater wiring harness con nector 4 Using a slight twisting motion separate the CCV breather tube from the heater 5 Separate the CCV heater from the turbo charger air inlet du...

Страница 2146: ...n passage into the cylinder head cover Fig 2 The oil separator removes oil from the blow by gasses to reduce MAF sensor contamination For service procedures refer to Refer to 25 EMISSIONS CON TROL EVA...

Страница 2147: ...s to 11 N m 97 in lbs Fig 3 4 Connect the CCV breather outlet hose Fig 3 5 Install the engine cover Refer to 9 ENGINE INSTALLATION Fig 3 CCV BREATHER 1 FUEL RAIL 6 CAM POSITION SENSOR 2 FUEL RAIL PRES...

Страница 2148: ...g high engine idle to avoid carbon build up on the valve The EGR also deactivates if the EGR temperature is too high The EGR also has a self cleaning function that opens and closes twice after the eng...

Страница 2149: ...reduced because the exhaust gas is low in oxygen The result is that the combustion rate is reduced as is the combustion temperature This reduces the quantity of NOx that are emitted in the exhaust gas...

Страница 2150: ...connect the electrical connector at the EGR positioner Fig 3 5 Disconnect the EGR cooler hose 6 Remove the EGR fasteners and EGR with cooler assembly Fig 3 INSTALLA TION 1 Clean all gasket mating surf...

Страница 2151: ...d Cooler are serviced as an assembly refer to Refer to 25 EMISSIONS CON TROL EXHAUST GAS RECIRCULATION VALVE REMOVAL Fig 4 EGR AND COOLER 1 EGR VALVE 2 EGR COOLER 3 INTAKE MANIFOLD VA EXHAUST GAS RECI...

Страница 2152: ......

Страница 2153: ...SC BRAKE CALIPERS 5 11 DOME LAMP INTRUSION SENSOR BULB 8L 33 DOME LAMP INTRUSION SENSOR 8L 33 DOME READING LAMP BULB 8L 32 DOME READING LAMP UNIT 8L 32 DOOR GLASS 23 15 23 30 23 46 DOOR JAMB SWITCH 8L...

Страница 2154: ...ATION DOOR ACTUATOR 24 22 REFRIGERANT LINE COUPLER 24 98 REFRIGERANT OIL 24 81 REFRIGERANT 24 80 RELAY 8W 97 4 REMOTE KEYLESS ENTRY TRANSMITTER 8N 1 REPEATER LAMP BULB 8L 23 REPEATER LAMP UNIT 8L 24 R...

Страница 2155: ...___________________________________________________ ______________________________________________________________________________________ _____________________________________________________________...

Страница 2156: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Страница 2157: ...ODE ERASURE 5 3 4 USING THE DRBIII 5 3 5 DRBIII ERROR MESSAGES 5 3 5 1 DRBIII DOES NOT POWER UP BLANK SCREEN 5 3 5 2 DISPLAY IS NOT VISIBLE 5 4 0 DISCLAIMERS SAFETY AND WARNINGS 5 4 1 DISCLAIMERS 5 4...

Страница 2158: ...42 ABS RR SENSOR MESSAGE 44 ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT 46 CAN BUS CIRCUIT 48 CAN MESSAGE FROM ECM FROM SLA 53 CONTROL MODULE TCM IS NOT CODED 55 ENGINE CAN MESSAGE INCORRECT 56 ENGINE C...

Страница 2159: ...8 0 COMPONENT LOCATIONS 129 8 1 ENGINE CONTROL MODULE 129 8 2 TRANSMISSION CONTROL MODULE 129 8 3 TRANSMISSION SOLENOID ASSEMBLY 129 9 0 CONNECTOR PINOUTS 131 ELECTROHYDRAULIC CONTROL UNIT BLACK 131...

Страница 2160: ...NOTES iv...

Страница 2161: ...ears are actuated electronically hydraulically The electronic control system enables precise adaptation of pres sures to the respective operating conditions and to the engine output during a shift pha...

Страница 2162: ...d or may result in engine or transmission failure the transmission will be placed in the neutral position Improper Ratio Input Sensor Overspeed or Engine Overspeed DTC s will cause the loss of drive C...

Страница 2163: ...nhibitor is part of the Shift Lever Assembly and is controlled by the Shift Lever Assembly module Trans temp sensor P N Sw itch circuit The TCM will detect the selector lever in park and neutral posit...

