2003 Dodge Caravan & Voyager Service Manual – PDF DOWNLOAD
FILE DETAILS:
2003 Dodge Caravan & Voyager Service Manual – PDF DOWNLOAD
Language : English
Pages : 4732
Downloadable : Yes
File Type : PDF
Size: 90.6 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2003 Dodge Caravan & Voyager Service Manual – PDF DOWNLOAD
FOREWORD:
- The information contained in this service manual has been prepared for the professional automotive technician
involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle. - Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components.
To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
first page of the group has a contents section that lists major topics within the group. - A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions. - Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed. - DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
TABLE OF CONTENTS:
2003 Dodge Caravan & Voyager Service Manual – PDF DOWNLOAD
sm-front pdf 1
16151-rs pdf 3
RG Gas Powertrain 0
RG Diesel Powertrain 0
RG Body 0
RG Chassis 0
RG Transmission 0
RG 2 5L Diesel Supplement 0
RG Service Manual 3
FOREWORD 0
GROUP TAB LOCATOR 3
in-INTRODUCTION 4
BODY CODE PLATE 4
DESCRIPTION 4
BODY CODE PLATE – LINE 3 4
BODY CODE PLATE LINE 2 5
BODY CODE PLATE LINE 1 5
IF TWO BODY CODE PLATES ARE REQUIRED 5
FASTENER IDENTIFICATION 5
DESCRIPTION 5
FASTENER USAGE 8
DESCRIPTION 8
DESCRIPTION – FASTENER USAGE 8
DESCRIPTION – THREADED HOLE REPAIR 8
INTERNATIONAL SYMBOLS 8
DESCRIPTION 8
METRIC SYSTEM 9
DESCRIPTION 9
TORQUE REFERENCES 11
DESCRIPTION 11
VEHICLE IDENTIFICATION NUMBER 12
DESCRIPTION 12
VEHICLE SAFETY CERTIFICATION LABEL 14
DESCRIPTION 14
E-MARK LABEL 14
DESCRIPTION 14
VECI LABEL 14
DESCRIPTION 14
MANUFACTURER PLATE 14
DESCRIPTION 14
0-LUBRICATION & MAINTENANCE 16
INTERNATIONAL SYMBOLS 16
DESCRIPTION 16
FLUID TYPES 16
DESCRIPTION 16
DESCRIPTION – ENGINE OIL AND LUBRICANTS 16
API SERVICE GRADE CERTIFIED 17
SAE VISCOSITY 17
ENERGY CONSERVING OIL 17
CONTAINER IDENTIFICATION 17
SYNTHETIC ENGINE OILS 17
ENGINE OIL ADDITIVES/SUPPLEMENTS 17
GEAR LUBRICANTS 17
LUBRICANTS AND GREASES 18
SPECIALIZED LUBRICANTS AND OILS 18
DESCRIPTION – ENGINE COOLANT 18
DESCRIPTION – FLEXIBLE FUEL ENGINE OIL 18
ETHANOL FUEL (E-85) 18
FUEL REQUIREMENTS 19
FFV STARTING 19
Engine Operating on E-85 Fuel 19
CRUISING RANGE 19
DESCRIPTION – TRANSMISSION FLUID 19
TRANSMISSION FLUID 19
DESCRIPTION – FUEL REQUIREMENTS 19
REFORMULATED GASOLINE 20
GASOLINE/OXYGENATE BLENDS 20
MMT IN GASOLINE 20
SULFUR IN GASOLINE 20
MATERIALS ADDED TO FUEL 20
FUEL SYSTEM CAUTIONS 20
DESCRIPTION – FUEL REQUIREMENTS – DIESEL ENGINE 21
DESCRIPTION – ENGINE OIL – DIESEL ENGINES 21
SAE VISCOSITY GRADE 21
FLUID CAPACITIES 21
SPECIFICATIONS – FLUID CAPACITIES 21
FLUID FILL/CHECK LOCATIONS 22
DESCRIPTION 22
LUBRICATION POINTS 22
DESCRIPTION 22
MAINTENANCE SCHEDULES 22
DESCRIPTION 22
SCHEDULE “B” 22
SCHEDULE “A” 28
HOISTING 30
STANDARD PROCEDURE – HOISTING 30
JUMP STARTING 30
STANDARD PROCEDURE – JUMP STARTING 30
DISCONNECT CABLE CLAMPS AS FOLLOWS: 31
TOWING 32
STANDARD PROCEDURE – TOWING 32
WARNINGS AND CAUTIONS 32
RECOMMENDED TOWING EQUIPMENT 32
GROUND CLEARANCE 32
LOCKED VEHICLE TOWING 32
FLAT TOWING WITH TOW BAR 32
FLAT BED TOWING TIE DOWNS 32
TOWING – FRONT WHEEL LIFT 33
TOWING – REAR WHEEL LIFT 33
0a-MAINTENANCE SCHEDULES 34
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S , CANADA and MEXICO 34
DESCRIPTION 34
DESCRIPTION 34
SCHEDULE “B” 34
SCHEDULE “A” 40
DESCRIPTION — DIESEL ENGINES 42
SCHEDULE “B” 42
SCHEDULE “A” 44
2-SUSPENSION 46
FRONT SUSPENSION 46
FRONT SUSPENSION 47
DESCRIPTION – FRONT SUSPENSION 47
OPERATION – FRONT SUSPENSION 47
STANDARD PROCEDURE – LUBRICATION 47
SPECIFICATIONS 48
FRONT SUSPENSION FASTENER TORQUE 48
SPECIAL TOOLS 48
FRONT SUSPENSION 48
BUSHINGS 49
REMOVAL – STABILIZER BAR CUSHION 49
INSTALLATION – STABILIZER BAR CUSHION 49
HUB / BEARING 50
DESCRIPTION 50
OPERATION 50
DIAGNOSIS AND TESTING – HUB AND BEARING 50
REMOVAL 50
INSTALLATION 50
KNUCKLE 51
DESCRIPTION 51
OPERATION 52
REMOVAL – STEERING KNUCKLE 52
INSPECTION – STEERING KNUCKLE 54
INSTALLATION – STEERING KNUCKLE 54
LOWER BALL JOINT 55
DESCRIPTION 55
OPERATION 55
DIAGNOSIS AND TESTING – LOWER BALL JOINT 55
LOWER BALL JOINT SEAL BOOT 55
DESCRIPTION – EXPORT 55
REMOVAL 56
REMOVAL – BALL JOINT SEAL BOOT 56
REMOVAL – EXPORT 56
INSTALLATION 56
INSTALLATION – BALL JOINT SEAL BOOT 56
INSTALLATION – EXPORT 57
LOWER CONTROL ARM 57
DESCRIPTION 57
OPERATION 57
REMOVAL – LOWER CONTROL ARM 57
DISASSEMBLY 58
DISASSEMBLY – LOWER CONTROL ARM (REAR BUSHING – STANDARD) 58
DISASSEMBLY – LOWER CONTROL ARM (REAR BUSHING – HYDRO) 59
INSPECTION – LOWER CONTROL ARM 59
ASSEMBLY 59
ASSEMBLY – LOWER CONTROL ARM (REAR BUSHING – STANDARD) 59
ASSEMBLY – LOWER CONTROL ARM (REAR BUSHING – HYDRO) 59
INSTALLATION – LOWER CONTROL ARM 60
STABILIZER BAR 61
DESCRIPTION 61
OPERATION 61
REMOVAL 62
INSPECTION 62
INSTALLATION 62
STRUT 64
DESCRIPTION – STRUT ASSEMBLY 64
OPERATION – STRUT ASSEMBLY 64
DIAGNOSIS AND TESTING – STRUT ASSEMBLY 65
REMOVAL – STRUT ASSEMBLY 65
DISASSEMBLY – STRUT ASSEMBLY 66
ASSEMBLY – STRUT ASSEMBLY 68
INSTALLATION – STRUT ASSEMBLY 70
REAR SUSPENSION 71
REAR SUSPENSION 71
DESCRIPTION – REAR SUSPENSION 71
OPERATION – REAR SUSPENSION 71
SPECIFICATIONS 72
REAR SUSPENSION FASTENER TORQUE 72
SPECIAL TOOLS 73
REAR SUSPENSION 73
BUSHINGS 73
REMOVAL – LEAF SPRING FRONT BUSHING 73
INSTALLATION – LEAF SPRING FRONT BUSHING 74
HUB / BEARING 75
DESCRIPTION 75
OPERATION 75
DIAGNOSIS AND TESTING – HUB AND BEARING 75
REMOVAL 76
FRONT-WHEEL-DRIVE VEHICLES 76
ALL-WHEEL-DRIVE VEHICLES 77
INSTALLATION 77
FRONT-WHEEL-DRIVE VEHICLES 77
ALL-WHEEL-DRIVE VEHICLES 78
JOUNCE BUMPER 80
DESCRIPTION 80
OPERATION 80
REMOVAL 80
REMOVAL – AWD AND HEAVY DUTY 80
REMOVAL – FRONT-WHEEL-DRIVE 80
INSTALLATION 80
INSTALLATION – AWD AND HEAVY DUTY 80
INSTALLATION – FRONT-WHEEL-DRIVE 81
SHOCK ABSORBER 81
DESCRIPTION 81
OPERATION 81
REMOVAL – SHOCK ABSORBER 81
DISASSEMBLY – SHOCK ABSORBER (UPPER BUSHING) 81
ASSEMBLY – SHOCK ABSORBER (UPPER BUSHING) 82
INSTALLATION – SHOCK ABSORBER 83
SPRING – AWD 83
REMOVAL – AWD 83
INSTALLATION – AWD 84
SPRING – FWD 85
REMOVAL – FWD 85
INSTALLATION – FWD 86
SPRING MOUNTS – FRONT 87
REMOVAL 87
INSTALLATION 87
SPRING MOUNTS – REAR 88
REMOVAL 88
INSTALLATION 88
STABILIZER BAR 88
DESCRIPTION 88
OPERATION 89
REMOVAL 89
REMOVAL – AWD 89
REMOVAL – FWD 89
INSTALLATION 89
INSTALLATION – AWD 89
INSTALLATION – FWD 89
TRACK BAR 89
DESCRIPTION 89
OPERATION 89
REMOVAL 89
INSTALLATION 90
WHEEL ALIGNMENT 91
WHEEL ALIGNMENT 91
DESCRIPTION – WHEEL ALIGNMENT 91
CAMBER 91
CROSS CAMBER 91
CASTER 92
CROSS CASTER 92
TOE 92
TOE-OUT ON TURNS 93
DYNAMIC TOE PATTERN 93
STEERING AXIS INCLINATION (S A I ) 93
INCLUDED ANGLE (I A ) 93
THRUST ANGLE 94
DIAGNOSIS AND TESTING – SUSPENSION AND STEERING 94
STANDARD PROCEDURE 96
STANDARD PROCEDURE – WHEEL ALIGNMENT 96
PRE-WHEEL ALIGNMENT INSPECTION 96
WHEEL ALIGNMENT SETUP 96
CAMBER AND CASTER 96
TOE 98
STANDARD PROCEDURE – CURB HEIGHT MEASUREMENT 99
SPECIFICATIONS 100
WHEEL ALIGNMENT 100
3-DIFFERENTIAL & DRIVELINE 102
HALF SHAFT – FRONT 102
HALF SHAFT – FRONT 102
DESCRIPTION 102
DIAGNOSIS AND TESTING – HALF SHAFT 102
VEHICLE INSPECTION 102
NOISE AND/OR VIBRATION IN TURNS 102
CLUNKING NOISE DURING ACCELERATION 102
SHUDDER OR VIBRATION DURING ACCELERATION 103
VIBRATION AT HIGHWAY SPEEDS 103
REMOVAL 103
INSTALLATION 105
SPECIFICATIONS – HALF SHAFT – FRONT 107
CV BOOT – INNER 107
REMOVAL 107
INSTALLATION 107
CRIMP TYPE BOOT CLAMP 110
LATCHING TYPE BOOT CLAMP 111
CV BOOT – OUTER 111
REMOVAL 111
INSTALLATION 111
HALF SHAFT – REAR 114
HALF SHAFT – REAR 114
DESCRIPTION 114
DIAGNOSIS AND TESTING – HALF SHAFT 114
VEHICLE INSPECTION 114
NOISE AND/OR VIBRATION IN TURNS 114
CLUNKING NOISE DURING ACCELERATION 114
SHUDDER OR VIBRATION DURING ACCELERATION 114
VIBRATION AT HIGHWAY SPEEDS 114
REMOVAL 114
INSTALLATION 115
SPECIFICATIONS – HALF SHAFT – FRONT 116
CV BOOT – INNER/OUTER 116
REMOVAL 116
INSTALLATION 118
CRIMP TYPE BOOT CLAMP 120
LATCHING TYPE BOOT CLAMP 121
PROPELLER SHAFT 122
PROPELLER SHAFT 122
DESCRIPTION 122
OPERATION 122
REMOVAL 122
INSTALLATION 123
SPECIFICATIONS – PROPELLER SHAFT 123
REAR DRIVELINE MODULE 124
REAR DRIVELINE MODULE 124
DESCRIPTION 124
OPERATION 124
DIAGNOSIS AND TESTING 125
DIAGNOSIS AND TESTING – REAR DRIVELINE MODULE NOISE 125
DRIVELINE MODULE ASSEMBLY NOISE 125
TIRE NOISE 126
GEAR NOISE (DRIVE PINION AND RING GEAR) 126
BEARING NOISE (DRIVE PINION AND DIFFERENTIAL) 126
ENGINE AND TRANSMISSION NOISE 126
DIAGNOSIS AND TESTING – REAR DRIVELINE MODULE OPERATION 127
REMOVAL 127
DISASSEMBLY 128
ASSEMBLY 130
INSTALLATION 134
SPECIFICATIONS – REAR DRIVELINE MODULE 135
SPECIAL TOOLS 135
BI-DIRECTIONAL OVERRUNNING CLUTCH 135
DESCRIPTION 135
OPERATION 137
STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION 137
TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION 137
STEADY STATE, HIGH SPEED, NO WHEEL SLIP 138
DIFFERENTIAL ASSEMBLY 140
DESCRIPTION 140
OPERATION 140
FLUID – DIFFERENTIAL ASSEMBLY 141
STANDARD PROCEDURE – DIFFERENTIAL ASSEMBLY FLUID CHANGE 141
FLUID – OVERRUNNING CLUTCH HOUSING 142
STANDARD PROCEDURE – OVERRUNNING CLUTCH HOUSING FLUID CHANGE 142
VISCOUS COUPLER 142
DESCRIPTION 142
OPERATION 143
TORQUE ARM 145
REMOVAL 145
INSTALLATION 145
INPUT FLANGE SEAL 145
REMOVAL 145
INSTALLATION 146
OUTPUT FLANGE SEAL 146
REMOVAL 146
INSTALLATION 147
5-BRAKES 150
BRAKES – BASE 150
BRAKES – BASE 152
DESCRIPTION 152
DESCRIPTION – BASE BRAKES 152
DESCRIPTION – BASE BRAKES (EXPORT) 152
OPERATION – BASE BRAKES 152
WARNING 153
CAUTION 153
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 153
RED BRAKE WARNING INDICATOR LAMP 154
BRAKE NOISE 154
OTHER BRAKE CONDITIONS 155
STANDARD PROCEDURE – BASE BRAKE BLEEDING 156
MANUAL BLEEDING PROCEDURE 157
PRESSURE BLEEDING PROCEDURE 157
SPECIFICATIONS 158
BRAKE FASTENER TORQUE 158
SPECIAL TOOLS 159
BASE BRAKE SYSTEM 159
BRAKE FLUID LEVEL SWITCH 159
DESCRIPTION 159
OPERATION 159
REMOVAL 160
INSTALLATION 160
HYDRAULIC/MECHANICAL 160
DESCRIPTION 160
DESCRIPTION – DISC BRAKES (FRONT) 160
DESCRIPTION – DISC BRAKES (REAR) 161
DESCRIPTION – DISC BRAKES (EXPORT) 162
DESCRIPTION – DRUM BRAKES (REAR) 162
OPERATION 162
OPERATION – DISC BRAKES (FRONT) 162
OPERATION – DISC BRAKES (REAR) 162
DIAGNOSIS AND TESTING – DRUM BRAKE AUTOMATIC ADJUSTER 162
BRAKE LINES 163
DESCRIPTION – BRAKE TUBES AND HOSES 163
OPERATION – BRAKE TUBES AND HOSES 163
INSPECTION – BRAKE TUBES AND HOSES 163
BRAKE PADS/SHOES – FRONT 163
REMOVAL 163
REMOVAL – FRONT DISC BRAKE SHOES (DISC/DISC BRAKES) 163
REMOVAL – FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) 164
CLEANING – DISC BRAKE SHOES 165
INSPECTION – DISC BRAKE SHOES 165
INSTALLATION 165
INSTALLATION – FRONT DISC BRAKE SHOES (DISC/DISC BRAKES) 165
INSTALLATION – FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) 166
BRAKE PADS/SHOES – REAR DISC 166
REMOVAL – REAR DISC BRAKE SHOES 166
CLEANING – DISC BRAKE SHOES 167
INSPECTION – DISC BRAKE SHOES 167
INSTALLATION – REAR DISC BRAKE SHOES 168
BRAKE PADS/SHOES – REAR DRUM 168
REMOVAL – REAR DRUM BRAKE SHOES 168
INSPECTION – REAR DRUM BRAKE SHOE LINING 171
INSTALLATION – REAR DRUM BRAKE SHOES 171
ADJUSTMENTS 172
ADJUSTMENT – REAR DRUM BRAKE SHOES 172
DISC BRAKE CALIPER – FRONT 173
REMOVAL 173
REMOVAL – FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) 173
REMOVAL – FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES) 173
DISASSEMBLY 173
DISASSEMBLY – CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 173
DISASSEMBLY – CALIPER PISTON AND SEAL 173
CLEANING – CALIPER 174
INSPECTION – CALIPER 174
ASSEMBLY 174
ASSEMBLY – CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 174
ASSEMBLY – CALIPER PISTON AND SEAL 175
INSTALLATION 176
INSTALLATION – FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) 176
INSTALLATION – FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES) 176
DISC BRAKE CALIPER – REAR 176
REMOVAL – REAR DISC BRAKE CALIPER 176
DISASSEMBLY – CALIPER PISTON AND SEAL 177
CLEANING – CALIPER 178
INSPECTION – CALIPER 178
ASSEMBLY – CALIPER PISTON AND SEAL 178
INSTALLATION – REAR DISC BRAKE CALIPER 179
DISC BRAKE CALIPER ADAPTER 180
REMOVAL – FRONT DISC BRAKE CALIPER ADAPTER 180
INSTALLATION – FRONT DISC BRAKE CALIPER ADAPTER 180
DISC BRAKE CALIPER GUIDE PINS 180
REMOVAL – DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) 180
INSTALLATION – DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) 180
DRUM 181
REMOVAL 181
INSTALLATION 181
FLUID 181
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 181
STANDARD PROCEDURE – BRAKE FLUID LEVEL CHECKING 181
SPECIFICATIONS 182
BRAKE FLUID 182
JUNCTION BLOCK 182
DESCRIPTION – NON-ABS JUNCTION BLOCK 182
OPERATION – NON-ABS JUNCTION BLOCK 182
REMOVAL – NON-ABS JUNCTION BLOCK 182
INSTALLATION – NON-ABS JUNCTION BLOCK 182
MASTER CYLINDER 183
DESCRIPTION 183
DESCRIPTION 183
DESCRIPTION – RHD 184
OPERATION 184
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 184
REMOVAL 185
REMOVAL – LHD 185
REMOVAL – RHD 186
DISASSEMBLY – MASTER CYLINDER (FLUID RESERVOIR) 186
ASSEMBLY – MASTER CYLINDER (FLUID RESERVOIR) 187
INSTALLATION 187
INSTALLATION – LHD 187
INSTALLATION – RHD 188
PEDAL TORQUE SHAFT – RHD 188
REMOVAL 188
INSTALLATION 188
POWER BRAKE BOOSTER 189
DESCRIPTION 189
OPERATION 190
DIAGNOSIS AND TESTING – POWER BRAKE BOOSTER 190
BASIC TEST 190
VACUUM LEAK TEST 191
REMOVAL 191
REMOVAL – LHD 191
REMOVAL – RHD 192
INSTALLATION 195
INSTALLATION – LHD 195
INSTALLATION – RHD 196
PROPORTIONING VALVE 197
DESCRIPTION – PROPORTIONING VALVE (HEIGHT SENSING) 197
OPERATION – PROPORTIONING VALVE (HEIGHT SENSING) 197
DIAGNOSIS AND TESTING – PROPORTIONING VALVE (HEIGHT SENSING) 198
REMOVAL – PROPORTIONING VALVE (HEIGHT SENSING) 199
INSTALLATION – PROPORTIONING VALVE (HEIGHT SENSING) 200
ROTOR 200
DIAGNOSIS AND TESTING – BRAKE ROTOR 200
BRAKING SURFACE INSPECTION 200
ROTOR MINIMUM THICKNESS 200
ROTOR THICKNESS VARIATION 200
ROTOR RUNOUT 201
STANDARD PROCEDURE – BRAKE ROTOR MACHINING 202
REMOVAL – FRONT BRAKE ROTOR 203
INSTALLATION – FRONT BRAKE ROTOR 203
SPECIFICATIONS 204
BRAKE ROTOR 204
BRAKE ROTOR – EXPORT 204
SUPPORT PLATE – DRUM BRAKE 205
REMOVAL 205
INSTALLATION 205
WHEEL CYLINDERS 206
REMOVAL 206
INSPECTION 206
INSTALLATION 206
PARKING BRAKE 206
DESCRIPTION 206
DESCRIPTION 206
DESCRIPTION – EXPORT 207
OPERATION 207
STANDARD PROCEDURE 207
STANDARD PROCEDURE – PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE 207
STANDARD PROCEDURE – PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET 208
CABLES – PARKING BRAKE 208
REMOVAL 208
REMOVAL – PARKING BRAKE CABLE (FRONT) 208
REMOVAL – PARKING BRAKE CABLE (INTERMEDIATE) 209
REMOVAL – PARKING BRAKE CABLE (RIGHT REAR) 209
REMOVAL – PARKING BRAKE CABLE (LEFT REAR) 211
INSTALLATION 212
INSTALLATION – PARKING BRAKE CABLE (FRONT) 212
INSTALLATION – PARKING BRAKE CABLE (INTERMEDIATE) 212
INSTALLATION – PARKING BRAKE CABLE (RIGHT REAR) 212
INSTALLATION – PARKING BRAKE CABLE (LEFT REAR) 213
ADJUSTMENTS 213
ADJUSTMENT – PARKING BRAKE CABLES 213
CABLES – PARKING BRAKE (EXPORT) 213
REMOVAL – FRONT CABLE 213
INSTALLATION – FRONT CABLE 213
LEVER – PARKING BRAKE 213
REMOVAL 213
INSTALLATION 214
LEVER – PARKING BRAKE (EXPORT) 214
REMOVAL – PARKING BRAKE LEVER AND FRONT CABLE 214
INSTALLATION – PARKING BRAKE LEVER AND FRONT CABLE 215
SHOES – PARKING BRAKE 216
REMOVAL 216
INSTALLATION 221
ADJUSTMENTS 222
ADJUSTMENT – PARKING BRAKE SHOES 222
BRAKES – ABS 224
BRAKES – ABS 224
DESCRIPTION 224
DESCRIPTION – ANTILOCK BRAKE SYSTEM 224
DESCRIPTION – ANTILOCK BRAKE SYSTEM (EXPORT) 224
DESCRIPTION – ELECTRONIC VARIABLE BRAKE PROPORTIONING 224
DESCRIPTION – TRACTION CONTROL SYSTEM 225
HYDRAULIC SHUTTLE VALVES 225
TRACTION CONTROL LAMP 225
OPERATION 225
OPERATION – ANTILOCK BRAKE SYSTEM 225
NORMAL BRAKING 225
ABS BRAKING 225
NOISE AND BRAKE PEDAL FEEL 225
TIRE NOISE AND MARKS 225
START-UP CYCLE 226
PREMATURE ABS CYCLING 226
OPERATION – ELECTRONIC VARIABLE BRAKE PROPORTIONING 226
OPERATION – TRACTION CONTROL SYSTEM 226
CAUTION 227
CAUTIONS 227
STANDARD PROCEDURE – ANTILOCK BRAKE SYSTEM BLEEDING 227
BLEEDING 228
SPECIFICATIONS 228
ABS FASTENER TORQUE 228
TONE WHEEL RUNOUT 228
WHEEL SPEED SENSOR AIR GAP 228
FRONT WHEEL SPEED SENSOR 228
REMOVAL 228
INSTALLATION 229
REAR WHEEL SPEED SENSOR – AWD 229
REMOVAL 229
INSTALLATION 229
REAR WHEEL SPEED SENSOR – FWD 230
REMOVAL 230
INSTALLATION 230
TONE WHEEL 231
INSPECTION – TONE WHEEL 231
TRACTION CONTROL SWITCH 231
DIAGNOSIS AND TESTING – TRACTION CONTROL SWITCH 231
HYDRAULIC/MECHANICAL 232
OPERATION – HYDRAULIC CIRCUITS AND VALVES 232
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION 232
ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) 233
ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) 234
NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) 235
ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) 236
ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) 237
HCU (HYDRAULIC CONTROL UNIT) 238
DESCRIPTION 238
OPERATION 238
VALVES AND SOLENOIDS 238
BRAKE FLUID ACCUMULATORS 238
PUMP/MOTOR 238
ICU (INTEGRATED CONTROL UNIT) 238
DESCRIPTION 238
OPERATION 239
REMOVAL 239
REMOVAL – LHD 239
REMOVAL – RHD 240
DISASSEMBLY – ICU 242
ASSEMBLY – ICU 243
INSTALLATION 243
INSTALLATION – LHD 243
INSTALLATION – RHD 244
6-CLUTCH 246
CLUTCH 246
DESCRIPTION 246
CLUTCH COMPONENTS 246
RELEASE SYSTEM 248
DIAGNOSIS AND TESTING 248
DIAGNOSIS AND TESTING – CLUTCH SYSTEM 248
DIAGNOSIS AND TESTING – DRIVE PLATE MISALIGNMENT 251
DIAGNOSIS AND TESTING – CLUTCH COVER AND DISC RUNOUT 251
DIAGNOSIS AND TESTING – CLUTCH CHATTER COMPLAINTS 251
SPECIAL TOOLS – T850 TRANSAXLE 251
CLUTCH RELEASE LEVER AND BEARING 251
REMOVAL 251
INSTALLATION 252
MASTER CYLINDER – RHD 253
REMOVAL 253
INSTALLATION 254
MASTER CYLINDER – LHD 254
REMOVAL 254
INSTALLATION 255
MODULAR CLUTCH ASSY – 2 4L GAS 256
REMOVAL 256
INSTALLATION 256
SLAVE CYLINDER 256
REMOVAL 256
INSTALLATION 256
CLUTCH DISC AND PRESSURE PLATE – 2 5L TD 256
REMOVAL 256
INSTALLATION 257
FLYWHEEL 257
REMOVAL 257
INSTALLATION 257
CLUTCH PEDAL INTERLOCK SWITCH 258
REMOVAL 258
LHD 258
RHD 258
INSTALLATION 259
LHD 259
RHD 259
CLUTCH PEDAL UPSTOP SWITCH 260
REMOVAL 260
LHD 260
RHD 261
INSTALLATION 261
LHD 261
RHD 261
7-COOLING 262
COOLING 262
DESCRIPTION 262
DESCRIPTION – COOLING SYSTEM 262
DESCRIPTION – HOSE CLAMPS 262
OPERATION 263
OPERATION – COOLING SYSTEM 263
OPERATION – HOSE CLAMPS 263
DIAGNOSIS AND TESTING 263
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAK TEST 263
DIAGNOSIS AND TESTING – COOLING SYSTEM FLOW CHECK 264
PREFERRED METHOD 264
ALTERNATIVE METHOD 264
DIAGNOSIS AND TESTING – COOLING SYSTEM AERATION 264
DIAGNOSIS AND TESTING – COOLING SYSTEM DEAERATION 265
STANDARD PROCEDURE 265
STANDARD PROCEDURE – COOLING SYSTEM DRAINING 265
STANDARD PROCEDURE – COOLING SYSTEM FILLING 266
STANDARD PROCEDURE – ADDING ADDITIONAL COOLANT 266
STANDARD PROCEDURE – COOLANT LEVEL CHECK 266
SPECIFICATIONS 266
ACCESSORY DRIVE BELT TENSION 266
TORQUE 266
SPECIAL TOOLS 267
COOLING SYSTEM 267
ACCESSORY DRIVE 268
DRIVE BELTS 268
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT 268
DRIVE BELTS – 2 4L 269
STANDARD PROCEDURE – CHECKING POWER STEERING BELT TENSION 269
REMOVAL 269
GENERATOR AND AIR CONDITIONING BELT 269
POWER STEERING PUMP 270
CLEANING 270
INSPECTION 270
INSTALLATION 271
GENERATOR AND AIR CONDITIONING BELT 271
POWER STEERING PUMP 271
ADJUSTMENTS 271
BELT TENSIONER – 2 4L 271
REMOVAL 271
INSTALLATION 271
DRIVE BELTS – 3 3/3 8L 272
REMOVAL 272
CLEANING 272
INSPECTION 272
INSTALLATION 273
BELT TENSIONER – 3 3/3 8L 273
REMOVAL 273
INSTALLATION 273
ENGINE 274
ENGINE 275
DIAGNOSIS AND TESTING – ENGINE COOLING SYSTEM0 – 2 RS (Continued) 275
DRIVING TECHNIQUES 275
TRAILER TOWING 275
VISUAL INSPECTION 275
CLEANING 279
INSPECTION 279
COOLANT 280
DESCRIPTION – ENGINE COOLANT 280
DIAGNOSIS AND TESTING – COOLANT CONCENTRATION TESTING 280
STANDARD PROCEDURE – COOLANT SERVICE 280
COOLANT RECOVERY CONTAINER 280
DESCRIPTION 280
OPERATION 280
DIAGNOSIS AND TESTING – COOLANT RECOVERY SYSTEM 281
REMOVAL 281
INSTALLATION 281
ENGINE BLOCK HEATER 281
DESCRIPTION 281
OPERATION 281
DIAGNOSIS AND TESTING – ENGINE BLOCK HEATER TESTING 281
REMOVAL 281
INSTALLATION 281
ENGINE COOLANT TEMPERATURE SENSOR – 2 4L 282
DESCRIPTION 282
REMOVAL 282
INSTALLATION 282
ENGINE COOLANT TEMPERATURE SENSOR – 3 3/3 8L 282
DESCRIPTION 282
REMOVAL 282
INSTALLATION 283
ENGINE COOLANT THERMOSTAT 283
DESCRIPTION 283
OPERATION 283
DIAGNOSIS AND TESTING – ENGINE COOLANT THERMOSTAT 284
ENGINE COOLANT THERMOSTAT – 2 4L 284
REMOVAL 284
INSTALLATION 284
ENGINE COOLANT THERMOSTAT – 3 3/3 8L 284
REMOVAL 284
INSTALLATION 285
RADIATOR 286
REMOVAL 286
INSTALLATION 286
RADIATOR DRAINCOCK 287
REMOVAL 287
INSTALLATION 287
RADIATOR PRESSURE CAP 287
DESCRIPTION 287
OPERATION 288
DIAGNOSIS AND TESTING 288
DIAGNOSIS AND TESTING – COOLING SYSTEM PRESSURE CAP TESTING 288
DIAGNOSIS AND TESTING – RADIATOR CAP TO FILLER NECK SEAL 288
CLEANING 289
INSPECTION 289
RADIATOR FAN 289
DESCRIPTION 289
OPERATION 290
DIAGNOSIS AND TESTING – RADIATOR FAN MOTOR 290
REMOVAL 291
INSTALLATION 291
RADIATOR FAN RELAY 291
DESCRIPTION 291
OPERATION 291
REMOVAL 291
INSTALLATION 291
WATER PUMP – 2 4L 292
DESCRIPTION 292
REMOVAL 292
CLEANING 293
INSPECTION 293
INSTALLATION 293
WATER PUMP – 3 3/3 8L 294
DESCRIPTION 294
REMOVAL 294
CLEANING 295
INSPECTION 295
INSTALLATION 295
WATER PUMP INLET TUBE – 2 4L 296
DESCRIPTION 296
REMOVAL 296
INSTALLATION 296
WATER PUMP INLET TUBE – 3 3/3 8L 297
REMOVAL 297
INSTALLATION 297
TRANSMISSION 298
TRANSMISSION OIL COOLER 298
DESCRIPTION 298
REMOVAL 298
INSPECTION 298
INSTALLATION 298
TRANSMISSION OIL COOLER LINES 299
REMOVAL 299
INSTALLATION 299
8a-AUDIO 300
AUDIO/VIDEO 300
DESCRIPTION 300
OPERATION 301
DIAGNOSIS AND TESTING – AUDIO 301
ANTENNA BODY AND CABLE 303
DESCRIPTION 303
OPERATION 303
DIAGNOSIS AND TESTING – ANTENNA BODY AND CABLE 303
TEST 1 303
TEST 2 304
TEST 3 304
REMOVAL 304
INSTALLATION 305
ANTENNA MODULE – EXPORT 305
DESCRIPTION 305
OPERATION 305
DIAGNOSIS AND TESTING – ANTENNA MODULE – EXPORT 306
REMOVAL 306
INSTALLATION 306
CD CHANGER 306
DESCRIPTION 306
OPERATION 306
REMOVAL 307
INSTALLATION 307
DVD PLAYER 307
DESCRIPTION 307
OPERATION 307
REMOVAL 307
INSTALLATION 307
INSTRUMENT PANEL ANTENNA CABLE 307
REMOVAL 307
INSTALLATION 308
QUARTER GLASS INTEGRAL ANTENNA – EXPORT 308
DESCRIPTION 308
OPERATION 308
DIAGNOSIS AND TESTING – QUARTER GLASS INTEGRAL ANTENNA – EXPORT 308
RADIO 309
DESCRIPTION 309
OPERATION 309
DIAGNOSIS AND TESTING – RADIO 309
REMOVAL 310
INSTALLATION 310
RADIO NOISE SUPPRESSION COMPONENTS 310
DESCRIPTION 310
OPERATION 311
REMOTE SWITCHES 311
DESCRIPTION 311
OPERATION 311
DIAGNOSIS AND TESTING – REMOTE SWITCHES 311
REMOVAL 312
INSTALLATION 313
SPEAKER 313
DIAGNOSIS AND TESTING – SPEAKER 313
REMOVAL 313
D-PILLAR SPEAKER 313
FRONT DOOR SPEAKER 313
INSTRUMENT PANEL SPEAKER 314
QUARTER PANEL SPEAKER 314
INSTALLATION 314
D-PILLAR SPEAKER 314
FRONT DOOR SPEAKER 315
INSTRUMENT PANEL SPEAKER 315
QUARTER PANEL SPEAKER 315
VIDEO SCREEN 315
DESCRIPTION 315
OPERATION 315
REMOVAL 315
INSTALLATION 315
8b-CHIME/BUZZER 316
CHIME/BUZZER 316
DESCRIPTION 316
HIGH SPEED WARNING – EXPORT 316
OPERATION 316
HIGH SPEED WARNING – EXPORT 316
WARNING 316
DIAGNOSIS AND TESTING – CHIME SYSTEM 316
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER’S SEAT BELT IS NOT BUCKLED 316
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON 317
FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER’S DOOR IS CLOSED 317
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER’S DOOR IS OPEN 317
8e-ELECTRONIC CONTROL MODULES 318
ELECTRONIC CONTROL MODULES 319
STANDARD PROCEDURE – PCM/SKIM PROGRAMMING 319
PROGRAMMING THE PCM (SBEC) 319
PROGRAMMING THE SKIM 319
PROGRAMMING IGNITION KEYS TO THE SKIM 319
BODY CONTROL MODULE 320
DESCRIPTION 320
OPERATION 320
REMOVAL 321
INSTALLATION 322
CONTROLLER ANTILOCK BRAKE 322
DESCRIPTION 322
OPERATION 322
CAB INPUTS 323
CAB OUTPUTS 323
REMOVAL 323
INSTALLATION 323
DATA LINK CONNECTOR 323
DESCRIPTION 323
OPERATION 324
FRONT CONTROL MODULE 324
DESCRIPTION 324
OPERATION 324
DIAGNOSIS AND TESTING – FRONT CONTROL MODULE 324
REMOVAL 325
INSTALLATION 325
HEATED SEAT MODULE 325
DESCRIPTION 325
OPERATION 326
DIAGNOSIS AND TESTING – HEATED SEAT MODULE 326
REMOVAL 326
