2001 Jeep XJ Cherokee Diesel Powertrain Service Manual – PDF DOWNLOAD
DESCRIPTION:
2001 Jeep XJ Cherokee Diesel Powertrain Service Manual – PDF DOWNLOAD
INTRODUCTION:
- The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose engine control module (ECM), powertrain control module (PCM) and sentry key immobilizer module (SKIM) problems; they are no start, diagnostic trouble code, and no trouble code problems.
- The diagnostics in this manual are based on the trouble condition or symptom being present at the time of diagnosis. When repairs are required, refer to the appropriate volume of the service manual for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE MANUAL TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES.
Please follow the recommendations below when choosing your diagnostic path.
1. First make sure the DRBIIIt is communicating with the appropriate modules; ie., if the DRBIIIt displays a 9No Response9 condition, you must diagnose this first before proceeding.
2. Read DTC’s (diagnostic trouble codes) with the DRBIIIt.
3. If no DTC’s are present, identify the customer complaint.
4. Once the DTC or customer complaint is identified, locate the matching test in the Table of Contents and begin to diagnose the symptom. All component location views are in Section 8.0. All connector pinouts are in Section 9.0. All system schematics are in Section 10.0. An * placed before the symptom description indicates a no DTC customer complaint.
TABLE OF CONTENTS:
2001 Jeep XJ Cherokee Diesel Powertrain Service Manual – PDF DOWNLOAD
1 0 INTRODUCTION 1
1 1 SYSTEM COVERAGE 1
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 1
2 0 IDENTIFICATION OF SYSTEM 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 GENERAL DESCRIPTION 1
3 2 FUNCTIONAL OPERATION 1
3 2 1 PCM ON-BOARD DIAGNOSTICS 1
3 2 2 ECM OPERATING MODES 2
3 2 3 MONITORED CIRCUITS 2
3 2 4 SKIS ON-BOARD DIAGNOSTICS 2
3 2 5 SKIS OVERVIEW 2
3 2 6 SKIS OPERATION 2
3 3 DIAGNOSTIC TROUBLE CODES 3
3 3 1 HARD CODE 3
3 3 2 INTERMITTENT CODE 3
3 3 4 ECM DIAGNOSTIC TROUBLE CODES 4
3 3 5 HANDLING NO TROUBLE CODE PROBLEMS 5
3 4 USING THE DRBIIIT 5
3 5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 5
3 5 1 DRBIIIT DOES NOT POWER UP 5
3 5 2 DISPLAY IS NOT VISIBLE 5
4 0 DISCLAIMERS, SAFETY, WARNINGS 6
4 1 DISCLAIMERS 6
4 2 SAFETY 6
4 2 1 TECHNICIAN SAFETY INFORMATION 6
4 2 2 VEHICLE PREPARATION FOR TESTING 6
4 2 3 SERVICING SUB-ASSEMBLIES 6
4 2 4 DRBIIIT SAFETY INFORMATION 6
4 3 WARNINGS 7
4 3 1 VEHICLE DAMAGE WARNINGS 7
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 7
5 0 REQUIRED TOOLS AND EQUIPMENT 7
6 0 GLOSSARY OF TERMS 7
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9
CHARGING
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY – DIESEL 10
P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH – DIESEL 12
P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW – DIESEL 15
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH – DIESEL 17
P1600-BATTERY VOLTAGE SRC HIGH EXCEEDED – DIESEL 19
P1682-CHARGING SYSTEM VOLTAGE TOO LOW – DIESEL 21
*CHECKING THE CHARGING SYSTEM OPERATION – DIESEL 21
i
TABLE OF CONTENTS – Continued
COMMUNICATION