Страница 2164: ...lems can be misinterpreted as a transmission prob lem Ensure that the engine is running properly and that no ECM DTC s are present that could cause a transmission complaint If there is a communicatio...

Страница 2165: ...n ignition cycle which will place the DTC in an intermittent status Stored DTC When there are no diagnostic trouble codes stored in memory the DRBIII w ill display NO DTC s DETECTED 3 4 USING THE DRBI...

Страница 2166: ...asses without failure 4 2 3 SERVICING SUB ASSEMBLIES Some components of the Transmission system are intended to be serviced in assembly only Attempt ing to remove or repair certain system sub componen...

Страница 2167: ...rs performed fixed the vehicle correctly Always operate and observe the vehicle under ac tual driving conditions J ust as important as the road test is there are preliminary inspections that should be...

Страница 2168: ...ically Modulated Converter Clutch PWM Pulse width modulated SKREEM Sentry Key Remote Entry Module SLA Shift Lever Assembly SW Switch TCC Torque Converter Clutch TCM Transmission Control Module TP Thro...

Страница 2169: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...

Страница 2170: ...orted condition Repair as necessary Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Shifter Assembly harness connector Disconnect the DRBIII from th...

Страница 2171: ...at of a direct connection to the battery Does the test light illuminate brightly All Yes Repair the K ABS Shifter Assembly circuit for a short to voltage Perform NAG1 TRANSMISSION VERIFICATION TEST VE...

Страница 2172: ...EST VER 1 No Go To 2 2 Turn the ignition off Disconnect the TCM harness connectors Disconnect the DRBIII from the DLC Measure the resistance between ground and the K TCM circuit Is the resistance belo...

Страница 2173: ...ween the TCM connector and the DLC Is the resistance below 5 0 ohms All Yes Replace the Transmission Control Module in accordance with the Service Information Perform NAG1 TRANSMISSION VERIFICATION TE...

Страница 2174: ...ever Assembly harness connector Isolate the Backup Lamp circuit remove the Backup Lamp bulbs NOTE Check Backup Lamp bulbs and socket for a short or corrosion Measure the resistance between ground and...

Страница 2175: ...ge above 0 5 volts All Yes Repair the Backup Lamp circuit for a short to voltage No Replace the Shift Lever Assembly per the Service Information 3 Turn the ignition off to the lock position Disconnect...

Страница 2176: ...a 12 volt test light connected to ground check the Fused Ignition Switch Output circuit NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the batter...

Страница 2177: ...f the ECM is reporting a CAN bus failure refer to its respective test first No Go To 2 2 Turn the ignition off to the lock position Disconnect the ECM harness connector Disconnect the SLA harness conn...

Страница 2178: ...e per the Service Information Ignition on engine not running With the DRBIII erase Transmission DTCs Start the engine and with the brakes firmly applied place the gear selector into Drive With the DRB...

Страница 2179: ...INTERNAL CONTROLLER POSSIBLE CAUSES INTERNAL CONTROLLER Repair Instructions INTERNAL CONTROLLER The Shift Lever Assembly has detected an internal fault Replace the Shift Lever Assembly 19 SHIFT LEVER...

Страница 2180: ...CAN bus or Wheel Speed Sensor DTCs present All Yes Refer to the ABS category and perform the appropriate symptom No Go To 2 2 Replace the ABS Control Module per the Service Information Verify if the D...

Страница 2181: ...off to the lock position Disconnect the Shift Lever Assembly harness connector Start the engine and raise the engine speed to 1500 RPM Measure the Transmission Relay Output voltage at the Shift Lever...

Страница 2182: ...CAN bus or Wheel Speed Sensor DTCs present All Yes Refer to the ABS category and perform the appropriate symptom No Go To 2 2 Replace the ABS Control Module per the Service Information Verify if the D...

Страница 2183: ...rm the appropriate symptom No Go To 2 2 Turn the ignition off to the lock position Disconnect the Shift Lever Assembly harness connector Start the engine Increase the Engine Speed to 1500 RPM Measure...

Страница 2184: ...id open solenoid or an open or shorted solenoid control circuit driver in the TCM 1 2 4 5 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Страница 2185: ...2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 1 2 4 5 SOLENOID CIRCUIT reset All Yes Go To 3 No Go To 7 3...

Страница 2186: ...ectors Clean repair as necessary Measure the resistance between the 1 2 4 5 Solenoid Control circuit and the Solenoid Supply Voltage Circuit in the Transmission Control Module C2 harness connector Is...