INSTALLATION 327
MEMORY SEAT/MIRROR MODULE 327
DESCRIPTION 327
OPERATION 327
DIAGNOSIS AND TESTING – MEMORY SEAT/MIRROR MODULE 327
REMOVAL 327
INSTALLATION 327
POWER LIFTGATE CONTROL MODULE 327
DESCRIPTION 327
OPERATION 328
REMOVAL 328
INSTALLATION 328
POWERTRAIN CONTROL MODULE 328
DESCRIPTION 328
DESCRIPTION 328
TRANSMISSION CONTROL (2 4L MODELS ONLY) 330
OPERATION – SENSOR RETURN – PCM INPUT 332
OPERATION – DATA BUS COMMUNICATION RECEIVE – PCM INPUT 332
OPERATION – IGNITION SENSE – PCM INPUT 332
OPERATION – PCM GROUND 332
OPERATION 332
OPERATION – 8-VOLT SUPPLY – PCM OUTPUT – SBEC CONTROLLER 332
OPERATION – 5 VOLT SUPPLY – PCM OUTPUT 332
STANDARD PROCEDURE 332
STANDARD PROCEDURE – OBTAINING DIAGNOSTIC TROUBLE CODES 332
BULB CHECK 332
OBTAINING DTC’S USING DRB SCAN TOOL 332
STANDARD PROCEDURE – PINION FACTOR SETTING 332
STANDARD PROCEDURE – QUICK LEARN PROCEDURE 333
REMOVAL 333
REMOVAL – SBEC CONTROLLER 333
REMOVAL – NGC CONTROLLER 334
INSTALLATION 334
INSTALLATION – SBEC CONTROLLER 334
INSTALLATION 334
SENTRY KEY IMMOBILIZER MODULE 335
DESCRIPTION 335
OPERATION 335
REMOVAL 335
INSTALLATION 336
SLIDING DOOR CONTROL MODULE 336
DESCRIPTION 336
OPERATION 336
REMOVAL 336
INSTALLATION 337
TRANSMISSION CONTROL MODULE 337
DESCRIPTION 337
OPERATION 337
CLUTCH VOLUME INDEX (CVI) 338
SHIFT SCHEDULES 339
STANDARD PROCEDURE 340
STANDARD PROCEDURE – PINION FACTOR SETTING 340
STANDARD PROCEDURE – QUICK LEARN PROCEDURE 340
REMOVAL 340
INSTALLATION 341
8f-ENGINE SYSTEMS 342
BATTERY SYSTEM 342
BATTERY SYSTEM 342
DESCRIPTION 342
OPERATION 343
DIAGNOSIS AND TESTING – BATTERY SYSTEM 343
MICRO 420 BATTERY TESTER 343
ABNORMAL BATTERY DISCHARGING 345
CLEANING 346
INSPECTION 346
SPECIFICATIONS 347
SPECIAL TOOLS 348
BATTERY SYSTEM SPECIAL TOOLS 348
BATTERY 348
DESCRIPTION 348
SPIRAL PLATE BATTERY – DIESEL ENGINE 348
CONVENTIONAL BATTERY – GASOLINE ENGINE 348
OPERATION 350
DIAGNOSIS AND TESTING – BATTERY 350
MICRO 420 BATTERY TESTER 350
STANDARD PROCEDURE 351
STANDARD PROCEDURE – SPIRAL PLATE BATTERY CHARGING 351
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY 351
CHARGING TIME REQUIRED 352
STANDARD PROCEDURE – CONVENTIONAL BATTERY CHARGING 352
CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY 353
CHARGING TIME REQUIRED 353
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 354
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 354
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVEL 355
REMOVAL – BATTERY 356
INSTALLATION 356
BATTERY HOLDDOWN 356
DESCRIPTION 356
OPERATION 356
REMOVAL 357
INSTALLATION 357
BATTERY CABLES 357
DESCRIPTION 357
OPERATION 357
DIAGNOSIS AND TESTING – BATTERY CABLE 357
VOLTAGE DROP TEST 358
REMOVAL 359
INSTALLATION 359
BATTERY TRAY 359
DESCRIPTION 359
OPERATION 360
REMOVAL 360
INSTALLATION 360
THERMOWRAP 360
DESCRIPTION 360
OPERATION 360
REMOVAL 360
INSTALLATION 360
CHARGING 361
CHARGING 361
DESCRIPTION – CHARGING SYSTEM 361
OPERATION – CHARGING SYSTEM 361
DIAGNOSIS AND TESTING – ON-BOARD DIAGNOSTIC SYSTEM 362
SPECIFICATIONS 363
GENERATOR 363
TORQUE 363
SPECIFICATIONS – BATTERY TEMPERATURE SENSOR 363
SPECIAL TOOLS 364
BATTERY TEMPERATURE SENSOR 364
DESCRIPTION 364
OPERATION 364
REMOVAL 364
GENERATOR 364
DESCRIPTION 364
OPERATION 364
REMOVAL 364
REMOVAL – 2 4L 364
REMOVAL – 3 3/3 8L 365
INSTALLATION 365
INSTALLATION – 2 4L 365
INSTALLATION – 3 3/3 8L 365
GENERATOR DECOUPLER PULLEY 366
DESCRIPTION 366
OPERATION 366
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER PULLEY 366
REMOVAL 367
INSTALLATION 367
VOLTAGE REGULATOR 368
DESCRIPTION 368
OPERATION 368
STARTING 369
STARTING 369
DESCRIPTION 369
OPERATION 369
DIAGNOSIS AND TESTING 369
DIAGNOSIS AND TESTING – STARTING SYSTEM TEST 369
INSPECTION 369
DIAGNOSIS AND TESTING – CONTROL CIRCUIT TEST 371
STARTER SOLENOID 371
STARTER RELAY 372
RELAY TEST 372
RELAY CIRCUIT TEST 373
SAFETY SWITCHES 373
IGNITION SWITCH 373
BATTERY 373
ALL RELATED WIRING AND CONNECTORS 373
DIAGNOSIS AND TESTING – FEED CIRCUIT RESISTANCE TEST 373
DIAGNOSIS AND TESTING – FEED CIRCUIT TEST 374
SPECIFICATIONS 374
Torques 374
STARTER 375
STARTER MOTOR 375
REMOVAL 375
REMOVAL – 2 4L 375
REMOVAL – 3 3/3 8L 376
INSTALLATION 376
INSTALLATION – 2 4L 376
INSTALLATION – 3 3/3 8L 377
8g-HEATED SYSTEMS 378
HEATED GLASS 378
HEATED GLASS 378
DESCRIPTION 378
OPERATION 378
DEFOGGER RELAY 379
DESCRIPTION 379
REAR WINDOW DEFOGGER GRID 379
STANDARD PROCEDURE – GRID LINE REPAIR REAR 379
REAR WINDOW DEFOGGER SWITCH 379
DESCRIPTION 379
OPERATION 379
WINDSHIELD GRID 380
DIAGNOSIS AND TESTING – SYSTEM TEST 380
STANDARD PROCEDURE – GRID LINE AND TERMINAL REPAIR 380
HEATED MIRRORS 382
HEATED MIRRORS 382
DESCRIPTION 382
OPERATION 382
DIAGNOSIS AND TESTING – HEATED MIRROR TEST 382
MIRROR SWITCH 382
DESCRIPTION 382
OPERATION 382
HEATED MIRROR GRID 383
STANDARD PROCEDURE – HEATED MIRROR 383
RELAY 383
DESCRIPTION 383
HEATED SEAT SYSTEM 384
HEATED SEAT SYSTEM 384
DESCRIPTION 384
OPERATION 385
DIAGNOSIS AND TESTING – HEATED SEAT SYSTEM 385
DRIVER HEATED SEAT SWITCH 385
DESCRIPTION 385
OPERATION 385
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCH 386
CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE 386
CHECKING SWITCH ONLY 386
REMOVAL 387
INSTALLATION 387
HEATED SEAT ELEMENTS 387
DESCRIPTION 387
OPERATION 387
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENTS 387
SEAT CUSHION ELEMENT 388
SEAT BACK ELEMENT 388
REMOVAL 388
INSTALLATION 388
HEATED SEAT SENSOR 388
DESCRIPTION 388
OPERATION 389
DIAGNOSIS AND TESTING – HEATED SEAT SENSOR 389
PASSENGER HEATED SEAT SWITCH 389
DESCRIPTION 389
OPERATION 389
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCH 390
CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE 390
CHECKING SWITCH ONLY 390
REMOVAL 391
INSTALLATION 391
8h-HORN 392
HORN SYSTEM 392
DESCRIPTION 392
OPERATION 392
DIAGNOSIS AND TESTING – HORN SYSTEM 392
HORN 394
DIAGNOSIS AND TESTING – HORN 394
HORN 394
HORNS SOUND CONTINUOUSLY 394
HORNS WILL NOT SOUND 395
FUSE BLOWN 395
FUSE OK 395
REMOVAL 396
INSTALLATION 396
HORN RELAY 396
DIAGNOSIS AND TESTING – HORN RELAY 396
REMOVAL 396
INSTALLATION 396
HORN SWITCH 396
DESCRIPTION 396
8i-IGNITION CONTROL 398
IGNITION CONTROL 398
DESCRIPTION – IGNITION SYSTEM 398
OPERATION – IGNITION SYSTEM 398
SPECIFICATIONS 399
TORQUE 399
SPARK PLUG CABLE RESISTANCE 399
SPARK PLUG 399
FIRING ORDER 400
AUTO SHUT DOWN RELAY 400
DESCRIPTION 400
OPERATION 400
CAMSHAFT POSITION SENSOR 400
DESCRIPTION 400
OPERATION 400
REMOVAL 401
REMOVAL – 2 4L 401
REMOVAL – 3 3/3 8L 402
INSTALLATION 402
INSTALLATION – 2 4L 402
INSTALLATION – 3 3/3 8L 403
IGNITION COIL 403
DESCRIPTION 403
OPERATION 403
REMOVAL 404
REMOVAL – 2 4L 404
REMOVAL – 3 3/3 8L 404
INSTALLATION 404
INSTALLATION – 2 4L 404
INSTALLATION – 3 3/3 8L 404
KNOCK SENSOR 405
DESCRIPTION 405
OPERATION 405
REMOVAL 405
REMOVAL – 2 4L 405
REMOVAL – 3 8L 405
INSTALLATION 405
INSTALLATION – 2 4L 405
INSTALLATION – 3 8L 406
SPARK PLUG 406
DESCRIPTION 406
DESCRIPTION – STANDARD 4 CYLINDER 406
DESCRIPTION – PLATINUM PLUGS 406
REMOVAL 407
INSTALLATION 407
SPARK PLUG CABLE 407
DESCRIPTION 407
REMOVAL – 2 0/2 4L 407
INSTALLATION – 2 0/2 4L 407
8j-INSTRUMENT CLUSTER 408
INSTRUMENT CLUSTER 408
DESCRIPTION 408
WATER IN FUEL LAMP – EXPORT 408
OPERATION 408
WATER IN FUEL LAMP – EXPORT 408
DIAGNOSIS AND TESTING 409
DIAGNOSIS AND TESTING – SELF-DIAGNOSTICS 409
CALIBRATION TEST 409
ODOMETER SEGMENT TEST 409
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST 409
DIAGNOSIS AND TESTING – CLUSTER DIAGNOSIS 409
CONDITIONS 409
REMOVAL 417
INSTALLATION 417
CLUSTER LENS 417
REMOVAL 417
INSTALLATION 417
8l-LAMPS 418
LAMPS/LIGHTING – EXTERIOR 418
LAMPS/LIGHTING – EXTERIOR 419
DESCRIPTION 419
LAMP SYSTEMS 419
AUTOMATIC HEADLAMP SYSTEM 419
DAYTIME RUNNING LAMPS 419
HEADLAMPS ON WITH WINDSHIELD WIPERS 419
HEADLAMP SYSTEM 419
HEADLAMP TIME DELAY SYSTEM 420
OPERATION 420
AUTOMATIC HEADLAMP SYSTEM 420
DAYTIME RUNNING LAMPS 420
HEADLAMP SYSTEM 420
HEADLAMP TIME DELAY SYSTEM 420
OPTICAL HORN/HIGH BEAMS 420
WARNING 421
SPECIFICATIONS 421
EXTERIOR LAMPS 421
BRAKE LAMP SWITCH 421
DESCRIPTION 421
OPERATION 421
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCH 422
REMOVAL 422
INSTALLATION 422
CENTER HIGH MOUNTED STOP LAMP 423
REMOVAL 423
INSTALLATION 423
CENTER HIGH MOUNTED STOP LAMP UNIT 423
REMOVAL 423
INSTALLATION 424
FRONT FOG LAMP 424
DIAGNOSIS AND TESTING – FRONT FOG LAMP 424
REMOVAL 426
INSTALLATION 426
FRONT FOG LAMP – EXPORT 426
REMOVAL 426
INSTALLATION 426
FRONT FOG LAMP UNIT 426
STANDARD PROCEDURE 426
STANDARD PROCEDURE – FRONT FOG LAMP UNIT ALIGNMENT 426
FOG LAMP UNIT ALIGNMENT 426
STANDARD PROCEDURE – FRONT FOG LAMP UNIT ALIGNMENT – EXPORT 426
REMOVAL 427
INSTALLATION 427
FRONT POSITION LAMP – EXPORT 427
REMOVAL 427
INSTALLATION 427
HEADLAMP 428
DIAGNOSIS AND TESTING – HEADLAMP 428
REMOVAL 430
INSTALLATION 430
HEADLAMP – EXPORT 430
REMOVAL 430
INSTALLATION 430
HEADLAMP LEVELING MOTOR – EXPORT 431
DIAGNOSIS AND TESTING – HEADLAMP LEVELING MOTOR – EXPORT 431
REMOVAL 431
INSTALLATION 432
HEADLAMP LEVELING SWITCH – EXPORT 432
DESCRIPTION 432
DIAGNOSIS AND TESTING – HEADLAMP LEVELING SWITCH – EXPORT 432
HEADLAMP SWITCH 432
DIAGNOSIS AND TESTING 432
DIAGNOSIS AND TESTING – HEADLAMP SWITCH 432
DIAGNOSIS AND TESTING – HEADLAMP SWITCH – EXPORT 433
REMOVAL 434
INSTALLATION 434
HEADLAMP UNIT 434
STANDARD PROCEDURE 434
STANDARD PROCEDURE – HEADLAMP UNIT ALIGNMENT 434
HEADLAMP UNIT ALIGNMENT PREPARATION 434
ALIGNMENT SCREEN PREPARATION 434
HEADLAMP UNIT ADJUSTMENT 434
STANDARD PROCEDURE – HEADLAMP UNIT ALIGNMENT – EXPORT 434
HEADLAMP UNIT ALIGNMENT PREPARATION 434
ALIGNMENT SCREEN PREPARATION 435
HEADLAMP UNIT ADJUSTMENT 435
REMOVAL 436
INSTALLATION 437
HEADLAMP UNIT – EXPORT 437
REMOVAL 437
INSTALLATION 437
LICENSE LAMP 437
REMOVAL 437
INSTALLATION 437
MULTI-FUNCTION SWITCH 438
DESCRIPTION – TURN SIGNAL SYSTEM 438
OPERATION – TURN SIGNAL SYSTEM 438
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCH 438
REMOVAL 438
INSTALLATION 438
PARK/TURN SIGNAL LAMP 438
REMOVAL 438
INSTALLATION 438
PARK/TURN SIGNAL LAMP – EXPORT 439
REMOVAL 439
INSTALLATION 439
REAR FOG LAMP – EXPORT 439
DESCRIPTION 439
REPEATER LAMP – EXPORT 439
REMOVAL 439
INSTALLATION 439
TAIL LAMP 439
REMOVAL 439
INSTALLATION 439
TAIL LAMP – EXPORT 440
REMOVAL 440
INSTALLATION 440
TAIL LAMP UNIT 440
REMOVAL 440
INSTALLATION 440
LAMPS/LIGHTING – INTERIOR 442
LAMPS/LIGHTING – INTERIOR 442
SPECIFICATIONS 442
INTERIOR LAMPS 442
CENTER CONSOLE LAMP SWITCH 443
REMOVAL 443
INSTALLATION 443
CLUSTER ILLUMINATION LAMPS 443
REMOVAL 443
INSTALLATION 443
COURTESY LAMP 443
REMOVAL 443
INSTALLATION 443
DOME/CARGO LAMP 443
REMOVAL 443
INSTALLATION 443
GLOVE BOX LAMP SWITCH 443
REMOVAL 443
INSTALLATION 443
LIFTGATE LAMP 444
REMOVAL 444
INSTALLATION 444
READING LAMP 444
REMOVAL 444
INSTALLATION 445
VANITY LAMP 445
REMOVAL 445
INSTALLATION 445
8m-MESSAGE SYSTEMS 446
OVERHEAD CONSOLE 446
DESCRIPTION 446
DESCRIPTION – COMPASS 446
DESCRIPTION – TEMPERATURE 447
OPERATION 447
DIAGNOSIS AND TESTING – OVERHEAD CONSOLE 447
SELF-DIAGNOSTIC TEST 447
STANDARD PROCEDURE 448
STANDARD PROCEDURE – READING/COURTESY LAMP REPLACEMENT 448
STANDARD PROCEDURE – MODULE LAMP REPLACEMENT 448
STANDARD PROCEDURE – COMPASS CALIBRATION 448
STANDARD PROCEDURE – COMPASS DEMAGNETIZING 449
STANDARD PROCEDURE – COMPASS VARIATION ADJUSTMENT 450
REMOVAL – OVERHEAD CONSOLE 451
INSTALLATION 451
SPECIAL TOOLS0 – 4 RS (Continued) 451
OVERHEAD CONSOLE 451
ELECTRONIC VEHICLE INFO CENTER 451
DESCRIPTION 451
OPERATION 452
DIAGNOSIS AND TESTING – ELECTRONIC VEHICLE INFORMATION CENTER 452
STANDARD PROCEDURE – ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING 452
EVIC PROGRAMMING MODE 452
PROGRAMMABLE FEATURES 453
REMOVAL 454
INSTALLATION 454
COMPASS/MINI-TRIP COMPUTER 454
DESCRIPTION 454
OPERATION 454
DIAGNOSIS AND TESTING – COMPASS MINI-TRIP COMPUTER 455
REMOVAL 455
INSTALLATION 455
UNIVERSAL TRANSMITTER 455
DESCRIPTION 455
OPERATION 455
DIAGNOSIS AND TESTING – UNIVERSAL TRANSMITTER 455
STANDARD PROCEDURE 456
STANDARD PROCEDURE – SETTING TRANSMITTER CODES 456
STANDARD PROCEDURE – ERASING TRANSMITTER CODES 456
REMOVAL 456
AMBIENT TEMP SENSOR 456
DESCRIPTION 456
OPERATION 456
DIAGNOSIS AND TESTING 457
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR 457
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR CIRCUIT 457
REMOVAL 457
INSTALLATION 457
8n-POWER SYSTEMS 458
POWER LIFTGATE SYSTEM 458
POWER LIFTGATE SYSTEM 459
DESCRIPTION 459
OPERATION 460
POWER LIFTGATE SYSTEM INHIBITORS 460
POWER LIFTGATE SYSTEM CAUTIONS AND WARNINGS 461
DIAGNOSIS AND TESTING – POWER LIFTGATE SYSTEM 461
STANDARD PROCEDURE 466
STANDARD PROCEDURE – LIFTGATE ADJUSTMENT 466
STANDARD PROCEDURE – POWER LIFTGATE LEARN CYCLE 466
SPECIFICATIONS 466
SPECIFICATIONS TABLE 466
CHIME/THERMISTOR 467
DESCRIPTION 467
OPERATION 467
REMOVAL 467
INSTALLATION 467
ENGAGE ACTUATOR 467
DESCRIPTION 467
OPERATION 468
REMOVAL 468
INSTALLATION 468
EXTERIOR HANDLE SWITCH 468
DESCRIPTION 468
OPERATION 468
REMOVAL 468
INSTALLATION 469
FULL OPEN SWITCH 469
DESCRIPTION 469
OPERATION 469
REMOVAL 470
INSTALLATION 470
LATCH 470
DESCRIPTION 470
OPERATION 470
REMOVAL 470
INSTALLATION 471
LATCH ACTUATOR 471
DESCRIPTION 471
OPERATION 471
REMOVAL 471
INSTALLATION 471
LIFTGATE MOTOR 472
DESCRIPTION 472
OPERATION 472
REMOVAL 472
INSTALLATION 472
LIFT GEAR & LINK ROD 473
DESCRIPTION 473
OPERATION 473
REMOVAL 473
INSTALLATION 473
PINCH SENSOR 474
DESCRIPTION 474
OPERATION 474
REMOVAL 474
INSTALLATION 474
TRANSVERSE BRACKET 475
DESCRIPTION 475
OPERATION 475
REMOVAL 475
INSTALLATION 475
POWER SLIDING DOOR SYSTEM 476
POWER SLIDING DOOR SYSTEM 476
DESCRIPTION 476
OPERATION 478
POWER SLIDING DOOR SYSTEM INHIBITORS 478
POWER SLIDING DOOR SYSTEM WARNINGS 479
DIAGNOSIS AND TESTING – POWER SLIDING DOOR SYSTEM 479
STANDARD PROCEDURE 485
STANDARD PROCEDURE – POWER DOOR LEARN CYCLE 485
STANDARD PROCEDURE – PUSH-PIN GROMMET REPLACEMENT 485
STANDARD PROCEDURE – SLIDING DOOR ADJUSTMENT 485
SPECIFICATIONS 486
SPECIFICATIONS TABLE 486
LATCH 486
DESCRIPTION 486
OPERATION 486
REMOVAL 486
INSTALLATION 486
SLIDING DOOR MOTOR 487
DESCRIPTION 487
OPERATION 487
REMOVAL 487
INSTALLATION 488
FULL OPEN SWITCH 488
DESCRIPTION 488
OPERATION 488
LEFT B-PILLAR SWITCH 489
DESCRIPTION 489
OPERATION 489
REMOVAL 489
INSTALLATION 489
RIGHT B-PILLAR SWITCH 489
DESCRIPTION 489
OPERATION 489
REMOVAL 489
INSTALLATION 489
LOWER DRIVE UNIT 489
DESCRIPTION 489
OPERATION 489
REMOVAL 490
INSTALLATION 490
LOWER DRIVE UNIT TRACK & RACK 491
DESCRIPTION 491
OPERATION 491
REMOVAL 491
INSTALLATION 491
WIRING HARNESS 492
DESCRIPTION 492
OPERATION 492
REMOVAL 492
INSTALLATION 493
FLEX DRIVE 493
DESCRIPTION 493
OPERATION 493
REMOVAL 494
INSTALLATION 494
POWER LOCKS 495
POWER LOCKS 495
DESCRIPTION 495
POWER DOOR LOCK SYSTEM 495
AUTOMATIC DOOR LOCK 495
AUTOMATIC DOOR UNLOCK 495
DOOR LOCK INHIBIT 495
CENTRAL LOCKING 495
DOOR LOCK CIRCUIT PROTECTION 495
REMOTE KEYLESS ENTRY SYSTEM 496
OPERATION 496
POWER DOOR LOCK SYSTEM 496
AUTOMATIC DOOR LOCKS 496
DOOR LOCK INHIBIT 496
CENTRAL LOCKING 496
DOOR LOCK CIRCUIT PROTECTION 496
REMOTE KEYLESS ENTRY SYSTEM 497
DOOR CYLINDER LOCK SWITCH 497
DESCRIPTION 497
OPERATION 497
DIAGNOSIS AND TESTING – DOOR CYLINDER LOCK SWITCH 497
REMOVAL 498
INSTALLATION 498
DOOR LOCK MOTOR 498
DIAGNOSIS AND TESTING – DOOR LOCK MOTOR 498
DOOR LOCK SWITCH 498
DIAGNOSIS AND TESTING – DOOR LOCK SWITCH 498
REMOVAL 499
INSTALLATION 499
KEYLESS ENTRY TRANSMITTER 499
DIAGNOSIS AND TESTING – KEYLESS ENTRY TRANSMITTER 499
STANDARD PROCEDURE 499
STANDARD PROCEDURE – HORN CHIRP PREFERENCE 499
DISABLING 499
ENABLING 499
STANDARD PROCEDURE – BATTERY REPLACEMENT 499
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMING 500
SPECIFICATIONS 500
RANGE 500
BATTERY 500
REMOTE KEYLESS ENTRY MODULE 500
DESCRIPTION 500
OPERATION 500
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY MODULE 500
REMOVAL 501
INSTALLATION 501
SLIDING DOOR LOCK MOTOR 501
REMOVAL 501
INSTALLATION 501
POWER MIRRORS 502
POWER MIRRORS 502
DESCRIPTION 502
OPERATION 502
DIAGNOSIS AND TESTING – POWER MIRRORS 503
AUTOMATIC DAY / NIGHT MIRROR 504
DESCRIPTION 504
OPERATION 504
DIAGNOSIS AND TESTING – AUTOMATIC DAY / NIGHT MIRROR 504
POWER FOLDAWAY MIRROR SWITCH – EXPORT 505
DESCRIPTION 505
OPERATION 505
REMOVAL 505
INSTALLATION 506
REMOTE SWITCH 506
DIAGNOSIS AND TESTING – REMOTE SWITCH 506
REMOVAL 506
INSTALLATION 506
SIDEVIEW MIRROR 506
REMOVAL 506
POWER SEAT SYSTEM 507
POWER SEAT SYSTEM 507
DESCRIPTION 507
DESCRIPTION 507
DESCRIPTION – MEMORY SYSTEM 508
OPERATION 509
OPERATION – POWER SEAT SYSTEM 509
OPERATION – MEMORY SYSTEM 509
ELECTRONIC VEHICLE INFORMATION CENTER 509
DIAGNOSIS AND TESTING 509
DIAGNOSIS AND TESTING – POWER SEAT SYSTEM 509
DIAGNOSIS AND TESTING – MEMORY SYSTEM 510
DRIVER SEAT SWITCH 510
DESCRIPTION 510
OPERATION 511
DIAGNOSIS AND TESTING – DRIVER SEAT SWITCH 511
REMOVAL 512
INSTALLATION 512
MEMORY SET SWITCH 512
DESCRIPTION 512
OPERATION 513
DIAGNOSIS AND TESTING – MEMORY SWITCH 513
REMOVAL 513
INSTALLATION 513
PASSENGER SEAT SWITCH 513
DESCRIPTION 513
OPERATION 513
DIAGNOSIS AND TESTING – PASSENGER SEAT SWITCH 514
REMOVAL 514
INSTALLATION 514
DRIVER POWER SEAT TRACK 515
DESCRIPTION 515
OPERATION 515
DIAGNOSIS AND TESTING – DRIVER POWER SEAT TRACK 515
TESTING POWER SEAT TRACK MOTORS 516
REMOVAL 516
INSTALLATION 516
PASSENGER POWER SEAT TRACK 516
DESCRIPTION 516
OPERATION 517
DIAGNOSIS AND TESTING – POWER SEAT TRACK 517
REMOVAL 518
INSTALLATION 518
POWER WINDOWS 519
POWER WINDOWS 519
DESCRIPTION 519
OPERATION 519
DIAGNOSIS AND TESTING – POWER WINDOWS 519
POWER WINDOW MOTOR TEST 519
WIRING VOLTAGE TEST 520
VENT WINDOW MOTOR 520
DIAGNOSIS AND TESTING – VENT WINDOW MOTOR 520
REMOVAL 520
INSTALLATION 521
WINDOW MOTOR 521
REMOVAL 521
WINDOW SWITCH 521
DIAGNOSIS AND TESTING – WINDOW SWITCH 521
REMOVAL 522
INSTALLATION 522
8o-RESTRAINTS 524
RESTRAINTS 525
DESCRIPTION 525
OPERATION 525
WARNING 525
DIAGNOSIS AND TESTING – AIRBAG SYSTEM 525
STANDARD PROCEDURE 526
STANDARD PROCEDURE – HANDLING AIRBAGS 526
DEPLOYED AIRBAG 526
UNDEPLOYED AIRBAG 526
STANDARD PROCEDURE – SERVICE AFTER AN AIRBAG DEPLOYMENT 526
DRIVER AIRBAG 526
PASSENGER AIRBAG 526
SEAT AIRBAG 526
SEAT BELT TENSIONERS 526
CLEAN UP PROCEDURE 526
CLOCK SPRING 527
DESCRIPTION 527
OPERATION 527
STANDARD PROCEDURE – CLOCK SPRING CENTERING 527
REMOVAL 527
INSTALLATION 528
DRIVER AIRBAG 528
DESCRIPTION 528
OPERATION 528
CARE OF UNDEPLOYED AIRBAGS 528
REMOVAL 528
DEPLOYED AIRBAG 528
UNDEPLOYED AIRBAG 528
INSTALLATION 529
DEPLOYED AIRBAG 529
UNDEPLOYED AIRBAG 529
DRIVER AIRBAG TRIM COVER 529
REMOVAL 529
INSTALLATION 530
OCCUPANT RESTRAINT CONTROLLER 530
DESCRIPTION 530
OPERATION 530
REMOVAL 530
INSTALLATION 530
PASSENGER AIRBAG 530
DESCRIPTION 530
OPERATION 531
CARE OF UNDEPLOYED AIRBAGS 531
REMOVAL 531
DEPLOYED AIRBAG 531
UNDEPLOYED AIRBAG 531
INSTALLATION 532
DEPLOYED AIRBAG 532
UNDEPLOYED AIRBAG 532
SEAT AIRBAG 533
DESCRIPTION 533
OPERATION 534
SEAT BELT BUCKLE – FRONT INBOARD 534
REMOVAL 534
INSTALLATION 534
SEAT BELT BUCKLE – FIRST ROW INBOARD – QUAD BUCKET 534
REMOVAL 534
INSTALLATION 534
SEAT BELT BUCKLE – FIRST ROW – BENCH 535
REMOVAL 535
INSTALLATION 535
SEAT BELT BUCKLE – SECOND ROW INBOARD – 50/50 BENCH 535
REMOVAL 535
INSTALLATION 535
SEAT BELT HEIGHT ADJUSTER – B OR C-PILLAR 535
REMOVAL 535
INSTALLATION 535
SEAT BELT HEIGHT ADJUSTER KNOB 536
REMOVAL 536
INSTALLATION 536
SEAT BELT & RETRACTOR – OUTBOARD – FRONT 536
REMOVAL 536
INSTALLATION 536
SEAT BELT & RETRACTOR – FIRST ROW – OUTBOARD 536
REMOVAL 536
INSTALLATION 536
SEAT BELT BUCKLE – SECOND ROW – THREE PASSENGER BENCH 537
REMOVAL 537
INSTALLATION 537
SEAT BELT & RETRACTOR – SECOND ROW – RIGHT OUTBOARD 537
REMOVAL 537
INSTALLATION 537
SEAT BELT & RETRACTOR – SECOND ROW – RIGHT OUTBOARD WITH REAR HVAC – LWB 538
REMOVAL 538
INSTALLATION 538
SEAT BELT & RETRACTOR – SECOND ROW – LEFT OUTBOARD 539
REMOVAL 539
INSTALLATION 539
SEAT BELT TENSIONER 539
DESCRIPTION 539
OPERATION 539
SIDE IMPACT AIRBAG CONTROL MODULE 540
DESCRIPTION 540
OPERATION 540
REMOVAL 540
INSTALLATION 540
8p-SPEED CONTROL 542
SPEED CONTROL 542
DESCRIPTION 542
OPERATION 542
OPERATION 542
OPERATION – INTERACTIVE SPEED CONTROL (4 Speed EATX Only) 543
CLIMBING A GRADE 543
GRADE HUNTING 543
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION 544
DIAGNOSIS AND TESTING – ROAD TEST 544
SPECIFICATIONS – TORQUE 544
CABLE 545
DESCRIPTION 545
OPERATION 545
REMOVAL 545
INSTALLATION 545
SERVO 545
DESCRIPTION 545
OPERATION 545
REMOVAL 546
INSTALLATION 546
SWITCH 547
DESCRIPTION 547
OPERATION 547
REMOVAL 547
INSTALLATION 547
VACUUM RESERVOIR 547
DESCRIPTION 547
OPERATION 547
REMOVAL 547
INSTALLATION 547
8q-VEHICLE THEFT SECURITY 548
VEHICLE THEFT SECURITY 548
DESCRIPTION 548
VEHICLE THEFT SECURITY SYSTEM 548
SENTRY KEY IMMOBILIZER SYSTEM 548
OPERATION 548
VEHICLE THEFT SECURITY SYSTEM 548
ARMING THE VTSS – METHOD A 549
ARMING THE VTSS – METHOD B 549
TRIGGERING THE VTSS 549
SENTRY KEY IMMOBILIZER SYSTEM 549
DIAGNOSIS AND TESTING 550
DIAGNOSIS AND TESTING – SENTRY KEY IMMOBILIZER SYSTEM 550
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY SYSTEM 550
HOOD AJAR SWITCH – EXPORT 550
REMOVAL 550
INSTALLATION 550
TRANSPONDER KEY 550
DESCRIPTION 550
OPERATION 550
STANDARD PROCEDURE – TRANSPONDER PROGRAMMING 551
USING A DRB III SCAN TOOL 551
“CUSTOMER LEARN” MODE 551
VTSS/SKIS INDICATOR LAMP 552
DESCRIPTION 552
OPERATION 552
8r-WIPERS/WASHERS 554
WIPERS/WASHERS 554
DESCRIPTION 554
FRONT WIPER/WASHER SYSTEM 554
REAR WIPER/WASHER SYSTEM 554
OPERATION 555
FRONT WIPER/WASHER SYSTEM 555
REAR WIPER/WASHER SYSTEM 555
DIAGNOSIS AND TESTING 555
DIAGNOSIS AND TESTING – FRONT WIPER SYSTEM 555
DIAGNOSIS AND TESTING – FRONT WIPER/WASHER SWITCH 555
DIAGNOSIS AND TESTING – FAILED PARK SWITCH 555
DIAGNOSIS AND TESTING – REAR WIPER SYSTEM 557
DIAGNOSIS AND TESTING – WASHER SYSTEM 557
FRONT WASHER PUMP MOTOR 561
REMOVAL 561
INSTALLATION 561
FRONT WIPER ARMS 561
STANDARD PROCEDURE – FRONT WIPER ARM ALIGNMENT 561
REMOVAL 562
INSTALLATION 562
FRONT WIPER MOTOR 562
REMOVAL 562
INSTALLATION 562
HEADLAMP WASHERS – EXPORT 563
DESCRIPTION 563
OPERATION 563
DIAGNOSIS AND TESTING – HEADLAMP WASHERS – EXPORT 563
REMOVAL 565
INSTALLATION 565
HEADLAMP WASHER HOSE – EXPORT 565
REMOVAL 565
INSTALLATION 565
HEADLAMP WASHER PUMP MOTOR – EXPORT 565
REMOVAL 565
INSTALLATION 566
REAR WASHER PUMP MOTOR 566
REMOVAL 566
INSTALLATION 567
REAR WIPER ARM 567
REMOVAL 567
INSTALLATION 567
REAR WIPER MOTOR 567
REMOVAL 567
INSTALLATION 568
REAR WIPER/WASHER SWITCH 568
DESCRIPTION 568
OPERATION 568
WASHER FLUID LEVEL SWITCH 568
REMOVAL 568
INSTALLATION 569
WASHER HOSES 569
REMOVAL 569
INSTALLATION 569
WASHER RESERVOIR 569
REMOVAL 569
INSTALLATION 570
WIPER BLADES 570
REMOVAL 570
CLEANING 570
INSTALLATION 570
WIPER LINKAGE 570
REMOVAL 570
INSTALLATION 571
WIPER MODULE 571
REMOVAL 571
INSTALLATION 571
8w-WIRING 572
8W-01 WIRING DIAGRAM INFORMATION 574
WIRING DIAGRAM INFORMATION 574
DESCRIPTION 574
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 574
SYMBOLS 574
TERMINOLOGY 578
DESCRIPTION – CIRCUIT INFORMATION 578
DESCRIPTION – CIRCUIT FUNCTIONS 579
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 579
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 580
IDENTIFICATION 580
LOCATIONS 580
WARNING 580
WARNINGS – GENERAL 580
DIAGNOSIS AND TESTING – WIRING HARNESS 580
TROUBLESHOOTING TOOLS 580
INTERMITTENT AND POOR CONNECTIONS 581
TROUBLESHOOTING WIRING PROBLEMS 581
STANDARD PROCEDURE 581
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 581
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 582
STANDARD PROCEDURE – TESTING FOR CONTINUITY 582
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 582
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 583
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 583
SPECIAL TOOLS 583
WIRING/TERMINAL 583
CONNECTOR 584
REMOVAL 584
INSTALLATION 584
DIODE 587
REMOVAL 587
INSTALLATION 587
TERMINAL 587
REMOVAL 587
INSTALLATION 587
WIRE 588
STANDARD PROCEDURE – WIRE SPLICING 588
8W-02 COMPONENT INDEX 590
8W-10 POWER DISTRIBUTION 592
8W-15 GROUND DISTRIBUTION 664
8W-18 BUS COMMUNICATIONS 692
8W-20 CHARGING SYSTEM 700
8W-21 STARTING SYSTEM 704
8W-30 FUEL/IGNITION SYSTEM 708
8W-31 TRANSMISSION CONTROL SYSTEM 750
8W-33 VEHICLE SPEED CONTROL 766
8W-35 ANTILOCK BRAKES 772
8W-39 VEHICLE THEFT SECURITY SYSTEM 776
8W-40 INSTRUMENT CLUSTER 792