P-1685 INVALID SKIM KEY 25
P-1686 NO SKIM BUS MESSAGE RECEIVED 27
P0600-PCM FAILURE SPI COMMUNICATIONS – DIESEL 29
P0601-PCM INTERNAL CONTROLLER FAILURE – DIESEL 29
P1696-PCM FAILURE EEPROM WRITE DENIED 29
P1687-NO CLUSTER BUS MESSAGE – DIESEL 30
*NO RESPONSE FROM ECM AND PCM (DIESEL ONLY) 32
*NO RESPONSE FROM POWERTRAIN CONTROL MODULE (DIESEL ONLY) 35
DRIVEABILITY – DIESEL
P0115-TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED 37
P0115-TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED 39
P0117-ECT SENSOR VOLTAGE TOO LOW 41
P0118-ECT SENSOR VOLTAGE TOO HIGH 43
P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED 45
P0180-FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED 48
P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY 51
P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED 53
P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED 56
P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED 59
P0235-TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED 61
P0400-EGR OPEN CIRCUIT 63
P0400-EGR SHORT CIRCUIT 65
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 67
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW 69
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH 71
P0500-VEH SPEED SENSOR PEC FREQUENCY TOO HIGH 73
P0500-VEH SPEED SENSOR PLAUSIBILITY 73
P0500-VEH SPEED SENSOR SRC HIGH EXCEEDED 73
P0522-OIL PRESSURE VOLTAGE TOO LOW 79
P0523-OIL PRESSURE VOLTAGE TOO HIGH 81
P0725-ENGINE SPEED SENSOR DYN PLAUSIBILITY 84
P0725-ENGINE SPEED SENSOR STATIC PLAUSIBILITY 84
P0725-ENGINE SPEED SENSOR OVERSPEED RECOGNITION 87
P1105-ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED 89
P1105-ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED 89
P1610-REGULATOR LOWER REGULATOR LIMIT 89
P1610-REGULATOR UPPER REGULATOR LIMIT 89
P1615-MICROCONTROLLER GATE-ARRAY MONITORING 89
P1615-MICROCONTROLLER GATE-ARRAY WATCHDOG 89
P1615-MICROCONTROLLER PREPARE FUEL QUANTITY STOP 89
P1615-MICROCONTROLLER RECOVERY HAS OCCURRED 89
P1615-MICROCONTROLLER REDUNDANT OVERRUN MONITORING 89
P1620 – U-REF (2 5V) 89
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ (EGR) 89
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212 89
P1680-EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM 89
P1680-EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING 89
P1680-EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING 89
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR 89
P1110-AIR TEMP SENSOR SRC HIGH EXCEEDED 91
P1110-AIR TEMP SENSOR SRC LOW EXCEEDED 93
ii
TABLE OF CONTENTS – Continued
P1201-NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED 95
P1201-NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED 98
P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD 100
P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM 102
P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD 104
P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM 104
P1225-CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED 106
P1225-CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDED 106
P1225-CONTROL SLEEVE SENSOR START END POS NOT ATTAINED 109
P1225-CONTROL SLEEVE SENSOR STOP END POS NOT ATTAINED 109