Страница 2187: ...lenoid open solenoid or an open or shorted solenoid control circuit driver in the TCM 2 3 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Страница 2188: ...ue Go To 2 2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 2 3 SOLENOID CIRCUIT reset All Yes Go To 3 No Go...

Страница 2189: ...nnectors Clean repair as necessary Measure the resistance between the 2 3 Solenoid Control circuit and the Solenoid Supply Voltage circuit in the Transmission Control Module C2 harness connector Is th...

Страница 2190: ...lenoid open solenoid or an open or shorted solenoid control circuit driver in the TCM 3 4 SOLENOID CIRCUIT SHORT TO GROUND When Monitored Always monitored with system active at each ignition cycle Set...

Страница 2191: ...ue Go To 2 2 Ignition on engine not running With the DRBIII erase DTCs With the DRBIII perform the Solenoid Test With the DRBIII read DTCs Did the DTC 3 4 SOLENOID CIRCUIT reset All Yes Go To 3 No Go...

Страница 2192: ...ectors Clean repair as necessary Measure the resistance between the 3 4 Solenoid Control circuit and the Solenoid Supply Voltage circuit in the Transmission Control Module C2 harness connector Is the...

Страница 2193: ...smission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagra...

Страница 2194: ...ce and program the ABS Control Module With the DRBIII erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selector into drive With the DRBIII read Transmission DTCs...

Страница 2195: ...minal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle...

Страница 2196: ...TY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw...

Страница 2197: ...r NOTE Check connectors Clean repair as necessary Measure the resistance of the CAN Bus circuit between the ABS harness connector and the TCM C2 harness connector Measure the resistance of the CAN Bus...

Страница 2198: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Страница 2199: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Страница 2200: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Страница 2201: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Страница 2202: ...prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Страница 2203: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Страница 2204: ...rior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs...

Страница 2205: ...n the ignition off to the lock position Replace the ABS Control Module per the Service Information With the DRBIII erase Transmission DTCs Road test the Vehicle With the DRBIII read Transmission DTCs...

Страница 2206: ...d repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engi...

Страница 2207: ...there any Accel Pedal DTCs present All Yes Refer to the Driveability category and perform the appropriate symptom Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 6 6 Replace the Transmissio...

Страница 2208: ...CAN C Bus circuit CAN C Bus circuit shorted to CAN C Bus circuit or a TCM failure Note All CAN message missing DTCS will also be present which indicates a Bus Failure POSSIBLE CAUSES CAN BUS CIRCUITS...

Страница 2209: ...y Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII read the active and stored DTCs for all modules that use CAN Bus communication NOTE Due to capabilities of ce...

Страница 2210: ...Bus module the vehicle is equipped with Monitor and note the voltmeter reading NOTE Repeat the above step for each CAN Bus module until all the modules have been disconnected NOTE Refer to the w irin...

Страница 2211: ...nect the SKREEM harness connector Disconnect the ECM harness connectors Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit Is the resistance below 50 0 ohms after disconnec...

Страница 2212: ...20 0 ohms 5 0 ohms All Yes Replace the Sentry Key Remote Entry Module per the Service Information Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Repair the CAN C Bus and or CAN C Bus circuit for...

Страница 2213: ...iagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a g...

Страница 2214: ...Turn the ignition off to the lock position Disconnect the Shift Lever harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Shift Lever harness conne...

Страница 2215: ...ODED POSSIBLE CAUSES TRANSMISSION CONTROL MODULE FLASH TEST ACTION APPLICABILITY 1 View repair All Repair Flash the Transmission Control Module to the proper level Perform NAG1 TRANSMISSION VERIFICATI...

Страница 2216: ...transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring di...

Страница 2217: ...into drive With the DRBIII read Transmission DTCs Did the DTC ENGINE CAN MESSAGE INCORRECT reset All Yes Go To 4 No Test Complete Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 4 If there are no po...

Страница 2218: ...ir the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTC...

Страница 2219: ...n repair as necessary Measure the resistance of the CAN Bus circuit between the ECM harness connector and the TCM C2 harness connector Measure the resistance of the CAN Bus circuit between the ECM har...

Страница 2220: ...s prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DT...

Страница 2221: ...echanical problems and be operating normally before proceeding w ith this test Turn the ignition off to the lock position Replace and program the PCM ECM Control Module per the Service Information Wit...

Страница 2222: ...ion symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram sch...

Страница 2223: ...ignition off to the lock position Replace and program the ECM per the Service Information With the DRBIII erase Transmission DTCs Start the engine With the brakes firmly applied shift the gear selecto...