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 808
8W-42 AIR CONDITIONING-HEATER 812
8W-43 AIRBAG SYSTEM 832
8W-44 INTERIOR LIGHTING 840
8W-45 BODY CONTROL MODULE 848
8W-46 MESSAGE CENTER 868
8W-47 AUDIO SYSTEM 870
8W-48 REAR WINDOW DEFOGGER 884
8W-49 OVERHEAD CONSOLE 888
8W-50 FRONT LIGHTING 892
8W-51 REAR LIGHTING 904
8W-52 TURN SIGNALS 910
8W-53 WIPERS 916
8W-54 TRAILER TOW 922
8W-60 POWER WINDOWS 926
8W-61 POWER DOOR LOCKS 934
8W-62 POWER MIRRORS 954
8W-63 POWER SEATS 964
8W-64 POWER SUNROOF 974
8W-70 SPLICE INFORMATION 978
8W-80 CONNECTOR PIN-OUTS 982
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 1116
CONNECTOR/GROUND/SPLICE LOCATION 1116
DESCRIPTION 1116
8W-97 POWER DISTRIBUTION SYSTEM 1174
POWER DISTRIBUTION SYSTEM 1174
DESCRIPTION 1174
OPERATION 1174
SPECIAL TOOLS 1175
POWER DISTRIBUTION SYSTEMS 1175
ACCESSORY RELAY 1175
DESCRIPTION 1175
OPERATION 1175
DIAGNOSIS AND TESTING 1175
DIAGNOSIS & TESTING – ACCESSORY RELAY 1175
DIAGNOSIS & TESTING – RELAY CIRCUIT TEST 1175
REMOVAL 1176
INSTALLATION 1176
INTEGRATED POWER MODULE 1176
DESCRIPTION 1176
OPERATION 1176
REMOVAL 1177
INSTALLATION 1177
IOD FUSE 1177
DESCRIPTION 1177
OPERATION 1178
REMOVAL 1178
INSTALLATION 1178
POWER OUTLET 1178
DESCRIPTION 1178
OPERATION 1178
DIAGNOSIS AND TESTING 1179
DIAGNOSIS & TESTING – POWER OUTLET 1179
REMOVAL 1179
INSTALLATION 1179
9-ENGINE 1182
ENGINE 2 4L 1182
ENGINE 2 4L 1184
DESCRIPTION 1184
DIAGNOSIS AND TESTING 1184
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – INTRODUCTION 1184
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1185
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 1187
DIAGNOSIS AND TESTING – ENGINE OIL LEAK INSPECTION 1189
INSPECTION FOR REAR SEAL AREA LEAKS 1189
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE TEST 1190
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1190
STANDARD PROCEDURE 1191
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 1191
STANDARD PROCEDURE – REPAIR OF DAMAGED OR WORN THREADS 1191
STANDARD PROCEDURE – HYDROSTATIC LOCKED ENGINE 1191
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS AND SEALERS 1192
SEALER APPLICATION 1192
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 1192
STANDARD PROCEDURE – MEASURING BEARING CLEARANCE USING PLASTIGAGE 1193
REMOVAL – ENGINE ASSEMBLY 1194
INSTALLATION – ENGINE ASSEMBLY 1197
SPECIFICATIONS 1198
SPECIFICATIONS – 2 4L ENGINE 1198
SPECIFICATIONS – TORQUE 1201
SPECIAL TOOLS 1202
2 4L ENGINE 1202
AIR CLEANER ELEMENT 1205
REMOVAL 1205
INSTALLATION 1205
AIR CLEANER HOUSING 1205
REMOVAL 1205
INSTALLATION 1205
CYLINDER HEAD 1205
DESCRIPTION 1205
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET 1205
CYLINDER-TO-CYLINDER LEAKAGE TEST 1206
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1206
REMOVAL – CYLINDER HEAD 1206
CLEANING 1207
INSPECTION 1207
INSTALLATION – CYLINDER HEAD 1207
CAMSHAFT OIL SEAL(S) 1208
REMOVAL 1208
INSTALLATION 1209
CAMSHAFT(S) 1209
DESCRIPTION 1209
OPERATION 1209
STANDARD PROCEDURE – MEASURING CAMSHAFT END PLAY 1210
REMOVAL 1210
CLEANING 1210
INSPECTION 1211
INSTALLATION 1211
CYLINDER HEAD COVER 1212
REMOVAL 1212
CLEANING 1212
INSPECTION 1212
INSTALLATION 1212
INTAKE/EXHAUST VALVES & SEATS 1213
DESCRIPTION 1213
CLEANING 1213
VALVE SPRINGS & SEALS 1213
REMOVAL 1213
REMOVAL – CYLINDER HEAD ON 1213
REMOVAL – CYLINDER HEAD OFF 1213
INSPECTION 1213
INSTALLATION 1214
INSTALLATION – CYLINDER HEAD ON 1214
INSTALLATION – CYLINDER HEAD OFF 1214
HYDRAULIC LASH ADJUSTERS 1215
DIAGNOSIS AND TESTING – HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS0 – 6 RS (Continued) 1215
REMOVAL 1215
INSTALLATION 1215
ROCKER ARMS 1215
REMOVAL 1215
INSPECTION 1216
INSTALLATION 1216
ENGINE BLOCK 1216
DESCRIPTION 1216
STANDARD PROCEDURE – CYLINDER BORE HONING 1216
CLEANING 1217
INSPECTION 1217
ENGINE BLOCK 1217
CYLINDER BORE 1217
CRANKSHAFT 1217
STANDARD PROCEDURE – CRANKSHAFT END PLAY 1217
REMOVAL – CRANKSHAFT 1218
INSPECTION 1218
INSTALLATION – CRANKSHAFT 1219
CRANKSHAFT MAIN BEARING LOCATION 1219
CRANKSHAFT OIL SEAL – FRONT 1221
REMOVAL 1221
INSTALLATION 1221
CRANKSHAFT OIL SEAL – REAR 1222
REMOVAL 1222
INSTALLATION 1223
PISTON & CONNECTING ROD 1223
DESCRIPTION 1223
STANDARD PROCEDURE – PISTON TO CYLINDER BORE FITTING 1223
REMOVAL 1224
INSTALLATION 1225
CONNECTING ROD BEARINGS 1226
STANDARD PROCEDURE 1226
CONNECTING ROD – FITTING 1226
PISTON RINGS 1226
STANDARD PROCEDURE 1226
PISTON RING – FITTING 1226
REMOVAL 1227
INSTALLATION 1227
VIBRATION DAMPER 1228
REMOVAL 1228
INSTALLATION 1228
STRUCTURAL COLLAR 1228
REMOVAL 1228
INSTALLATION 1229
ENGINE MOUNTING 1229
DESCRIPTION 1229
FRONT MOUNT 1230
REMOVAL 1230
INSTALLATION 1230
LEFT MOUNT 1230
REMOVAL 1230
INSTALLATION 1231
REAR MOUNT 1231
REMOVAL 1231
INSTALLATION 1231
RIGHT MOUNT 1232
REMOVAL 1232
INSTALLATION 1232
LUBRICATION 1233
DESCRIPTION 1233
OPERATION 1233
DIAGNOSIS AND TESTING – CHECKING ENGINE OIL PRESSURE 1233
OIL 1234
STANDARD PROCEDURE 1234
ENGINE OIL LEVEL CHECK 1234
STANDARD PROCEDURE – ENGINE OIL AND FILTER CHANGE 1234
OIL FILTER 1234
DESCRIPTION 1234
REMOVAL 1234
INSTALLATION 1234
OIL PAN 1235
REMOVAL 1235
INSTALLATION 1235
OIL PRESSURE SWITCH 1235
REMOVAL 1235
INSTALLATION 1235
OIL PUMP 1236
REMOVAL 1236
DISASSEMBLY 1236
CLEANING 1237
INSPECTION 1237
ASSEMBLY 1237
INSTALLATION 1238
INTAKE MANIFOLD 1239
DESCRIPTION 1239
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 1239
INTAKE MANIFOLD – UPPER 1239
REMOVAL 1239
INSPECTION 1240
INSTALLATION 1240
INTAKE MANIFOLD – LOWER 1241
REMOVAL 1241
INSPECTION 1241
INSTALLATION 1241
EXHAUST MANIFOLD 1242
REMOVAL 1242
CLEANING 1242
INSPECTION 1242
INSTALLATION 1242
TIMING BELT COVER(S) 1242
REMOVAL 1242
FRONT COVER – UPPER 1242
FRONT COVER – LOWER 1242
REAR COVER 1242
INSTALLATION 1243
FRONT COVER – UPPER 1243
FRONT COVER – LOWER 1243
REAR COVER 1243
TIMING BELT AND SPROCKET(S) 1244
REMOVAL 1244
REMOVAL – TIMING BELT 1244
REMOVAL – CAMSHAFT SPROCKETS 1245
REMOVAL – CRANKSHAFT SPROCKET 1245
CLEANING 1245
INSTALLATION 1246
INSTALLATION – CRANKSHAFT SPROCKET 1246
INSTALLATION – CAMSHAFT SPROCKETS 1246
INSTALLATION – TIMING BELT 1246
TIMING BELT TENSIONER & PULLEY 1249
REMOVAL 1249
INSTALLATION 1250
BALANCE SHAFTS AND CARRIER ASSEMBLY 1250
DESCRIPTION 1250
OPERATION 1250
REMOVAL 1250
BALANCE SHAFTS/CHAIN/SPROCKETS 1250
BALANCE SHAFT CARRIER 1251
INSTALLATION 1253
BALANCE SHAFT INSTALLATION/TIMING 1253
ENGINE 3 3/3 8L 1255
ENGINE 3 3/3 8L 1257
DESCRIPTION 1257
DIAGNOSIS AND TESTING 1257
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – INTRODUCTION 1257
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1259
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 1261
DIAGNOSIS AND TESTING – ENGINE OIL LEAK INSPECTION 1263
INSPECTION FOR REAR SEAL AREA LEAKS 1263
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE TEST 1264
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1264
STANDARD PROCEDURE 1265
STANDARD PROCEDURE – MEASURING BEARING CLEARANCE USING PLASTIGAGE 1265
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS AND SEALERS 1265
SEALER APPLICATION 1266
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 1266
STANDARD PROCEDURE – HYDROSTATIC LOCKED ENGINE 1266
STANDARD PROCEDURE – REPAIR OF DAMAGED OR WORN THREADS 1267
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 1267
REMOVAL – ENGINE ASSEMBLY 1267
INSTALLATION – ENGINE ASSEMBLY 1270
SPECIFICATIONS 1272
3 3/3 8L ENGINE 1272
SPECIFICATIONS – TORQUE 1276
SPECIAL TOOLS 1276
3 3/3 8L ENGINE 1276
AIR CLEANER ELEMENT 1279
REMOVAL 1279
INSTALLATION 1279
AIR CLEANER HOUSING 1280
REMOVAL 1280
INSTALLATION 1280
CYLINDER HEAD 1280
DESCRIPTION 1280
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET 1280
CYLINDER-TO-CYLINDER LEAKAGE TEST 1280
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1280
REMOVAL – CYLINDER HEAD 1281
CLEANING 1281
INSPECTION 1282
INSTALLATION – CYLINDER HEAD 1282
CYLINDER HEAD COVER(S) 1283
DESCRIPTION 1283
CYLINDER HEAD COVER – RIGHT 1283
REMOVAL 1283
INSTALLATION 1284
CYLINDER HEAD COVER – LEFT 1284
REMOVAL 1284
INSTALLATION 1284
INTAKE/EXHAUST VALVES & SEATS 1285
DESCRIPTION 1285
OPERATION 1285
STANDARD PROCEDURE – REFACING VALVES AND VALVE SEATS 1285
VALVES 1285
VALVE SEATS 1285
REMOVAL 1286
CLEANING 1286
INSPECTION 1286
VALVES 1286
VALVE GUIDES 1286
INSTALLATION 1287
VALVE SPRINGS 1287
DESCRIPTION 1287
OPERATION 1287
REMOVAL 1287
REMOVAL – CYLINDER HEAD OFF 1287
REMOVAL – CYLINDER HEAD ON 1287
INSPECTION 1289
INSTALLATION 1289
INSTALLATION – CYLINDER HEAD OFF 1289
INSTALLATION – CYLINDER HEAD ON 1289
ROCKER ARMS 1290
DESCRIPTION 1290
DESCRIPTION – ROCKER ARMS 1290
DESCRIPTION – PUSHRODS 1290
OPERATION 1290
OPERATION – ROCKER ARMS 1290
OPERATION – PUSHRODS 1290
REMOVAL – ROCKER ARMS AND SHAFT 1290
DISASSEMBLY – ROCKER ARMS AND SHAFT 1290
ASSEMBLY – ROCKER ARMS AND SHAFT 1290
INSTALLATION – ROCKER ARMS AND SHAFT 1291
VALVE STEM SEALS 1292
DESCRIPTION 1292
REMOVAL 1293
INSTALLATION 1293
ENGINE BLOCK 1293
DESCRIPTION 1293
STANDARD PROCEDURE – CYLINDER BORE HONING 1293
CLEANING 1293
INSPECTION 1293
ENGINE BLOCK 1293
CYLINDER BORE 1294
HYDRAULIC LIFTERS (CAM IN BLOCK) 1294
DESCRIPTION 1294
DIAGNOSIS AND TESTING – HYDRAULIC LIFTERS 1294
HYDRAULIC LIFTERS DIAGNOSIS – PRELIMINARY STEP 1294
OIL LEVEL TOO HIGH 1294
OIL LEVEL TOO LOW 1294
VALVE TRAIN NOISE 1294
REMOVAL 1295
INSTALLATION 1295
CAMSHAFT & BEARINGS (IN BLOCK) 1296
DESCRIPTION 1296
OPERATION 1296
REMOVAL 1296
INSPECTION 1296
INSTALLATION 1296
PISTON & CONNECTING ROD 1297
DESCRIPTION 1297
STANDARD PROCEDURE 1297
STANDARD PROCEDURE – FITTING CONNECTING RODS 1297
STANDARD PROCEDURE – FITTING PISTONS 1298
REMOVAL 1298
INSTALLATION 1299
CONNECTING ROD BEARINGS 1301
STANDARD PROCEDURE – MEASURING CONNECTING ROD BEARING CLEARANCE 1301
PISTON RINGS 1302
STANDARD PROCEDURE – PISTON RING FITTING 1302
REMOVAL 1302
INSTALLATION 1302
CRANKSHAFT MAIN BEARINGS 1304
STANDARD PROCEDURE – MAIN BEARING FITTING 1304
CRANKSHAFT BEARING OIL CLEARANCE 1304
REMOVAL – CRANKSHAFT MAIN BEARINGS 1305
INSTALLATION – CRANKSHAFT MAIN BEARINGS 1305
CRANKSHAFT 1306
DESCRIPTION 1306
DESCRIPTION – 3 3L 1306
DESCRIPTION – 3 8L 1306
STANDARD PROCEDURE – MEASURING CRANKSHAFT END PLAY 1306
REMOVAL 1306
INSTALLATION 1307
CRANKSHAFT OIL SEAL – FRONT 1308
REMOVAL 1308
INSTALLATION 1308
CRANKSHAFT OIL SEAL – REAR 1309
REMOVAL 1309
INSTALLATION 1310
CRANKSHAFT REAR OIL SEAL RETAINER 1310
REMOVAL 1310
INSTALLATION 1310
VIBRATION DAMPER 1311
REMOVAL 1311
INSTALLATION 1311
FLEX PLATE 1312
REMOVAL 1312
INSTALLATION 1312
ENGINE MOUNTING 1312
DESCRIPTION 1312
FRONT MOUNT 1312
REMOVAL 1312
INSTALLATION 1312
LEFT MOUNT 1314
REMOVAL 1314
INSTALLATION 1314
REAR MOUNT 1314
REMOVAL 1314
INSTALLATION 1315
RIGHT MOUNT 1316
REMOVAL 1316
INSTALLATION 1316
LUBRICATION 1317
DESCRIPTION 1317
OPERATION 1317
DIAGNOSIS AND TESTING – ENGINE OIL PRESSURE 1317
OIL 1318
STANDARD PROCEDURE 1318
STANDARD PROCEDURE – ENGINE OIL AND FILTER CHANGE 1318
STANDARD PROCEDURE – ENGINE OIL LEVEL CHECK 1318
OIL COOLER & LINES 1319
DESCRIPTION 1319
OPERATION 1319
REMOVAL 1319
INSTALLATION 1319
OIL FILTER 1320
REMOVAL 1320
INSTALLATION 1320
OIL FILTER ADAPTER 1320
REMOVAL 1320
INSTALLATION 1320
OIL PAN 1321
REMOVAL 1321
CLEANING 1321
INSPECTION 1321
INSTALLATION 1321
OIL PRESSURE RELIEF VALVE 1322
REMOVAL 1322
INSTALLATION 1322
OIL PRESSURE SWITCH 1322
DESCRIPTION 1322
OPERATION 1322
REMOVAL 1322
INSTALLATION 1322
OIL PUMP 1323
DESCRIPTION 1323
REMOVAL 1323
DISASSEMBLY 1323
CLEANING 1323
INSPECTION 1323
ASSEMBLY 1324
INSTALLATION 1325
INTAKE MANIFOLD 1325
DESCRIPTION 1325
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 1326
INTAKE MANIFOLD – UPPER 1326
STANDARD PROCEDURE 1326
STANDARD PROCEDURE – MANIFOLD STRIPPED THREAD REPAIR 1326
STANDARD PROCEDURE – INTAKE MANIFOLD VACUUM PORT REPAIR 1326
REMOVAL – UPPER INTAKE MANIFOLD 1326
CLEANING 1327
INSPECTION 1327
INSTALLATION – UPPER INTAKE MANIFOLD 1328
INTAKE MANIFOLD – LOWER 1329
REMOVAL – LOWER INTAKE MANIFOLD 1329
CLEANING 1329
INSPECTION 1329
INSTALLATION – LOWER INTAKE MANIFOLD 1330
EXHAUST MANIFOLD – RIGHT 1331
REMOVAL 1331
CLEANING 1332
INSPECTION 1332
INSTALLATION 1332
EXHAUST MANIFOLD – LEFT 1333
REMOVAL 1333
CLEANING 1333
INSPECTION 1333
INSTALLATION 1333
VALVE TIMING 1334
STANDARD PROCEDURE 1334
STANDARD PROCEDURE – VALVE TIMING VERIFICATION 1334
STANDARD PROCEDURE – MEASURING TIMING CHAIN WEAR 1334
TIMING CHAIN COVER 1334
REMOVAL 1334
INSTALLATION 1336
TIMING CHAIN AND SPROCKETS 1337
REMOVAL 1337
REMOVAL – TIMING CHAIN AND CAMSHAFT SPROCKET 1337
REMOVAL – CRANKSHAFT SPROCKET 1337
INSTALLATION 1337
INSTALLATION – CRANKSHAFT SPROCKET 1337
INSTALLATION – TIMING CHAIN AND CAMSHAFT SPROCKET 1338
11-EXHAUST SYSTEM 1340
EXHAUST SYSTEM 1340
DESCRIPTION 1340
DIAGNOSIS AND TESTING 1341
DIAGNOSIS AND TESTING – EXCESSIVE EXHAUST SYSTEM NOISE 1341
DIAGNOSIS AND TESTING – EXHAUST SYSTEM RESTRICTION CHECK 1341
INSPECTION 1342
ADJUSTMENTS 1342
SPECIFICATIONS 1342
TORQUE 1342
SPECIAL TOOLS 1343
EXHAUST SYSTEM 1343
CATALYTIC CONVERTER 1343
DESCRIPTION 1343
OPERATION 1343
REMOVAL 1344
INSPECTION 1344
INSTALLATION 1345
CROSS-OVER PIPE – 3 3/3 8L 1345
REMOVAL 1345
INSTALLATION 1345
HEAT SHIELDS 1345
DESCRIPTION 1345
OPERATION 1346
REMOVAL 1346
INSTALLATION 1346
MUFFLER 1346
REMOVAL 1346
INSTALLATION 1346
RESONATOR 1348
REMOVAL 1348
INSTALLATION 1348
13-FRAME & BUMPERS 1350
BUMPERS 1350
SPECIFICATIONS – TORQUE 1350
FRONT FASCIA 1350
REMOVAL 1350
INSTALLATION 1350
FRONT BUMPER REINFORCEMENT 1351
REMOVAL 1351
INSTALLATION 1351
REAR FASCIA 1351
REMOVAL 1351
INSTALLATION 1351
REAR BUMPER REINFORCEMENT 1352
REMOVAL 1352
INSTALLATION 1352
REAR FASCIA – SCUFF PAD 1352
REMOVAL 1352
INSTALLATION 1353
FRAME 1353
SPECIFICATIONS 1353
FRAME DIMENSIONS 1353
VEHICLE PREPARATION 1353
SPECIFICATIONS – TORQUE 1353
FRONT CRADLE CROSSMEMBER 1358
DESCRIPTION 1358
DESCRIPTION – FRONT CRADLE CROSSMEMBER 1358
DESCRIPTION – FRONT CRADLE CROSSMEMBER THREAD REPAIR 1358
TOOL REQUIREMENT FOR M8x1 25 Thread 1358
TOOL REQUIREMENT FOR M10x1 5 Thread 1358
REMOVAL 1358
REMOVAL 1358
INSTALLATION 1360
FRONT CROSSMEMBER MOUNT BUSHINGS 1361
REMOVAL 1361
INSTALLATION 1361
14-FUEL SYSTEM 1362
FUEL DELIVERY 1362
FUEL DELIVERY 1363
DESCRIPTION 1363
DESCRIPTION 1363
DESCRIPTION – FFV REPLACEMENT PARTS 1363
OPERATION 1363
DIAGNOSIS AND TESTING – FUEL DELIVERY SYSTEM 1363
STANDARD PROCEDURE 1363
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1363
STANDARD PROCEDURE – DRAINING FUEL TANK 1363
SPECIFICATIONS 1364
FUEL SYSTEM PRESSURE 1364
TORQUE 1364
SPECIAL TOOLS 1364
FUEL 1364
FUEL FILTER 1365
REMOVAL 1365
INSTALLATION 1365
FUEL LEVEL SENDING UNIT / SENSOR 1365
DESCRIPTION 1365
OPERATION 1366
REMOVAL 1366
INSTALLATION 1366
FUEL LINES 1367
DESCRIPTION – FUEL LINES/HOSES AND CLAMPS 1367
STANDARD PROCEDURE – HOSES AND CLAMP 1367
FUEL PRESSURE REGULATOR 1368
OPERATION 1368
REMOVAL 1368
INSTALLATION 1368
FUEL PUMP 1368
DESCRIPTION 1368
OPERATION 1368
FUEL PUMP MODULE 1369
DESCRIPTION 1369
OPERATION 1369
FUEL PUMP ELECTRICAL CONTROL 1369
ELECTRICAL PUMP REPLACEMENT 1369
REMOVAL 1369
INSTALLATION 1370
FUEL RAIL 1370
REMOVAL 1370
REMOVAL – 2 4L 1370
REMOVAL – 3 3/3 8L 1370
INSTALLATION 1371
INSTALLATION – 2 4L 1371
INSTALLATION – 3 3/3 8L 1371
FUEL TANK 1371
DESCRIPTION 1371
OPERATION 1371
REMOVAL 1372
INSTALLATION 1372
FUEL TANK FILLER TUBE 1373
REMOVAL 1373
INSTALLATION 1373
INLET FILTER 1374
REMOVAL 1374
INSTALLATION 1374
QUICK CONNECT FITTING 1374
STANDARD PROCEDURE – QUICK-CONNECT FITTINGS 1374
REMOVAL 1374
INSTALLATION 1375
TWO-TAB TYPE FITTING 1375
PLASTIC RETAINER RING TYPE FITTING 1376
FUEL INJECTION 1378
FUEL INJECTION 1379
OPERATION 1379
OPERATION – INJECTION SYSTEM 1379
OPERATION – MODES OF OPERATION 1379
IGNITION SWITCH ON (ZERO RPM) MODE 1379
ENGINE START-UP MODE 1380
ENGINE WARM-UP MODE 1380
CRUISE OR IDLE MODE 1380
ACCELERATION MODE 1381
DECELERATION MODE 1381
WIDE-OPEN-THROTTLE MODE 1381
IGNITION SWITCH OFF MODE 1381
FUEL CORRECTION or ADAPTIVE MEMORIES 1381
DESCRIPTION 1381
OPERATION 1381
PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS 1382
DESCRIPTION 1382
OPERATION 1382
SYSTEM DIAGNOSIS 1383
OPERATION 1383
SPECIFICATIONS 1383
TORQUE 1383
SPECIAL TOOLS 1384
FUEL 1384
ACCELERATOR PEDAL 1384
REMOVAL 1384
INSTALLATION 1385
CRANKSHAFT POSITION SENSOR 1385
DESCRIPTION 1385
OPERATION 1385
REMOVAL 1386
INSTALLATION – 2 4L 1386
ENGINE SPEED SENSOR 1386
DESCRIPTION 1386
OPERATION 1387
FUEL INJECTOR 1387
DESCRIPTION 1387
OPERATION 1387
REMOVAL 1387
REMOVAL – 2 4L 1387
REMOVAL – 3 3/3 8L 1388
INSTALLATION 1388
INSTALLATION – 2 4L 1388
INSTALLATION – 3 3/3 8L 1388
FUEL PUMP RELAY 1389
DESCRIPTION 1389
OPERATION 1389
IDLE AIR CONTROL MOTOR 1389
DESCRIPTION 1389
OPERATION 1389
Target Idle 1390
REMOVAL 1390
INSTALLATION 1390
INLET AIR TEMPERATURE SENSOR 1390
DESCRIPTION 1390
OPERATION 1390
Inlet/Intake Air Temperature (NGC) 1390
Battery Temperature (SBEC Vehicles without Battery Temperature sensor) 1390
MAP SENSOR 1391
DESCRIPTION 1391
OPERATION 1391
REMOVAL 1392
REMOVAL – 2 4L 1392
REMOVAL – 3 3/3 8L 1392
INSTALLATION 1392
INSTALLATION – 2 4L 1392
INSTALLATION – 3 3/3 8L 1392
O2 SENSOR 1392
DESCRIPTION 1392
OPERATION 1392
UPSTREAM OXYGEN SENSOR 1393
DOWNSTREAM OXYGEN SENSOR 1394
REMOVAL 1394
REMOVAL – UPSTREAM 1/1 – 2 4L 1394
REMOVAL – UPSTREAM 1/1 – 3 3/3 8L 1394
REMOVAL – DOWNSTREAM 1/2 – 2 4/3 3/3 8L 1394
INSTALLATION 1394
INSTALLATION – UPSTREAM 1/1 – 2 4L 1394
INSTALLATION – UPSTREAM 1/1 – 3 3/3 8L 1395
INSTALLATION DOWNSTREAM 2/1 – 2 4/3 3/3 8L 1395
THROTTLE BODY 1395
DESCRIPTION 1395
OPERATION 1395
REMOVAL 1396
INSTALLATION 1396
THROTTLE CONTROL CABLE 1396
REMOVAL 1396
INSTALLATION 1396
THROTTLE POSITION SENSOR 1397
DESCRIPTION 1397
OPERATION 1397
REMOVAL – 3 3/3 8L 1397
INSTALLATION – 3 3/3 8L 1397
19-STEERING 1398
STEERING 1398
DESCRIPTION – POWER STEERING SYSTEM 1398
OPERATION – POWER STEERING SYSTEM 1398
DIAGNOSIS AND TESTING 1398
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM FLOW AND PRESSURE TEST 1398
ALL ENGINES 1398
DIAGNOSIS AND TESTING – STEERING SYSTEM DIAGNOSIS CHARTS 1400
POWER STEERING NOISE 1400
STEERING WHEEL FEEL 1402
POWER STEERING FLUID 1405
SPECIFICATIONS 1406
POWER STEERING FASTENER TORQUE 1406
SPECIAL TOOLS 1406
POWER STEERING 1406
COLUMN 1407
COLUMN 1407
DESCRIPTION – STEERING COLUMN 1407
WARNING 1407
WARNINGS AND CAUTIONS 1407
DIAGNOSIS AND TESTING – STEERING COLUMN 1409
REMOVAL 1409
INSTALLATION 1410
SPECIFICATIONS 1411
COLUMN TORQUE 1411
IGNITION SWITCH 1411
REMOVAL 1411
INSTALLATION 1413
LOCK CYLINDER HOUSING 1414
DESCRIPTION – IGNITION INTERLOCK 1414
REMOVAL 1414
INSTALLATION 1416
KEY/LOCK CYLINDER 1417
DESCRIPTION 1417
OPERATION 1417
REMOVAL 1417
INSTALLATION 1417
GEAR SHIFT LEVER 1418
REMOVAL 1418
INSTALLATION 1418
SHROUD – LOWER 1418
REMOVAL 1418
INSTALLATION 1419
SHROUD – UPPER 1420
REMOVAL 1420
INSTALLATION 1420
STEERING WHEEL 1420
REMOVAL 1420
INSTALLATION 1421
GEAR 1423
GEAR 1423
DESCRIPTION 1423
OPERATION 1424
WARNING 1424
WARNINGS AND CAUTIONS 1424
REMOVAL 1424
REMOVAL – LHD GEAR 1424
REMOVAL – RHD GEAR 1428
INSTALLATION 1429
INSTALLATION – LHD GEAR 1429
INSTALLATION – RHD GEAR 1430
SPECIAL TOOLS 1431
POWER STEERING GEAR 1431
OUTER TIE ROD 1431
REMOVAL 1431
INSTALLATION 1431
PUMP 1433
PUMP 1433
DESCRIPTION 1433
DESCRIPTION – PUMP (2 4L/3 3L/3 8L ENGINE) 1433
DESCRIPTION – PUMP (2 5L DIESEL) 1433
OPERATION 1434
WARNING 1434
CAUTION 1434
STANDARD PROCEDURE – POWER STEERING PUMP INITIAL OPERATION 1434
REMOVAL 1435
REMOVAL – PUMP (2 4L ENGINE) 1435
REMOVAL – PUMP (3 3L/3 8L ENGINE) 1437
REMOVAL – PUMP (2 5L DIESEL) 1437
DISASSEMBLY – PUMP (PULLEY) 1438
ASSEMBLY – PUMP (PULLEY)0 – 8 RS (Continued) 1438
INSTALLATION 1439
INSTALLATION – PUMP (2 4L ENGINE) 1439
INSTALLATION – PUMP (3 3L/3 8L ENGINE) 1440
INSTALLATION – PUMP (2 5L DIESEL) 1440
SPECIAL TOOLS 1440
POWER STEERING PUMP 1440
FLUID 1441
STANDARD PROCEDURE – POWER STEERING FLUID LEVEL CHECKING 1441
FLUID COOLER 1441
DESCRIPTION 1441
OPERATION 1441
REMOVAL 1441
INSTALLATION 1442
HOSE – POWER STEERING PRESSURE 1442
REMOVAL 1442
REMOVAL – 2 4L ENGINE 1442
REMOVAL – 3 3L/3 8L ENGINE 1442
INSTALLATION 1443
INSTALLATION – 2 4L ENGINE 1443
INSTALLATION – 3 3L/3 8L ENGINE 1444
HOSE – POWER STEERING RETURN 1445
REMOVAL 1445
REMOVAL – 2 4L ENGINE 1445
REMOVAL – 3 3L/3 8L ENGINE 1445
INSTALLATION 1446
INSTALLATION – 2 4L ENGINE 1446
INSTALLATION – 3 3L/3 8L ENGINE 1446
HOSE – POWER STEERING SUPPLY 1447
REMOVAL 1447
REMOVAL – 2 4L ENGINE 1447
REMOVAL – 3 3L/3 8L ENGINE 1447
INSTALLATION 1447
INSTALLATION – 2 4L ENGINE 1447
INSTALLATION – 3 3L/3 8L ENGINE 1447
RESERVOIR – POWER STEERING FLUID 1448
DESCRIPTION 1448
DESCRIPTION – 2 4L/3 3L/3 8L ENGINE 1448
DESCRIPTION – 2 5L DIESEL 1448
OPERATION 1448
REMOVAL 1448
REMOVAL – 2 4L ENGINE 1448
REMOVAL – 3 3L/3 8L ENGINE 1448
REMOVAL – 2 5L DIESEL 1448
INSTALLATION 1449
INSTALLATION – 2 4L ENGINE 1449
INSTALLATION – 3 3L/3 8L ENGINE 1449
INSTALLATION – 2 5L DIESEL 1449
21-TRANSMISSION/TRANSAXLE 1450
POWER TRANSFER UNIT 1450
POWER TRANSFER UNIT 1450
DESCRIPTION 1450
OPERATION 1452
DIAGNOSIS AND TESTING 1452
SEAL IDENTIFICATION 1452
FLUID LEAK DIAGNOSIS 1452
STANDARD PROCEDURE 1453
STANDARD PROCEDURE – FLUID LEVEL INSPECTION 1453
STANDARD PROCEDURE – PTU FLUID CHANGE 1454
REMOVAL 1454
INSTALLATION 1455
ADJUSTMENTS 1456
OUTPUT FLANGE SHIM SELECTION 1456
SPECIFICATIONS 1456
TORQUE 1456
SPECIAL TOOLS 1457
SDP POWER TRANSFER UNIT 1457
DIFFERENTIAL CARRIER SEAL 1458
REMOVAL 1458
INSTALLATION 1458
END COVER BALL BEARING 1458
REMOVAL 1458
INSTALLATION 1459
END COVER SEAL 1460
REMOVAL 1460
INSTALLATION 1460
HALF SHAFT INNER SEAL 1461
REMOVAL 1461
INSTALLATION 1461
INPUT SHAFT COVER SEAL 1462
REMOVAL 1462
INSTALLATION 1463
INPUT SHAFT END SEAL 1464
REMOVAL 1464
INSTALLATION 1465
INPUT SHAFT SEAL 1466
REMOVAL 1466
INSTALLATION 1467
OUTER HALF SHAFT SEAL 1468
REMOVAL 1468
INSTALLATION 1468
REAR COVER O-RING 1468
REMOVAL 1468
INSTALLATION 1469
T850 MANUAL TRANSAXLE 1470
T850 MANUAL TRANSAXLE 1470
DESCRIPTION 1470
TRANSAXLE IDENTIFICATION 1472
OPERATION 1473
NEUTRAL 1473
1ST GEAR 1474
2ND GEAR 1475
3RD GEAR 1476
4TH GEAR 1477
5TH GEAR 1478
REVERSE GEAR 1479
DIAGNOSIS AND TESTING – COMMON PROBLEM CAUSES 1479
HARD SHIFTING 1479
NOISY OPERATION 1480
SLIPS OUT OF GEAR 1480
LOW LUBRICANT LEVEL 1480
CLUTCH PROBLEMS 1480
REMOVAL 1480
REMOVAL – 2 4L GAS 1480
REMOVAL – 2 5L TD 1482
DISASSEMBLY 1484
ASSEMBLY 1491
INSTALLATION 1500
INSTALLATION – 2 4L GAS 1500
INSTALLATION – 2 5L TD 1501
SPECIFICATIONS – T850 MANUAL TRANSAXLE 1505
SPECIAL TOOLS – T850 TRANSAXLE 1507
AXLE SEALS 1510
REMOVAL 1510
INSTALLATION 1510
BACK-UP LAMP SWITCH 1511
REMOVAL 1511
INSTALLATION 1511
DIFFERENTIAL 1511
DESCRIPTION 1511
OPERATION 1511
DISASSEMBLY 1511
ASSEMBLY 1515
ADJUSTMENTS 1518
ADJUSTMENT – DIFFERENTIAL TURNING TORQUE 1518
ADJUSTMENT – DIFFERENTIAL SIDE GEAR END PLAY 1519
FLUID 1520
STANDARD PROCEDURE 1520
STANDARD PROCEDURE – FLUID LEVEL CHECK 1520
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1520
FLUID DRAIN 1521
FLUID FILL 1521
GEARSHIFT BOOT 1521
REMOVAL 1521
INSTALLATION 1522
GEARSHIFT CABLE – CROSSOVER 1522
REMOVAL 1522
INSTALLATION 1525
ADJUSTMENTS 1528
ADJUSTMENT 1528
GEARSHIFT CABLE – SELECTOR 1530
REMOVAL 1530
INSTALLATION 1533
GEARSHIFT KNOB 1536
REMOVAL 1536
INSTALLATION 1536
GEARSHIFT MECHANISM 1536
REMOVAL 1536
INSTALLATION 1538
INPUT SHAFT 1542
DESCRIPTION 1542
DISASSEMBLY 1542
ASSEMBLY 1545
INTERMEDIATE SHAFT 1549
DESCRIPTION 1549
DISASSEMBLY 1549
ASSEMBLY 1556
SHIFT COVER 1562
DESCRIPTION 1562
SHIFT FORK AND SHAFT 1562
DESCRIPTION 1562
SYNCHRONIZER 1563
DESCRIPTION 1563
DISASSEMBLY 1563
CLEANING 1563
CLEAN 1563
INSPECTION 1563
INSPECT 1563
ASSEMBLY 1563
VEHICLE SPEED SENSOR 1564
REMOVAL 1564
INSTALLATION 1564
41TE AUTOMATIC TRANSAXLE 1565
41TE AUTOMATIC TRANSAXLE 1566
DESCRIPTION 1566
TRANSAXLE IDENTIFICATION 1567
OPERATION 1568
DIAGNOSIS AND TESTING 1568
DIAGNOSIS AND TESTING – 41TE TRANSAXLE GENERAL DIAGNOSIS 1568
DIAGNOSIS AND TESTING – ROAD TEST 1568
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TESTS 1569
TEST ONE-SELECTOR IN LOW (1st GEAR) 1569
TEST TWO-SELECTOR IN DRIVE (2nd GEAR) 1570
TEST TWO A–SELECTOR IN OD (4th Gear) 1570
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear) 1570
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear) 1570
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on) 1570