P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION 111
P1230-TIMING GOVERNING POSITIVE GOVERNOR DEVIATION 113
P1515-ACCEL PEDAL SENSOR PLAUSIBILITY 115
P1515-ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER 115
P1515-ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED 115
P1515-ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED 115
P1515-ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED 115
P1520-VEHICLE SPEED GOV ANALOG CTRL – CONTROL CONTACT ALONE 123
P1605-TERMINAL 15 PLAUSIBILITY AFTER START UP 124
P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE 126
P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON 129
P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT 131
P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT 134
P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT 136
P1635-GLOW RELAY 1 CONTROLLER SHORT CIRCUIT 138
P1645-GLOW DISPLAY OPEN CIRCUIT 140
P1645-GLOW DISPLAY SHORT CIRCUIT 143
P1660-REDUNDANT EMERG STOP PLAUSIBILITY IN AFTER-RUN 146
P1660-REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE 148
P1685-VEHICLE THEFT ALARM IMMOBILIZER SIG LOST 151
P1685-VEHICLE THEFT ALARM INVALID SKIM MESSAGE 151
P1690-FAN CONTROL OPEN CIRCUIT 154
P1690-FAN CONTROL SHORT CIRCUIT 156
P1703-BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT 158
P1725-INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY 162
P1725-INDUCTIVE AUX SPEED SENSOR OVERSPEED RECOGNITION 162
P1725-INDUCTIVE AUX SPEED SENSOR PLAUSIBILITY 162
P1725-INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY 162
*CHECKING THE A/C SYSTEM 165
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION 170
*CHECKING THE CHECK ENGINE LAMP OPERATION 171
*CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS 174
*CHECKING THE EGR SYSTEM 176
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION 177
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION 179
*CHECKING THE ENGINE MECHANICAL SYSTEMS 180
*CHECKING THE FUEL COMPUTER 181
*CHECKING THE FUEL HEATER OPERATION 183
*CHECKING THE FUEL INJECTION PUMP 185
*CHECKING THE FUEL LEVEL GAUGE OPERATION 186
*CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION 188
*CHECKING THE GLOW PLUG LAMP OPERATION 189
*CHECKING THE GLOW PLUG OPERATION 191
iii
TABLE OF CONTENTS – Continued
*CHECKING THE LOW COOLANT LAMP OPERATION 192
*CHECKING THE OIL PRESSURE GAUGE OPERATION 196
*CHECKING THE SPEEDOMETER OPERATION 199
*CHECKING THE TACHOMETER OPERATION 202
*CHECKING THE TURBOCHARGER BOOST PRESSURE SENSOR
CALIBRATION 204
*CHECKING THE TURBOCHARGER OPERATION 205
*CHECKING THE VEHICLE SPEED SIGNAL 207
*CHECKING THE WATER IN FUEL LAMP OPERATION 212
HEATING & A/C
P1655-AC CONTROL OPEN CIRCUIT – DIESEL 214
P1655-AC CONTROL SHORT CIRCUIT – DIESEL 216
SPEED CONTROL
P1596-SPEED CONTROL SWITCH ALWAYS HIGH – DIESEL 218
P1597-SPEED CONTROL SWITCH ALWAYS LOW – DIESEL 220
*CHECKING THE SPEED CONTROL OPERATION 222
STARTING
*NO CRANK CONDITION 228
*NO START CONDITION 231
VEHICLE THEFT/SECURITY
ANTENNA FAILURE 234
COP FAILURE 234
EEPROM FAILURE 234
INTERNAL FAULT 234
RAM FAILURE 234
SERIAL LINK INTERNAL FAULT 234
STACK OVERFLOW FAILURE 234