Страница 2224: ...vice information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transm...

Страница 2225: ...Temperature Sensor DTCs present All Yes Refer to the Driveability category and perform the appropriate symptom Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Replace and program the EC...

Страница 2226: ...the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as neces...

Страница 2227: ...ts With the DRBIII read Transmission DTCs Did the DTC ENGINE TORQUE MESSAGE INCORRECT reset All Yes Go To 4 No Test Complete Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 4 If there are no possibl...

Страница 2228: ...djust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engin...

Страница 2229: ...it open All Yes Repair the CAN C BUS or circuit for an open Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Ignition on engine not running With the DRBIII read Engine DTCs Are there any...

Страница 2230: ...agnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a gu...

Страница 2231: ...4 4 Turn the ignition off to the lock position Disconnect the Instrument Cluster C1 harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Instrument C...

Страница 2232: ...ecessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be se...

Страница 2233: ...r an open 6 NOTE If vehicle is equipped w ith Air Conditioning diagnose the ATC system first Ignition on engine not running With the DRBIII read Instrument Cluster or Automatic Temp Control DTCs Are t...

Страница 2234: ...ION APPLICABILITY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service infor...

Страница 2235: ...ansmission Valve Body and Electrohydraulic Control Unit Assembly per the Service Information NOTE This DTC is usually set due to a internal transmission problem such as but not limited to stuck soleno...

Страница 2236: ...OTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays p...

Страница 2237: ...ction procedures Is there any Debris plugged Transmission Oil filter or signs of an Internal Transmission problem All Yes Refer to the Service Information for the proper repair procedure Pay particula...

Страница 2238: ...level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnos...

Страница 2239: ...nsmission problem All Yes Repair Internal Transmission as necessary Pay particular atten tion to the Electrohydraulic Control unit Refer to the Service Information for proper repair procedures Perform...

Страница 2240: ...arged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Tra...

Страница 2241: ...d Transmission Oil Filter or signs of an Internal Transmission problem All Yes Repair Internal Transmission as necessary Pay particular atten tion to the Electrohydraulic Control unit Refer to the Ser...

Страница 2242: ...is Internal Controller DTC is set with any Solenoid DTC s repair the Solenoid DTC s first erase all DTC s then verify the Internal Controller DTC sets before replacing the TCM POSSIBLE CAUSES TCM INTE...

Страница 2243: ...s a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run Note Verify flash level...

Страница 2244: ...locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII rea...

Страница 2245: ...Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Mod Pr...

Страница 2246: ...Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Replace the Mod Press Solenoid per the Service Information Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set this...

Страница 2247: ...from the ABS system Set Condition If the N2 input speed sensor is equal to 0 rpm or a short to ground short to battery open input speed sensor faulty input speed sensor open sensor supply circuit POS...

Страница 2248: ...To 2 2 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid harness connector NOTE Check connectors Clean repair as necessary Measure...

Страница 2249: ...or Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disco...

Страница 2250: ...and increase vehicle speed to engage 2nd gear CAUTION BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Compare the Scope Pattern on the DRBIII with a typical 5 volt square wave pattern Does th...

Страница 2251: ...d gear is 3rd or 4th and the detected gear is the actual vehicle gear Set Condition If the N3 input speed sensor is equal to 0 rpm or a short to ground short to battery open input speed sensor faulty...

Страница 2252: ...To 2 2 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Disconnect the Transmission Solenoid harness connector NOTE Check connectors Clean repair as necessary Measure...

Страница 2253: ...r Signal circuit for a short to other circuit s Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off to the lock position Disconnect the TCM C2 harness connector Discon...

Страница 2254: ...and increase vehicle speed to engage 2nd gear CAUTION BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Compare the Scope Pattern on the DRBIII with a typical 5 volt square wave pattern Does th...

Страница 2255: ...perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics Wi...

Страница 2256: ...cessary Measure the resistance of the Sensor Supply circuit to chassis ground in the Transmission Solenoid Assembly harness connector Is the resistance below 5 0 ohms All Yes Repair the Sensor Supply...

Страница 2257: ...ram schematic as a guide inspect the wiring and connectors Repair as necessary Most DTCs set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run Note Ver...

Страница 2258: ...e resistance between the CAN C Bus circuit and the CAN C Bus circuit in the Shift Lever harness connector Is the resistance 60 ohms 3 0 ohms All Yes Replace the Shift Lever Assembly per the service in...

Страница 2259: ...roblems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid f...