TEST SIX-SELECTOR IN REVERSE 1570
TEST RESULT INDICATIONS 1570
DIAGNOSIS AND TESTING – CLUTCH AIR PRESSURE TESTS 1571
OVERDRIVE CLUTCH 1571
REVERSE CLUTCH 1571
2/4 CLUTCH 1571
LOW/REVERSE CLUTCH 1572
UNDERDRIVE CLUTCH 1572
DIAGNOSIS AND TESTING – TORQUE CONVERTER HOUSING FLUID LEAKAGE 1572
TORQUE CONVERTER LEAKAGE 1573
REMOVAL 1573
DISASSEMBLY 1574
ASSEMBLY 1593
INSTALLATION 1615
SCHEMATICS AND DIAGRAMS 1618
41TE TRANSAXLE HYDRAULIC SCHEMATICS 1618
SPECIFICATIONS – 41TE TRANSAXLE 1630
SPECIAL TOOLS 1632
41TE AUTOMATIC TRANSAXLE 1632
ACCUMULATOR 1637
DESCRIPTION 1637
OPERATION 1638
AUTOSTICK SWITCH 1638
DESCRIPTION 1638
OPERATION 1638
DRIVING CLUTCHES 1639
DESCRIPTION 1639
OPERATION 1639
UNDERDRIVE CLUTCH 1639
OVERDRIVE CLUTCH 1639
REVERSE CLUTCH 1639
FINAL DRIVE 1639
DISASSEMBLY 1639
ASSEMBLY 1644
ADJUSTMENTS 1648
ADJUSTMENT – DIFFERENTIAL BEARING PRELOAD 1648
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM 1648
PRELOAD ADJUSTMENT W/O SHIM 1650
FLUID 1650
STANDARD PROCEDURE 1650
FLUID LEVEL AND CONDITION CHECK 1650
FLUID LEVEL CHECK 1650
FLUID LEVEL CHECK USING DRB 1650
FLUID CONDITION 1651
STANDARD PROCEDURE – FLUID AND FILTER SERVICE 1652
FLUID/FILTER SERVICE (RECOMMENDED) 1652
DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1652
GEAR SHIFT CABLE 1653
REMOVAL 1653
INSTALLATION 1654
ADJUSTMENTS 1655
GEARSHIFT CABLE ADJUSTMENT 1655
VERIFICATION 1655
ADJUSTMENT 1656
HOLDING CLUTCHES 1656
DESCRIPTION 1656
OPERATION 1656
2/4 CLUTCH 1656
LOW/REVERSE CLUTCH 1656
INPUT CLUTCH ASSEMBLY 1657
DISASSEMBLY 1657
ASSEMBLY 1665
OIL PUMP 1679
DESCRIPTION 1679
OPERATION 1679
DISASSEMBLY 1679
ASSEMBLY 1681
PLANETARY GEARTRAIN 1681
DESCRIPTION 1681
OPERATION 1681
SEAL – OIL PUMP 1681
REMOVAL 1681
INSTALLATION 1682
SHIFT INTERLOCK SOLENOID 1682
DESCRIPTION 1682
OPERATION 1682
DIAGNOSIS AND TESTING – BRAKE/TRANSMISSION SHIFT INTERLOCK SOLENOID 1684
REMOVAL 1684
INSTALLATION 1685
SOLENOID/PRESSURE SWITCH ASSY 1686
DESCRIPTION 1686
OPERATION 1686
SOLENOIDS 1686
PRESSURE SWITCHES 1687
REMOVAL 1687
INSTALLATION 1688
SPEED SENSOR – INPUT 1688
DESCRIPTION 1688
OPERATION 1689
REMOVAL 1689
INSTALLATION 1689
SPEED SENSOR – OUTPUT 1690
DESCRIPTION 1690
OPERATION 1690
VEHICLE SPEED SIGNAL 1690
REMOVAL 1690
INSTALLATION 1691
TORQUE CONVERTER 1691
DESCRIPTION 1691
IMPELLER 1692
TURBINE 1693
STATOR 1694
TORQUE CONVERTER CLUTCH (TCC) 1694
OPERATION 1694
TURBINE 1695
STATOR 1695
TORQUE CONVERTER CLUTCH (TCC) 1696
REMOVAL 1696
INSTALLATION 1696
TRANSMISSION CONTROL RELAY 1696
DESCRIPTION 1696
OPERATION 1697
TRANSMISSION RANGE SENSOR 1697
DESCRIPTION 1697
OPERATION 1697
TRANSMISSION TEMPERATURE SENSOR 1698
CALCULATED TEMPERATURE 1698
REMOVAL 1698
INSTALLATION 1698
TRD LINK 1698
DESCRIPTION 1698
OPERATION 1698
VALVE BODY 1699
DESCRIPTION 1699
OPERATION 1699
REGULATOR VALVE 1699
SOLENOID SWITCH VALVE 1699
MANUAL VALVE 1700
CONVERTER CLUTCH SWITCH VALVE 1700
CONVERTER CLUTCH CONTROL VALVE 1700
T/C REGULATOR VALVE 1700
LOW/REVERSE SWITCH VALVE 1700
REMOVAL 1700
DISASSEMBLY 1701
ASSEMBLY 1706
INSTALLATION 1711
22-TIRES/WHEELS 1714
TIRES/WHEELS 1714
DIAGNOSIS AND TESTING – TIRE AND WHEEL VIBRATION 1714
VISUAL INSPECTION 1714
ROAD TEST 1715
TIRE AND WHEEL BALANCE 1715
TIRE AND WHEEL RUNOUT/MATCH MOUNTING 1715
RADIAL FORCE VARIATION 1717
STANDARD PROCEDURE 1718
STANDARD PROCEDURE – TIRE AND WHEEL BALANCE 1718
STANDARD PROCEDURE – TIRE AND WHEEL MATCH MOUNTING 1720
STANDARD PROCEDURE – TIRE AND WHEEL ROTATION 1720
NON-DIRECTIONAL TREAD PATTERN TIRES 1720
DIRECTIONAL TREAD PATTERN TIRES 1720
REMOVAL 1720
REMOVAL – TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL) 1720
REMOVAL – TIRE AND WHEEL ASSEMBLY (STEEL WHEEL) 1721
INSTALLATION 1721
INSTALLATION – TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL) 1721
INSTALLATION – TIRE AND WHEEL ASSEMBLY (STEEL WHEEL) 1721
TIRE PRESSURE MONITORING 1722
DESCRIPTION 1722
OPERATION 1722
SENSOR – TPM 1723
DESCRIPTION 1723
OPERATION 1723
CAUTION 1723
DIAGNOSIS AND TESTING – TIRE PRESSURE SENSOR 1723
STANDARD PROCEDURE – TIRE PRESSURE SENSOR RETRAIN 1723
REMOVAL 1724
INSTALLATION 1725
TIRES 1726
DESCRIPTION 1726
DESCRIPTION – TIRE 1726
TIRE IDENTIFICATION 1726
TIRE CHAINS 1727
DESCRIPTION – RADIAL-PLY TIRES 1727
DESCRIPTION – REPLACEMENT TIRES 1727
DESCRIPTION – SPARE TIRE (TEMPORARY) 1727
DIAGNOSIS AND TESTING 1727
DIAGNOSIS AND TESTING – TIRE NOISE 1727
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD 1727
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 1729
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 1729
STANDARD PROCEDURE 1729
STANDARD PROCEDURE – TIRE INFLATION PRESSURES 1729
STANDARD PROCEDURE – TIRE PRESSURE FOR HIGH SPEED OPERATION 1730
STANDARD PROCEDURE – TIRE LEAK REPAIRING 1730
CLEANING – TIRES 1730
WHEELS 1731
DESCRIPTION – WHEEL 1731
DIAGNOSIS AND TESTING – WHEEL INSPECTION 1731
CLEANING – ALUMINUM WHEEL CARE 1731
SPECIFICATIONS 1732
WHEEL 1732
WHEEL COVER 1732
DESCRIPTION 1732
REMOVAL 1732
INSTALLATION 1732
WHEEL MOUNTING STUDS – FRONT 1733
REMOVAL 1733
INSTALLATION 1734
WHEEL MOUNTING STUDS – REAR 1734
REMOVAL 1734
INSTALLATION 1735
23-BODY 1736
BODY 1736
DESCRIPTION – VEHICLE IDENTIFICATION 1736
WARNING 1736
SAFETY PRECAUTIONS AND WARNINGS 1736
DIAGNOSIS AND TESTING 1737
DIAGNOSIS AND TESTING – WATER LEAKS 1737
VISUAL INSPECTION BEFORE WATER LEAK TESTS 1737
WATER LEAK TESTS 1737
WATER LEAK DETECTION 1737
DIAGNOSIS AND TESTING – WIND NOISE 1738
VISUAL INSPECTION BEFORE TESTS 1738
STANDARD PROCEDURE 1738
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 1738
Rigid Plastics: 1738
Semi-Rigid Plastics: 1738
Flexible Plastics: 1738
Repair Procedure: 1738
Adhesion Promoter/Surface Modifier: 1738
SAFETY PRECAUTION AND WARNINGS 1738
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 1739
PANEL SECTIONING 1741
PANEL REINFORCEMENT 1741
VISUAL INSPECTION 1742
PANEL SURFACE PREPARATION 1742
PATCHING PANELS 1742
PANEL PATCH FABRICATIONS 1742
PANEL PATCH INSTALLATION 1743
PATCHED PANEL SURFACING 1744
STANDARD PROCEDURE – HEAT STAKING 1745
SPECIFICATIONS 1746
TORQUE 1746
BODY LUBRICATION 1747
LUBRICATION REQUIREMENTS 1747
LUBRICANT APPLICATION 1747
LUBRICANT USAGE 1748
SPECIAL TOOLS 1748
BODY 1748
DOOR – FRONT 1749
APPLIQUE 1749
REMOVAL 1749
INSTALLATION 1749
CHECK STRAP 1750
REMOVAL 1750
INSTALLATION 1750
DOOR 1750
REMOVAL 1750
INSTALLATION 1751
DOOR GLASS 1752
REMOVAL 1752
INSTALLATION 1752
FRAME CLOSEOUT MOLDING 1752
REMOVAL – A-PILLAR-HEADER, OR B-PILLAR 1752
INSTALLATION – A-PILLAR-HEADER, OR B-PILLAR 1752
HINGE 1753
REMOVAL 1753
INSTALLATION 1753
LATCH 1753
REMOVAL 1753
INSTALLATION 1754
LATCH STRIKER 1754
REMOVAL 1754
INSTALLATION 1754
LOCK CYLINDER 1754
REMOVAL 1754
INSTALLATION 1755
TRIM PANEL 1755
REMOVAL 1755
INSTALLATION 1755
WATERSHIELD 1756
REMOVAL 1756
INSTALLATION 1756
WINDOW CRANK 1756
REMOVAL 1756
INSTALLATION 1756
EXTERIOR HANDLE 1757
REMOVAL 1757
INSTALLATION 1757
WINDOW REGULATOR – POWER 1757
REMOVAL 1757
INSTALLATION 1757
WINDOW REGULATOR – MANUAL 1758
REMOVAL 1758
INSTALLATION 1758
DOORS – SLIDING 1759
CENTER HINGE 1759
REMOVAL 1759
INSTALLATION 1759
SLIDING DOOR STOP BUMPER BEZEL 1760
REMOVAL 1760
INSTALLATION 1760
STOP BUMPER 1760
REMOVAL 1760
INSTALLATION 1760
HOLD OPEN LATCH 1760
REMOVAL 1760
INSTALLATION 1760
HOLD OPEN LATCH STRIKER 1761
REMOVAL 1761
INSTALLATION 1761
LATCH / LOCK ASSEMBLY 1761
REMOVAL 1761
INSTALLATION 1762
CENTER STRIKER 1762
REMOVAL 1762
INSTALLATION 1762
LOWER HINGE 1763
REMOVAL 1763
INSTALLATION 1763
REAR LATCH STRIKER 1763
REMOVAL 1763
INSTALLATION 1763
SLIDING DOOR 1764
REMOVAL 1764
INSTALLATION 1764
ADJUSTMENTS 1765
SLIDING DOOR ADJUSTMENTS 1765
PRELIMINARY CHECKS 1765
DOOR FLUSHNESS ADJUSTMENT 1765
DOOR GAP ADJUSTMENT – UP/DOWN 1765
DOOR GAP ADJUSTMENT – FORE/AFT 1766
DOOR SEAL COMPRESSION 1766
STABILIZER ADJUSTMENT – UPPER/LOWER 1767
STABILIZER 1767
REMOVAL 1767
INSTALLATION 1767
STABILIZER SOCKET 1767
REMOVAL 1767
INSTALLATION 1767
TRIM PANEL 1768
REMOVAL 1768
INSTALLATION 1768
INSIDE LATCH HANDLE 1768
REMOVAL 1768
INSTALLATION 1768
BELLCRANK 1769
REMOVAL 1769
INSTALLATION 1769
OUTSIDE HANDLE 1770
REMOVAL 1770
INSTALLATION 1770
UPPER HINGE 1770
REMOVAL 1770
INSTALLATION 1770
OUTSIDE HANDLE CABLE 1771
REMOVAL 1771
INSTALLATION 1771
INSIDE HANDLE CABLE 1772
REMOVAL 1772
INSTALLATION 1772
HOLD OPEN LATCH CABLE 1772
REMOVAL 1772
INSTALLATION 1773
DECKLID/HATCH/LIFTGATE/TAILGATE 1774
EXTERIOR HANDLE 1774
REMOVAL 1774
INSTALLATION 1774
HINGE 1774
REMOVAL 1774
INSTALLATION 1774
LATCH 1775
REMOVAL 1775
INSTALLATION 1775
LATCH STRIKER 1775
REMOVAL 1775
INSTALLATION 1775
LIFTGATE 1776
REMOVAL 1776
INSTALLATION 1776
LIFTGATE SPOILER 1776
REMOVAL 1776
INSTALLATION 1776
LOCK CYLINDER 1776
REMOVAL 1776
INSTALLATION 1776
SUPPORT CYLINDER 1777
REMOVAL 1777
INSTALLATION 1777
TRIM PANEL 1777
REMOVAL 1777
INSTALLATION 1778
SLAM BUMPER 1778
REMOVAL 1778
REMOVAL 1778
REMOVAL – LIFTGATE SIDE 1778
INSTALLATION 1778
INSTALLATION 1778
INSTALLATION – LIFTGATE SIDE 1778
EXTERIOR 1779
BODY SIDE MOLDINGS 1779
REMOVAL 1779
INSTALLATION 1780
COWL GRILLE 1784
REMOVAL 1784
INSTALLATION 1785
EXTERIOR NAME PLATES – TAPE ATTACHED 1785
REMOVAL 1785
INSTALLATION 1785
EXTERIOR NAME PLATES – ADHESIVE ATTACHED 1785
REMOVAL 1785
INSTALLATION 1785
FRONT FENDER 1786
REMOVAL 1786
INSTALLATION 1786
FUEL FILL DOOR 1786
REMOVAL 1786
INSTALLATION 1786
FUEL FILL DOOR BLOCKER LATCH 1787
REMOVAL 1787
INSTALLATION 1787
FUEL FILL DOOR BLOCKER LATCH STRIKER 1787
REMOVAL 1787
INSTALLATION 1787
FUEL FILL DOOR BLOCKER LOCKOUT LINK 1787
REMOVAL 1787
INSTALLATION 1788
GRILLE OPENING REINFORCEMENT 1788
REMOVAL 1788
INSTALLATION 1788
FRONT WHEELHOUSE SPLASH SHIELD 1789
REMOVAL 1789
INSTALLATION 1789
LUGGAGE RACK RISER 1789
REMOVAL 1789
INSTALLATION 1790
LUGGAGE RACK CROSSBAR 1790
REMOVAL 1790
INSTALLATION 1791
REAR QUARTER PANEL/FENDER AIR EXHAUSTER 1791
DESCRIPTION 1791
REMOVAL 1791
INSTALLATION 1792
ROOF JOINT MOLDING 1792
REMOVAL 1792
INSTALLATION 1792
SIDE VIEW MIRROR 1792
REMOVAL 1792
INSTALLATION 1792
SIDE VIEW MIRROR GLASS 1793
REMOVAL 1793
INSTALLATION 1793
HOOD 1794
HINGE 1794
REMOVAL 1794
INSTALLATION 1794
HOOD 1794
REMOVAL 1794
INSTALLATION 1795
LATCH 1795
REMOVAL 1795
INSTALLATION 1795
LATCH RELEASE CABLE 1795
REMOVAL 1795
INSTALLATION 1796
LATCH STRIKER 1796
REMOVAL 1796
INSTALLATION 1796
INSTRUMENT PANEL 1797
CLUSTER BEZEL 1797
REMOVAL 1797
INSTALLATION 1797
CUP HOLDER 1798
REMOVAL 1798
INSTALLATION 1798
GLOVE BOX 1798
REMOVAL 1798
INSTALLATION 1798
GLOVE BOX LATCH 1798
REMOVAL 1798
INSTALLATION 1798
GLOVE BOX LATCH STRIKER 1799
REMOVAL 1799
INSTALLATION 1799
INSTRUMENT PANEL ASSEMBLY 1799
REMOVAL 1799
INSTALLATION 1800
INSTRUMENT PANEL CENTER BEZEL 1802
REMOVAL 1802
INSTALLATION 1802
INSTRUMENT PANEL END CAP 1802
REMOVAL0 – 10 RS (Continued) 1802
INSTALLATION 1802
INSTRUMENT PANEL TOP COVER 1802
REMOVAL 1802
INSTALLATION 1802
LOWER CONSOLE 1803
REMOVAL 1803
INSTALLATION 1803
LOWER INSTRUMENT PANEL 1803
REMOVAL 1803
INSTALLATION 1803
LOWER STEERING COLUMN COVER 1804
REMOVAL 1804
INSTALLATION 1804
STEERING COLUMN COVER BACKING PLATE 1804
REMOVAL 1804
INSTALLATION 1804
OVER STEERING COLUMN COVER 1804
REMOVAL 1804
INSTALLATION 1804
INSTRUMENT PANEL TOP PAD ASSEMBLY 1805
REMOVAL 1805
INSTALLATION 1805
INTERIOR 1807
A-PILLAR LOWER EXTENSION TRIM 1808
REMOVAL 1808
INSTALLATION 1808
A-PILLAR TRIM 1808
REMOVAL 1808
INSTALLATION 1808
ASSIST HANDLE 1808
REMOVAL 1808
INSTALLATION 1808
B-PILLAR LOWER TRIM 1808
REMOVAL 1808
INSTALLATION 1809
B-PILLAR UPPER TRIM 1809
REMOVAL 1809
INSTALLATION 1809
CARPETS AND FLOOR MATS 1809
REMOVAL 1809
INSTALLATION 1810
COWL TRIM 1810
REMOVAL 1810
INSTALLATION 1810
C-PILLAR TRIM 1810
REMOVAL 1810
INSTALLATION 1811
DOOR SILL TRIM PLATE 1811
REMOVAL 1811
INSTALLATION 1811
HEADLINER 1811
REMOVAL 1811
INSTALLATION 1811
LEFT D-PILLAR TRIM PANEL 1812
REMOVAL 1812
INSTALLATION 1812
LIFTGATE SILL PLATE 1812
REMOVAL 1812
INSTALLATION 1812
QUARTER TRIM BOLSTER 1812
REMOVAL 1812
INSTALLATION 1812
RIGHT QUARTER TRIM PANEL 1813
REMOVAL 1813
INSTALLATION 1813
LEFT QUARTER TRIM PANEL 1813
REMOVAL 1813
INSTALLATION 1813
REAR HEADER TRIM 1814
REMOVAL 1814
INSTALLATION 1814
REAR HVAC LOUVER 1814
REMOVAL 1814
INSTALLATION 1814
REAR VIEW MIRROR 1814
REMOVAL 1814
INSTALLATION 1815
RIGHT D-PILLAR TRIM PANEL 1815
REMOVAL 1815
INSTALLATION 1815
SLIDING DOOR SILL PLATE 1815
REMOVAL 1815
INSTALLATION 1815
SUN VISOR 1816
REMOVAL 1816
INSTALLATION 1816
SUN VISOR SUPPORT 1816
REMOVAL 1816
INSTALLATION 1816
FLOOR CONSOLE TRAY 1816
REMOVAL 1816
INSTALLATION 1816
FLOOR CONSOLE TRAY – BRACKET ASSEMBLY 1817
REMOVAL 1817
INSTALLATION 1817
PAINT 1818
PAINT 1818
SPECIFICATIONS – COLOR CODE CHARTS 1818
BASE COAT/CLEARCOAT FINISH 1819
DESCRIPTION 1819
PAINT CODE 1819
DESCRIPTION 1819
PAINTED TOUCH-UP 1819
DESCRIPTION 1819
TOUCH UP PROCEDURE 1819
FINESSE SANDING/BUFFING & POLISHING 1819
DESCRIPTION 1819
SEATS 1820
CHILD SEAT MODULE, BENCH SEAT 1821
REMOVAL 1821
INSTALLATION 1822
INSTALLATION 1822
SYNCHRONIZING CABLE ADJUSTMENT 1822
QUAD CHILD SEAT 1823
REMOVAL 1823
INSTALLATION 1823
HEADREST 1823
REMOVAL 1823
INSTALLATION 1823
HEADREST SLEEVE 1824
REMOVAL 1824
INSTALLATION 1824
RECLINER HANDLE 1824
REMOVAL 1824
INSTALLATION 1824
ARMREST 1825
REMOVAL 1825
INSTALLATION 1825
FRONT SEAT 1825
REMOVAL 1825
INSTALLATION 1825
FRONT SEATBACK 1826
REMOVAL 1826
INSTALLATION 1826
FRONT SEATBACK ASSIST STRAP 1826
REMOVAL 1826
INSTALLATION 1826
FRONT SEATBACK PANEL 1826
REMOVAL 1826
INSTALLATION 1827
FRONT SEATBACK COVER 1827
REMOVAL 1827
INSTALLATION 1827
FRONT/QUAD SEAT CUSHION 1827
REMOVAL 1827
INSTALLATION 1827
FRONT SEAT CUSHION SIDE COVER 1828
REMOVAL 1828
INSTALLATION 1828
FRONT SEAT RISER – MANUAL TRACK 1828
REMOVAL 1828
INSTALLATION 1828
FRONT SEAT TRACK POWER ADJUSTER 1829
REMOVAL 1829
INSTALLATION 1829
FRONT SEAT TRACK MANUAL ADJUSTER 1829
REMOVAL 1829
INSTALLATION 1829
FRONT SEAT TRACK – REAR COVER 1830
REMOVAL 1830
INSTALLATION 1830
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER 1830
REMOVAL 1830
INSTALLATION 1830
QUAD BUCKET SEAT SIDE SHIELD – NO CUP HOLDER 1831
REMOVAL 1831
INSTALLATION 1831
QUAD BUCKET SEAT RISER 1831
REMOVAL 1831
INSTALLATION 1831
BUCKET SEAT BACK – QUAD BUCKET 1832
REMOVAL 1832
INSTALLATION 1832
BENCH SEATBACK PANEL 1833
REMOVAL 1833
INSTALLATION 1833
SEAT CUSHION COVER – QUAD BUCKET, 50/50 SPLIT, BENCH 1833
REMOVAL 1833
BENCH SEAT & 50/50 SPLIT 1833
QUAD BUCKET 1833
INSTALLATION 1834
BENCH SEAT & 50/50 SPLIT 1834
QUAD BUCKET 1834
BENCH SEAT RISER – 50/50 SPLIT 1834
REMOVAL 1834
INSTALLATION 1834
BENCH SEAT RISER – SECOND ROW 1834
REMOVAL 1834
INSTALLATION 1835
BENCH SEAT RISER – THIRD ROW 1835
REMOVAL 1835
INSTALLATION 1835
SEAT BACK HINGE COVERS – QUAD BUCKET, 50/50 SPLIT, BENCH 1835
REMOVAL 1835
INSTALLATION 1835
BENCH SEAT BACK HINGE 1835
REMOVAL 1835
INSTALLATION 1835
INSTALLATION 1835
SYNCHRONIZING CABLE ADJUSTMENT 1836
BENCH SEAT BACK 1836
REMOVAL 1836
INSTALLATION 1836
BENCH SEAT BACK COVER 1837
REMOVAL 1837
INSTALLATION 1837
BENCH SEAT TRACK 1837
REMOVAL 1837
INSTALLATION 1837
PLASTIC GROCERY BAG RETAINER 1838
REMOVAL 1838
3-PASS BENCH SEAT 1838
50/50 SPLIT BENCH SEAT 1838
INSTALLATION 1838
3-PASS BENCH SEAT 1838
50/50 SPLIT BENCH SEAT 1838
UNDER SEAT STORAGE BIN 1838
REMOVAL 1838
INSTALLATION 1838
UNDER SEAT STORAGE BIN GUIDE 1839
REMOVAL 1839
INSTALLATION 1839
UNDER SEAT STORAGE BIN LOCK/LATCH 1839
REMOVAL 1839
INSTALLATION 1839
LUMBAR SUPPORT 1839
REMOVAL 1839
INSTALLATION 1839
STATIONARY GLASS 1840
WINDSHIELD 1840
DESCRIPTION 1840
WARNING 1840
WINDSHIELD SAFETY PRECAUTIONS 1840
REMOVAL 1840
WINDSHIELD REMOVAL – EXTERIOR METHOD 1840
WINDSHIELD REMOVAL – INTERIOR METHOD 1841
INSTALLATION 1841
SLIDING DOOR GLASS 1842
REMOVAL 1842
INSTALLATION 1842
QUARTER WINDOW 1843
REMOVAL 1843
INSTALLATION 1843
REAR DOOR GLASS 1843
REMOVAL 1843
REAR WINDOW REMOVAL – EXTERIOR METHOD 1843
REAR WINDOW REMOVAL – INTERIOR METHOD 1843
INSTALLATION 1843
WEATHERSTRIP/SEALS 1845
FRONT DOOR GLASS RUN WEATHERSTRIP 1845
REMOVAL 1845
INSTALLATION 1845
FRONT DOOR OUTER BELT MOLDING 1845
REMOVAL 1845
INSTALLATION 1845
FRONT DOOR WEATHERSTRIP 1846
REMOVAL 1846
INSTALLATION 1846
SLIDING DOOR WEATHERSTRIP 1847
REMOVAL 1847
INSTALLATION 1847
FRONT DOOR INNER BELT MOLDING 1847
REMOVAL 1847
INSTALLATION 1847
SUNROOF 1848
SUNROOF 1848
DESCRIPTION 1848
DIAGNOSIS AND TESTING – SUNROOF 1848
WATER DRAINAGE AND WIND NOISE DIAGNOSIS 1851
DRAIN TUBE 1851
REMOVAL 1851
FRONT HOSES 1851
REAR HOUSING HOSE 1851
INSTALLATION 1852
FRONT HOSES 1852
REAR HOUSING HOSE 1852
GLASS PANEL 1852
REMOVAL 1852
INSTALLATION 1852
ADJUSTMENTS 1852
SUNROOF GLASS PANEL ADJUSTMENT 1852
SUNROOF ASSEMBLY 1852
REMOVAL 1852
INSTALLATION 1852
SUNSHADE 1852
REMOVAL 1852
INSTALLATION 1853
WIND DEFLECTOR 1853
REMOVAL 1853
INSTALLATION 1853
WATER CHANNEL 1853
REMOVAL 1853
INSTALLATION 1853
SUNROOF MOTOR 1853
REMOVAL 1853
INSTALLATION 1853
ADJUSTMENTS 1854
ADJUSTMENT 1854
SUNROOF SWITCH 1855
REMOVAL 1855
INSTALLATION 1855
BODY STRUCTURE 1856
GAP AND FLUSH 1856
SPECIFICATIONS – GAP AND FLUSH MEASUREMENTS 1856
OPENING DIMENSIONS 1859
SPECIFICATIONS – BODY OPENING DIMENSIONS 1859
SEALER LOCATIONS 1862
SPECIFICATIONS – BODY SEALING LOCATIONS 1862
STUCTURAL ADHESIVE LOCATIONS 1888
SPECIFICATIONS – STRUCTURAL ADHESIVE LOCATIONS 1888
WELD LOCATIONS 1896
SPECIFICATIONS – WELD LOCATIONS 1896
24-HEATING & AIR CONDITIONING 2000
HEATING & AIR CONDITIONING 2000
DESCRIPTION 2000
DESCRIPTION – SINGLE ZONE 2000
DESCRIPTION – DUAL ZONE 2000
DESCRIPTION – MANUAL THREE ZONE 2000
FRONT CONTROL PANEL 2000
REAR CONTROL PANEL 2001
DESCRIPTION – AUTOMATIC TEMPERATURE CONTROL 2001
FRONT CONTROL PANEL 2001
REAR CONTROL PANEL 2002
OPERATION 2002
OPERATION – DUAL ZONE 2002
OPERATION – MANUAL THREE ZONE 2002
FRONT CONTROL PANEL 2002
REAR CONTROL PANEL 2002
OPERATION – THREE ZONE ATC 2002
FRONT CONTROL PANEL 2003
REAR CONTROL PANEL 2003
DIAGNOSIS AND TESTING 2003
DIAGNOSIS AND TESTING – A/C COOL DOWN TEST 2003
DIAGNOSIS AND TESTING – A/C PERFORMANCE TEST 2004
DIAGNOSIS AND TESTING – HEATER PERFORMANCE TEST 2005
SPECIFICATIONS – HEATER-A/C SYSTEM 2006
CONTROLS – FRONT 2007
A/C HEATER CONTROL 2007
STANDARD PROCEDURE – HEATER-A/C CONTROL CALIBRATION 2007
REMOVAL 2008
INSTALLATION 2008
A/C PRESSURE TRANSDUCER 2009
DESCRIPTION – A/C PRESSURE TRANSDUCER 2009
OPERATION 2009
DIAGNOSIS AND TESTING – A/C PRESSURE TRANSDUCER 2009
REMOVAL 2009
INSTALLATION 2010
BLEND DOOR ACTUATOR 2010
DESCRIPTION 2010
OPERATION 2010
REMOVAL 2011
INSTALLATION 2011
BLOWER MOTOR RELAY 2012
DESCRIPTION 2012
OPERATION 2012
DIAGNOSIS AND TESTING – BLOWER MOTOR RELAY 2013
REMOVAL 2013
INSTALLATION 2013
BLOWER MOTOR RESISTOR 2013
DESCRIPTION 2013
OPERATION 2014
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR 2014
REMOVAL 2015
INSTALLATION 2015
COMPRESSOR CLUTCH 2015
DESCRIPTION 2015
OPERATION 2016
STANDARD PROCEDURE 2016
STANDARD PROCEDURE – COMPRESSOR CLUTCH AIR GAP 2016
STANDARD PROCEDURE – COMPRESSOR CLUTCH BREAK-IN 2016
REMOVAL 2016
INSPECTION – COMPRESSOR CLUTCH/COIL 2017
INSTALLATION 2018
COMPRESSOR CLUTCH COIL 2019
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH COIL 2019
COMPRESSOR CLUTCH RELAY 2020
DESCRIPTION 2020
OPERATION 2020
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH RELAY 2021
REMOVAL 2021
INSTALLATION 2021
EVAPORATOR TEMPERATURE SENSOR 2021
DESCRIPTION 2021
OPERATION 2022
REMOVAL 2022
INSTALLATION 2022
INFRARED TEMPERATURE SENSOR 2022
DESCRIPTION 2022
OPERATION 2023
MODE DOOR ACTUATOR 2023
DESCRIPTION 2023
OPERATION 2023
REMOVAL 2024
INSTALLATION 2024
POWER MODULE 2024
DESCRIPTION 2024
OPERATION 2025
REMOVAL 2025
INSTALLATION 2025
RECIRCULATION DOOR ACTUATOR 2026
DESCRIPTION 2026
OPERATION 2026
REMOVAL 2026
INSTALLATION 2027
CONTROLS – REAR 2028
A/C-HEATER CONTROL 2028
REMOVAL 2028
INSTALLATION 2028
BLEND DOOR ACTUATOR 2029
DESCRIPTION 2029
OPERATION 2029
REMOVAL 2030
INSTALLATION 2030
BLOWER MOTOR RELAY 2031
DESCRIPTION 2031
OPERATION 2031
DIAGNOSIS AND TESTING – BLOWER MOTOR RELAY 2032
REMOVAL 2032
INSTALLATION 2032
BLOWER MOTOR RESISTOR 2033
DESCRIPTION 2033
OPERATION 2033
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR 2033
REMOVAL 2034
INSTALLATION 2034
INFRARED TEMPERATURE SENSOR 2034
DESCRIPTION 2034
OPERATION 2034
MODE DOOR ACTUATOR 2035
REMOVAL 2035
INSTALLATION 2035
POWER MODULE 2036
DESCRIPTION 2036
OPERATION 2036
REMOVAL 2036
INSTALLATION 2037
DISTRIBUTION – FRONT 2038
AIR FILTER 2038
DESCRIPTION 2038
REMOVAL 2038
INSTALLATION 2039
AIR OUTLETS 2039
DESCRIPTION 2039
REMOVAL 2039
REMOVAL – CENTER BEZEL OUTLETS 2039
REMOVAL – DEMISTER OUTLET 2040
REMOVAL – FRONT DOOR REAR OUTLET 2040
REMOVAL – INSTRUMENT PANEL OUTLET 2041
INSTALLATION 2041
INSTALLATION – CENTER BEZEL OUTLETS 2041
INSTALLATION – DEMISTER OUTLET 2041
INSTALLATION – FRONT DOOR REAR OUTLET 2041
INSTALLATION – INSTRUMENT PANEL OUTLET 2041
BLOWER MOTOR 2042
DESCRIPTION 2042
OPERATION 2042
DIAGNOSIS AND TESTING – BLOWER MOTOR 2042
REMOVAL 2045
INSTALLATION 2045
DEFROSTER DUCT 2046
REMOVAL 2046
INSTALLATION 2047
DEMISTER DUCTS 2047
REMOVAL 2047
INSTALLATION 2047
FLOOR DISTRIBUTION DUCTS 2047
REMOVAL 2047
INSTALLATION 2048
HVAC HOUSING 2048
REMOVAL 2048
INSTALLATION 2049
PANEL DUCTS 2050
REMOVAL 2050
INSTALLATION 2050
DISTRIBUTION – REAR 2051
AIR OUTLETS 2051
DESCRIPTION 2051
REMOVAL 2051
INSTALLATION 2051
A/C DISTRIBUTION DUCT 2052
REMOVAL 2052
INSTALLATION 2052
BLOWER MOTOR 2052
DESCRIPTION 2052
OPERATION 2053
DIAGNOSIS AND TESTING – BLOWER MOTOR 2053
REMOVAL 2055
INSTALLATION 2055
REAR HEATER-A/C HOUSING 2055
REMOVAL 2055
INSTALLATION 2057
REAR HEATER DISTRIBUTION DUCT 2058
REMOVAL 2058
INSTALLATION 2058
PLUMBING – FRONT 2059
PLUMBING – FRONT 2060
WARNING 2060
WARNING 2060
WARNING – A/C PLUMBING 2060
CAUTION – A/C PLUMBING 2060
A/C COMPRESSOR 2062
DESCRIPTION 2062
OPERATION 2062
DIAGNOSIS AND TESTING – COMPRESSOR NOISE DIAGNOSIS 2062
REMOVAL 2063
REMOVAL – COMPRESSOR – 2 4/3 3/3 8L ENGINES 2063
REMOVAL – COMPRESSOR MOUNTING BRACKET – 2 4L ENGINE 2064
INSTALLATION 2064
INSTALLATION – COMPRESSOR 2064
INSTALLATION – COMPRESSOR MOUNTING BRACKET – 2 4L ENGINE 2065
CONDENSER 2065
DESCRIPTION 2065
OPERATION 2065
REMOVAL 2065
INSTALLATION 2066
DISCHARGE LINE 2067
REMOVAL 2067
INSTALLATION 2068
EVAPORATOR 2068
DESCRIPTION 2068
OPERATION 2069
REMOVAL 2069
INSTALLATION 2070
EXPANSION VALVE 2071
DESCRIPTION 2071
OPERATION 2071
DIAGNOSIS AND TESTING – EXPANSION VALVE 2071
REMOVAL 2072
INSTALLATION 2073
HEATER CORE 2073
DESCRIPTION 2073
OPERATION 2073
REMOVAL 2074
REMOVAL- HEATER CORE EXTENSION TUBES 2074
REMOVAL – HEATER CORE 2075
INSTALLATION 2076
INSTALLATION- HEATER CORE EXTENSION TUBES 2076
INSTALLATION – HEATER CORE 2077
HEATER HOSE 2077
REMOVAL 2077
INSTALLATION 2079
LIQUID LINE 2079
REMOVAL 2079
INSTALLATION 2081
RECEIVER/DRIER 2082
DESCRIPTION 2082
OPERATION 2083
REMOVAL 2083
INSTALLATION 2083
REFRIGERANT 2084
DESCRIPTION 2084
OPERATION 2084
DIAGNOSIS AND TESTING 2084
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM CHARGE LEVEL 2084
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKS 2085
STANDARD PROCEDURE 2086
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENT 2086
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE 2087
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE 2088
STANDARD PROCEDURE – REFRIGERANT RECOVERY 2088
REFRIGERANT OIL 2089
DESCRIPTION 2089
OPERATION 2089
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL 2089
SUCTION LINE 2089
REMOVAL 2089
INSTALLATION 2090
SERVICE PORTS 2091
REMOVAL 2091
INSTALLATION 2092
PLUMBING – REAR 2093
EVAPORATOR 2093
DESCRIPTION 2093
OPERATION 2093
REMOVAL 2093
REMOVAL – REAR EVAPORATOR 2093
REMOVAL – EVAPORATOR LINE EXTENSION 2094
INSTALLATION 2095
INSTALLATION – REAR EVAPORATOR 2095
INSTALLATION – EVAPORATOR LINE EXTENSION 2095
EXPANSION VALVE 2095
DESCRIPTION 2095
OPERATION 2096
DIAGNOSIS AND TESTING – EXPANSION VALVE 2096
REMOVAL 2096
INSTALLATION 2097
HEATER CORE 2097
DESCRIPTION 2097
OPERATION 2097
STANDARD PROCEDURE – HEATER CORE FILLING 2097
REMOVAL 2098
INSTALLATION 2099
HEATER HOSE 2099
REMOVAL 2099
INSTALLATION 2100
SUCTION LINE 2100
REMOVAL 2100
INSTALLATION 2101
UNDERBODY LINES 2102
DESCRIPTION 2102
OPERATION 2102
REMOVAL 2103
REMOVAL – REAR HEATER LINES 2103
REMOVAL – REAR AIR CONDITIONING LINES 2103
INSTALLATION 2104
INSTALLATION – REAR HEATER LINES 2104
INSTALLATION – REAR AIR CONDITIONING LINES 2104
