2005 Dodge Viper SRT-10 ZB Service Manual – PDF DOWNLOAD
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2005 Dodge Viper SRT-10 ZB Service Manual – PDF DOWNLOAD
Language : English
Pages : 1873
Downloadable : Yes
File Type : PDF
Size: 40 MB
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2005 Dodge Viper SRT-10 ZB 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 on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. - The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the information
you need, look up the Component/System in the alphabetical index located in the rear of this manual.
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:
2005 Dodge Viper SRT-10 ZB Service Manual – PDF DOWNLOAD
sm-front pdf 1
2005-Viper FSM pdf 5
MAIN WELCOME PAGE 0
ZB SRT-10 BUX Powertrain 0
ZB SRT-10 BUX Body 0
ZB SRT-10 BUX Chassis 0
2005 ZB SRT-10 Service Manual 5
FOREWORD 0
GROUP TAB LOCATOR 5
in-INTRODUCTION 6
BODY CODE PLATE 6
DESCRIPTION 6
E-MARK LABEL 6
DESCRIPTION 6
FASTENER IDENTIFICATION 7
DESCRIPTION 7
FASTENER USAGE 9
DESCRIPTION 9
FASTENER USAGE 9
THREADED HOLE REPAIR 9
INTERNATIONAL SYMBOLS 9
DESCRIPTION 9
MANUFACTURE PLATE 10
DESCRIPTION 10
METRIC SYSTEM 10
DESCRIPTION 10
TORQUE REFERENCES 12
DESCRIPTION 12
VECI LABEL 14
DESCRIPTION 14
VEHICLE IDENTIFICATION NUMBER 14
DESCRIPTION 14
VIN CHECK DIGIT 15
VEHICLE CERTIFICATION LABEL 15
DESCRIPTION 15
0-LUBRICATION & MAINTENANCE 16
INTERNATIONAL SYMBOLS 16
DESCRIPTION 16
PARTS & LUBRICANT RECOMMENDATION 16
DESCRIPTION 16
LUBRICANT RECOMMENDATIONS 16
Chassis 16
Body 17
FLUID TYPES 17
API QUALITY CLASSIFICATION 17
GEAR LUBRICANTS 17
FLUID TYPES 17
DESCRIPTION 17
ENGINE OIL 17
API SERVICE GRADE CERTIFIED 17
SAE VISCOSITY 17
SYNTHETIC ENGINE OILS 17
ENERGY CONSERVING OIL 18
CONTAINER IDENTIFICATION 18
ENGINE OIL ADDITIVES/SUPPLEMENTS 18
ENGINE COOLANT 18
AXLE 19
POWER STEERING FLUID 19
MANUAL TRANSMISSION 19
FLUID CAPACITIES 19
SPECIFICATIONS 19
FLUID CAPACITIES 19
FLUID CAPACITIES – EXPORT 19
FLUID FILL/CHECK LOCATIONS 19
DESCRIPTION 19
LUBRICATION POINTS 19
DESCRIPTION 19
MAINTENANCE SCHEDULES 19
DESCRIPTION 19
MAINTENANCE SCHEDULES 19
SCHEDULE B 20
SCHEDULE A 23
HOISTING 25
STANDARD PROCEDURE – HOISTING 25
JUMP STARTING 25
STANDARD PROCEDURE – JUMP STARTING 25
TO JUMP START A DISABLED VEHICLE 25
DISCONNECT CABLE CLAMPS AS FOLLOWS 25
TOWING 26
STANDARD PROCEDURE – TOWING 26
VEHICLE STORAGE 26
STANDARD PROCEDURE 26
VEHICLE PREPARATION 26
ENGINE COMPONENT PREPARATION 26
FUEL SYSTEM PREPARATION 27
BRAKE SYSTEM PREPARATION 27
REAR AXLE PREPARATION 27
WHEELS AND TIRES PREPARATION 27
INTERIOR TRIM PREPARATION 27
BODY PREPARATION 27
RETURNING VEHICLE FROM LONG TERM STORAGE 28
2-SUSPENSION 30
SUSPENSION 30
WARNINGS AND CAUTIONS 30
STANDARD PROCEDURE – LUBRICATION 30
FRONT SUSPENSION 32
SPECIFICATIONS 33
FRONT SUSPENSION FASTENER TORQUE 33
SPECIAL TOOLS 33
FRONT SUSPENSION 33
HUB / BEARING 34
DESCRIPTION 34
DIAGNOSIS AND TESTING – HUB AND BEARING (FRONT) 34
REMOVAL 35
INSTALLATION 36
KNUCKLE 36
REMOVAL 36
INSTALLATION 37
KNUCKLE/ABS TONE WHEEL SEAL 38
REMOVAL 38
INSTALLATION 39
LOWER BALL JOINT 40
DESCRIPTION 40
DIAGNOSIS AND TESTING – LOWER BALL JOINT (FRONT) 40
LOWER BALL JOINT SEAL BOOT 40
REMOVAL 40
INSTALLATION 41
LOWER CONTROL ARM 42
REMOVAL 42
DISASSEMBLY – LOWER CONTROL ARM (ISOLATOR BUSHINGS) 43
ASSEMBLY – LOWER CONTROL ARM (ISOLATOR BUSHINGS) 44
INSTALLATION 45
SHOCK ASSEMBLY 45
REMOVAL 45
DISASSEMBLY 45
ASSEMBLY 47
INSTALLATION 47
STABILIZER BAR 49
REMOVAL 49