PCM STATUS FAILURE 236
SERIAL LINK EXTERNAL FAULT 236
ROLLING CODE FAILURE 238
VIN MISMATCH 238
TRANSPONDER COMMUNICATION FAILURE 240
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE 240
TRANSPONDER ID MISMATCH 240
TRANSPONDER RESPONSE MISMATCH 240
VERIFICATION TESTS
VERIFICATION TESTS 243
8 0 COMPONENT LOCATIONS 247
8 1 ENGINE CONTROL MODULE, POWERTRAIN CONTROL MODULE AND
SENTRY KEY IMMOBILIZER MODULE 247
8 2 CONTROLS AND SOLENOIDS 248
8 3 DATA LINK CONNECTOR 248
8 4 SENSORS 249
8 5 RELAYS 250
8 6 SWITCHES 251
8 7 LAMPS 252
iv
TABLE OF CONTENTS – Continued
9 0 CONNECTOR PINOUTS 253
A/C COMPRESSOR CLUTCH (DIESEL) – BLACK 2 WAY 253
A/C HIGH PRESSURE SWITCH – 4 WAY 253
A/C LOW PRESSURE SWITCH – 2 WAY 253
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) – BLACK 10 WAY 253
BATTERY TEMPERATURE SENSOR (DIESEL) – BLACK 2 WAY 254
BRAKE LAMP SWITCH – GRAY 6 WAY 254
CLOCKSPRING C1 – NATURAL 4 WAY 254
CLOCKSPRING C2 – YELLOW 2 WAY 254
CLUTCH INTERLOCK SWITCH – GREEN 2 WAY 254
DATA LINK CONNECTOR – BLACK 16 WAY 255
EGR SOLENOID (DIESEL) – 4 WAY 255
ENGINE CONTROL MODULE C1 (DIESEL) – BLACK 51 WAY 256
ENGINE CONTROL MODULE C2 (DIESEL) – BLACK 29 WAY 257
ENGINE COOLANT TEMPERATURE SENSOR NO 1 (DIESEL ECM) – BLACK 2
WAY 257
ENGINE COOLANT TEMPERATURE SENSOR NO 2 (DIESEL PCM) – BLACK 2
WAY 258
ENGINE SPEED SENSOR (DIESEL) – BLACK 3 WAY 258
FUEL HEATER (DIESEL) – 2 WAY 258
FUEL INJECTION PUMP (DIESEL) – BLACK 10 WAY 258
FUEL LEVEL SENSOR (DIESEL) – BLACK 6 WAY 259
GENERATOR – BLACK 2 WAY 259
GENERATOR – 3 WAY 259
GLOW PLUG RELAY (DIESEL) – 4 WAY 259
INSTRUMENT CLUSTER C2 – BLACK 10 WAY 260
LOW COOLANT SWITCH (DIESEL) – 2 WAY 260
MESSAGE CENTER (DIESEL) – BLACK 8 WAY 260
NEEDLE MOVEMENT SENSOR (DIESEL) – 2 WAY 260
FUSES (DIESEL) 262
A/C COMPRESSOR CLUTCH RELAY (DIESEL) – BLACK 2 WAY 262
AUTOMATIC SHUT DOWN RELAY (DIESEL) 262
ENGINE STARTER MOTOR RELAY (DIESEL) 263
FUEL HEATER RELAY (DIESEL) 263
RADIATOR FAN RELAY 263
POWERTRAIN CONTROL MODULE C1 (DIESEL) – 32 WAY 264
POWERTRAIN CONTROL MODULE C2 (DIESEL) – 32 WAY 265
POWERTRAIN CONTROL MODULE C3 (DIESEL) – 32 WAY 266
RADIATOR FAN MOTOR – LT GRAY 2 WAY 266
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 266
TURBO BOOST PRESSURE SENSOR (DIESEL) – BLACK 4 WAY 267
VEHICLE SPEED SENSOR (DIESEL) – 3 WAY 267
WATER IN FUEL SENSOR (DIESEL) – BLACK 2 WAY 267
10 0 SCHEMATIC DIAGRAMS 269
10 1 ENGINE CONTROL MODULE 269
10 2 POWERTRAIN CONTROL MODULE 270
3 1 GENERAL DESCRIPTION 1
3 2 FUNCTIONAL OPERATION 1
3 2 1 PCM ON-BOARD DIAGNOSTICS 1
3 2 2 ECM OPERATING MODES 2
3 2 3 MONITORED CIRCUITS 2
3 2 4 SKIS ON-BOARD DIAGNOSTICS 2
3 2 5 SKIS OVERVIEW 2
3 2 6 SKIS OPERATION 2
3 3 DIAGNOSTIC TROUBLE CODES 3
3 3 1 HARD CODE 3
3 3 2 INTERMITTENT CODE 3
3 3 4 ECM DIAGNOSTIC TROUBLE CODES 4
3 3 5 HANDLING NO TROUBLE CODE PROBLEMS 5
3 4 USING THE DRBIIIT 5
3 5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 5
3 5 1 DRBIIIT DOES NOT POWER UP 5
3 5 2 DISPLAY IS NOT VISIBLE 5
4 0 DISCLAIMERS, SAFETY, WARNINGS 6
4 1 DISCLAIMERS 6
4 2 SAFETY 6
4 2 1 TECHNICIAN SAFETY INFORMATION 6
4 2 2 VEHICLE PREPARATION FOR TESTING 6
4 2 3 SERVICING SUB-ASSEMBLIES 6
4 2 4 DRBIIIT SAFETY INFORMATION 6