DIESEL SUPPLEMENTAL HEATER – DCHA – EXPORT 2105
DIESEL SUPPLEMENTAL HEATER – DCHA – EXPORT 2105
DESCRIPTION 2105
OPERATION 2105
OPERATION 2105
OPERATION – TWO ZONE ATC 2105
DIAGNOSIS AND TESTING – DIESEL SUPPLEMENTAL HEATER – DCHA 2106
EXHAUST TUBE 2106
REMOVAL 2106
INSTALLATION 2106
FUEL DOSING PUMP 2107
DESCRIPTION 2107
OPERATION 2107
REMOVAL 2107
INSTALLATION 2107
FUEL LINE 2108
STANDARD PROCEDURE – CLEANING 2108
REMOVAL 2108
INSTALLATION 2109
HEATER UNIT 2110
REMOVAL 2110
INSTALLATION 2110
SUPPLEMENTAL DIESEL HEATER WIRING 2111
REMOVAL 2111
INSTALLATION 2111
AIR INTAKE PIPE 2111
REMOVAL 2111
INSTALLATION 2112
25-EMISSIONS CONTROL 2114
EMISSIONS CONTROL 2114
DESCRIPTION 2114
DESCRIPTION – VEHICLE EMISSION CONTROL INFORMATION LABEL 2114
DESCRIPTION – TRIP DEFINITION 2114
DESCRIPTION – MONITORED COMPONENT 2114
OPERATION – NON-MONITORED CIRCUITS 2118
DESCRIPTION – MONITORED SYSTEMS 2119
DESCRIPTION – HIGH AND LOW LIMITS 2121
OPERATION 2122
OPERATION – SYSTEM 2122
DRB III STATE DISPLAY TEST MODE 2122
OPERATION 2122
EVAPORATIVE EMISSIONS 2123
EVAPORATIVE EMISSIONS 2123
OPERATION – EVAPORATION CONTROL SYSTEM 2123
SPECIFICATIONS 2124
TORQUE 2124
EVAP/PURGE SOLENOID 2125
DESCRIPTION 2125
OPERATION 2125
REMOVAL 2125
INSTALLATION 2125
FUEL FILLER CAP 2125
DESCRIPTION 2125
OPERATION 2125
NATURAL VAC LEAK DETECTION ASSY 2126
REMOVAL 2126
INSTALLATION 2126
LEAK DETECTION PUMP 2126
REMOVAL 2126
INSTALLATION 2126
ORVR 2127
OPERATION 2127
DIAGNOSIS AND TESTING – VEHICLE DOES NOT FILL 2129
PCV VALVE 2129
DESCRIPTION 2129
OPERATION 2129
DIAGNOSIS AND TESTING – PCV SYSTEM 2130
VAPOR CANISTER 2131
DESCRIPTION 2131
OPERATION 2131
Purge Free Cells0 – 12 RS (Continued) 2131
REMOVAL 2131
REMOVAL 2131
REMOVAL – WITH NVLD 2132
REMOVAL – REAR EVAP CANISTER 2132
INSTALLATION 2132
INSTALLATION 2132
INSTALLATION – WITH NVLD 2133
INSTALLATION – REAR EVAP CANISTER 2133
EXHAUST GAS RECIRCULATION 2134
EXHAUST GAS RECIRCULATION 2134
SPECIFICATIONS 2134
TORQUE 2134
TUBE 2134
REMOVAL – 2 4L 2134
INSTALLATION – 2 4L 2134
VALVE 2135
DESCRIPTION 2135
OPERATION 2135
REMOVAL – 2 4L 2136
INSTALLATION – 2 4L 2136
ON-BOARD DIAGNOSTICS 2137
TASK MANAGER 2137
DESCRIPTION 2137
OPERATION 2137
INDEX 2142
COMMENTS 2178
sup-front pdf 2180
15870-rspwr_sgmldiag pdf 2184
RG Service Manual 0
RG 2 5L Diesel Supplement 0
RG Diesel Powertrain 0
RG Body 0
RG Chassis 0
RG Transmission 0
RG Gas Powertrain 2184
TABLE OF CONTENTS 2184
1 0 INTRODUCTION 2192
1 1 SYSTEM COVERAGE 2192
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 2192
2 0 IDENTIFICATION OF SYSTEM 2192
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 2193
3 1 GENERAL DESCRIPTION 2193
3 2 FUNCTIONAL OPERATION 2193
3 2 1 FUEL CONTROL 2193
3 2 2 ON-BOARD DIAGNOSTICS 2193
3 2 3 OTHER CONTROLS 2197
3 2 4 PCM OPERATING MODES 2205
3 2 5 NON-MONITORED CIRCUITS 2205
3 2 6 SKIS OVERVIEW 2206
3 2 7 SKIM ON-BOARD DIAGNOSTICS 2206
3 2 8 SKIS OPERATION 2206
3 2 9 PROGRAMMING THE POWERTRAIN CONTROL MODULE 2207
3 2 10 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 2207
3 2 11 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE 2207
3 3 DIAGNOSTIC TROUBLE CODES 2208
3 3 1 HARD CODE 2208
3 3 2 INTERMITTENT CODE 2208
3 3 3 STARTS SINCE SET COUNTER 2208
3 3 4 DISTANCE SINCE MI SET 2208
3 4 USING THE DRBIII 2209
3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN 2209
3 5 1 DRBIII DOES NOT POWER UP 2209
3 5 2 DISPLAY IS NOT VISIBLE 2209
4 0 DISCLAIMERS, SAFETY, WARNINGS 2209
4 1 DISCLAIMERS 2209
4 2 SAFETY 2209
4 2 1 TECHNICIAN SAFETY INFORMATION 2209
4 2 2 VEHICLE PREPARATION FOR TESTING 2210
4 2 3 SERVICING SUB ASSEMBLIES 2210
4 2 4 DRBIII SAFETY INFORMATION 2210
4 3 WARNINGS AND CAUTIONS 2210
4 3 1 ROAD TEST WARNINGS 2210
4 3 2 VEHICLE DAMAGE CAUTIONS 2210
5 0 REQUIRED TOOLS AND EQUIPMENT 2211
6 0 GLOSSARY OF TERMS 2211
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 2214
COMMUNICATION 2215
*NO RESPONSE FROM PCM (PCI BUS) – NGC 2215
*NO RESPONSE FROM PCM (PCI BUS) – SBEC 2216
*NO RESPONSE FROM PCM (PCM SCI ONLY) – NGC 2218
*NO RESPONSE FROM PCM (SCI ONLY) – SBEC 2221
*PCI BUS COMMUNICATION FAILURE 2224
DRIVEABILITY – SBEC 2227
P0106-BAROMETRIC PRESSURE OUT OF RANGE 2227
P0107-MAP SENSOR VOLTAGE TOO LOW 2230
P0108-MAP SENSOR VOLTAGE TOO HIGH 2233
P0111-INTAKE AIR TEMP SENSOR PERFORMANCE 2235
P0117-ECT SENSOR VOLTAGE TOO LOW 2237
P0118-ECT SENSOR VOLTAGE TOO HIGH 2239
P0121-TPS VOLTAGE DOES NOT AGREE WITH MAP 2241
P0122-THROTTLE POSITION SENSOR VOLTAGE LOW 2246
P0123-THROTTLE POSITION SENSOR VOLTAGE HIGH 2249
P0125-CLOSED LOOP TEMP NOT REACHED 2252
P0131-1/1 O2 SENSOR SHORTED TO GROUND 2254
P0137-1/2 O2 SENSOR SHORTED TO GROUND 2254
P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE 2256
P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE 2256
P0133-1/1 O2 SENSOR SLOW RESPONSE 2259
P0139-1/2 O2 SENSOR SLOW RESPONSE 2259
P0134-1/1 O2 SENSOR STAYS AT CENTER 2261
P0140-1/2 O2 SENSOR STAYS AT CENTER 2261
P0135-1/1 O2 SENSOR HEATER FAILURE 2264
P0141-1/2 O2 SENSOR HEATER FAILURE 2266
P0171-1/1 FUEL SYSTEM LEAN 2268
P0172-1/1 FUEL SYSTEM RICH 2273
P0201-INJECTOR #1 CONTROL CIRCUIT 2278
P0202-INJECTOR #2 CONTROL CIRCUIT 2278
P0203-INJECTOR #3 CONTROL CIRCUIT 2278
P0204-INJECTOR #4 CONTROL CIRCUIT 2278
P0205-INJECTOR #5 CONTROL CIRCUIT 2278
P0206-INJECTOR #6 CONTROL CIRCUIT 2278
P0300-MULTIPLE CYLINDER MIS-FIRE 2281
P0301-CYLINDER #1 MISFIRE 2281
P0302-CYLINDER #2 MISFIRE 2281
P0303-CYLINDER #3 MISFIRE 2281
P0304-CYLINDER #4 MISFIRE 2281
P0305-CYLINDER #5 MISFIRE 2281
P0306-CYLINDER #6 MISFIRE 2281
P0320-NO CRANK REFERENCE SIGNAL AT PCM 2288
P0340-NO CAM SIGNAL AT PCM 2293
P0351-IGNITION COIL #1 PRIMARY CIRCUIT 2297
P0352-IGNITION COIL #2 PRIMARY CIRCUIT 2297
P0353-IGNITION COIL #3 PRIMARY CIRCUIT 2297
P0401 – EGR SYSTEM FAILURE 2300
P0403 – EGR SOLENOID CIRCUIT 2304
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 2306
P0441-EVAP PURGE FLOW MONITOR 2308
P0442-EVAP LEAK MONITOR 040 LEAK DETECTED 2310
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 2310
P0456 – EVAP LEAK MONITOR 020 LEAK DETECTED 2310
P0443-EVAP PURGE SOLENOID CIRCUIT 2314
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 2316
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW 2318
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH 2318
P0500-NO VEHICLE SPEED SIGNAL (3SP AUTO AND MANUAL TRANSMISSIONS) 2319
P0500-NO VEHICLE SPEED SIGNAL (4SP AUTO TRANS) 2321
P0508 – IAC MOTOR SENSE CIRCUIT LOW 2323
P0509 – IAC MOTOR SENSE CIRCUIT HIGH 2325
P0600-PCM FAILURE SPI COMMUNICATIONS 2327
P0601-PCM INTERNAL CONTROLLER FAILURE 2327
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 2328
P0645-A/C CLUTCH RELAY CKT 2330
P0700-EATX CONTROLLER DTC PRESENT 2333
P0703-BRAKE SWITCH SENSE CIRCUIT 2334
P1192-INLET AIR TEMP SENSOR VOLTAGE LOW 2337
P1193-INLET AIR TEMP SENSOR VOLTAGE HIGH 2339
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR 2341
P1281-ENGINE IS COLD TOO LONG 2343
P1282-FUEL PUMP RELAY CONTROL CIRCUIT 2344
P1294-TARGET IDLE NOT REACHED 2346
P1297-NO CHANGE IN MAP FROM START TO RUN 2348
P1299-VACUUM LEAK FOUND (IAC FULLY SEATED) 2351
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 2353
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 2355
P1391-INTERMITTENT LOSS OF CMP OR CKP 2360
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 2364
P1478-BATTERY TEMP SENSOR VOLTS OUT OF LIMIT 2366
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 2367
P1491-RAD FAN CONTROL RELAY CIRCUIT 2370
P1494-LEAK DETECT PUMP SW OR MECHANICAL FAULT 2373
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 2375
P1496-5 VOLT SUPPLY, OUTPUT TOO LOW 2377
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 2381
P1595-SPEED CONTROL SOLENOID CIRCUITS 2383
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT 2383
P1598-A/C PRESSURE SENSOR VOLTS TOO HIGH 2388
P1599-A/C PRESSURE SENSOR VOLTS TOO LOW 2391
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 2394
P1685-WRONG OR INVALID KEY MSG RECEIVED FROM SKIM 2397
P1686-NO SKIM BUS MESSAGE RECEIVED 2399
P1695-NO CCD/J1850 MESSAGE FROM BODY CONTROL MODULE 2401
P1696-PCM FAILURE EEPROM WRITE DENIED 2403
P1697-PCM FAILURE SRI MILE NOT STORED 2403
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE 2405
P1899-P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRNAS) 2407
*CHECKING PCM POWER AND GROUND CIRCUITS 2409
*CHECKING RADIATOR FAN RELAY OUTPUT 2410
*CHECKING THE A/C RELAY OUTPUT 2411
DRIVEABILITY – NGC 2413
INTERMITTENT CONDITION 2413
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT 2414
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW 2418
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW 2418
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH 2420
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH 2420
P0068-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION – HIGH FLOW/VACUUM LEAK 2423
P0070-AMBIENT TEMP SENSOR STUCK 2429
P0071-AMBIENT TEMP SENSOR PERFORMANCE 2429
P0072-AMBIENT TEMP SENSOR LOW 2433
P0073-AMBIENT TEMP SENSOR HIGH 2435
P0106-MAP SENSOR PERFORMANCE 2437
P0107-MAP SENSOR LOW 2441
P0108-MAP SENSOR HIGH 2444
P0110-INTAKE AIR TEMPERATURE SENSOR STUCK 2447
P0111-INTAKE AIR TEMPERATURE SENSOR PERFORMANCE 2447
P0112-INTAKE AIR TEMPERATURE SENSOR LOW 2450
P0113-INTAKE AIR TEMPERATURE SENSOR HIGH 2452
P0116-ENGINE COOLANT TEMPERATURE PERFORMANCE 2454
P0117-ENGINE COOLANT TEMPERATURE SENSOR LOW 2457
P0118-ENGINE COOLANT TEMPERATURE SENSOR HIGH 2459
P0121-THROTTLE POSITION SENSOR #1 PERFORMANCE 2461
P0122-THROTTLE POSITION SENSOR #1 LOW 2467
P0123-THROTTLE POSITION SENSOR #1 HIGH 2470
P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL 2473
P0128-THERMOSTAT RATIONALITY 2475
P0129-BAROMETRIC PRESSURE OUT-OF-RANGE LOW 2480
P0131-O2 SENSOR 1/1 VOLTAGE LOW 2483
P0137-O2 SENSOR 1/2 VOLTAGE LOW 2483
P0132-O2 SENSOR 1/1 VOLTAGE HIGH 2486
P0138-O2 SENSOR 1/2 VOLTAGE HIGH 2486
P0133-O2 SENSOR 1/1 SLOW RESPONSE 2489
P0139-O2 SENSOR 1/2 SLOW RESPONSE 2489
P0135-O2 SENSOR 1/1 HEATER PERFORMANCE 2491
P0141-O2 SENSOR 1/2 HEATER PERFROMANCE 2491
P0171-FUEL SYSTEM 1/1 LEAN 2494
P0172-FUEL SYSTEM 1/1 RICH 2499
P0201-FUEL INJECTOR #1 2503
P0202-FUEL INJECTOR #2 2503
P0203-FUEL INJECTOR #3 2503
P0204-FUEL INJECTOR #4 2503
P0300-MULTIPLE CYLINDER MISFIRE 2506
P0301-CYLINDER #1 MISFIRE 2506
P0302-CYLINDER #2 MISFIRE 2506
P0303-CYLINDER #3 MISFIRE 2506
P0304-CYLINDER #4 MISFIRE 2506
P0315-NO CRANK SENSOR LEARNED 2514
P0325-KNOCK SENSOR #1 CIRCUIT 2516
P0335-CRANKSHAFT POSITION SENSOR CIRCUIT 2519
P0339-CRANKSHAFT POSITION SENSOR INTERMITTENT 2524
P0340-CAMSHAFT POSITION SENSOR CIRCUIT 2528
P0344-CAMSHAFT POSITION SENSOR INTERMITTENT 2533
P0351-IGNITION COIL #1 CIRCUIT 2537
P0352-IGNITION COIL #2 CIRCUIT 2537
P0420-CATALYTIC 1/1 EFFICIENCY 2539
P0432-CATALYTIC 2/1 EFFICIENCY 2539
P0440-GENERAL EVAP SYSTEM FAILURE 2541
P0441-EVAP PURGE SYSTEM PERFORMANCE 2546
P0442-EVAP SYSTEM MEDIUM LEAK 2548
P0455-EVAP SYSTEM LARGE LEAK 2548
P0443-EVAP PURGE SOLENOID CIRCUIT 2553
P0452-NVLD PRESSURE SWITCH SENSE CIRCUIT LOW 2556
P0453-NVLD PRESSURE SWITCH SENSE CIRCUIT HIGH 2559
P0456-EVAP SYSTEM SMALL LEAK 2561
P0461-FUEL LEVEL SENSOR #1 PERFORMANCE 2563
P0462-FUEL LEVEL SENSOR #1 LOW 2565
P0463-FUEL LEVEL SENSOR #1 HIGH 2565
P0480-LOW SPEED FAN CONTROL RELAY CIRCUIT 2566
P0498-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW 2570
P0499-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH 2571
P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (AUTO TRANS) 2573
P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (MANUAL TRANS) 2574
P0506-IDLE SPEED LOW PERFORMANCE 2576
P0507-IDLE SPEED HIGH PERFORMANCE 2576
P0519-IDLE SPEED PERFORMANCE 2576
P0508-IAC VALVE SENSE CIRCUIT LOW 2578
P0509-IAC VALVE SENSE CIRCUIT HIGH 2581
P0513-INVALID SKIM KEY 2583
P0516-BATTERY TEMPERATURE SENSOR LOW 2585
P0517-BATTERY TEMPERATURE SENSOR HIGH 2587
P0522 PRESSURE SENSOR LOW 2589
P0532-A/C PRESSURE SENSOR LOW 2590
P0533-A/C PRESSURE SENSOR HIGH 2593
P0551-POWER STEERING SWITCH PERFORMANCE 2596
P0562-BATTERY VOLTAGE LOW 2598
P0563-BATTERY VOLTAGE HIGH 2601
P0579-SPEED CONTROL SWITCH #1 PERFORMANCE 2603
P0580-SPEED CONTROL SWITCH #1 LOW 2606
P0581-SPEED CONTROL SWITCH #1 HIGH 2608
P0582-SPEED CONTROL VACUUM SOLENOID CIRCUIT 2610
P0586-SPEED CONTROL VENT SOLENOID CIRCUIT 2612
P0594-SPEED CONTROL SERVO POWER CIRCUIT 2614
P0600-SERIAL COMMUNICATION LINK 2617
P0601-INTERNAL MEMORY CHECKSUM INVALID 2617
P0622-GENERATOR FIELD CONTROL CIRCUIT 2618
P0627-FUEL PUMP RELAY CIRCUIT 2620
P0630-VIN NOT PROGRAMMED IN PCM 2623
P0632-ODOMETER NOT PROGRAMMED IN PCM 2624
P0633-SKIM KEY NOT PROGRAMMED IN PCM 2625
P0645-A/C CLUTCH RELAY CIRCUIT 2626
P0685-ASD RELAY CONTROL CIRCUIT 2629
P0688-ASD RELAY SENSE CIRCUIT LOW 2632
P0700-TRANSMISSION CONTROL SYSTEM/READ TRANSMISSION DTCS ON THE DRBIII 2635
P0703-BRAKE SWITCH #2 CIRCUIT 2636
P0833-CLUTCH RELEASED SWITCH CIRCUIT 2639
P0850-PARK/NEUTRAL SWITCH PERFORMANCE 2641
P1602-PCM NOT PROGRAMMED 2642
P1603-PCM INTERNAL DUAL-PORT RAM COMMUNICATION 2643
P1604-PCM INTERNAL DUAL-PORT RAM READ/WRITE INTEGRITY FAILURE 2643
P1607-PCM INTERNAL SHUTDOWN TIMER RATIONALITY 2643
P1681-NO FUEL LEVEL BUS MESSAGE 2644
P1686-NO SKIM BUS MESSAGES 2646
P1687-NO CLUSTER BUS MESSAGE 2648
P1696-EEPROM MEMORY WRITE DENIED/INVALID 2649
P1697-EMR (SRI) MILEAGE NOT STORED 2649
P1698-NO TRANSMISSION BUS MESSAGE 2651
P2302-IGNITION COIL #1 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION 2653
P2305-IGNITION COIL #2 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION 2653
P2503-CHARGING SYSTEM VOLTAGE LOW 2655
*CHECKING PCM POWER AND GROUND CIRCUITS 2658
*CHECKING THE A/C RELAY OUTPUT 2659
SENTRY KEY IMMOBILIZER 2661
ANTENNA FAILURE 2661
COP FAILURE 2661
EEPROM FAILURE 2661
INTERNAL FAULT 2661
RAM FAILURE 2661
SERIAL LINK INTERNAL FAULT 2661
STACK OVERFLOW FAILURE 2661
PCM STATUS FAILURE 2663
SERIAL LINK EXTERNAL FAULT 2663
ROLLING CODE FAILURE 2665
VIN MISMATCH 2665
TRANSPONDER COMMUNICATION FAILURE 2667
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE 2667
TRANSPONDER ID MISMATCH 2667
TRANSPONDER RESPONSE MISMATCH 2667
STARTING 2670
*CHECKING FUEL DELIVERY 2670
*CHECKING FUEL PRESSURE LEAK DOWN 2673
*CHECKING HARD START (FUEL DELIVERY SYSTEM) 2674
*ENGINE CRANKS DOES NOT START 2676
*NO CRANK CONDITION 2681
*NO RESPONSE FROM PCM WITH A NO START CONDITION 2684
*START AND STALL CONDITION 2685
VERIFICATION TESTS 2688
VERIFICATION TESTS 2688
8 0 COMPONENT LOCATIONS 2700
8 1 CONTROL MODULES AND FUSE & RELAY CENTER 2700
8 2 CONTROLS AND SOLENOID 2700
8 3 DATA LINK CONNECTOR 2702
8 4 SENSORS 2703
8 5 FUEL SYSTEM 2705
8 6 SWITCHES 2706
9 0 CONNECTOR PINOUTS 2708
A/C COMPRESSOR CLUTCH 2708
A/C PRESSURE SENSOR 2708
AMBIENT TEMPERATURE SENSOR (EXCEPT BASE) 2708
BODY CONTROL MODULE C3 2709
BRAKE LAMP SWITCH 2710
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID (EATX) 2710
CAMSHAFT POSITION SENSOR (GAS) 2710
CLUTCH PEDAL INTERLOCK SWITCH (MTX) 2710
CRANKSHAFT POSITION SENSOR (GAS) 2711
DATA LINK CONNECTOR 2711
EGR SOLENOID (3 3L/3 8L EXPORT) 2711
ENGINE COOLANT TEMP SENSOR (GAS) 2711
ENGINE OIL PRESSURE SWITCH (GAS) 2712
EVAP/PURGE SOLENOID (GAS) 2712
FUEL INJECTOR NO 1 (2 4L/3 3L/3 8L) 2712
FUEL INJECTOR NO 2 (2 4L/3 3L/3 8L) 2712
FUEL INJECTOR NO 3 (2 4L/3 3L/3 8L) 2713
FUEL INJECTOR NO 5 (3 3L/3 8L) 2713
FUEL INJECTOR NO 6 (3 3L/3 8L) 2713
FUEL PUMP MODULE 2713
GENERATOR 2714
GENERATOR (GENERATOR SIDE) 2714
IDLE AIR CONTROL MOTOR (GAS) 2714
IGNITION COIL (2 4L) 2714
IGNITION COIL (3 3L/3 8L) 2715
INLET AIR TEMPERATURE SENSOR 2715
FUSES (IPM) 2717
FUEL PUMP RELAY (GAS) 2717
INTEGRATED POWER MODULE C1 2718
INTEGRATED POWER MODULE C2 2718
INTEGRATED POWER MODULE C3 2719
INTEGRATED POWER MODULE C4 2720
INTEGRATED POWER MODULE C5 2720
INTEGRATED POWER MODULE C6 2720
INTEGRATED POWER MODULE C7 2721
INTEGRATED POWER MODULE C8 2721
INTEGRATED POWER MODULE C9 2721
KNOCK SENSOR (3 3L/3 8L ABS EXCEPT EXPORT) 2722
LEAK DETECTION PUMP (3 3L/3 8L EXCEPT EXPORT) 2722
LEFT SPEED CONTROL SWITCH 2722
MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) 2722
NATURAL VACUUM LEAK DETECTION ASSEMBLY (2 4L EXCEPT EXPORT) 2723
OXYGEN SENSOR 1/1 UPSTREAM (GAS) 2723
OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) 2723
POWERTRAIN CONTROL MODULE C1 (NGC) 2724
POWERTRAIN CONTROL MODULE C1 (SBEC) 2725
POWERTRAIN CONTROL MODULE C2 (NGC) 2726
POWERTRAIN CONTROL MODULE C2 (SBEC) 2727
POWERTRAIN CONTROL MODULE C3 (NGC) 2728
POWERTRAIN CONTROL MODULE C4 (NGC) (EATX) 2729
RIGHT SPEED CONTROL SWITCH 2729
SENTRY KEY IMMOBILIZER MODULE 2730
SPEED CONTROL SERVO (GAS) 2730
THROTTLE POSITION SENSOR (GAS) 2730
TRANSMISSION RANGE SENSOR (EATX) 2730
10 0 SCHEMATIC DIAGRAMS 2732
10 1 2003 RS 2 4L 2732
10 2 2003 RS 3 3L/3 8L 2734
11 0 CHARTS AND GRAPHS 2736
15871-rsbd_sgmldiag pdf 2740
RG Service Manual 0
RG 2 5L Diesel Supplement 0
RG Gas Powertrain 0
RG Diesel Powertrain 0
RG Chassis 0
RG Transmission 0
RG Body 2740
TABLE OF CONTENTS 2740
1 0 INTRODUCTION 2764
1 1 SYSTEM COVERAGE 2764
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 2764
2 0 IDENTIFICATION OF SYSTEM 2764
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 2764
3 1 AIRBAG SYSTEM 2765
3 1 1 DRIVER AIRBAG 2766
3 1 2 CLOCKSPRING 2766
3 1 3 PASSENGER AIRBAG 2767
3 1 4 SEAT BELT TENSIONER (SBT) 2768
3 1 5 SEAT BELT SWITCHES (SBS) 2768
3 1 6 SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 2768
3 1 7 SEAT AIRBAGS (SAB) 2769
3 1 8 DIAGNOSTIC TROUBLE CODES 2769
3 1 9 SPECIAL TOOLS 2770
3 1 10 ACTIVE CODES 2770
3 1 11 STORED CODES 2770
3 2 AUDIO SYSTEM 2770
3 2 1 REMOTE RADIO CONTROLS 2771
3 2 2 CD CHANGER 2771
3 3 BODY CONTROL MODULE 2771
3 4 CHIME WARNING SYSTEM 2772
3 4 1 CHIME PRIORITY 2772
3 4 2 CHIME ON CONDITIONS 2773
3 4 3 WARNING LAMP ANNOUNCEMENT 2773
3 4 4 OTHER CHIME ON CONDITIONS 2773
3 5 COMMUNICATION 2774
3 6 DOOR AJAR SYSTEM 2775
3 7 EXTERIOR LIGHTING SYSTEM 2776
3 7 1 HEADLAMP POWER 2776
3 7 2 HEADLAMP SWITCH 2776
3 7 3 PARK LAMP RELAY 2776
3 7 4 FOG LAMP RELAY 2776
3 7 5 FOG LAMPS 2776
3 7 6 EXTERIOR LIGHTING BATTERY SAVER 2776
3 7 7 AUTO HEADLAMPS 2776
3 8 FRONT CONTROL MODULE 2776
3 8 1 CONTROLLED POWER FEEDS 2777
3 8 2 RELAY CONTROLS 2778
3 8 3 ELECTRICAL INPUTS 2779
3 9 HEATING & A/C SYSTEM 2779
3 9 1 AUTOMATIC TEMPERATURE CONTROL (ATC) 2779
3 9 1 1 SYSTEM AVAILABILITY 2779
3 9 1 2 SYSTEM CONTROLS 2780
3 9 1 3 SYSTEM REVISIONS 2780
3 9 1 4 SYSTEM DIAGNOSTICS 2781
3 9 2 MANUAL TEMPERATURE CONTROL (MTC) 2782
3 9 2 1 SYSTEM AVAILABILITY 2782
3 9 2 2 SYSTEM CONTROLS 2782
3 9 2 3 SYSTEM REVISIONS 2783
3 9 2 4 SYSTEM DIAGNOSTICS 2783
3 10 CABIN HEATER 2784
3 10 1 GENERAL SAFETY INFORMATION 2784
3 10 2 COMPONENT DESCRIPTION AND OPERATION 2785
3 10 2 1 DCHA ASSEMBLY 2785
3 10 2 2 COMBUSTION AIR FAN 2785
3 10 2 3 BURNER HOUSING 2785
3 10 2 4 BURNER INSERT 2785
3 10 2 5 CONTROL UNIT/HEAT EXCHANGER 2785
3 10 2 6 DOSING PUMP 2786
3 10 3 OPERATION 2786
3 10 3 1 VENTING THE DCHA’S EXHAUST 2786
3 10 3 2 ACTIVATION 2786
3 10 3 3 HEATING 2787
3 10 3 4 DEACTIVATION 2787
3 10 4 DIAGNOSTICS 2787
3 11 INSTRUMENT CLUSTER 2788
3 11 1 INSTRUMENT CLUSTER SELF TEST 2788
3 11 2 MESSAGE CENTER 2788
3 12 INTERIOR LIGHTING 2788
3 12 1 COURTESY LAMP CONTROL 2788
3 12 2 ILLUMINATED ENTRY 2788
3 12 3 INTERIOR LIGHTING BATTERY SAVER 2789
3 13 MEMORY SYSTEM 2789
3 13 1 POWER SEAT 2789
3 13 2 MEMORY MIRRORS 2789
3 14 OVERHEAD CONSOLE 2789
3 14 1 VEHICLE INFORMATION DISPLAY 2790
3 14 2 TRAVELER DISPLAY FUNCTIONS 2791
3 14 3 SETTING MAGNETIC ZONE VARIANCE 2791
3 14 4 COMPASS CALIBRATION 2792
3 14 5 SELF-CHECK DIAGNOSTICS 2792
3 14 6 AMBIENT TEMPERATURE SENSOR 2793
3 14 7 AMBIENT TEMPERATURE SENSOR FAULT CODES 2793
3 14 8 HOMELINK UNIVERSAL TRANSMITTER 2793
3 14 9 TIRE PRESSURE MONITORING SYSTEM (TPM) 2793
3 14 9 1 TRAINING THE EVIC 2794
3 14 9 2 PRESSURE THRESHOLDS 2794
3 14 9 3 CRITICAL AND NON-CRITICAL SYSTEM ALERTS 2794
3 14 9 4 SYSTEM FAULTS 2795
3 14 9 5 SPARE WHEEL AUTO-DETECT 2795
3 14 9 6 DIAGNOSING AND CLEARING SYSTEM FAULTS 2795
3 14 9 7 SYSTEM TEST 2795
3 15 POWER DOOR LOCK SYSTEM 2795
3 15 1 DOOR LOCK INHIBIT 2796
3 15 2 AUTOMATIC DOOR LOCKS 2796
3 15 3 REMOTE KEYLESS ENTRY (RKE) 2796
3 16 POWER FOLDING MIRRORS 2796
3 17 POWER LIFTGATE SYSTEM 2796
3 17 1 POWER LIFTGATE 2796
3 17 2 DIAGNOSTIC FEATURES 2797
3 17 3 SYSTEM INHIBITORS 2797
3 18 POWER SLIDING DOOR SYSTEM 2797
3 18 1 POWER SLIDING DOOR 2797
3 18 2 DIAGNOSTIC FEATURES 2797
3 18 3 SYSTEM INHIBITORS 2797
3 19 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE (IF EQUIPPED) 2797
3 20 VEHICLE THEFT SECURITY SYSTEM 2798
3 20 1 THATCHAM ALARM SYSTEM (EXPORT ONLY) 2798
3 21 WIPER SYSTEM 2798
3 21 1 FRONT WIPER 2798
3 21 2 SPEED SENSITIVE INTERMITTENT WIPE MODE 2799
3 21 3 PULSE WIPE 2799
3 21 4 PARK AFTER IGNITION OFF 2799
3 21 5 WIPE AFTER WASH 2799
3 21 6 REAR WIPER 2799
3 21 7 SPEED SENSITIVE INTERMITTENT WIPE MODE 2799
3 21 8 WIPE AFTER WASH 2799
3 22 USING THE DRBIII 2799
3 23 DRBIII ERROR MESSAGES 2799
3 24 DRBIII DOES NOT POWER UP (BLANK SCREEN) 2799
3 25 DISPLAY IS NOT VISIBLE 2800
4 0 DISCLAIMERS, SAFETY, WARNINGS 2800
4 1 DISCLAIMERS 2800
4 2 SAFETY 2800
4 2 1 TECHNICIAN SAFETY INFORMATION 2800
4 2 2 VEHICLE PREPARATION FOR TESTING 2800
4 2 3 SERVICING SUB-ASSEMBLIES 2800
4 2 4 DRBIII SAFETY INFORMATION 2800
4 3 WARNINGS 2801
4 3 1 VEHICLE DAMAGE WARNINGS 2801
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 2801
5 0 REQUIRED TOOLS AND EQUIPMENT 2801
6 0 GLOSSARY OF TERMS 2801
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 2804
AIRBAG 2805
ACCELEROMETER 1 2805
ACCELEROMETER 2 2805
INTERNAL 1 2805
INTERNAL 2 2805
OUTPUT DRIVER 1 2805
OUTPUT DRIVER 2 2805
STORED ENERGY FIRING 1 2805
AIRBAG WARNING INDICATOR OPEN 2807
AIRBAG WARNING INDICATOR SHORT 2807
CALIBRATION MISMATCH 2809
CLUSTER MESSAGE MISMATCH 2811
DRIVER SEAT BELT SWITCH CIRCUIT OPEN 2813
DRIVER SEAT BELT SWITCH SHORT TO BATTERY 2815
DRIVER SEAT BELT SWITCH SHORT TO GROUND 2817
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN 2819
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT 2821
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY 2823
DRIVER SEAT BELT TENSIONER SHORT TO GROUND 2825
DRIVER SQUIB 1 CIRCUIT OPEN 2827
DRIVER SQUIB 1 CIRCUIT SHORT 2830
DRIVER SQUIB 1 SHORT TO BATTERY 2833
DRIVER SQUIB 1 SHORT TO GROUND 2836
DRIVER SQUIB 2 CIRCUIT OPEN 2839
DRIVER SQUIB 2 CIRCUIT SHORT 2842
DRIVER SQUIB 2 SHORT TO BATTERY 2845
DRIVER SQUIB 2 SHORT TO GROUND 2848
INTERROGATE LEFT SIACM 2851
INTERROGATE RIGHT SIACM 2853
LOSS OF IGNITION RUN – START 2855
ORC RUN – START DRIVER OPEN 2855
ORC RUN – START DRIVER OVER CURRENT 2855
ORC RUN – START DRIVER OVER TEMP 2855
ORC RUN – START DRIVER OVER VOLT 2855
ORC RUN – START DRIVER SHORT TO GROUND 2855
SIACM RUN – START DRIVER OPEN 2855
SIACM RUN – START DRIVER OVER CURRENT 2855
SIACM RUN – START DRIVER OVER TEMP 2855
SIACM RUN – START DRIVER OVER VOLT 2855
SIACM RUN – START DRIVER SHORT TO GROUND 2855
LOSS OF IGNITION RUN ONLY 2865
ORC RUN ONLY DRIVER OPEN 2865
ORC RUN ONLY DRIVER OVER CURRENT 2865
ORC RUN ONLY DRIVER OVER TEMP 2865
ORC RUN ONLY DRIVER OVER VOLT 2865
ORC RUN ONLY DRIVER SHORT TO GROUND 2865
MODULE NOT CONFIGURED FOR SAB 2871
NO CLUSTER MESSAGE 2873
NO LEFT SIACM MESSAGE 2875
NO ODOMETER MESSAGE 2877
NO PCI TRANSMISSION 2879
NO PCM MESSAGE 2882
NO RIGHT SIACM MESSAGE 2884
PASSENGER SEAT BELT SWITCH CIRCUIT OPEN 2886
PASSENGER SEAT BELT SWITCH SHORT TO BATTERY 2888
PASSENGER SEAT BELT SWITCH SHORT TO GROUND 2890
PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN 2892
PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT 2894
PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY 2896
PASSENGER SEAT BELT TENSIONER SHORT TO GROUND 2898
PASSENGER SQUIB 1 CIRCUIT OPEN 2900
PASSENGER SQUIB 1 CIRCUIT SHORT 2903
PASSENGER SQUIB 1 SHORT TO BATTERY 2905
PASSENGER SQUIB 1 SHORT TO GROUND 2907
PASSENGER SQUIB 2 CIRCUIT OPEN 2910
PASSENGER SQUIB 2 CIRCUIT SHORT 2913
PASSENGER SQUIB 2 SHORT TO BATTERY 2915
PASSENGER SQUIB 2 SHORT TO GROUND 2917
SEAT SQUIB CIRCUIT OPEN 2920
SEAT SQUIB CIRCUIT SHORT 2923
SEAT SQUIB SHORT TO BATTERY 2926
SEAT SQUIB SHORT TO GROUND 2929
VEHICLE BODY STYLE UNKNOWN 2932
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 2934
AUDIO 2935
ALL OUTPUTS SHORT 2935
CASSETTE PLAYER INOP 2938
CD MECHANICAL FAILURE 2938
REAR TRANSMITTER FAILURE 2938