Страница 2260: ...ion Control Module C2 harness connector Disconnect the Transmission Solenoid Assembly harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Sh...

Страница 2261: ...Control Module Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Replace the Shift Pressure Solenoid Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set this DTC ar...

Страница 2262: ...t by driving the vehicle such that all diagnostic monitors have run Note Verify flash level of transmission controller Some problems are corrected by softw are upgrades to the transmission controller...

Страница 2263: ...h a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and re...

Страница 2264: ...Yes Repair the Solenoid Supply Voltage circuit for a short to ground or high resistance Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Discon...

Страница 2265: ...d the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as nece...

Страница 2266: ...r circuits in the TCM harness connector Is the resistance below 5 0 ohms between Solenoid Supply and any other circuit All Yes Repair the Solenoid Supply circuit short to other circuits Perform NAG1 T...

Страница 2267: ...orming transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wi...

Страница 2268: ...ors Clean repair as necessary Start the engine Increase the Engine Speed to 1500 RPM Measure the voltage of the Transmission Relay Output circuit in the TCM C1 harness connector Is the voltage below 1...

Страница 2269: ...l engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connection...

Страница 2270: ...e of the Transmission Relay Output circuit in the TCM C1 harness connector Is the voltage below 9 0 volts All Yes Repair the Transmission Relay Output circuit for an open or high resistance Perform NA...

Страница 2271: ...OTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Most DT...

Страница 2272: ...n check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and rep...

Страница 2273: ...the TCC Solenoid Control circuit for a short to ground Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Disconnect the Transmission Control Mod...

Страница 2274: ...ing and connectors specific to this circuit Wiggle the wires while checking for shorts and open circuits NOTE Check for any Technical Service Bulletins that may apply Were there any problems found All...

Страница 2275: ...l per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to perf...

Страница 2276: ...tor Measure the resistance between ground and the TCC Solenoid Control circuit Is the resistance below 5 0 ohms All Yes Repair the TCC Solenoid Control circuit for a short to ground Perform NAG1 TRANS...

Страница 2277: ...the leak then check and adjust the fluid level per the service information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read the engine DTCs...

Страница 2278: ...or and the Transmission Solenoid Assembly harness connector Is the resistance above 5 0 ohms All Yes Repair the Transmission Temp Sensor P N Switch circuit for an open Perform NAG1 TRANSMISSION VERIFI...

Страница 2279: ...nition off to the lock position Disconnect the TCM C2 harness connector NOTE Make sure the Transmission Solenoid Assembly harness connector is connected or the results of the test w ill be invalid Wit...

Страница 2280: ...d and record all Transmission DTCs NOTE Check connectors Clean repair as necessary Poor pin to terminal connections can set DTCs Using the wiring diagram schematic as a guide inspect the wiring and co...

Страница 2281: ...e Service Information Perform W5J 400 TRANSMISSION VERIFICATION TEST VER 1 Did the DTC TRANS TEMP SENSOR ERRATIC reset All Yes Replace the Transmission Control Module Perform NAG1 TRANSMISSION VERIFIC...

Страница 2282: ...charged battery to avoid false symptoms With the DRBIII read the engine DTCs Check and repair all engine DTCs prior to performing transmission symptom diagnostics With the DRBIII read and record all...

Страница 2283: ...is procedure With the gear selector in park attempt to start the vehicle Does the vehicle start All Yes Replace the Transmission Temperature Sensor P N Switch Assembly per the Service Information Perf...

Страница 2284: ...ILITY 8 If there are no possible causes remaining view repair All Repair Replace the Transmission Control Module Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 124 TRANSMISSION NAG1 TRANS TEMP SENS...

Страница 2285: ...ABILITY 1 NOTE Low fluid level can be the cause of many transmission problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the service information NOT...

Страница 2286: ...for the proper procedures Were there any problems found All Yes Refer to the Service Information for proper repair procedures Perform NAG1 TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Determine...

Страница 2287: ...airs w ere performed and the shift quality is still poor it may be necessary to check the internal repair Also check for any TSBs and or Controller Flash updates that may apply 9 ROAD TEST PROCEDURE 1...

Страница 2288: ...NOTES 128...

Страница 2289: ...8 0 COMPONENT LOCATIONS 8 1 ENGINE CONTROL MODULE 8 2 TRANSMISSION CONTROL MODULE 8 3 TRANSMISSION SOLENOID ASSEMBL Y C O M P O N E N T L O C A T I O N S 129 COMPONENT LOCATIONS...

Страница 2290: ...NOTES 130...