4 3 WARNINGS 7
4 3 1 VEHICLE DAMAGE WARNINGS 7
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 7
5 0 REQUIRED TOOLS AND EQUIPMENT 7
6 0 GLOSSARY OF TERMS 7
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9
CHARGING
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY – DIESEL 10
P1492-AMBIENT/BATT TEMP SEN VOLTS TOO HIGH – DIESEL 12
P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW – DIESEL 15
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH – DIESEL 17
P1600-BATTERY VOLTAGE SRC HIGH EXCEEDED – DIESEL 19
P1682-CHARGING SYSTEM VOLTAGE TOO LOW – DIESEL 21
*CHECKING THE CHARGING SYSTEM OPERATION – DIESEL 21
i
TABLE OF CONTENTS – Continued
COMMUNICATION
P-1685 INVALID SKIM KEY 25
P-1686 NO SKIM BUS MESSAGE RECEIVED 27
P0600-PCM FAILURE SPI COMMUNICATIONS – DIESEL 29
P0601-PCM INTERNAL CONTROLLER FAILURE – DIESEL 29
P1696-PCM FAILURE EEPROM WRITE DENIED 29
P1687-NO CLUSTER BUS MESSAGE – DIESEL 30
*NO RESPONSE FROM ECM AND PCM (DIESEL ONLY) 32
*NO RESPONSE FROM POWERTRAIN CONTROL MODULE (DIESEL ONLY) 35
DRIVEABILITY – DIESEL
P0115-TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED 37
P0115-TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED 39
P0117-ECT SENSOR VOLTAGE TOO LOW 41
P0118-ECT SENSOR VOLTAGE TOO HIGH 43
P0180-FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED 45
P0180-FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED 48
P0235-TURBOCHARGER BOOST SENSOR PLAUSIBILITY 51
P0235-TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED 53
P0235-TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED 56
P0235-TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED 59
P0235-TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED 61
P0400-EGR OPEN CIRCUIT 63
P0400-EGR SHORT CIRCUIT 65
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 67
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW 69
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH 71
P0500-VEH SPEED SENSOR PEC FREQUENCY TOO HIGH 73
P0500-VEH SPEED SENSOR PLAUSIBILITY 73
P0500-VEH SPEED SENSOR SRC HIGH EXCEEDED 73
P0522-OIL PRESSURE VOLTAGE TOO LOW 79
P0523-OIL PRESSURE VOLTAGE TOO HIGH 81
P0725-ENGINE SPEED SENSOR DYN PLAUSIBILITY 84
P0725-ENGINE SPEED SENSOR STATIC PLAUSIBILITY 84
P0725-ENGINE SPEED SENSOR OVERSPEED RECOGNITION 87
P1105-ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED 89
P1105-ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED 89
P1610-REGULATOR LOWER REGULATOR LIMIT 89
P1610-REGULATOR UPPER REGULATOR LIMIT 89
P1615-MICROCONTROLLER GATE-ARRAY MONITORING 89
P1615-MICROCONTROLLER GATE-ARRAY WATCHDOG 89
P1615-MICROCONTROLLER PREPARE FUEL QUANTITY STOP 89
P1615-MICROCONTROLLER RECOVERY HAS OCCURRED 89
P1615-MICROCONTROLLER REDUNDANT OVERRUN MONITORING 89
P1620 – U-REF (2 5V) 89
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ (EGR) 89
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212 89
P1680-EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM 89
P1680-EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING 89
P1680-EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING 89
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR 89
P1110-AIR TEMP SENSOR SRC HIGH EXCEEDED 91