*AM/FM SWITCH INOPERATIVE 2938
*ANY STATION PRESET SWITCH INOPERATIVE 2938
*BALANCE INOPERATIVE 2938
*CD EJECT SWITCH INOPERATIVE 2938
*EQUALIZER INOPERATIVE 2938
*FADER INOPERATIVE 2938
*FF/RW SWITCH INOPERATIVE 2938
*HOUR/MINUTE SWITCHES INOPERATIVE 2938
*PAUSE/PLAY SWITCH INOPERATIVE 2938
*PWR SWITCH INOPERATIVE 2938
*SCAN SWITCH INOPERATIVE 2938
*SEEK SWITCH INOPERATIVE 2938
*SET SWITCH INOPERATIVE 2938
*TAPE EJECT SWITCH INOPERATIVE 2938
*TIME SWITCH INOPERATIVE 2938
*TUNE SWITCH INOPERATIVE 2938
CD CHANGER MECHANICAL FAILURE 2940
CD CHANGER READ FAILURE 2941
CD CHANGER TEMPERATURE HIGH 2942
CD PLAY FAILURE 2943
CD READ FAILURE 2944
CD TEMPERATURE HIGH 2945
LOW VOLTAGE LEVEL 2946
NBS OUTPUT 1 OPEN 2947
NBS OUTPUT 2 OPEN 2947
NBS OUTPUT 1 SHORT TO BATT 2949
NBS OUTPUT 2 SHORT TO BATT 2949
NO ANTENNA CONNECTION 2951
POWER AMP SHUTDOWN 2952
REMOTE RADIO SWITCH STUCK 2955
*REMOTE RADIO CONTROLS INOPERATIVE 2958
AUTOMATIC TEMPERATURE CONTROL 2961
AC PRESSURE TOO HIGH (ACTIVE) 2961
AC PRESSURE TOO HIGH (STORED) 2962
DRIVER BLEND DOOR NOT RESPONDING (STORED) 2962
DRIVER BLEND DOOR RANGE TOO LARGE (STORED) 2962
DRIVER BLEND DOOR TRAVEL TOO SMALL (STORED) 2962
EVAP TEMP SENSOR OPEN (STORED) 2962
EVAP TEMP SENSOR SHORTED (STORED) 2962
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (STORED) 2962
FRONT IR SENSOR CHANGE TOO LARGE (STORED) 2962
FRONT IR SENSOR HIGH (STORED) 2962
FRONT IR SENSOR LOW (STORED) 2962
FRONT IR SENSOR NOT CALIBRATED (STORED) 2962
FRONT KEYBOARD COMMUNICATION FAULT (STORED) 2962
FRONT KEYBOARD FAULT (STORED) 2962
FRONT MODE DOOR NOT RESPONDING (STORED) 2962
FRONT MODE DOOR TRAVEL TOO LARGE (STORED) 2962
FRONT MODE DOOR TRAVEL TOO SMALL (STORED) 2962
PASS BLEND DOOR NOT RESPONDING (STORED) 2962
PASS BLEND DOOR TRAVEL TOO LARGE (STORED) 2962
PASS BLEND DOOR TRAVEL TOO SMALL (STORED) 2962
PCI BUS SHORTED HIGH (STORED) 2962
PCI BUS SHORTED LOW (STORED) 2962
REAR BLEND DOOR NOT RESPONDING (STORED) 2962
REAR BLEND DOOR RANGE TOO LARGE (STORED) 2962
REAR BLEND DOOR TRAVEL TOO SMALL (STORED) 2962
REAR FAN POT OPEN (STORED) 2962
REAR FAN POT SHORTED (STORED) 2962
REAR KEYBOARD FAULT (STORED) 2962
REAR MODE DOOR NOT RESPONDING (STORED) 2962
REAR MODE DOOR TRAVEL TOO LARGE (STORED) 2962
REAR MODE DOOR TRAVEL TOO SMALL (STORED) 2962
REAR MODE POT OPEN (STORED) 2962
REAR MODE POT SHORTED (STORED) 2962
RECIRC DOOR NOT RESPONDING (STORED) 2962
RECIRC DOOR TRAVEL TOO LARGE (STORED) 2962
RECIRC DOOR TRAVEL TOO SMALL (STORED) 2962
COOLDOWN TEST FAILED 2969
DRIVER BLEND DOOR NOT RESPONDING (ACTIVE) 2971
DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE) 2973
DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE) 2974
EEPROM CHECKSUM ERROR (ACTIVE) 2976
EVAP TEMP SENSOR OPEN (ACTIVE) 2977
EVAP TEMP SENSOR SHORTED (ACTIVE) 2980
FRONT AND REAR BLOWER OUTPUT 1 OPEN 2982
FRONT AND REAR BLOWER OUTPUT 2 OPEN 2982
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT 2983
FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT 2983
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (ACTIVE) 2984
FRONT IR SENSOR CHANGE TOO LARGE (ACTIVE) 2984
FRONT IR SENSOR HIGH (ACTIVE) 2984
FRONT IR SENSOR LOW (ACTIVE) 2984
FRONT IR SENSOR NOT CALIBRATED (ACTIVE) 2985
FRONT KEYBOARD FAULT (ACTIVE) 2985
FRONT KEYBOARD COMMUNICATION FAULT (ACTIVE) 2990
FRONT MODE DOOR NOT RESPONDING (ACTIVE) 2991
FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE) 2993
FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE) 2994
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERATURE TOO LOW 2995
PASS BLEND DOOR NOT RESPONDING (ACTIVE) 2998
PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE) 3000
PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE) 3001
PCI BUS SHORTED HIGH (ACTIVE) 3003
PCI BUS SHORTED LOW (ACTIVE) 3003
REAR BLEND DOOR NOT RESPONDING (ACTIVE) 3004
REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE) 3006
REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE) 3007
REAR FAN POT OPEN (ACTIVE) 3008
REAR FAN POT SHORTED (ACTIVE) 3008
REAR MODE POT OPEN (ACTIVE) 3008
REAR MODE POT SHORTED (ACTIVE) 3008
REAR KEYBOARD FAULT (ACTIVE) 3009
REAR MODE DOOR NOT RESPONDING (ACTIVE) 3013
REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE) 3015
REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE) 3016
RECIRC DOOR NOT RESPONDING (ACTIVE) 3017
RECIRC DOOR TRAVEL TOO LARGE (ACTIVE) 3019
RECIRC DOOR TRAVEL TOO SMALL (ACTIVE) 3020
*ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE 3021
*FRONT BLOWER MOTOR INOPERATIVE 3023
*FRONT BLOWER RUNS AT ONLY ONE SPEED 3029
*HVAC SYSTEM TEST 3031
*REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE 3035
*REAR BLOWER MOTOR INOPERATIVE 3037
*REAR BLOWER RUNS AT ONLY ONE SPEED 3043
CABIN HEATER 3045
A CABIN HEATER PRE-TEST 3045
CABIN HEATER CONTROL CIRCUIT OPEN (STORED) 3045
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (STORED) 3045
B1000 CONTROL UNIT ERRONEOUS 3049
B1800 NO START 3050
B1801 FLAME OUT: DURING HEATING CYCLE 3050
B1801 FLAME OUT: UNSTABLE OPERATION 3050
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD 3054
B1802 POWER SUPPLY OUT OF RANGE: VOLTAGE ABOVE 15 5 VOLTS 3057
B1803 FLAME DETECTED PRIOR TO COMBUSTION 3058
B1811 HEATER OVERHEATED 3059
B1813 HEATER IN LOCKOUT MODE 3063
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY 3065
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND 3068
B1821 COMBUSTION AIR FAN CIRCUIT: OPEN 3071
B1821 COMBUSTION AIR FAN CIRCUIT: SHORT TO GROUND 3071
B1822 GLOW PIN/FLAME SENSOR: OPEN 3072
B1822 GLOW PIN/FLAME SENSOR: SHORT TO GROUND 3072
B1823 WATER PUMP CIRCUIT: OPEN 3073
B1823 WATER PUMP CIRCUIT: SHORT TO GROUND 3073
B1824 FAN SWITCH LINE SHORT TO GROUND 3074
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE) 3075
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE) 3079
*CABIN HEATER INOPERABLE FROM A/C – HEATER MODULE (MTC) 3082
*CABIN HEATER INOPERABLE FROM AUTO TEMP CONTROL (ATC) 3084
CHIME 3087
*CHIME INOPERATIVE 3087
*KEY IN IGNITION AND DRIVER’S DOOR OPEN CHIME NOT OPERATING PROPERLY 3089
*PROBLEM WITH THE VEHICLE SPEED WARNING CHIME 3090
COMMUNICATION 3091
ATC MODULE MESSAGES NOT RECEIVED 3091
AUDIO MESSAGES NOT RECEIVED 3092
BCM, PCI BUS SHORTED TO BATTERY 3093
BCM, PCI BUS SHORTED TO GROUND 3093
FCM, PCI BUS SHORTED TO BATTERY 3093
FCM, PCI BUS SHORTED TO GROUND 3093
COUNTRY CODE NOT PROGRAMMED 3095
FCM MESSAGES NOT RECEIVED 3096
FCM, BCM COMMUNICATION FAULT 3097
FCM, HVAC COMMUNICATION FAULT 3098
FCM, PCI INTERNAL FAULT 3099
FCM, PCM COMMUNICATION FAULT 3100
FCM, RADIO COMMUNICATION FAULT 3102
FCM, TCM COMMUNICATION FAULT 3103
INTERNAL BCM FAILURE 3104
LEFT PSD MESSAGES NOT RECEIVED 3105
LIFTGATE MODULE MESSAGES NOT RECEIVED 3107
MIC MESSAGES NOT RECEIVED 3109
MSM MESSAGES NOT RECEIVED 3111
NO PCI MESSAGES FROM CD CHANGER 3112
ORC MESSAGES NOT RECEIVED 3114
OTIS MODULE MESSAGES NOT RECEIVED 3115
PCI INTERNAL HARDWARE FAILURE 3116
PCM MESSAGES NOT RECEIVED 3117
RADIO MEM MSG NOT RECEIVED 3119
RIGHT PSD MESSAGES NOT RECEIVED 3120
SKIM MESSAGES NOT RECEIVED 3122
TCM MESSAGES NOT RECEIVED 3123
*NO RESPONSE FROM AIRBAG CONTROL MODULE 3124
*NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL MODULE 3126
*NO RESPONSE FROM BODY CONTROL MODULE 3128
*NO RESPONSE FROM CABIN HEATER ASSIST – DIESEL ONLY 3130
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 3132
*NO RESPONSE FROM ECM (PCI BUS) – DIESEL ONLY 3134
*NO RESPONSE FROM ECM (SCI ONLY) – DIESEL ONLY 3135
*NO RESPONSE FROM FRONT CONTROL MODULE 3137
*NO RESPONSE FROM HVAC 3139
*NO RESPONSE FROM INSTRUMENT CLUSTER 3141
*NO RESPONSE FROM LEFT SIACM 3144
*NO RESPONSE FROM LEFT SLIDING DOOR CONTROL MODULE 3146
*NO RESPONSE FROM MEMORY SEAT/MIRROR MODULE 3149
*NO RESPONSE FROM OVERHEAD CONSOLE 3151
*NO RESPONSE FROM PCM (PCI BUS) – NGC 3153
*NO RESPONSE FROM PCM (PCI BUS) – SBEC 3154
*NO RESPONSE FROM PCM (PCM SCI ONLY) – NGC 3156
*NO RESPONSE FROM PCM (SCI ONLY) – SBEC 3159
*NO RESPONSE FROM POWER LIFTGATE MODULE 3162
*NO RESPONSE FROM RADIO 3165
*NO RESPONSE FROM RIGHT SIACM 3167
*NO RESPONSE FROM RIGHT SLIDING DOOR CONTROL MODULE 3169
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE 3172
*NO RESPONSE FROM THATCHAM ALARM MODULE 3174
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE – EATX 3176
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE – NGC 3179
*PCI BUS COMMUNICATION FAILURE 3182
DOOR AJAR 3185
*HOOD AJAR CIRCUIT OPEN (EXPORT ONLY) 3185
*HOOD AJAR CIRCUIT SHORTED TO GROUND (EXPORT ONLY) 3186
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN 3187
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND 3188
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN 3189
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND 3191
*LIFTGATE AJAR CIRCUIT OPEN 3192
*LIFTGATE AJAR CIRCUIT SHORTED TO GROUND 3193
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN 3194
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND 3195
*RIGHT SLIDING DOOR AJAR CIRCUIT OPEN 3196
*RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND 3198
ELECTRICALLY HEATED SYSTEMS 3199
EBL RUN ONLY RELAY OPEN 3199
EBL RUN ONLY RELAY SHORTED TO BATTERY 3201
EXTERIOR LIGHTING 3202
BACKUP LAMP OUTPUT OPEN 3202
BACKUP LAMP OUTPUT SHORT 3204
FRONT FOG LAMP RELAY OPEN 3205
FRONT FOG LAMP SHORTED TO BATTERY 3207
HEADLAMP SWITCH MISMATCH 3208
HEADLAMP SWITCH OPEN 3209
HEADLAMP SWITCH SHORT TO GROUND 3211
HIGH BEAM SWITCH INPUT OPEN 3213
HIGH BEAM SWITCH INPUT SHORT 3215
LEFT FRONT TURN SIGNAL OUTPUT OPEN 3217
LEFT FRONT TURN SIGNAL OUTPUT SHORT 3219
LEFT HIGH BEAM HEADLAMP CIRCUIT OPEN 3221
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND 3223
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE 3225
LEFT LOW BEAM HEADLAMP CIRCUIT OPEN 3227
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND 3229
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE 3231
LEFT REAR TURN SIGNAL OUTPUT OPEN 3233
LEFT REAR TURN SIGNAL OUTPUT SHORT 3235
LEFT SIDE PARK LAMP OPEN 3237
PARK LAMP OUTPUT 1 OPEN 3239
PARK LAMP OUTPUT 1 SHORT TO BATTERY 3241
PARK LAMP OUTPUT 2 OPEN 3242
PARK LAMP OUTPUT 2 SHORT TO BATTERY 3244
RIGHT FRONT TURN SIGNAL OUTPUT OPEN 3245
RIGHT FRONT TURN SIGNAL OUTPUT SHORT 3247
RIGHT HIGH BEAM HEADLAMP CIRCUIT OPEN 3249
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND 3251
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE 3253
RIGHT LOW BEAM HEADLAMP CIRCUIT OPEN 3255
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND 3257
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE 3259
RIGHT REAR TURN SIGNAL OUTPUT OPEN 3261
RIGHT REAR TURN SIGNAL OUTPUT SHORT 3263
RIGHT SIDE PARK LAMP OPEN 3265
TURN SIGNAL SWITCH INPUT OPEN 3267
TURN SIGNAL SWITCH INPUT SHORT 3269
HEATING & A/C 3271
A/C SWITCH FAULT (ACTIVE) – MTC 3271
CHECKSUM FAILURE (ACTIVE) – MTC 3271
DEFOG SWITCH FAULT (ACTIVE) – MTC 3271
POWER SWITCH FAULT (ACTIVE) – MTC 3271
RECIRC SWITCH FAULT (ACTIVE) – MTC 3271
A/C SWITCH FAULT (STORED) – MTC 3273
BACKLIGHT DIMMING RX FAILURE (STORED) – MTC 3273
BLEND OVERCURRENT (STORED) – MTC 3273
CHECKSUM FAILURE (STORED) – MTC 3273
DEFOG SWITCH FAULT (STORED) – MTC 3273
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (STORED) – MTC 3273
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (STORED) – MTC 3273
LOOPBACK TEST FAILURE (STORED) – MTC 3273
MODE OVERCURRENT (STORED) – MTC 3273
NO FUEL LEVEL MESSAGE RECEIVED (STORED) – MTC 3273
PCM COMMUNICATION FAILURE (STORED) – MTC 3273
POWER SWITCH FAULT (STORED) – MTC 3273
REAR BLEND OVERCURRENT (STORED) – MTC 3273
REAR BLEND POT CIRCUIT OPEN (STORED) – MTC 3273
REAR BLEND POT CIRCUIT SHORT (STORED) – MTC 3273
REAR MODE OVERCURRENT (STORED) – MTC 3273
RECIRC OVERCURRENT (STORED) – MTC 3273
RECIRC SWITCH FAULT (STORED) – MTC 3273
TX FAILURE (STORED) – MTC 3273
VEHICLE ODOMETER FAILURE (STORED) – MTC 3273
ZONE OVERCURRENT (STORED) – MTC 3273
ACT CKT TEST PASSED, OVERCURRENT DTCS ACTIVE – MTC 3278
BLEND CIRCUIT SHORTED TO GROUND – MTC 3278
BLEND CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
COMMON DRIVER SHORTED TO GROUND – MTC 3278
COMMON DRIVER SHORTED TO IGN OR BATT – MTC 3278
MODE CIRCUIT SHORTED TO GROUND – MTC 3278
MODE CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
REAR BLEND CIRCUIT SHORTED TO GROUND – MTC 3278
REAR BLEND CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
REAR MODE CIRCUIT SHORTED TO GROUND – MTC 3278
REAR MODE CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
RECIRC CIRCUIT SHORTED TO GROUND – MTC 3278
RECIRC CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
SHORT TOO COMPLEX – MTC 3278
ZONE CIRCUIT SHORTED TO GROUND – MTC 3278
ZONE CIRCUIT SHORTED TO IGN OR BATT – MTC 3278
BACKLIGHT DIMMING RX FAILURE (ACTIVE) – MTC 3285
BLEND CALIBRATION FAULT – MTC 3286
MODE CALIBRATION FAULT – MTC 3286
REAR BLEND CALIBRATION FAULT – MTC 3286
REAR MODE CALIBRATION FAULT – MTC 3286
RECIRCULATION CALIBRATION FAULT – MTC 3286
ZONE CALIBRATION FAULT – MTC 3286
BLEND OVERCURRENT (ACTIVE) – MTC 3294
MODE OVERCURRENT (ACTIVE) – MTC 3294
REAR BLEND OVERCURRENT (ACTIVE) – MTC 3294
REAR MODE OVERCURRENT (ACTIVE) – MTC 3294
RECIRC OVERCURRENT (ACTIVE) – MTC 3294
ZONE OVERCURRENT (ACTIVE) – MTC 3294
BLOWER NOT ON HIGH – MTC 3296
COOLDOWN TEST SENSOR FAILURE – MTC 3297
COOLDOWN TIME EXCESSIVE FAULT – MTC 3297
COOLDOWN TEST TOO COLD TO START – MTC 3299
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE) – MTC 3302
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (ACTIVE) – MTC 3305
FRONT AND REAR BLOWER OUTPUT 1 OPEN 3307
FRONT AND REAR BLOWER OUTPUT 2 OPEN 3307
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT 3309
FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT 3309
LOOPBACK TEST FAILURE (ACTIVE) – MTC 3311
NO FUEL LEVEL MESSAGE RECEIVED (ACTIVE) – MTC 3312
PCM COMMUNICATION FAILURE (ACTIVE) – MTC 3312
VEHICLE ODOMETER FAILURE (ACTIVE) – MTC 3312
REAR BLEND POT CIRCUIT OPEN (ACTIVE) – MTC 3314
REAR BLEND POT CIRCUIT SHORT (ACTIVE) – MTC 3317
TX FAILURE (ACTIVE) – MTC 3319
*A/C STATUS INDICATOR FLASHING – MTC 3321
*RECIRC STATUS INDICATOR FLASHING – MTC 3321
*BLEND/MODE/RECIRC DOOR OPERATION IMPROPER — DUAL & THREE-ZONE MTC 3323
*BLEND/MODE/RECIRC DOOR OPERATION IMPROPER — SINGLE-ZONE MTC 3327
*FRONT A/C – HEATER CONTROL ILLUMINATION INOPERATIVE – MTC 3329
*FRONT BLOWER MOTOR INOPERATIVE – MTC 3331
*FRONT BLOWER MOTOR SPEEDS INCORRECT – MTC 3336
*HVAC SYSTEM TEST – MTC 3338
*REAR A/C – HEATER CONTROL ILLUMINATION INOPERATIVE – MTC 3340
*REAR BLOWER MOTOR INOPERATIVE – MTC 3342
*REAR BLOWER MOTOR SPEEDS INCORRECT – MTC 3346
*REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS – MTC 3350
IGNITION, POWER, ACCESSORY 3352
ACCESSORY POWER OUTPUT 1 OPEN 3352
ACCESSORY POWER OUTPUT 1 SHORT TO B+ 3354
ACCESSORY POWER OUTPUT 2 OPEN 3356
ACCESSORY POWER OUTPUT 2 SHORT TO B+ 3358
CPA NOT ENGAGED 3360
HORN INPUT STUCK 3362
HORN RELAY OPEN 3363
HORN RELAY SHORTED TO B+ 3365
IGNITION MUX SWITCH INPUT OPEN 3367
IGNITION MUX SWITCH INPUT SHORT 3369
IGNITION RUN OUTPUT SHORT 3371
IGNITION RUN/START INPUT WIRING 3373
IGNITION START INPUT WIRING 3375
INTERNAL DRIVER FAULT #1 3377
INTERNAL DRIVER FAULT #2 3378
INTERNAL DRIVER FAULT #3 3379
RUN/START HARDWARE INPUT FAILURE 3380
INSTRUMENT CLUSTER 3382
ABS LAMP CKT SHORT 3382
ABS LAMP OPEN 3382
AIRBAG LAMP CKT SHORT 3382
AIRBAG LAMP OPEN 3382
EL PANEL SHORT 3383
FRONT FOG LAMP INDICATOR OPEN 3385
FRONT FOG LAMP INDICATOR SHORT TO GROUND 3387
FUEL GAUGE CHECKSUM FAILURE 3389
SPEEDOMETER CHECKSUM FAILURE 3389
TACHOMETER CHECKSUM FAILURE 3389
TEMPERATURE GAUGE CHECKSUM FAILURE 3389
FUEL LEVEL SENDING UNIT INPUT OPEN 3390
FUEL LEVEL SENDING UNIT INPUT SHORT 3392
IOD WAKEUP CLUSTER OUTPUT OPEN 3394
IOD WAKEUP CLUSTER OUTPUT SHORT 3396
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE) 3398
LEFT TURN SIGNAL INDICATOR OPEN (LOWLINE) 3400
LEFT TURN SIGNAL INDICATOR SHORT (HIGHLINE) 3402
LEFT TURN SIGNAL INDICATOR SHORT (LOWLINE) 3404
LOOPBACK FAILURE 3406
NO ABS BUS MESSAGES RECEIVED 3407
NO BCM BUS MESSAGES RECEIVED 3407
NO FCM BUS MESSAGES RECEIVED 3407
NO ORC BUS MESSAGES RECEIVED 3407
NO TCM BUS MESSAGES RECEIVED 3407
NO PCM BUS MESSAGES RECEIVED 3408
PANEL DIMMING OUTPUT SHORT 3409
REAR FOG INDICATOR OUTPUT OPEN 3414
REAR FOG INDICATOR OUTPUT SHORT 3416
RIGHT TURN SIGNAL INDICATOR OPEN (HIGHLINE) 3418
RIGHT TURN SIGNAL INDICATOR OPEN (LOWLINE) 3420
RIGHT TURN SIGNAL INDICATOR SHORT (HIGHLINE) 3422
RIGHT TURN SIGNAL INDICATOR SHORT (LOWLINE) 3424
TCM MESSAGE MISMATCH 3426
*ANY PCI BUS INDICATOR INOPERATIVE 3427
*SEAT BELT INDICATOR ALWAYS ON 3428
INTERIOR LIGHTING 3429
DOOR/LIFTGATE LAMP OUTPUT SHORT 3429
FRONT COURTESY LAMPS OUTPUT SHORT 3430
READING LAMP OUTPUT SHORT 3431
MEMORY SEAT 3432
BCM MESSAGE NOT RECEIVED 3432
CHARGING VOLTAGE HIGH MESSAGE 3433
CHARGING VOLTAGE LOW MESSAGE 3434
EEPROM REFRESH FAILURE 3435
FRONT RISER DOWN POSITION STUCK 3436
FRONT RISER SENSOR OUT OF RANGE HIGH 3438
FRONT RISER SENSOR OUT OF RANGE LOW 3441
FRONT RISER UP POSITION STUCK 3444
HORIZONTAL FORWARD POSITION STUCK 3446
HORIZONTAL REARWARD POSITION STUCK 3448
HORIZONTAL SENSOR OUT OF RANGE HIGH 3450
HORIZONTAL SENSOR OUT OF RANGE LOW 3453
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH 3456
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW 3458
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH 3460
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE LOW 3462
MEMORY POSITION SWITCH STUCK 3464
MEMORY SWITCH INPUT OPEN 3466
MEMORY SWITCH INPUT SHORT 3468
REAR RISER DOWN POSITION STUCK 3470
REAR RISER SENSOR OUT OF RANGE HIGH 3472
REAR RISER SENSOR OUT OF RANGE LOW 3475
REAR RISER UP POSITION STUCK 3478
RECLINER DOWN POSITION STUCK 3480
RECLINER SENSOR OUT OF RANGE HIGH 3482
RECLINER SENSOR OUT OF RANGE LOW 3485
RECLINER UP POSITION STUCK 3488
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH 3490
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW 3492
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH 3494
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE LOW 3496
OVERHEAD CONSOLE 3498
BUS MESSAGES MISSING 3498
COMPASS TEST FAILURE 3500
DEMAGNETIZE COMPASS AS PER SERVICE MANUAL 3501
EC MIRROR DAY/NIGHT LINE FAULT 3502
EVIC INTERNAL FAILURE 3504
LOOPBACK FAILURE 3505
NO BCM MESSAGES RECEIVED 3506
NO FCM MESSAGES RECEIVED 3507
NO PCM MESSAGES RECEIVED 3508
NO TCM MESSAGES RECEIVED 3509
OTIS MODULE MESSAGE MISMATCH 3510
OTIS MODULE MESSAGE MISMATCH (DIESEL) 3512
*REPAIRING CMTC DISPLAYS DOUBLE DASH ( – – ) IN TEMP DISPLAY 3514
POWER DOOR LOCKS/RKE 3517
DRIVER DOOR LOCK SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3517
DRIVER DOOR LOCK SWITCH INPUT SHORT 3519
DRIVER DOOR LOCK SWITCH INPUT STUCK 3521
LEFT CYLINDER LOCK SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3523
LEFT CYLINDER LOCK SWITCH INPUT SHORT 3525
LEFT CYLINDER LOCK SWITCH INPUT STUCK 3527
LEFT UNLOCK OUTPUT FAILURE 3529
LIFTGATE CYLINDER LOCK SWITCH INPUT OPEN OR SHORT TO VOLTAGE – (EXPORT ONLY) 3531
LIFTGATE CYLINDER LOCK SWITCH INPUT SHORT – (EXPORT ONLY) 3533
LIFTGATE CYLINDER LOCK SWITCH INPUT STUCK – (EXPORT ONLY) 3535
LIFTGATE POWER RELEASE OUTPUT SHORT 3537
LOCK OUTPUT FAILURE 3539
PASSENGER DOOR LOCK SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3542
PASSENGER DOOR LOCK SWITCH INPUT SHORT 3544
PASSENGER DOOR LOCK SWITCH INPUT STUCK 3546
RIGHT CYLINDER LOCK SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3548
RIGHT CYLINDER LOCK SWITCH INPUT SHORT 3550
RIGHT CYLINDER LOCK SWITCH INPUT STUCK 3552
RIGHT UNLOCK OUTPUT FAILURE 3554
RKE PROGRAM LINE OUTPUT OPEN 3556
RKE PROGRAM LINE OUTPUT SHORT 3558
*REMOTE KEYLESS ENTRY PROBLEM 3559
POWER DOORS – LIFTGATE 3561
AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN 3561
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND 3563
CONTROL MODULE FAILURE – INTERNAL FAILURE 3565
INCOMPLETE LATCH CINCH – NO PAWL TRANSITION 3566
INCOMPLETE LATCH CINCH – OVERCURRENT 3568
INCOMPLETE LATCH RELEASE – RATCHET SWITCH FAILURE 3571
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE 3573
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE 3575
INCOMPLETE POWER CLOSE – FULL OPEN SWITCH FAILURE/NON ENGAGEMENT 3576
INCOMPLETE POWER CLOSE – EXCESSIVE H E COUNTS/NON ENGAGEMENT 3578
INCOMPLETE POWER CLOSE – HALL EFFECT SIGNAL MISSING 3582
INCOMPLETE POWER CLOSE – OVER CURRENT 3585
INCOMPLETE POWER CLOSE – TRANSISTOR SHORTED 3588
INCOMPLETE POWER CLOSE – VOLTAGE BELOW MINIMUM LEVEL 3589
INCOMPLETE POWER OPEN – FULL OPEN SWITCH FAILURE/NON ENGAGEMENT 3591
INCOMPLETE POWER OPEN – EXCESSIVE H E COUNTS/NON ENGAGEMENT 3593
INCOMPLETE POWER OPEN – HALL EFFECT SIGNAL MISSING 3597
INCOMPLETE POWER OPEN – OVERCURRENT 3600
INCOMPLETE POWER OPEN – TRANSISTOR SHORTED 3603
INCOMPLETE POWER OPEN – VOLTAGE BELOW MINIMUM LEVEL 3604
IOD WAKE UP OPEN – PLG 3606
LOOPBACK TEST FAILURE 3608
LOSS OF BCM MESSAGES 3609
LOSS OF EATX MESSAGES 3610
LOSS OF SBEC MESSAGES 3611
OUTSIDE LIFTGATE HANDLE INPUT SHORT 3612
OUTSIDE LIFTGATE HANDLE INPUT STUCK 3613
OVERHEAD LIFTGATE SWITCH INPUT STUCK 3614
OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN OR SHT TO VOLTAGE 3615
OVERHEAD LIFTGATE/LOCKOUT SWITCHES SHORT 3617
PINCH SENSOR CIRCUIT OPEN 3618
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND 3621
*POWER LIFTGATE INOPERATIVE 3623
POWER DOORS – SLIDING 3624
AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN 3624
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND 3625
CONTROL MODULE FAILURE – INTERNAL FAILURE 3626
INCOMPLETE LATCH CINCH – NO PAWL TRANSITION 3627
INCOMPLETE LATCH CINCH – OVERCURRENT 3629
INCOMPLETE LATCH RELEASE – FULL OPEN SWITCH FAILURE 3631
INCOMPLETE LATCH RELEASE – RATCHET SWITCH FAILURE 3634
INCOMPLETE LATCH RELEASE- NO REVERSE TO UNLOAD CLUTCH 3636
INCOMPLETE LATCH RELEASE- OVERCURRENT 3637
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE 3639
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE 3641
INCOMPLETE POWER CLOSE – FULL OPEN SWITCH FAILURE 3642
INCOMPLETE POWER CLOSE – EXCESSIVE HALL EFFECT SIGNAL 3644
INCOMPLETE POWER CLOSE – LATCH FAILURE 3647
INCOMPLETE POWER CLOSE – OVERCURRENT 3653
INCOMPLETE POWER CLOSE – TIME OUT 3655
INCOMPLETE POWER CLOSE- VOLTAGE BELOW MINIMUM LEVEL 3656
INCOMPLETE POWER OPEN – FULL OPEN SWITCH FAILURE 3658
INCOMPLETE POWER OPEN – EXCESSIVE HALL EFFECT SIGNAL 3660
INCOMPLETE POWER OPEN – LATCH FAILURE 3663
INCOMPLETE POWER OPEN – OVERCURRENT 3668
INCOMPLETE POWER OPEN – TIME OUT 3670
INCOMPLETE POWER OPEN – VOLTAGE BELOW MINIMUM LEVEL 3671
IOD WAKE UP OPEN – PSD 3673
IOD WAKE UP PSD & PLG SHORT 3675
LEFT B-PILLAR SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3677
LEFT B-PILLAR SWITCH INPUT SHORT 3679
LEFT B-PILLAR SWITCH INPUT STUCK 3680
LOOPBACK TEST FAILURE 3681
LOSS OF BCM MESSAGES 3682
LOSS OF EATX MESSAGES 3683
LOSS OF FCM MESSAGES 3684
LOSS OF SBEC MESSAGES 3685
OVERHEAD LEFT SWITCH INPUT STUCK 3686
OVERHEAD RIGHT SWITCH INPUT STUCK 3687
OVERHEAD RIGHT/LEFT SWITCHES SHORT 3688
RIGHT B-PILLAR SWITCH INPUT OPEN OR SHORT TO VOLTAGE 3689
RIGHT B-PILLAR SWITCH INPUT SHORT 3691
RIGHT B-PILLAR SWITCH INPUT STUCK 3692
*POWER SLIDING DOOR INOPERATIVE 3693
POWER MIRROR 3694
FOLD MIRROR OUTPUT FAILURE (EXPORT ONLY) 3694
PASSENGER MIRROR RELAY OUTPUT OPEN (EXPORT ONLY) 3696
PASSENGER MIRROR RELAY OUTPUT SHORT (EXPORT ONLY) 3698
UNFOLD MIRROR OUTPUT FAILURE (EXPORT ONLY) 3699
*BOTH MIRRORS DO NOT UNFOLD EXCEPT WITH EITHER FRONT DOOR (EXPORT ONLY) 3702
*BOTH POWER FOLDING MIRRORS DO NOT FOLD (EXPORT ONLY) 3703
*DRIVER FOLDING MIRROR DOES NOT FOLD (EXPORT ONLY) 3704
*PASSENGER FOLDING MIRROR DOES NOT FOLD (EXPORT ONLY) 3706
TIRE PRESSURE MONITORING 3708
LF TIRE PRESSURE SENSOR BATTERY LOW 3708
LF TIRE PRESSURE SENSOR FAILURE 3708
LR TIRE PRESSURE SENSOR BATTERY LOW 3708
LR TIRE PRESSURE SENSOR FAILURE 3708
RF TIRE PRESSURE SENSOR BATTERY LOW 3708
RF TIRE PRESSURE SENSOR FAILURE 3708
RR TIRE PRESSURE SENSOR BATTERY LOW 3708
RR TIRE PRESSURE SENSOR FAILURE 3708
VEHICLE THEFT/SECURITY 3710
BCM MESSAGES NOT RECEIVED (EXPORT ONLY) 3710
INTERNAL EEPROM WRITE ERROR (EXPORT ONLY) 3711
INTERNAL TRANSMIT FAILURE (EXPORT ONLY) 3712
INTERNAL ULTRASONIC FAULT (EXPORT ONLY) 3713
LOOPBACK ERROR (EXPORT ONLY) 3717
NO VALID MESSAGES RECEIVED (EXPORT ONLY) 3718
PCI BUS SHORTED TO BATTERY (EXPORT ONLY) 3719
PCI BUS SHORTED TO GROUND (EXPORT ONLY) 3720
