2003 Jeep TJ Powertrain Service Manual – PDF DOWNLOAD
DESCRIPTION:
2003 Jeep TJ Powertrain Service Manual – PDF DOWNLOAD
INTRODUCTION:
The procedures contained in this manual include specifications, instructions, and graphics needed to diagnose the PCM Powertrain System. The diagnostics in this manual are based on the failure condition or symptom being present at the time of diagnosis. Please follow the recommendations below when choosing your diagnostic path.
- When repairs are required, refer to the appropriate service manual for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added; current systems may be enhanced.
- READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE DTC. It is recommended that you review the entire manual to become familiar with all new and enhanced diagnostic procedures. After using this book, if you have any comments or recommendations, please fill out the form at the back of the book and mail it back to us.
2003 Jeep TJ Powertrain Service Manual – PDF DOWNLOAD
1 0 INTRODUCTION 1
1 1 SYSTEM COVERAGE 1
1 2 SIX-STEP TROUBLE SHOOTING PROCEDURE 1
2 0 IDENTIFICATION OF SYSTEM 1
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1
3 1 GENERAL DESCRIPTION 1
3 2 FUNCTION OPERATION 1
3 2 1 FUEL CONTROL (GAS) 1
3 2 2 ON-BOARD DIAGNOSTICS 2
3 2 3 OTHER CONTROLS 5
3 2 4 NON-MONITORED CIRCUITS 10
3 2 5 SKIS OVERVIEW 10
3 2 6 SKIM ON-BOARD DIAGNOSTICS 10
3 2 7 SKIS OPERATION 10
3 2 8 PROGRAMMING THE POWERTRAIN CONTROL MODULE 11
3 2 9 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 11
3 2 10 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE 12
3 3 DIAGNOSTIC TROUBLE CODES 12
3 3 1 HARD CODE 12
3 3 2 INTERMITTENT CODE 12
3 3 3 STARTS SINCE SET COUNTER 13
3 3 4 NO START INFORMATION 13
3 4 USING THE DRBIIIT 13
3 5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 13
3 5 1 DRBIIIT DOES NOT POWER UP 13
3 5 2 DISPLAY IS NOT VISIBLE 14
4 0 DISCLAIMERS, SAFETY, WARNINGS 14
4 1 DISCLAIMERS 14
4 2 SAFETY 14
4 2 1 TECHNICIAN SAFETY INFORMATION 14
4 2 2 VEHICLE PREPARATION FOR TESTING 14
4 2 3 SERVICING SUB-ASSEMBLIES 14
4 2 4 DRBIIIT SAFETY INFORMATION 14
4 3 WARNINGS AND CAUTIONS 15
4 3 1 ROAD TEST WARNINGS 15
4 3 2 VEHICLE DAMAGE CAUTIONS 15
5 0 REQUIRED TOOLS AND EQUIPMENT 15
6 0 ACRONYMS 15
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 19
COMMUNICATION
*NO RESPONSE FROM PCM (PCI BUS) 20
*NO RESPONSE FROM PCM (SCI ONLY) 21
*PCI BUS COMMUNICATION FAILURE 24
i
TABLE OF CONTENTS – Continued
DRIVEABILITY – GAS
INTERMITTENT CONDITION 26
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW 27
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH 27
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW 27
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH 27
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW 27
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH 27
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE 30
P0107-MAP SENSOR VOLTAGE TOO LOW 33
P0108-MAP SENSOR VOLTAGE TOO HIGH 35
P0111-INTAKE AIR TEMP PERFORMANCE 37
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW 39
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH 41
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW 43
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH 45
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR 47
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW 52
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH 55
P0125-CLOSED LOOP TEMP NOT REACHED 58