Страница 2291: ...6YL BL TCC SOLENOID CONTROL 12 20PK SENSOR GROUND 13 16WT 1 2 4 5 SOLENOID CONTROL SHIFTER ASSEMBL Y BLACK CAV CIRCUIT FUNCTION 1 2 20GY DG RD LAMP DRIVER 3 20BL DG K ABS SHIFTER ASSEMBLY 4 18BR GROUN...

Страница 2292: ...NTROL 16 16WT BL 2 3 SOLENOID CONTROL 17 16YL BL TCC SOLENOID CONTROL 33 20PK SENSOR GROUND 34 20GY BL TEMPERATURE SENSOR P N SWITCH 35 20BL DG N3 INPUT SPEED SENSOR 36 16BR GY MODULATION PRESSURE SOL...

Страница 2293: ...LA Y RELA Y BLOCK CAV CIRCUIT FUNCTION 30 16BK DG TRANSMISSION RELAY OUTPUT 85 16BR GROUND 86 16BK YL FUSED IGNITION SWITCH OUTPUT RUN START 87 16RD FUSED B 87A C O N N E C T O R P I N O U T S 133 CON...

Страница 2294: ...NOTES 134...

Страница 2295: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 135 SCHEMATIC DIAGRAMS...

Страница 2296: ...NOTES 136...

Страница 2297: ...11 0 CHARTS AND GRAPHS 11 1 5 VOLT SQUARE WA VE TYPICAL PA TTERN C H A R T S A N D G R A P H S 137 CHARTS AND GRAPHS...

Страница 2298: ...11 2 TRANSMISSION TEMP SENSOR C H A R T S A N D G R A P H S 138 CHARTS AND GRAPHS...

Страница 2299: ...rocedures are appreciated To best understand your suggestion please complete the form giving us as much detail as possible Model Year Body Type Engine Transmission Vehicle Mileage MDH Diagnostic Proce...

Страница 2300: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Страница 2301: ...crobat Reader Main Page Creating Shortcuts from the CD Downloading CD onto your hard drive Troubleshooting Click on any tab for additional information The Main Page tab will take you back to the Main...

Страница 2302: ...er from the Adobe Website Alternately you may visit http www adobe com products acrobat readstep2 html to download the latest version of the reader After accessing the Adobe site exit out of the Acrob...

Страница 2303: ...en type 2005 or the correct Model Year and press the Enter key 2 Insert CD into CD Drive 3 Launch Windows Explorer by right clicking on the Start Button start button is located in the lower left corne...

Страница 2304: ...ck once on the first book folder to view the contents of that folder In the right hand pane of the explorer window right click on the welcome pdf and drag down to Copy 5 Now double click on the deskto...

Страница 2305: ...bat 5 0 Reader in conjunction with CD 6 Right click within this window and select Paste Shortcut Page 3 of 3 Installing Acrobat Reader Main Page Creating Shortcuts from the CD Downloading CD onto your...

Страница 2306: ...select New Folder then type 2005 and press the Enter key 2 Insert CD into CD Drive 3 Launch Windows Explorer by right clicking on the Start Button start button is located in the lower left corner of...

Страница 2307: ...olders and drag them to your newly created desktop folder Page 2 of 3 5 Now open each folder and select the welcome pdf 6 Right click with your mouse and drag down to Copy Next Installing Acrobat Read...

Страница 2308: ...ste Shortcut Page 3 of 3 8 Rename shortcut to Model Year Model 2005 an pdf 9 Repeat for each manual This will launch the default Acrobat Reader from your hard drive the CD no longer has to be in the C...

Страница 2309: ...hes and the welcome pdf is displayed but I can t access any other data Using your mouse move over the document until the cursor changes from an open hand to a pointing finger This indicates where the...

Страница 2310: ...FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to mak...

Страница 2311: ...ear safety goggles w henever w ork ing on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to...

Страница 2312: ...ren Michigan 48092 U S A MILLER SPECIAL TOOLS SPX Corporation Telephone 1 800 801 5420 FAX 1 800 578 7375 INTERNATIONAL The special service tools referred to herein are required for certain service op...

Страница 2313: ...ion that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manua...

Страница 2314: ...In order to serve you better valuable information links and tips are available to you on this disc Please choose the option that best meets your needs Help Helpful Informatio n Troublesh ooting and FA...

Страница 2315: ...Welcome 2006 VA Sprinter Technical Publications Click on the icon for the desired manual Service Manual Body Chassis Transmission Powertrain...

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