PCM MESSAGES NOT RECEIVED (EXPORT ONLY) 3721
*ALARM TRIPS ON ITS OWN 3722
*HOOD DOES NOT TRIP VTSS (EXPORT ONLY) 3723
*LEFT FRONT DOOR DOES NOT TRIP VTSS 3724
*LEFT SLIDING DOOR DOES NOT TRIP VTSS 3725
*LIFTGATE DOES NOT TRIP VTSS (EXPORT ONLY) 3726
*REPEATER LAMPS INOPERATIVE WITH ALARM (EXPORT ONLY) 3727
*RIGHT FRONT DOOR DOES NOT TRIP VTSS 3728
*RIGHT SLIDING DOOR DOES NOT TRIP VTSS 3729
*VTSS SIREN INOP (EXPORT ONLY) 3730
*VTSS WILL NOT ARM 3733
WINDSHIELD WIPER & WASHER 3734
FR WIPER HI-LO RELAY OPEN 3734
FR WIPER HI-LO RELAY SHORT TO BATT 3736
FRONT WASH SWITCH INPUT STUCK 3737
FRONT WASHER OUTPUT OPEN 3739
FRONT WIPER NOT PARKED 3741
FRONT WIPER ON RELAY OPEN 3743
FRONT WIPER ON RELAY SHORT TO BATT 3744
FRONT WIPER PARK SWITCH SHORT TO GND 3745
FRONT WIPER SWITCH MUX INPUT OPEN 3747
FRONT WIPER SWITCH MUX INPUT SHORT TO GROUND 3749
HEADLAMP WASHER RELAY OPEN 3751
HEADLAMP WASHER RELAY SHORT TO BATT 3753
REAR WASH SWITCH INPUT STUCK 3754
REAR WASHER OUTPUT OPEN 3755
REAR WIPER OUTPUT OPEN 3757
REAR WIPER OUTPUT SHORT TO GROUND 3759
REAR WIPER SWITCH MUX INPUT OPEN 3761
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND 3763
VERIFICATION TESTS 3765
VERIFICATION TESTS 3765
8 0 COMPONENT LOCATIONS 3772
8 1 AIRBAG SYSTEM 3772
8 2 BODY CONTROL MODULE 3773
8 3 POWERTRAIN CONTROL MODULE – NGC 3773
8 4 ENGINE CONTROL MODULE – DIESEL 3773
8 5 HEATING & A/C 3774
8 5 1 ACTUATORS – FRONT, LHD 3774
8 5 2 ACTUATOR – FRONT, LHD 3774
8 5 3 ACTUATORS – FRONT, RHD 3775
8 5 4 ACTUATOR – FRONT, RHD 3776
8 5 5 EVAPORATOR TEMPERATURE SENSOR, LHD 3776
8 5 6 EVAPORATOR TEMPERATURE SENSOR, RHD 3777
8 5 7 C202 CONNECTOR 3777
8 5 8 ACTUATORS – REAR 3778
8 5 9 REAR A/C HEATER UNIT CONNECTOR 3778
8 5 10 DIESEL CABIN HEATER ASSIST (DCHA) ASSEMBLY 3779
8 5 11 C330 HARNESS CONNECTOR (DCHA) 3779
8 5 12 C331 HARNESS CONNECTOR (DCHA) 3780
8 6 INTEGRATED POWER MODULE & FRONT CONTROL MODULE – TYPICAL 3780
8 7 MEMORY SYSTEM 3781
8 7 1 MEMORY SEAT MIRROR MODULE/SEAT MOTORS 3781
8 7 2 MEMORY SEAT MIRROR MODULE CIRCUIT BREAKER 3781
8 8 OVERHEAD CONSOLE 3781
8 9 POWER FOLDING MIRRORS 3782
8 10 POWER LIFTGATE SYSTEM 3782
8 10 1 MODULE 3782
8 10 2 PINCH SENSORS (TAPE SWITCH) 3783
8 10 3 LATCH ASSEMBLY 3783
8 11 POWER DOOR LOCK/RKE SYSTEM 3783
8 11 1 DOOR LOCK MOTOR/AJAR SWITCH 3783
8 11 2 CYLINDER LOCK SWITCH 3784
8 11 3 REMOTE KEYLESS ENTRY MODULE 3784
8 12 POWER SLIDING DOOR 3784
8 12 1 MODULE 3784
8 12 2 LOWER DRIVE UNIT 3785
8 12 3 LATCH ASSEMBLY 3785
8 13 VEHICLE THEFT SECURITY SYSTEM 3785
8 13 1 RKE/THATCHAM ALARM MODULE (EXPORT ONLY) 3785
8 13 2 RKE/THATCHAM ALARM MODULE CONNECTORS (EXPORT ONLY) 3786
8 13 3 VTSS SIREN (EXPORT ONLY) 3786
8 13 4 FRONT INTRUSION SENSOR (EXPORT ONLY) 3787
8 13 5 REAR INTRUSION SENSOR (EXPORT ONLY) 3787
9 0 CONNECTOR PINOUTS 3788
A/C-HEATER CONTROL C1 (MTC) 3788
A/C-HEATER CONTROL C2 (MTC) 3788
AIRBAG CONTROL MODULE (ORC) 3789
AMBIENT TEMPERATURE SENSOR (EXCEPT BASE) 3789
ATC REMOTE SENSOR (ATC) 3789
AUTO TEMP CONTROL C1 3790
AUTO TEMP CONTROL C2 3790
AUTO TEMP CONTROL C3 3790
BLOWER MOTOR RESISTOR C1 (MTC) 3790
BLOWER MOTOR RESISTOR C2 (MTC) 3791
BODY CONTROL MODULE C1 3791
BODY CONTROL MODULE C2 3792
BODY CONTROL MODULE C3 3793
BODY CONTROL MODULE C4 3794
BODY CONTROL MODULE C5 3795
BRAKE FLUID LEVEL SWITCH 3795
C200 – (BODY SIDE) 3796
C200 – (INSTRUMENT PANEL SIDE) 3797
C201 – (BODY SIDE) 3798
C201 – (INSTRUMENT PANEL SIDE) 3798
C202 – (COMPONENT SIDE) 3798
C202 – (INSTRUMENT PANEL SIDE) 3798
C304 – (BODY SIDE) 3799
C304 – (SEAT SIDE) 3799
C305 – (BODY SIDE) 3799
C305 – (SEAT SIDE) 3799
C306 – (BODY SIDE) 3800
C306 – (SEAT SIDE) 3800
C307 (HEATED SEATS) – (BODY SIDE) 3800
C307 (HEATED SEATS) – (SEAT SIDE) 3800
C311 – (BODY SIDE) 3801
C311 – (REAR A/C JUMPER SIDE) 3801
C316 (POWER SLIDING DOOR) – (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) 3802
C316 (POWER SLIDING DOOR) – (LEFT SLIDING DOOR SIDE) 3802
C317 (POWER SLIDING DOOR) – (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) 3802
C317 (POWER SLIDING DOOR) – (RIGHT SLIDING DOOR SIDE) 3802
C319 (LOWLINE) – (BODY SIDE) 3803
C319 (LOWLINE) – (LIFTGATE SIDE) 3803
C324 (MANUAL SLIDING DOOR) – (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) 3803
C324 (MANUAL SLIDING DOOR) – (LEFT MANUAL SLIDING DOOR SIDE) 3803
C325 (MANUAL SLIDING DOOR) – (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) 3803
C325 (MANUAL SLIDING DOOR) – (RIGHT MANUAL SLIDING DOOR SIDE) 3804
C326 – (SAFETY SEAT SIDE) 3804
C326 – (SEAT SIDE) 3804
C327 – (SAFETY SEAT SIDE) 3804
C327 – (SEAT SIDE) 3804
C330 (DIESEL) – (CABIN HEATER JUMPER SIDE) 3805
C330 (DIESEL) – (POWERTRAIN SIDE) 3805
C331 (DIESEL) – (CABIN HEATER COMPONENT SIDE) 3805
C331 (DIESEL) – (CABIN HEATER JUMPER SIDE) 3805
C332 (3 ZONE ATC) – (BODY SIDE) 3805
C332 (3 ZONE ATC) – (COMPONENT SIDE) 3806
CABIN HEATER ASSIST C1 (DIESEL) 3806
CABIN HEATER ASSIST C2 (DIESEL) 3806
CD CHANGER 3806
CLOCKSPRING C1 3807
CLOCKSPRING C2 3807
CLOCKSPRING C3 3807
CLOCKSPRING C4 3807
CONTROLLER ANTILOCK BRAKE 3808
DATA LINK CONNECTOR 3808
DOSING PUMP (DIESEL) 3808
DRIVER AIRBAG SQUIB 1 3809
DRIVER AIRBAG SQUIB 2 3809
DRIVER BLEND DOOR ACTUATOR (ATC) 3809
DRIVER BLEND DOOR ACTUATOR (MTC) 3809
DRIVER DOOR LOCK SWITCH 3810
DRIVER POWER SEAT FRONT RISER MOTOR 3810
DRIVER POWER SEAT FRONT RISER POSITION SENSOR 3810
DRIVER POWER SEAT HORIZONTAL MOTOR 3810
DRIVER POWER SEAT HORIZONTAL POSITION SENSOR 3810
DRIVER POWER SEAT REAR RISER MOTOR 3811
DRIVER POWER SEAT REAR RISER POSITION SENSOR 3811
DRIVER POWER SEAT RECLINER MOTOR 3811
DRIVER POWER SEAT RECLINER POSITION SENSOR 3811
DRIVER POWER SEAT SWITCH 3812
DRIVER SEAT BELT SWITCH 3812
DRIVER SEAT BELT TENSIONER 3812
ENGINE CONTROL MODULE C1 (DIESEL) 3813
EVAPORATOR TEMPERATURE SENSOR 3814
FRONT BLOWER MODULE C1 (ATC) 3814
FRONT BLOWER MODULE C2 (ATC) 3814
FRONT CONTROL MODULE 3815
FRONT INTRUSION SENSOR (UNITED KINGDOM) 3815
FRONT READING LAMPS/SWITCH 3816
FRONT WASHER PUMP MOTOR 3816
FUEL PUMP MODULE 3816
HEADLAMP SWITCH 3816
HEADLAMP WASHER PUMP MOTOR (EXPORT) 3817
HIGH NOTE HORN 3817
HOOD AJAR SWITCH (EXPORT) 3817
IGNITION SWITCH 3817
INSTRUMENT CLUSTER 3818
FUSES (IPM) 3820
ACCESSORY RELAY 3820
DEFOGGER RELAY 3820
FRONT BLOWER MOTOR RELAY 3820
FRONT FOG LAMP RELAY 3821
FRONT WIPER HIGH/LOW RELAY 3821
FRONT WIPER ON/OFF RELAY 3821
HEADLAMP WASHER RELAY (EXPORT) 3821
NAME BRAND SPEAKER RELAY 3821
PARK LAMP RELAY 3821
REAR BLOWER MOTOR RELAY (3 ZONE) 3821
INTEGRATED POWER MODULE C1 3822
INTEGRATED POWER MODULE C2 3822
INTEGRATED POWER MODULE C3 3823
INTEGRATED POWER MODULE C4 3823
INTEGRATED POWER MODULE C6 3824
INTEGRATED POWER MODULE C7 3824
INTEGRATED POWER MODULE C8 3824
LEFT B-PILLAR SWITCH (POWER SLIDING DOOR) 3825
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) 3825
LEFT CYLINDER LOCK SWITCH 3825
LEFT DOOR SPEAKER (LOWLINE) 3825
LEFT DOOR SPEAKER (MIDLINE/HIGHLINE) 3826
LEFT FOG LAMP (EXCEPT EXPORT) 3826
LEFT FOG LAMP (EXPORT) 3826
LEFT FRONT DOOR AJAR SWITCH (BASE) 3826
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) 3827
LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT EXPORT) 3827
LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) 3827
LEFT HEADLAMP (EXCEPT EXPORT) 3827
LEFT HIGH BEAM LAMP (EXPORT) 3828
LEFT INSTRUMENT PANEL SPEAKER 3828
LEFT POWER MIRROR 3828
LEFT REAR PILLAR SPEAKER 3828
LEFT REAR SPEAKER (LOWLINE) 3829
LEFT REAR SPEAKER (MIDLINE/HIGHLINE) 3829
LEFT REMOTE RADIO SWITCH 3829
LEFT SEAT AIRBAG 3829
LEFT SIDE IMPACT AIRBAG CONTROL MODULE 3830
LEFT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) 3830
LEFT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) 3830
LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) 3831
LEFT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) 3831
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) 3831
LEFT SLIDING DOOR MOTOR (POWER SLIDING DOOR) 3831
LICENSE LAMP (POWER LIFTGATE) 3832
LICENSE LAMP (POWER RELEASE) 3832
LIFTGATE AJAR SWITCH (MANUAL RELEASE) 3832
LIFTGATE AJAR SWITCH (POWER RELEASE) 3832
LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) 3833
LIFTGATE CYLINDER LOCK SWITCH (EXPORT) 3833
LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) 3833
LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) 3833
LOW NOTE HORN 3834
MEMORY SEAT/MIRROR MODULE C1 3834
MEMORY SEAT/MIRROR MODULE C2 3834
MEMORY SEAT/MIRROR MODULE C3 3835
MEMORY SEAT/MIRROR MODULE C4 3835
MEMORY SET SWITCH 3835
MESSAGE CENTER (HIGHLINE) 3836
MODE DOOR ACTUATOR (ATC) 3836
MODE DOOR ACTUATOR (MTC) 3836
OVERHEAD CONSOLE (EXCEPT BASE) 3837
PASSENGER AIRBAG 3837
PASSENGER BLEND DOOR ACTUATOR (ATC) 3837
PASSENGER BLEND DOOR ACTUATOR (MTC) 3837
PASSENGER DOOR LOCK SWITCH 3838
PASSENGER FOLDING MIRROR RELAY (EXPORT) 3838
PASSENGER SEAT BELT SWITCH 3838
PASSENGER SEAT BELT TENSIONER 3838
POWER LIFTGATE MODULE C1 3839
POWER LIFTGATE MODULE C2 3839
POWER LIFTGATE MOTOR 3839
POWER SEAT CIRCUIT BREAKER (30A) 3840
POWERTRAIN CONTROL MODULE C1 (NGC) 3840
POWERTRAIN CONTROL MODULE C2 (SBEC) 3841
RADIO C1 3842
RADIO C2 (CD CHANGER) 3842
REAR A/C-HEATER UNIT (3 ZONE MTC) 3842
REAR AUTO TEMP CONTROL SWITCH (3 ZONE ATC) 3843
REAR BLOWER FRONT CONTROL SWITCH (3 ZONE MTC) 3843
REAR BLOWER MOTOR POWER MODULE C1 (3 ZONE ATC) 3843
REAR BLOWER MOTOR POWER MODULE C2 (3 ZONE ATC) 3843
REAR BLOWER REAR CONTROL SWITCH C1 (3 ZONE MTC) 3844
REAR BLOWER REAR CONTROL SWITCH C2 (3 ZONE MTC) 3844
REAR INTRUSION SENSOR (UNITED KINGDOM) 3844
REAR MODE MOTOR (3 ZONE ATC) 3844
REAR TEMPERATURE MOTOR (3 ZONE ATC) 3845
REAR WASHER PUMP MOTOR 3845
REAR WIPER MOTOR 3845
RECIRCULATION DOOR ACTUATOR (ATC) 3845
RECIRCULATION DOOR ACTUATOR (MTC) 3846
REMOTE KEYLESS ENTRY MODULE 3846
RIGHT B-PILLAR SWITCH (POWER SLIDING DOOR) 3846
RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) 3846
RIGHT CYLINDER LOCK SWITCH (EXPORT) 3847
RIGHT DOOR SPEAKER (LOWLINE) 3847
RIGHT DOOR SPEAKER (MIDLINE/HIGHLINE) 3847
RIGHT FOG LAMP (EXCEPT EXPORT) 3847
RIGHT FOG LAMP (EXPORT) 3848
RIGHT FRONT DOOR AJAR SWITCH (BASE) 3848
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) 3848
RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) 3848
RIGHT INSTRUMENT PANEL SPEAKER 3849
RIGHT POWER MIRROR 3849
RIGHT REAR PILLAR SPEAKER 3849
RIGHT REAR SPEAKER (LOWLINE) 3849
RIGHT REAR SPEAKER (MIDLINE/HIGHLINE) 3850
RIGHT REMOTE RADIO SWITCH 3850
RIGHT SEAT AIRBAG 3850
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE 3850
RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) 3851
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) 3851
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) 3851
RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) 3852
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) 3852
RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) 3852
SENTRY KEY IMMOBILIZER MODULE 3852
SIREN (UNITED KINGDOM) 3852
THATCHAM ALARM MODULE (UNITED KINGDOM) 3853
TRANSMISSION CONTROL MODULE (3 3L/3 8L) 3854
WASHER FLUID LEVEL SWITCH 3855
10 0 SCHEMATIC DIAGRAMS 3856
10 1 AIRBAG SYSTEM 3856
10 2 AUDIO SYSTEM 3857
10 2 1 PREMIUM AUDIO SYSTEM 3857
10 2 2 BASE AUDIO SYSTEM 3858
10 2 3 CD CHANGER 3859
10 2 4 REMOTE RADIO CONTROLS 3859
10 3 AUTOMATIC TEMPERATURE CONTROL SYSTEM 3860
10 3 1 FRONT ATC – LHD, EXCEPT EXPORT 3860
10 3 2 FRONT ATC – LHD, EXPORT 3861
10 3 3 FRONT ATC – RHD 3862
10 3 4 REAR ATC – THREE ZONE 3863
10 4 COMMUNICATION 3864
10 4 1 PCM COMMUNICATION – SBEC 3865
10 4 2 PCM COMMUNICATION – NGC 3865
10 4 3 ECM & CABIN HEATER ASSIST COMMUNICATION – DIESEL ONLY 3866
10 5 DOOR AJAR SYSTEM 3867
10 5 1 DOOR AJAR SYSTEM WITH POWER SLIDING DOORS 3867
10 5 2 DOOR AJAR WITHOUT POWER SLIDING DOORS 3868
10 6 EXTERIOR LIGHTING 3869
10 7 IGNITION, POWER, ACCESSORY 3870
10 7 1 HORN SYSTEM 3870
10 7 2 IGNITION SWITCH 3871
10 7 3 INTEGRATED POWER MODULE/BODY CONTROL MODULE POWER AND GROUNDS 3872
10 8 INSTRUMENT CLUSTER 3873
10 8 1 INSTRUMENT CLUSTER — BASE 3873
10 8 2 INSTRUMENT CLUSTER & MESSAGE CENTER 3874
10 9 INTERIOR LIGHTING 3875
10 10 MANUAL TEMPERATURE CONTROLS 3876
10 10 1 BASE MANUAL TEMPERATURE CONTROL SYSTEM, LHD 3876
10 10 2 BASE MANUAL TEMPERATURE CONTROL SYSTEM, RHD 3877
10 10 3 DUAL-ZONE & THREE-ZONE (FRONT) MANUAL TEMPERATURE CONTROL SYSTEM, LHD 3878
10 10 4 DUAL-ZONE (FRONT) MANUAL TEMPERATURE CONTROL SYSTEM, RHD 3879
10 10 5 THREE ZONE REAR MANUAL TEMPERATURE CONTROL SYSTEM 3880
10 10 6 FRONT BLOWER MOTOR 3881
10 10 7 REAR BLOWER MOTOR 3882
10 10 8 DIESEL CABIN HEATER ASSIT (DCHA) 3883
10 11 MEMORY SYSTEM 3884
10 12 OVERHEAD CONSOLE 3885
10 13 POWER DOOR LOCKS/RKE 3886
10 14 POWER FOLDING MIRROR LHD (EXPORT ONLY) 3887
10 15 POWER FOLDING MIRROR RHD (EXPORT ONLY) 3888
10 16 POWER LIFTGATE SYSTEM 3889
10 17 POWER SLIDING DOOR SYSTEM 3890
10 17 1 LEFT POWER SLIDING DOOR 3890
10 17 2 RIGHT POWER SLIDING DOOR 3891
10 18 POWER SLIDING DOOR AND LIFTGATE SWITCHES 3892
10 19 REAR DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE 3893
10 20 VEHICLE THEFT SECURITY SYSTEM 3894
10 20 1 THATCHAM ALARM SYSTEM (EXPORT ONLY) 3895
10 21 WIPERS – FRONT AND REAR 3896
11 0 CHARTS AND GRAPHS 3898
11 1 KDB LAB SCOPE PATTERN 3898
11 2 PCI BUS LAB SCOPE PATTERN 3899
15872rschs_sgmldiag pdf 3900
RG Service Manual 0
RG 2 5L Diesel Supplement 0
RG Gas Powertrain 0
RG Diesel Powertrain 0
RG Body 0
RG Transmission 0
RG Chassis 3900
TABLE OF CONTENTS 3900
1 0 INTRODUCTION 3902
1 1 SYSTEM COVERAGE 3902
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 3902
2 0 IDENTIFICATION OF SYSTEM 3902
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3902
3 1 TEVES MARK 20e SYSTEM DESCRIPTION 3902
3 2 TRACTION CONTROL SYSTEM (TCS) DESCRIPTION (IF EQUIPPED) 3902
3 3 SYSTEM COMPONENTS 3903
3 3 1 ABS AND BRAKE WARNING INDICATORS 3903
3 3 2 CONTROLLER ANTILOCK BRAKE (CAB) 3903
3 3 3 HYDRAULIC CONTROL UNIT 3903
3 3 4 ABS SWITCHES/SENSORS 3904
3 3 5 ABS INITIALIZATION 3904
3 3 6 ABS DIAGNOSTIC MODE 3904
3 3 7 TRACTION CONTROL OPERATION (IF EQUIPPED) 3905
3 5 DIAGNOSTIC TROUBLE CODES 3905
3 6 FREEZE FRAME 3905
3 7 TIRE PRESSURE MONITORING SYSTEM 3905
3 7 1 TRAINING THE EVIC 3905
3 7 2 PRESSURE THRESHOLDS 3906
3 7 2 1 CRITICAL AND NON-CRITICAL SYSTEM ALERTS 3906
3 7 3 SYSTEM FAULTS 3906
3 7 4 SPARE WHEEL AUTO-DETECT 3906
3 7 5 DIAGNOSING AND CLEARING SYSTEM FAULTS 3907
3 7 6 SYSTEM TEST 3907
3 8 DRBIII ERROR MESSAGES AND BLANK SCREEN 3907
3 8 1 DRBIII DOES NOT POWER UP 3907
3 8 2 DISPLAY IS NOT VISIBLE 3907
4 0 DISCLAIMERS, SAFETY, WARNINGS 3908
4 1 DISCLAIMERS 3908
4 2 SAFETY 3908
4 2 1 TECHNICIAN SAFETY INFORMATION 3908
4 2 2 VEHICLE PREPARATION FOR TESTING 3908
4 2 3 SERVICING SUB-ASSEMBLIES 3908
4 2 4 DRBIII SAFETY INFORMATION 3908
4 3 WARNINGS 3909
4 3 1 VEHICLE DAMAGE WARNINGS 3909
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 3909
4 4 DIAGNOSIS 3909
5 0 REQUIRED TOOLS AND EQUIPMENT 3909
6 0 GLOSSARY OF TERMS 3910
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 3912
BRAKES (CAB) 3913
BUS SYSTEM COMMUNICATION FAILURE 3913
CAB INTERNAL FAILURE 3915
CLUSTER LAMP FAILURE 3917
INCORRECT TONE WHEEL FAILURE 3919
LEFT FRONT SENSOR CIRCUIT FAILURE 3920
LEFT REAR SENSOR CIRCUIT FAILURE 3920
RIGHT FRONT SENSOR CIRCUIT FAILURE 3920
RIGHT REAR SENSOR CIRCUIT FAILURE 3920
LEFT FRONT WHEEL SPEED SIGNAL FAILURE 3925
LEFT REAR WHEEL SPEED SIGNAL FAILURE 3925
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE 3925
RIGHT REAR WHEEL SPEED SIGNAL FAILURE 3925
PUMP CIRCUIT FAILURE 3928
SYSTEM OVER VOLTAGE 3932
SYSTEM UNDER VOLTAGE 3935
VALVE POWER FEED FAILURE 3937
*BRAKE LAMP SWITCH INOPERATIVE 3940
*TRAC OFF INDICATOR NEVER/ALWAYS ON 3941
*TRAC ON INDICATOR NEVER/ALWAYS ON 3944
COMMUNICATION 3945
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 3945
VERIFICATION TESTS 3947
VERIFICATION TESTS 3947
8 0 COMPONENT LOCATIONS 3948
8 1 CONTROLLER ANTILOCK BRAKE (CAB) 3948
8 2 DATA LINK CONNECTOR 3948
8 3 FUSES 3948
8 4 TRACTION CONTROL SWITCH 3949
8 4 1 TRACTION CONTROL INDICATORS 3949
8 5 WHEEL SPEED SENSORS 3949
8 5 1 FRONT 3949
8 5 2 REAR 3950
8 5A WHEEL SPEED SENSOR CONNECTORS 3950
8 5A 1 FRONT 3950
8 5A 2 REAR 3950
8 6 BRAKE LAMP SWITCH 3951
9 0 CONNECTOR PINOUTS 3952
ABS PUMP MOTOR 3952
BRAKE LAMP SWITCH 3952
CONTROLLER ANTILOCK BRAKE 3953
LEFT FRONT WHEEL SPEED SENSOR 3953
LEFT REAR WHEEL SPEED SENSOR 3953
RIGHT FRONT WHEEL SPEED SENSOR 3954
RIGHT REAR WHEEL SPEED SENSOR 3954
TRACTION CONTROL SWITCH 3954
10 0 SCHEMATIC DIAGRAMS 3956
10 1 TEVES MARK 20E ANTILOCK BRAKE SYSTEM – ABS 3956
15873-rstr_sgmldiag pdf 3958
RG Service Manual 0
RG 2 5L Diesel Supplement 0
RG Gas Powertrain 0
RG Diesel Powertrain 0
RG Body 0
RG Chassis 0
RG Transmission 3958
TABLE OF CONTENTS 3958
1 0 INTRODUCTION 3964
1 1 SYSTEM COVERAGE 3964
1 2 SIX -STEP TROUBLESHOOTING PROCEDURE 3964
2 0 IDENTIFICATION OF SYSTEM 3964
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3964
3 1 GENERAL DESCRIPTION 3964
3 2 FUNCTIONAL OPERATION 3964
3 2 1 AUTOSTICK FEATURE (IF EQUIPPED) 3965
3 2 2 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT VARIOUS OIL TEMPERATURES 3965
3 3 DIAGNOSTIC TROUBLE CODES 3965
3 3 1 HARD CODE 3966
3 3 2 ONE TRIP FAILURES 3966
3 3 3 INTERMITTENT CODE 3966
3 3 4 STARTS SINCE SET COUNTER 3966
3 3 5 TROUBLE CODE ERASURE 3966
3 3 6 QUICK LEARN 3966
3 3 7 CLUTCH VOLUMES 3967
3 3 8 EATX DTC EVENT DATA 3967
3 3 9 ELECTRONIC PINION FACTOR (IF APPLICABLE) 3967
3 4 USING THE DRBIII 3968
3 5 DRBIII ERROR MESSAGES 3968
3 5 1 DRBIII DOES NOT POWER UP (BLANK SCREEN) 3968
3 5 2 DISPLAY IS NOT VISIBLE 3968
3 5 3 SOME DISPLAY ITEMS READ ‘‘—’’ 3968
3 6 TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND FWD ADAPTER (MILLER TOOL #8333-1A) 3968
4 0 DISCLAIMERS, SAFETY, AND WARNINGS 3969
4 1 DISCLAIMERS 3969
4 2 SAFETY 3969
4 2 1 TECHNICIAN SAFETY INFORMATION 3969
4 2 2 VEHICLE PREPARATION FOR TESTING 3969
4 2 3 SERVICING SUB-ASSEMBLIES 3969
4 2 4 DRBIII SAFETY INFORMATION 3969
4 3 WARNINGS 3970
4 3 1 VEHICLE DAMAGE WARNINGS 3970
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 3970
4 3 3 ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) 3971
4 4 4 BULLETINS AND RECALLS 3971
5 0 REQUIRED TOOLS AND EQUIPMENT 3971
6 0 GLOSSARY OF TERMS 3971
6 1 ACRONYMS 3971
6 2 DEFINITIONS 3972
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 3974
COMMUNICATION 3975
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE – EATX 3975
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE – NGC 3978
TRANSMISSION – EATX 3981
P0122-TPS/APPS LOW 3981
P0123-TPS/APPS HIGH 3983
P0124-TPS/APPS INTERMITTENT 3985
P0218-HIGH TEMPERATURE OPERATION ACTIVATED 3987
P0562-LOW BATTERY VOLTAGE 3989
P0604-INTERNAL TCM 3992
P0605-INTERNAL TCM 3993
P0613-INTERNAL TCM 3994
P0706-CHECK SHIFTER SIGNAL 3995
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE 4001
P0712-TRANSMISSION TEMPERATURE SENSOR LOW 4004
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH 4007
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT 4010
P0715-INPUT SPEED SENSOR ERROR 4012
P0720-OUTPUT SPEED SENSOR ERROR 4016
P0725-ENGINE SPEED SENSOR CIRCUIT 4020
P0731-GEAR RATIO ERROR IN 1ST 4023
P0732-GEAR RATIO ERROR IN 2ND 4025
P0733-GEAR RATIO ERROR IN 3RD 4027
P0734-GEAR RATIO ERROR IN 4TH 4029
P0736-GEAR RATIO ERROR IN REVERSE 4031
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT 4033
P0750-LR SOLENOID CIRCUIT 4035
P0755-2/4 SOLENOID CIRCUIT 4038
P0760-OD SOLENOID CIRCUIT 4042
P0765-UD SOLENOID CIRCUIT 4046
P0841-LR PRESSURE SWITCH SENSE CIRCUIT 4050
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE 4054
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT 4058
P0870-OD HYDRAULIC PRESSURE TEST FAILURE 4062
P0871-OD PRESSURE SWITCH SENSE CIRCUIT 4066
P0884-POWER UP AT SPEED 4070
P0888-RELAY OUTPUT ALWAYS OFF 4071
P0890-SWITCHED BATTERY 4075
P0891-TRANSMISSION RELAY ALWAYS ON 4078
P0897-WORN OUT/BURNT TRANSAXLE FLUID 4081
P0944-LOSS OF PRIME 4083
P0952-AUTOSTICK INPUT CIRCUIT LOW 4085
P0953-AUTOSTICK INPUT CIRCUIT HIGH 4087
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE 4090
P1652-SERIAL COMMUNICATION LINK MALFUNCTION 4092
P1684-BATTERY WAS DISCONNECTED 4094
P1687-NO COMMUNICATION WITH THE MIC 4097
P1694-BUS COMMUNICATION WITH ENGINE MODULE 4099
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION 4101
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION 4105
P1790-FAULT IMMEDIATELY AFTER SHIFT 4109
P1793-TRD LINK COMMUNICATION ERROR 4110
P1794-SPEED SENSOR GROUND ERROR 4113
P1797-MANUAL SHIFT OVERHEAT 4115
*CHECKING PARK/NEUTRAL SWITCH OPERATION 4117
*INCORRECT TRANSMISSION FLUID LEVEL 4119
*NO SPEEDOMETER OPERATION 4120
*PRNDL FAULT CLEARING PROCEDURE 4121
*TRANSMISSION NOISY WITH NO DTC’S PRESENT 4122
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S 4123
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP 4124
TRANSMISSION – NGC 4125
P0122-THROTTLE POSITION SENSOR/APPS LOW 4125
P0123-THROTTLE POSITION SENSOR/APPS HIGH 4127
P0124-THROTTLE POSITION SENSOR/APPS INTERMITTENT 4129
P0218-HIGH TEMPERATURE OPERATION ACTIVATED 4131
P0562-LOW BATTERY VOLTAGE 4133
P0604-INTERNAL TCM 4137
P0605-INTERNAL TCM 4137
P0613-INTERNAL TCM 4137
P0706-CHECK SHIFTER SIGNAL 4138
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE 4146
P0712-TRANSMISSION TEMPERATURE SENSOR LOW 4149
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH 4152
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT 4156
P0715-INPUT SPEED SENSOR ERROR 4158
P0720-OUTPUT SPEED SENSOR ERROR 4162
P0725-ENGINE SPEED SENSOR CIRCUIT 4166
P0731-GEAR RATIO ERROR IN 1ST 4168
P0732-GEAR RATIO ERROR IN 2ND 4170
P0733-GEAR RATIO ERROR IN 3RD 4173
P0734-GEAR RATIO ERROR IN 4TH 4176
P0736-GEAR RATIO ERROR IN REVERSE 4179
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT 4181
P0750-LR SOLENOID CIRCUIT 4183
P0755-2/4 SOLENOID CIRCUIT 4187
P0760-OD SOLENOID CIRCUIT 4191
P0765-UD SOLENOID CIRCUIT 4195
P0841-LR PRESSURE SWITCH SENSE CIRCUIT 4198
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE 4202
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT 4207
P0870-OD HYDRAULIC PRESSURE TEST FAILURE 4211
P0871-OD PRESSURE SWITCH SENSE CIRCUIT 4216
P0884-POWER UP AT SPEED 4220
P0888-RELAY OUTPUT ALWAYS OFF 4222
P0890-SWITCHED BATTERY 4227
P0891-TRANSMISSION RLY ALWAYS ON 4230
P0897-WORN OUT/BURNT TRANSAXLE FLUID 4233
P0944-LOSS OF PRIME 4235
P0952-AUTOSTICK INPUT CIRCUIT LOW 4238
P0953-AUTOSTICK INPUT CIRCUIT HIGH 4240
P0992-2-4/OD HYDRAULIC PRESSURE TEST FAILURE 4243
P1652-SERIAL COMMUNICATION LINK MALFUNCTION 4245
P1684-BATTERY WAS DISCONNECTED 4247
P1687-NO COMMUNICATION WITH THE MIC 4250
P1694-BUS COMMUNICATION WITH ENGINE MODULE 4252
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION 4253
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION 4257
P1790-FAULT IMMEDIATELY AFTER SHIFT 4261
P1793-TRD LINK COMMUNICATION ERROR 4262
P1794-SPEED SENSOR GROUND ERROR 4263
P1797-MANUAL SHIFT OVERHEAT 4265
*CHECKING PARK/NEUTRAL SWITCH OPERATION 4267
*NO MANUAL AUTOSTICK OPERATION 4269
*PRNDL FAULT CLEARING PROCEDURE 4271
*TRANSMISSION NOISY WITH NO DTC’S PRESENT 4272
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S 4273
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP 4274
VERIFICATION TESTS 4275
VERIFICATION TESTS 4275
8 0 COMPONENT LOCATIONS 4278
8 1 CONTROL MODULE LOCATIONS 4278
8 2 PRESSURE PORT LOCATIONS 4278
8 3 TRANSMISSION COMPONENT LOCATIONS 4278
9 0 CONNECTOR PINOUTS 4280
AUTOSTICK SWITCH (EXCEPT EXPORT) 4280
CRANKSHAFT POSITION SENSOR (DIESEL) 4280
CRANKSHAFT POSITION SENSOR (GAS) 4280
DATA LINK CONNECTOR 4280
INPUT SPEED SENSOR (EATX) 4281
FUSES (IPM) 4283
TRANSMISSION CONTROL RELAY (EATX) 4283
INTEGRATED POWER MODULE C1 4284
INTEGRATED POWER MODULE C2 4284
INTEGRATED POWER MODULE C3 4285
INTEGRATED POWER MODULE C4 4286
INTEGRATED POWER MODULE C5 4286
INTEGRATED POWER MODULE C6 4286
INTEGRATED POWER MODULE C7 4287
INTEGRATED POWER MODULE C8 4287
INTEGRATED POWER MODULE C9 4287
LEFT REAR LAMP ASSEMBLY 4288
OUTPUT SPEED SENSOR (EATX) 4288
POWERTRAIN CONTROL MODULE C1 (NGC) 4289
POWERTRAIN CONTROL MODULE C1 (SBEC) 4290
POWERTRAIN CONTROL MODULE C2 (NGC) 4291
POWERTRAIN CONTROL MODULE C2 (SBEC) 4292
POWERTRAIN CONTROL MODULE C3 (NGC) 4293
POWERTRAIN CONTROL MODULE C4 (NGC) (EATX) 4294
RIGHT REAR LAMP ASSEMBLY 4294
SOLENOID/PRESSURE SWITCH ASSY (EATX) 4295
THROTTLE POSITION SENSOR (GAS) 4295
TRANSMISSION CONTROL MODULE (3 3L/3 8L) 4296