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW 60
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW 60
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW 60
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW 60
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH 63
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH 63
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH 63
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH 63
P0133-O2 SENSOR 1/1 SLOW RESPONSE 66
P0139-O2 SENSOR 1/2 SLOW RESPONSE 66
P0153-O2 SENSOR 2/1 SLOW RESPONSE 66
P0159-O2 SENSOR 2/2 SLOW RESPONSE 66
P0135-O2 SENSOR 1/1 HEATER FAILURE 69
P0141-O2 SENSOR 1/2 HEATER FAILURE 69
P0155-O2 SENSOR 2/1 HEATER FAILURE 69
P0161-O2 SENSOR 2/2 HEATER FAILURE 69
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION 72
P0171-1/1 FUEL SYSTEM LEAN 74
P0174-2/1 FUEL SYSTEM LEAN 74
P0172-1/1 FUEL SYSTEM RICH 79
P0175-2/1 FUEL SYSTEM RICH 79
P0201-INJECTOR #1 CONTROL CIRCUIT 84
P0202-INJECTOR #2 CONTROL CIRCUIT 84
P0203-INJECTOR #3 CONTROL CIRCUIT 84
P0204-INJECTOR #4 CONTROL CIRCUIT 84
P0205-INJECTOR #5 CONTROL CIRCUIT 84
P0206-INJECTOR #6 CONTROL CIRCUIT 84
P0300-MULTIPLE CYLINDER MIS-FIRE 87
P0301-CYLINDER #1 MISFIRE 87
P0302-CYLINDER #2 MISFIRE 87
P0303-CYLINDER #3 MISFIRE 87
P0304-CYLINDER #4 MISFIRE 87
P0305-CYLINDER #5 MISFIRE 87
ii
TABLE OF CONTENTS – Continued
P0306-CYLINDER #6 MISFIRE 87
P0320-NO CRANK REFERENCE SIGNAL AT PCM 94
P0340-NO CAM REFERENCE SIGNAL AT PCM 98
P0351-IGNITION COIL # 1 PRIMARY CIRCUIT 102
P0352-IGNITION COIL # 2 PRIMARY CIRCUIT 102
P0353-IGNITION COIL # 3 PRIMARY CIRCUIT 102
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 105
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY 105
P0441-EVAP PURGE FLOW MONITOR 107
P0442-EVAP LEAK MONITOR MEDIUM (0 040) LEAK DETECTED 109
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 109
P0456-EVAP LEAK MONITOR SMALL ( 020) LEAK DETECTED 109
P0443-EVAP PURGE SOLENOID CIRCUIT 112
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 114
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME 114
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW 115
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH 117
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT 119
P0505-IDLE AIR CONTROL MOTOR CIRCUITS 122
P0523-OIL PRESSURE VOLTAGE TOO HIGH 124
P0551-POWER STEERING SWITCH FAILURE 126
P0601-PCM INTERNAL CONTROLLER FAILURE 128
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 129
P0645-A/C CLUTCH RELAY CIRCUIT 131
P0700-EATX CONTROLLER DTC PRESENT 133
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR 134
P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR 134
P1281-ENGINE IS COLD TOO LONG 136
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT 137
P1294-TARGET IDLE NOT REACHED 139
P1296-NO 5-VOLTS TO MAP SENSOR 141
P1297-NO CHANGE IN MAP FROM START TO RUN 143
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 146
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 148
P1391-INTERMITTENT LOSS OF CMP OR CKP 150
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 154
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 156
P1491-COOLING FAN RELAY CONTROL CIRCUIT 158
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH 160
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW 162
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT 164
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 166
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 168