P1110-AIR TEMP SENSOR SRC LOW EXCEEDED 93
ii
TABLE OF CONTENTS – Continued
P1201-NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED 95
P1201-NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED 98
P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD 100
P1220-FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM 102
P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD 104
P1220-FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM 104
P1225-CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED 106
P1225-CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDED 106
P1225-CONTROL SLEEVE SENSOR START END POS NOT ATTAINED 109
P1225-CONTROL SLEEVE SENSOR STOP END POS NOT ATTAINED 109
P1230-TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION 111
P1230-TIMING GOVERNING POSITIVE GOVERNOR DEVIATION 113
P1515-ACCEL PEDAL SENSOR PLAUSIBILITY 115
P1515-ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER 115
P1515-ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED 115
P1515-ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED 115
P1515-ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED 115
P1520-VEHICLE SPEED GOV ANALOG CTRL – CONTROL CONTACT ALONE 123
P1605-TERMINAL 15 PLAUSIBILITY AFTER START UP 124
P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO LATE 126
P1625-ASD/DIESEL POWER RELAY SHUTS OFF TOO SOON 129
P1630-SOLENOID VALVE CONTROLLER OPEN CIRCUIT 131
P1630-SOLENOID VALVE CONTROLLER SHORT CIRCUIT 134
P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT 136
P1635-GLOW RELAY 1 CONTROLLER SHORT CIRCUIT 138
P1645-GLOW DISPLAY OPEN CIRCUIT 140
P1645-GLOW DISPLAY SHORT CIRCUIT 143
P1660-REDUNDANT EMERG STOP PLAUSIBILITY IN AFTER-RUN 146
P1660-REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE 148
P1685-VEHICLE THEFT ALARM IMMOBILIZER SIG LOST 151
P1685-VEHICLE THEFT ALARM INVALID SKIM MESSAGE 151
P1690-FAN CONTROL OPEN CIRCUIT 154
P1690-FAN CONTROL SHORT CIRCUIT 156
P1703-BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT 158
P1725-INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY 162
P1725-INDUCTIVE AUX SPEED SENSOR OVERSPEED RECOGNITION 162
P1725-INDUCTIVE AUX SPEED SENSOR PLAUSIBILITY 162
P1725-INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY 162
*CHECKING THE A/C SYSTEM 165
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION 170
*CHECKING THE CHECK ENGINE LAMP OPERATION 171
*CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS 174
*CHECKING THE EGR SYSTEM 176
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION 177
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION 179
*CHECKING THE ENGINE MECHANICAL SYSTEMS 180
*CHECKING THE FUEL COMPUTER 181
*CHECKING THE FUEL HEATER OPERATION 183
*CHECKING THE FUEL INJECTION PUMP 185
*CHECKING THE FUEL LEVEL GAUGE OPERATION 186
*CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION 188
*CHECKING THE GLOW PLUG LAMP OPERATION 189
*CHECKING THE GLOW PLUG OPERATION 191
iii
TABLE OF CONTENTS – Continued
*CHECKING THE LOW COOLANT LAMP OPERATION 192
*CHECKING THE OIL PRESSURE GAUGE OPERATION 196
*CHECKING THE SPEEDOMETER OPERATION 199
*CHECKING THE TACHOMETER OPERATION 202