TRANSMISSION RANGE SENSOR (EATX) 4297
10 0 SCHEMATIC DIAGRAMS 4298
10 1 EATX–3 3/3 8L 4298
10 2 NGC–2 4L 4299
11 0 CHARTS AND GRAPHS 4300
11 1 TRANSMISSION RANGE SENSOR STATES 4300
11 2 PRESSURE SWITCH STATES 4300
11 3 SOLENOID APPLICATION CHART 4301
11 4 SHIFT LEVER ERROR CODES 4301
11 5 TRANSMISSION TEMPERATURE SENSOR 4301
16194-rgs_intlpdf pdf 4302
RG Gas Powertrain 0
RG Diesel Powertrain 0
RG Body 0
RG Chassis 0
RG Transmission 0
RG Service Manual 0
RG 2 5L Diesel Supplement 4302
FOREWORD 0
GROUP TAB LOCATOR 4302
0-MAINTENANCE SCHEDULES 4303
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S , CANADA and MEXICO 4303
DESCRIPTION — DIESEL ENGINES 4303
SCHEDULE “B” 4303
SCHEDULE “A” 4305
7-COOLING 2 5L TURBO DIESEL 4307
COOLING 2 5L TURBO DIESEL 4307
DESCRIPTION – COOLING SYSTEM 4307
COOLING SYSTEM COMPONENTS 4307
DIAGNOSIS AND TESTING 4307
DIAGNOSIS AND TESTING – COOLING SYSTEM 4307
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAK TEST 4312
DIAGNOSIS AND TESTING – COOLING SYSTEM FLOW CHECK 4313
DIAGNOSIS AND TESTING – COOLING SYSTEM AERATION 4313
CLEANING 4313
INSPECTION 4313
SPECIFICATIONS 4314
SPECIFICATIONS – TORQUE 4314
SPECIFICATIONS – COOLING SYSTEM CAPACITY 4314
ACCESSORY DRIVE 4315
ACCESSORY DRIVE 4315
SPECIFICATIONS – ACCESSORY BELT TENSION 4315
BELT TENSIONER 4315
REMOVAL 4315
INSTALLATION 4315
IDLER PULLEY 4316
REMOVAL 4316
INSTALLATION 4316
DRIVE BELTS 4316
DESCRIPTION 4316
DESCRIPTION – ACCESSORY DRIVE BELT 4316
DESCRIPTION – POWER STEERING BELT 4316
OPERATION 4316
OPERATION-ACCESSORY DRIVE BELT 4316
OPERATION-POWER STEERING BELT 4317
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT 4317
REMOVAL 4317
REMOVAL-ACCESSORY DRIVE BELT 4317
REMOVAL 4317
INSTALLATION 4319
INSTALLATION-ACCESSORY DRIVE BELT 4319
INSTALLATION-POWER STEERING BELT 4319
ENGINE 4320
COOLANT 4321
DESCRIPTION 4321
DIAGNOSIS AND TESTING – COOLANT CONCENTRATION TESTING 4321
STANDARD PROCEDURE 4322
STANDARD PROCEDURE – COOLANT SERVICE 4322
STANDARD PROCEDURE – ADDING ADDITIONAL COOLANT 4322
STANDARD PROCEDURE – COOLANT LEVEL CHECK 4322
STANDARD PROCEDURE – COOLING SYSTEM FILLING 4322
STANDARD PROCEDURE – COOLING SYSTEM DRAINING 4323
COOLANT RECOVERY PRESS CONTAINER 4323
DESCRIPTION 4323
OPERATION 4323
REMOVAL 4324
INSTALLATION 4324
ENGINE COOLANT TEMP SENSOR 4324
DESCRIPTION 4324
OPERATION 4324
REMOVAL 4325
INSTALLATION 4325
ENGINE COOLANT THERMOSTAT 4326
DESCRIPTION 4326
OPERATION 4326
REMOVAL 4326
INSTALLATION 4326
RADIATOR 4327
DESCRIPTION 4327
OPERATION 4327
REMOVAL 4327
INSTALLATION 4327
RADIATOR DRAINCOCK 4328
REMOVAL 4328
INSTALLATION 4328
WATER PUMP 4328
DESCRIPTION 4328
OPERATION 4328
REMOVAL 4328
REMOVAL – WATER PUMP 4328
REMOVAL – WATER PUMP HOUSING 4328
CLEANING 4329
INSTALLATION 4329
INSTALLATION – WATER PUMP 4329
INSTALLATION – WATER PUMP HOUSING 4329
RADIATOR PRESSURE CAP 4329
DESCRIPTION 4329
OPERATION 4330
DIAGNOSIS AND TESTING 4331
DIAGNOSIS AND TESTING – COOLING SYSTEM PRESSURE CAP 4331
DIAGNOSIS AND TESTING – PRESSURE RELIEF TEST 4331
CLEANING 4332
INSPECTION 4332
RADIATOR FAN 4332
DESCRIPTION 4332
OPERATION 4332
DIAGNOSIS AND TESTING – RADIATOR FAN MOTOR 4333
REMOVAL 4333
INSTALLATION 4333
HOSE CLAMPS 4334
DESCRIPTION – HOSE CLAMPS 4334
OPERATION – HOSE CLAMPS 4334
RADIATOR FAN RELAY 4334
DESCRIPTION 4334
OPERATION 4334
COOLANT SYSTEM HOSES 4335
REMOVAL 4335
REMOVAL – UPPER RADIATOR HOSE 4335
REMOVAL – LOWER RADIATOR HOSE 4335
REMOVAL – COOLANT BYPASS HOSE 4335
INSTALLATION 4335
INSTALLATION – UPPER RADIATOR HOSE 4335
INSTALLATION – LOWER RADIATOR HOSE 4335
INSTALLATION – COOLANT BYPASS HOSE 4335
8e-ELECTRONIC CONTROL MODULES 4337
ENGINE CONTROL MODULE 4337
DESCRIPTION 4337
OPERATION 4337
ECM OPERATING MODES 4337
MONITORED CIRCUITS 4338
DIAGNOSTIC TROUBLE CODES 4338
STANDARD PROCEDURE – PCM/ECM/SKIM PROGRAMMING – DIESEL 4338
PCM/SKIM PROGRAMMING 4339
ECM/SKIM PROGRAMMING 4339
PROGRAMMING THE ECM (Bosch) 4339
PROGRAMMING THE PCM (JTEC) 4339
PROGRAMMING THE SKIM 4339
PROGRAMMING IGNITION KEYS TO THE SKIM 4339
REMOVAL 4340
INSTALLATION 4340
8f-ENGINE SYSTEMS 4341
CHARGING 4341
GENERATOR 4341
REMOVAL – 2 5L 4341
INSTALLATION – 2 5L 4343
STARTING 4344
STARTER MOTOR 4344
REMOVAL – 2 5L 4344
INSTALLATION – 2 5L 4344
8i-IGNITION CONTROL 4345
GLOW PLUG 4345
DESCRIPTION 4345
OPERATION 4345
GLOW PLUG RELAY 4345
DESCRIPTION 4345
OPERATION 4345
CAMSHAFT POSITION SENSOR 4346
DESCRIPTION 4346
OPERATION 4346
REMOVAL 4346
INSTALLATION 4346
9-ENGINE 4347
ENGINE 2 5L TURBO DIESEL 4349
DESCRIPTION 4349
DESCRIPTION – 2 5L COMMON RAIL DIESEL ENGINE 4349
DESCRIPTION – ENGINE COVER 4349
REMOVAL 4349
REMOVAL – 2 5L DIESEL ENGINE 4349
REMOVAL – ENGINE COVER 4353
INSTALLATION 4353
INSTALLATION – 2 5L TURBO DIESEL ENGINE 4353
INSTALLATION – ENGINE COVER 4354
SPECIFICATIONS 4355
SPECIFICATIONS – 2 5L COMMON RAIL DIESEL ENGINE 4355
SPECIFICATIONS – TORQUE 4357
SPECIAL TOOLS 4359
CYLINDER HEAD 4365
STANDARD PROCEDURE 4365
STANDARD PROCEDURE – VALVE SERVICE 4365
DISASSEMBLY 4365
VALVE CLEANING 4365
INSPECTION 4365
VALVE REFACING 4366
VALVE SEAT REFACING 4366
VALVE STAND DOWN 4366
VALVE GUIDES 4366
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 4366
STANDARD PROCEDURE – MEASURING PISTON PROTRUSION 4367
REMOVAL 4367
CLEANING 4369
INSPECTION 4369
INSTALLATION 4369
Cylinder Head Bolt Torquing Procedure 4370
CAMSHAFT(S) 4371
DESCRIPTION 4371
OPERATION 4371
REMOVAL 4371
INSTALLATION 4371
CHECKING CAMSHAFT ENDPLAY 4372
CYLINDER HEAD COVER(S) 4372
DESCRIPTION 4372
REMOVAL 4372
INSTALLATION 4374
CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE 4374
CAMSHAFT OIL SEAL(S) 4375
REMOVAL 4375
INSTALLATION 4375
ROCKER ARMS 4376
DESCRIPTION 4376
OPERATION 4376
REMOVAL 4376
INSTALLATION 4376
HYDRAULIC LIFTERS 4377
DESCRIPTION 4377
REMOVAL 4377
INSPECTION 4378
INSTALLATION 4378
ENGINE BLOCK 4378
DESCRIPTION 4378
CRANKSHAFT 4379
DESCRIPTION 4379
OPERATION 4379
STANDARD PROCEDURE – CHECKING CRANKSHAFT END PLAY 4379
REMOVAL 4380
INSTALLATION 4380
CYLINDER LINERS 4382
DESCRIPTION 4382
REMOVAL 4382
INSPECTION 4382
INSTALLATION 4383
INTERNAL VACUUM PUMP 4384
DESCRIPTION 4384
REMOVAL 4384
INSTALLATION 4384
PISTON & CONNECTING ROD 4385
DESCRIPTION 4385
STANDARD PROCEDURE – PISTON RING FITTING 4385
REMOVAL 4385
PISTON PIN – REMOVAL 4386
PISTON RING – REMOVAL 4386
INSPECTION 4386
PISTONS 4386
CONNECTING RODS 4386
PISTON PINS 4388
INSTALLATION 4388
PISTON PIN INSTALLATION 4388
PISTON RINGS – INSTALLATION 4388
INSTALLATION 4388
CRANKSHAFT OIL SEAL – FRONT 4390
REMOVAL 4390
INSTALLATION 4390
VIBRATION DAMPER 4391
REMOVAL 4391
INSTALLATION 4391
ENGINE COVER – FRONT 4391
DESCRIPTION 4391
REMOVAL 4391
INSTALLATION 4392
CRANKSHAFT MAIN BEARINGS 4393
REMOVAL 4393
CRANKSHAFT MAIN BEARINGS 4393
CRANKSHAFT FRONT MAIN BEARING 4393
INSTALLATION 4394
CRANKSHAFT MAIN BEARINGS 4394
FRONT CRANKSHAFT MAIN BEARING 4394
CRANKSHAFT OIL SEAL – REAR 4395
REMOVAL 4395
INSTALLATION 4395
OIL PAN 4395
REMOVAL 4395
INSTALLATION 4395
OIL PUMP 4396
REMOVAL 4396
REMOVAL 4396
REMOVAL 4396
INSTALLATION 4396
INSTALLATION 4396
INSTALLATION 4397
OIL PRESSURE SENSOR/SWITCH 4397
DESCRIPTION 4397
REMOVAL 4397
INSTALLATION 4397
OIL PRESSURE RELIEF VALVE 4397
DESCRIPTION 4397
REMOVAL 4397
INSTALLATION 4398
OIL COOLER & LINES 4398
REMOVAL 4398
INSTALLATION 4399
OIL FILTER 4399
DESCRIPTION 4399
REMOVAL 4399
INSTALLATION 4399
OIL JET 4400
DESCRIPTION 4400
REMOVAL 4400
INSTALLATION 4400
INTAKE MANIFOLD 4400
DESCRIPTION 4400
REMOVAL 4400
INSTALLATION 4400
VALVE TIMING 4401
STANDARD PROCEDURE – LOCKING ENGINE 90° AFTER TDC 4401
BALANCE SHAFT 4402
DESCRIPTION 4402
OPERATION 4402
REMOVAL 4402
INSTALLATION 4403
TIMING BELT COVER 4403
REMOVAL 4403
REMOVAL – TIMING BELT OUTER COVER 4403
REMOVAL – TIMING BELT INNER COVER 4404
INSTALLATION 4405
INSTALLATION – TIMING BELT OUTER COVER 4405
INSTALLATION – TIMING BELT INNER COVER 4405
TIMING BELT IDLER PULLEY 4405
REMOVAL 4405
INSTALLATION 4406
TIMING BELT TENSIONER & PULLEY 4406
REMOVAL 4406
INSTALLATION 4407
ADJUSTMENTS 4407
ADJUSTMENT – TIMING BELT TENSIONER 4407
TIMING BELT AND SPROCKETS 4407
REMOVAL 4407
INSTALLATION 4409
11-EXHAUST SYSTEM AND TURBOCHARGER 4411
EXHAUST SYSTEM AND TURBOCHARGER 4411
DESCRIPTION 4411
SPECIFICATIONS – TORQUE 4411
CHARGE AIR COOLER AND PLUMBING 4412
DESCRIPTION 4412
TURBOCHARGER 4412
DESCRIPTION 4412
OPERATION 4412
CLEANING 4414
INSPECTION 4414
HEAT SHIELDS 4415
REMOVAL 4415
INSTALLATION 4416
14-FUEL SYSTEM 4417
FUEL SYSTEM 2 5L TURBO DIESEL 4417
DESCRIPTION – DIESEL FUEL DELIVERY SYSTEM 4417
WARNING – HIGH FUEL SYSTEM PRESSURE 4417
DIAGNOSIS AND TESTING 4419
DIAGNOSIS AND TESTING – AIR IN FUEL SYSTEM 4419
DIAGNOSIS AND TESTING – FUEL SUPPLY RESTRICTIONS 4419
LOW-PRESSURE LINES 4419
HIGH-PRESSURE LINES 4419
DIAGNOSIS AND TESTING – FUEL DELIVERY SYSTEM 4419
STANDARD PROCEDURE 4420
STANDARD PROCEDURE – FUEL TRANSFER PUMP PRESSURE TEST 4420
STANDARD PROCEDURES – DRAINING WATER FROM FUEL FILTER 4420
STANDARD PROCEDURE – FUEL SYSTEM AIR PURGE 4420
STANDARD PROCEDURES – CLEANING FUEL SYSTEM COMPONENTS 4421
SPECIFICATIONS – TORQUE 4421
FUEL DELIVERY 4422
FUEL RAIL 4422
DESCRIPTION 4422
OPERATION 4422
REMOVAL – FUEL RAIL 4422
INSTALLATION – FUEL RAIL 4423
FUEL FILTER / WATER SEPARATOR 4423
DESCRIPTION 4423
OPERATION 4423
REMOVAL 4424
REMOVAL – FUEL FILTER 4424
REMOVAL 4424
INSTALLATION 4425
INSTALLATION – FUEL FILTER 4425
INSTALLATION 4425
FUEL INJECTION PUMP 4425
DESCRIPTION 4425
REMOVAL 4425
INSTALLATION 4426
FUEL LINES 4427
DESCRIPTION 4427
DESCRIPTION 4427
DESCRIPTION – HIGH PRESSURE FUEL LINES 4427
OPERATION – HIGH PRESSURE FUEL LINES 4427
DIAGNOSIS AND TESTING – HIGH PRESSURE FUEL LINES 4428
FUEL/LIFT PUMP RELAY 4429
DESCRIPTION 4429
OPERATION 4429
FUEL/LIFT PUMP 4429
DESCRIPTION 4429
OPERATION 4429
DIAGNOSIS AND TESTING – FUEL/LIFT PUMP 4430
REMOVAL 4430
INSTALLATION 4430
WATER IN FUEL SENSOR 4430
DESCRIPTION 4430
OPERATION 4430
REMOVAL 4430
INSTALLATION 4430
FUEL HEATER RELAY 4430
DESCRIPTION 4430
OPERATION 4430
FUEL HEATER 4431
DESCRIPTION 4431
OPERATION 4431
DIAGNOSIS AND TESTING – FUEL HEATER 4432
REMOVAL 4432
INSTALLATION 4432
FUEL INJECTION 4433
FUEL INJECTION 4433
STANDARD PROCEDURE – TESTING FUEL INJECTORS 4433
FUEL PRESSURE SOLENOID 4434
DESCRIPTION 4434
REMOVAL 4434
INSTALLATION 4434
FUEL INJECTOR 4435
DESCRIPTION 4435
FUEL INJECTOR 4435
OPERATION 4435
Injector closed (with high pressure applied) 4435
Injector opens (start of injection) 4435
Injector opens fully 4436
Injector closes (end of injection) 4436
REMOVAL 4436
INSTALLATION 4436
ACCELERATOR PEDAL POSITION SENSOR 4437
DESCRIPTION 4437
OPERATION 4437
REMOVAL – PEDAL POSITION SENSOR (LHD) 4437
INSTALLATION – PEDAL POSITION SENSOR (LHD) 4438
BOOST PRESSURE SENSOR 4438
DESCRIPTION 4438
OPERATION 4438
DIAGNOSIS AND TESTING – BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 4438
INTAKE AIR TEMPERATURE SENSOR 4438
DESCRIPTION 4438
OPERATION 4439
REMOVAL 4439
INSTALLATION 4439
CRANKSHAFT POSITION SENSOR 4439
DESCRIPTION 4439
OPERATION 4439
MASS AIR FLOW (MAF) SENSOR 4439
DESCRIPTION 4439
OPERATION 4439
REMOVAL 4440
INSTALLATION 4440
25-EMISSIONS CONTROL 2 5L TURBO DIESEL 4441
EMISSIONS CONTROL 2 5L TURBO DIESEL 4441
DESCRIPTION 4441
ECM MONITORED SYSTEMS 4441
ECM NON–MONITORED SYSTEMS 4441
HIGH AND LOW LIMITS 4441
SPECIFICATIONS – TORQUE 4442
EXHAUST GAS RECIRCULATION 4443
EXHAUST GAS RECIRCULATION 4443
DESCRIPTION 4443
OPERATION 4443
VALVE 4444
DESCRIPTION 4444
OPERATION 4444
REMOVAL 4444
INSTALLATION 4444
ON-BOARD DIAGNOSTICS 4445
ON-BOARD DIAGNOSTICS 4445
DESCRIPTION – DIAGNOSTIC TROUBLE CODES 4445
COMMENTS 4449
16257rgdpwr_sgmldiag pdf 4451
RG Service Manual 0
RG 2 5L Diesel Supplement 0
RG Gas Powertrain 0
RG Body 0
RG Chassis 0
RG Transmission 0
RG Diesel Powertrain 4451
TABLE OF CONTENTS 4451
1 0 INTRODUCTION 4457
1 1 SYSTEM COVERAGE 4457
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 4457
2 0 IDENTIFICATION OF SYSTEM 4457
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 4457
3 1 GENERAL DESCRIPTION 4457
3 2 FUNCTIONAL OPERATION 4457
3 2 1 ECM ON-BOARD DIAGNOSTICS 4457
3 2 2 ECM OPERATING MODES 4458
3 2 3 MONITORED CIRCUITS 4458
3 2 4 SKIS OVERIVEW 4458
3 2 5 SKIS ON-BOARD DIAGNOSTICS 4458
3 2 6 SKIS OPERATION 4458
3 3 DIAGNOSTIC TROUBLE CODES 4459
3 3 1 HARD CODE 4459
3 3 2 INTERMITTENT CODE 4459
3 3 3 ECM DIAGNOSTIC TROUBLE CODES 4459
3 3 4 SKIM DIAGNOSTIC TROUBLE CODES 4462
3 3 5 HANDLING NO TROUBLE CODE PROBLEMS 4462
3 4 USING THE DRBIII 4462
3 4 1 DRBIII DOES NOT POWER UP 4462
3 4 2 DISPLAY IS NOT VISIBLE 4462
4 0 DISCLAIMERS, SAFETY, WARNINGS 4462
4 1 DISCLAIMERS 4462
4 2 SAFETY 4463
4 2 1 TECHNICIAN SAFETY INFORMATION 4463
4 2 2 VEHICLE PREPARATION FOR TESTING 4463
4 2 3 SERVICING SUB-ASSEMBLIES 4463
4 2 4 DRBIII SAFETY INFORMATION 4463
4 3 WARNINGS AND CAUTIONS 4464
4 3 1 ROAD TEST WARNINGS 4464
4 3 2 VEHICLE DAMAGE CAUTIONS 4464
5 0 REQUIRED TOOLS AND EQUIPMENT 4464
6 0 GLOSSARY OF TERMS 4464
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 4465
COMMUNICATION 4466
*NO RESPONSE FROM ECM (PCI BUS) – DIESEL ONLY 4466
*NO RESPONSE FROM ECM (SCI ONLY) – DIESEL ONLY 4467
*PCI BUS COMMUNICATION FAILURE 4469
DRIVEABILITY – DIESEL 4472
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY 4472
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY POSITIVE AREA 4472
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH 4472
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW 4472
P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW 4472
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH 4478
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW 4478
P0606-ECM ERROR GATE ARRAY – COMMUNICATION 4478
P0606-ECM ERROR GATE ARRAY – COMMUNICATION NOT VERIFIED 4478
P0606-ECM ERROR GATE ARRAY – QUANTITY STOP 4478
P0606-ECM ERROR RECOVERY HAS OCCURRED 4478
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING 4478
P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH 4478
P1206-CALCULATED INJECTOR VOLTAGE TOO LOW 4478
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH 4478
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW 4478
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE 4478
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY 4478
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH 4478
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW 4478
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR 4478
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING 4478
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR 4478
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR 4478
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR 4478
P1680-EEPROM PLAUSIBILITY WRITE ERROR 4478
P1685-SKIM SYSTEM INVALID SECRET KEY IN EEPROM 4478
P1685-SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE 4478
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 4482
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 4485
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 4487
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 4490
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH 4492
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW 4496
P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR LOW 4499
P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE 4500
P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP 4500
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 4500
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE 4500
P0202-CYLINDER 2-INJECTOR CIRCUIT CURRENT DECREASE 4500
P0202-CYLINDER 2-INJECTOR CIRCUIT LOAD DROP 4500
P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 4500
P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT LOW SIDE 4500
P0203-CYLINDER 3-INJECTOR CIRCUIT CURRENT DECREASE 4500
P0203-CYLINDER 3-INJECTOR CIRCUIT LOAD DROP 4500
P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 4500
P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT LOW SIDE 4500
P0204-CYLINDER 4-INJECTOR CIRCUIT CURRENT DECREASE 4500
P0204-CYLINDER 4-INJECTOR CIRCUIT LOAD DROP 4500
P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 4500
P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT LOW SIDE 4500
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY 4506
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH 4508
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW 4511
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW 4514
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION 4517
P0340-CMP/CKP POSITION SENSOR CIRCUIT – CKP DYNAMIC PLAUSIBILITY 4519
P0340-CMP/CKP POSITION SENSOR CIRCUIT – CKP STATIC PLAUSIBILITY 4519
P0340-CMP/CKP POSITION SENSOR CIRCUIT – CMP DYNAMIC PLAUSIBILITY 4522
P0340-CMP/CKP POSITION SENSOR CIRCUIT – CMP SIGNAL FREQUENCY TOO HIGH 4522
P0340-CMP/CKP POSITION SENSOR CIRCUIT – STATIC PLAUSIBILITY 4522
P0340-CMP/CKP POSITION SENSOR CIRCUIT – CMP/CKP SYNC FAILURE 4527
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT 4530
P0380-GLOW PLUG CIRCUIT A SHORT CIRCUIT 4530
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT 4533
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT 4536
P0480-FAN 1 CONTROL CIRCUIT OPEN CIRCUIT 4538
P0480-FAN 1 CONTROL CIRCUIT SHORT CIRCUIT 4541
P0481-FAN 2 CONTROL CIRCUIT OPEN CIRCUIT 4543
P0481-FAN 2 CONTROL CIRCUIT SHORT CIRCUIT 4546
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH 4548
P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION 4548
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY 4548
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH 4548
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 4552
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 4554
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY 4556
P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH 4560
P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO LOW 4563
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW 4565
P0530-A/C PRESSURE SENSOR CIRCUIT PLAUSIBILITY 4568
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 4568
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 4568
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR LOW 4568
P0560-SYSTEM VOLTAGE TOO HIGH 4573
P0560-SYSTEM VOLTAGE TOO LOW 4575
*CHECKING THE CHARGING SYSTEM OPERATION 4575
P0579-S/C SWITCH SIGNAL CIRCUIT PLAUSIBILITY 4579
P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH 4581
P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW 4583
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT 4585
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO HIGH 4587
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO LOW 4587
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW 4587
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW 4587
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT 4587
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH 4591
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT 4591
P0620-GENERATOR FIELD CONTROL MALF UNSTABLE CURRENT 4591
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN CIRCUIT 4594
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORT CIRCUIT 4596
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH 4598
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW 4600
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT 4603
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT 4606
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH 4609
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW 4611
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY 4614
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE 4616
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT 4618
P0703-BRAKE SWITCH SIGNAL CKTS PLAUS W/REDUNDANT CONTACT AFTER INITIALIZATION 4618
P0833-CLUTCH PEDAL PLAUSIBILITY 4622
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED 4624
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT OFF 4624
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW 4624
P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN 4624
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT 4630
P1131-FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER-RUN 4630
P1131-FUEL PRESSURE SOLENOID SHORT CIRCUIT 4630
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH 4634
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW 4634
P1512-BATTERY SENSE LINE 2 VOLTAGE TOO HIGH 4634
P1512-BATTERY SENSE LINE 2 VOLTAGE TOO LOW 4634
P1605-IGNITION SWITCH PLAUSIBILITY 4638
P1651-MIL/DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ERROR 4640
P1651-MIL/DIAG LAMP VIA J1850 BUS STATUS ERROR 4640
P1652-J1850 COMMUNICATION BUS RECEIVE TIMEOUT 4642
P1652-J1850 COMMUNICATION BUS SHORT TO GROUND 4642
P1652-J1850 COMMUNICATION BUS SHORT TO VOLTAGE 4642
P1652-J1850 COMMUNICATION BUS SPI ERROR 4642
P1652-J1850 COMMUNICATION BUS TRANSMIT BUFFER OVERRUN 4642
P1652-J1850 COMMUNICATION BUS UNAUTHORIZED RESET 4642
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED 4644
P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT 4645
P1685-SKIM SYSTEM SKIM ERROR 4647
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE SWITCH 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH LOW IDLE SWITCH 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH POTENTIOMETER 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW 4649
P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH OR LOW 4649
*CHECKING THE A/C CLUTCH OPERATION 4658
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION 4660
*CHECKING THE BOOST PRESSURE SENSOR CALIBRATION 4661
*CHECKING THE ECM POWER AND GROUND CIRCUITS 4662
*CHECKING THE EGR SYSTEM 4664
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION 4665
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION 4672
*CHECKING THE ENGINE MECHANICAL SYSTEMS 4673
*CHECKING THE GLOW PLUG OPERATION 4674
*CHECKING THE LIFT PUMP MOTOR OPERATION 4676
*CHECKING THE MAF SENSOR CALIBRATION 4679
*CHECKING THE SPEED CONTROL OPERATION 4681
*CHECKING THE VEHICLE SPEED SIGNAL 4684
*ENGINE CRANKS BUT WILL NOT START 4687
*ENGINE WILL NOT CRANK 4691
SENTRY KEY IMMOBILIZER – BUX DSL 4695
ANTENNA FAILURE 4695
COP FAILURE 4695
EEPROM FAILURE 4695
INTERNAL FAULT 4695
RAM FAILURE 4695
SERIAL LINK INTERNAL FAULT 4695
PCM STATUS FAILURE 4697
SERIAL LINK EXTERNAL FAULT 4697
ROLLING CODE FAILURE 4699
VIN MISMATCH 4699
STACK OVERFLOW FAILURE 4701
TRANSPONDER COMMUNICATION FAILURE 4702
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE 4702
TRANSPONDER ID MISMATCH 4702
TRANSPONDER RESPONSE MISMATCH 4702
VERIFICATION TESTS 4705
VERIFICATION TESTS 4705
8 0 COMPONENT LOCATIONS 4709
8 1 CONTROL MODULES 4709
8 2 CONTROLS AND SOLENOIDS 4709
8 3 DATA LINK CONNECTOR 4709
8 4 FUEL SYSTEM 4710
8 5 RELAYS 4710
8 6 SENSORS 4711
8 7 SWITCHES 4712
9 0 CONNECTOR PINOUTS 4713
A/C COMPRESSOR CLUTCH 4713
A/C PRESSURE SENSOR 4713
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) 4713
BATTERY TEMPERATURE SENSOR 4713
BOOST PRESSURE SENSOR (DIESEL) 4714
BRAKE LAMP SWITCH 4714
CAMSHAFT POSITION SENSOR (DIESEL) 4714
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) 4714
CRANKSHAFT POSITION SENSOR (DIESEL) 4714
DATA LINK CONNECTOR 4715
EGR SOLENOID (DIESEL) 4715
ENGINE CONTROL MODULE C1 (DIESEL) 4716
ENGINE CONTROL MODULE C2 (DIESEL) 4717
ENGINE COOLANT TEMP SENSOR (DIESEL) 4717
ENGINE OIL PRESSURE SENSOR (DIESEL) 4718
FUEL HEATER (DIESEL) 4718
FUEL INJECTOR NO 1 (DIESEL) 4718
FUEL INJECTOR NO 2 (DIESEL) 4718
FUEL INJECTOR NO 3 (DIESEL) 4719
FUEL INJECTOR NO 4 (DIESEL) 4719
FUEL PRESSURE SENSOR (DIESEL) 4719
FUEL PRESSURE SOLENOID (DIESEL) 4719
GENERATOR 4719
GLOW PLUG RELAY (DIESEL) 4720
FUSES (IPM) 4722
A/C COMPRESSOR CLUTCH RELAY 4722
ECM/PCM RELAY (DIESEL) 4722
FUEL HEATER RELAY (DIESEL) 4723
LIFT PUMP RELAY (DIESEL) 4723
LEFT SPEED CONTROL SWITCH 4724
LIFT PUMP MOTOR (DIESEL) 4724
MASS AIR FLOW SENSOR (DIESEL) 4724
OVERHEAD CONSOLE (EXCEPT BASE) 4725
RADIATOR FAN NO 1 (DIESEL) 4725
RADIATOR FAN NO 2 (DIESEL) 4725
RADIATOR FAN RELAY NO 1 (DIESEL) 4726
RADIATOR FAN RELAY NO 2 (DIESEL) 4726
RADIATOR FAN RELAY NO 3 (DIESEL) 4726
RIGHT SPEED CONTROL SWITCH 4726
VEHICLE SPEED SENSOR (MTX) 4727
WATER IN FUEL SENSOR (DIESEL) 4727
10 0 SCHEMATIC DIAGRAMS 4729
10 1 2003 RG 2 5L TURBO DIESEL 4729
10 2 2003 RG 2 5L TURBO DIESEL 4730
11 0 CHARTS AND GRAPHS 4731
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V