P1595-SPEED CONTROL SOLENOID CIRCUITS 170
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT 170
P1596-SPEED CONTROL SWITCH ALWAYS HIGH 174
P1597-SPEED CONTROL SWITCH ALWAYS LOW 177
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 179
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM 182
P1686 NO SKIM BUS MESSAGE RECEIVED 184
P1687-NO CLUSTER BUS MESSAGE 186
P1696-PCM FAILURE EEPROM WRITE DENIED 187
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE 188
iii
TABLE OF CONTENTS – Continued
P1899-P/N SWITCH PERFORMANCE 190
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIT 192
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS 195
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS 198
*CHECKING HARD TO FILL WITH FUEL 200
*CHECKING RADIATOR FAN OPERATION WITH NO DTCS 201
*CHECKING THE PCM POWER AND GROUNDS 203
STARTING
*CHECKING FUEL DELIVERY 204
*CHECKING HARD START (FUEL DELIVERY SYSTEM) 207
*ENGINE CRANKS DOES NOT START 209
*FUEL PRESSURE LEAK DOWN 212
*NO CRANK CONDITION 213
*NO RESPONSE FROM PCM WITH A NO START CONDITION 216
*START AND STALL CONDITION 219
VERIFICATION TESTS
VERIFICATION TESTS 221
8 0 COMPONENT LOCATIONS 227
8 1 CONTROL MODULES AND PDC 227
8 2 DATA LINK CONNECTOR 227
8 3 SENSORS AND SOLENOIDS 228
8 4 FUEL SYSTEM 231
8 5 SWITCHES 232
9 0 CONNECTOR PINOUTS 233
A/C COMPRESSOR CLUTCH 233
A/C HIGH PRESSURE SWITCH (4 0L) 233
A/C LOW PRESSURE SWITCH (2 4L) 233
A/C LOW PRESSURE SWITCH (4 0L) 233
A/C PRESSURE TRANSDUCER (2 4L) 234
BATTERY TEMPERATURE SENSOR 234
BRAKE LAMP SWITCH 234
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID 234
C120 (2 4L) 234
C180 235
CAMSHAFT POSITION SENSOR (4 0L) 235
CLOCKSPRING C1 235
CLUTCH PEDAL POSITION SWITCH (M/T) 235
CRANKSHAFT POSITION SENSOR (2 4L/4 0L A/T) 235
CRANKSHAFT POSITION SENSOR (4 0L M/T) 236
DATA LINK CONNECTOR 236
ENGINE COOLANT TEMPERATURE SENSOR 236
ENGINE OIL PRESSURE SWITCH 236
EVAP/PURGE SOLENOID 237
FUEL INJECTOR NO 1 (2 4L) 237
FUEL INJECTOR NO 1 (4 0L) 237
FUEL INJECTOR NO 2 (2 4L) 237
FUEL INJECTOR NO 2 (4 0L) 237
FUEL INJECTOR NO 3 (2 4L) 237
iv
TABLE OF CONTENTS – Continued
FUEL INJECTOR NO 3 (4 0L) 238
FUEL INJECTOR NO 4 (2 4L) 238
FUEL INJECTOR NO 4 (4 0L) 238
FUEL INJECTOR NO 5 (4 0L) 238
FUEL INJECTOR NO 6 (4 0L) 238
FUEL PUMP MODULE (A/T) 239
FUEL PUMP MODULE (M/T) 239
FUSES (FUSE/RELAY BLOCK) 241
GENERATOR 241
GENERATOR 242
IDLE AIR CONTROL MOTOR 242
IGNITION COIL PACK (2 4L) 242
IGNITION COIL PACK (4 0L) 242
IGNITION SWITCH 243
INTAKE AIR TEMPERATURE SENSOR 243
LEAK DETECTION PUMP 243
MANIFOLD ABSOLUTE PRESSURE SENSOR (4 0L) 243
OVERDRIVE OFF SWITCH 243
OXYGEN SENSOR 1/1 UPSTREAM 244
OXYGEN SENSOR 1/2 DOWNSTREAM 244
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW
EMISSION VEHICLE) 244
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN
LOW EMISSION VEHICLE) 244
FUSES (PDC) 246
A/C COMPRESSOR CLUTCH RELAY 246
AUTOMATIC SHUT DOWN RELAY 246
ENGINE STARTER MOTOR RELAY 247
OXYGEN SENSOR DOWNSTREAM HEATER RELAY 247
POWER STEERING PRESSURE SWITCH (2 4L) 247
POWERTRAIN CONTROL MODULE C1 248
POWERTRAIN CONTROL MODULE C2 249
POWERTRAIN CONTROL MODULE C3 250
RADIATOR FAN MOTOR (2 4L) 250
RADIATOR FAN MOTOR CIRCUIT BREAKER (2 4L) 251
RADIATOR FAN MOTOR RELAY (2 4L) 251
SENTRY KEY IMMOBILIZER MODULE 251
SPEED CONTROL SERVO 251
THROTTLE POSITION SENSOR (4 0L) 252
VEHICLE SPEED SENSOR 252
10 0 SCHEMATIC DIAGRAMS 253
11 0 CHARTS AND GRAPHS 257
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