*CHECKING THE TURBOCHARGER BOOST PRESSURE SENSOR
CALIBRATION 204
*CHECKING THE TURBOCHARGER OPERATION 205
*CHECKING THE VEHICLE SPEED SIGNAL 207
*CHECKING THE WATER IN FUEL LAMP OPERATION 212
HEATING & A/C
P1655-AC CONTROL OPEN CIRCUIT – DIESEL 214
P1655-AC CONTROL SHORT CIRCUIT – DIESEL 216
SPEED CONTROL
P1596-SPEED CONTROL SWITCH ALWAYS HIGH – DIESEL 218
P1597-SPEED CONTROL SWITCH ALWAYS LOW – DIESEL 220
*CHECKING THE SPEED CONTROL OPERATION 222
STARTING
*NO CRANK CONDITION 228
*NO START CONDITION 231
VEHICLE THEFT/SECURITY
ANTENNA FAILURE 234
COP FAILURE 234
EEPROM FAILURE 234
INTERNAL FAULT 234
RAM FAILURE 234
SERIAL LINK INTERNAL FAULT 234
STACK OVERFLOW FAILURE 234
PCM STATUS FAILURE 236
SERIAL LINK EXTERNAL FAULT 236
ROLLING CODE FAILURE 238
VIN MISMATCH 238
TRANSPONDER COMMUNICATION FAILURE 240
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE 240
TRANSPONDER ID MISMATCH 240
TRANSPONDER RESPONSE MISMATCH 240
VERIFICATION TESTS
VERIFICATION TESTS 243
8 0 COMPONENT LOCATIONS 247
8 1 ENGINE CONTROL MODULE, POWERTRAIN CONTROL MODULE AND
SENTRY KEY IMMOBILIZER MODULE 247
8 2 CONTROLS AND SOLENOIDS 248
8 3 DATA LINK CONNECTOR 248
8 4 SENSORS 249
8 5 RELAYS 250
8 6 SWITCHES 251
8 7 LAMPS 252
iv
TABLE OF CONTENTS – Continued
9 0 CONNECTOR PINOUTS 253
A/C COMPRESSOR CLUTCH (DIESEL) – BLACK 2 WAY 253
A/C HIGH PRESSURE SWITCH – 4 WAY 253
A/C LOW PRESSURE SWITCH – 2 WAY 253
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) – BLACK 10 WAY 253
BATTERY TEMPERATURE SENSOR (DIESEL) – BLACK 2 WAY 254
BRAKE LAMP SWITCH – GRAY 6 WAY 254
CLOCKSPRING C1 – NATURAL 4 WAY 254
CLOCKSPRING C2 – YELLOW 2 WAY 254
CLUTCH INTERLOCK SWITCH – GREEN 2 WAY 254
DATA LINK CONNECTOR – BLACK 16 WAY 255
EGR SOLENOID (DIESEL) – 4 WAY 255
ENGINE CONTROL MODULE C1 (DIESEL) – BLACK 51 WAY 256
ENGINE CONTROL MODULE C2 (DIESEL) – BLACK 29 WAY 257
ENGINE COOLANT TEMPERATURE SENSOR NO 1 (DIESEL ECM) – BLACK 2
WAY 257
ENGINE COOLANT TEMPERATURE SENSOR NO 2 (DIESEL PCM) – BLACK 2
WAY 258
ENGINE SPEED SENSOR (DIESEL) – BLACK 3 WAY 258
FUEL HEATER (DIESEL) – 2 WAY 258
FUEL INJECTION PUMP (DIESEL) – BLACK 10 WAY 258
FUEL LEVEL SENSOR (DIESEL) – BLACK 6 WAY 259
GENERATOR – BLACK 2 WAY 259
GENERATOR – 3 WAY 259
GLOW PLUG RELAY (DIESEL) – 4 WAY 259
INSTRUMENT CLUSTER C2 – BLACK 10 WAY 260
LOW COOLANT SWITCH (DIESEL) – 2 WAY 260
MESSAGE CENTER (DIESEL) – BLACK 8 WAY 260
NEEDLE MOVEMENT SENSOR (DIESEL) – 2 WAY 260
FUSES (DIESEL) 262
A/C COMPRESSOR CLUTCH RELAY (DIESEL) – BLACK 2 WAY 262
AUTOMATIC SHUT DOWN RELAY (DIESEL) 262
ENGINE STARTER MOTOR RELAY (DIESEL) 263
FUEL HEATER RELAY (DIESEL) 263
RADIATOR FAN RELAY 263
POWERTRAIN CONTROL MODULE C1 (DIESEL) – 32 WAY 264
POWERTRAIN CONTROL MODULE C2 (DIESEL) – 32 WAY 265
POWERTRAIN CONTROL MODULE C3 (DIESEL) – 32 WAY 266
RADIATOR FAN MOTOR – LT GRAY 2 WAY 266
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 266
TURBO BOOST PRESSURE SENSOR (DIESEL) – BLACK 4 WAY 267
VEHICLE SPEED SENSOR (DIESEL) – 3 WAY 267
WATER IN FUEL SENSOR (DIESEL) – BLACK 2 WAY 267
10 0 SCHEMATIC DIAGRAMS 269
10 1 ENGINE CONTROL MODULE 269
10 2 POWERTRAIN CONTROL MODULE 270
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V