INSTALLATION 50
STABILIZER BAR BUSHINGS 50
REMOVAL 50
INSTALLATION 50
STABILIZER LINK 51
REMOVAL 51
INSTALLATION 51
UPPER BALL JOINT 51
DESCRIPTION 51
DIAGNOSIS AND TESTING – UPPER BALL JOINT (FRONT) 52
UPPER BALL JOINT SEAL BOOT 52
REMOVAL 52
INSTALLATION 52
UPPER CONTROL ARM 53
REMOVAL 53
DISASSEMBLY – UPPER CONTROL ARM (ISOLATOR BUSHINGS) 54
ASSEMBLY – UPPER CONTROL ARM (ISOLATOR BUSHINGS) 55
INSTALLATION 55
REAR SUSPENSION 57
SPECIFICATIONS 58
REAR SUSPENSION FASTENER TORQUE 58
SPECIAL TOOLS 58
REAR SUSPENSION 58
HUB / BEARING 59
DESCRIPTION 59
OPERATION 59
DIAGNOSIS AND TESTING – HUB AND BEARING (REAR) 60
REMOVAL 60
INSTALLATION 62
KNUCKLE 62
REMOVAL 62
INSTALLATION 64
LOWER BALL JOINT 64
DESCRIPTION 64
OPERATION 65
DIAGNOSIS AND TESTING – LOWER BALL JOINT (REAR) 65
WEAR INSPECTION PROCEDURE 65
LOWER BALL JOINT SEAL BOOT 65
REMOVAL 65
INSTALLATION 65
LOWER CONTROL ARM 66
REMOVAL 66
DISASSEMBLY – ISOLATOR BUSHINGS 68
INSPECTION – LOWER CONTROL ARM 68
ASSEMBLY – ISOLATOR BUSHINGS 69
INSTALLATION 69
SHOCK ASSEMBLY 70
REMOVAL 70
DISASSEMBLY 71
ASSEMBLY 72
INSTALLATION 74
STABILIZER BAR 76
REMOVAL 76
INSTALLATION 76
STABILIZER BAR BUSHINGS 77
REMOVAL 77
INSTALLATION 77
STABILIZER LINK 77
REMOVAL 77
INSTALLATION 78
TOE LINK 78
DESCRIPTION 78
OPERATION 78
REMOVAL 78
INSTALLATION 79
UPPER BALL JOINT 80
DESCRIPTION 80
OPERATION 80
DIAGNOSIS AND TESTING – UPPER BALL JOINT (REAR) 80
WEAR INSPECTION PROCEDURE 80
UPPER BALL JOINT SEAL BOOT 81
REMOVAL 81
INSTALLATION 81
UPPER CONTROL ARM 81
REMOVAL 81
DISASSEMBLY – ISOLATOR BUSHINGS 81
INSPECTION – UPPER CONTROL ARM 82
ASSEMBLY – ISOLATOR BUSHINGS 83
INSTALLATION 83
3-DIFFERENTIAL & DRIVELINE 106
PROPELLER SHAFT 106
WARNING 106
DIAGNOSIS AND TESTING – PROPELLER SHAFT 106
PROPELLER SHAFT VIBRATION 106
PROPELLER SHAFT BALANCE 107
PROPELLER SHAFT RUNOUT 108
PROPELLER SHAFT ANGLE 108
PROPELLER SHAFT MEASUREMENT 109
REMOVAL 109
INSTALLATION 109
SPECIFICATIONS 111
SPECIAL TOOLS 111
SINGLE CARDAN UNIVERSAL JOINTS 111
REMOVAL 111
INSTALLATION 111
HALF SHAFT 113
CAUTION 113
DIAGNOSIS AND TESTING – HALF SHAFT 113
CLUNKING NOISE DURING ACCELERATION 113
SHUDDER/VIBRATION DURING ACCELERATION 113
VIBRATION AT HIGHWAY SPEEDS 113
REMOVAL 113
INSTALLATION 114
SPECIFICATIONS 115
SPECIAL TOOLS 115
REAR AXLE – 226RIA 116
DESCRIPTION 116
OPERATION 116
HYDRA-LOK DIFFERENTIAL 116
DIAGNOSIS AND TESTING – REAR AXLE 116
GEAR NOISE 116
BEARING NOISE 117
LOW SPEED KNOCK 117
VIBRATION 117
DRIVELINE SNAP 117
HYDRA-LOK 119
STANDARD PROCEDURE – DRAIN AND REFILL 119
REMOVAL 120
INSTALLATION 120
SPECIFICATIONS 121
SPECIAL TOOLS 121
AXLE SHAFT SEALS 122
REMOVAL 122
INSTALLATION 122
PINION SEAL 122
REMOVAL 122
INSTALLATION 123
5-BRAKES 126
BRAKES – BASE 126
DESCRIPTION – BASE BRAKE SYSTEM 127
WARNINGS AND CAUTIONS 127
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM DIAGNOSIS CHARTS 128
RED BRAKE WARNING INDICATOR LAMP 128
BRAKE NOISE 128
OTHER BRAKE CONDITIONS 129
STANDARD PROCEDURE – BASE BRAKE BLEEDING 130
PRESSURE BLEEDING METHOD 130
MANUAL BLEEDING METHOD 132
SPECIFICATIONS 132
BRAKE ACTUATING SYSTEM 132
BRAKE FASTENER TORQUE 133
SPECIAL TOOLS 133
BASE BRAKE SYSTEM 133
ADJUSTABLE PEDALS SWITCH 134
DESCRIPTION 134
REMOVAL 134
INSTALLATION 134
BRAKE FLUID LEVEL SWITCH 134
DESCRIPTION 134
OPERATION 134
REMOVAL 134
INSTALLATION 135
HYDRAULIC/MECHANICAL 135
DESCRIPTION – HYDRAULIC DISC BRAKES 135
BRAKE LINES 136
DESCRIPTION – BRAKE TUBES AND HOSES 136
INSPECTION – BRAKE TUBES AND HOSES 136
BRAKE PADS/SHOES – FRONT/REAR 137
STANDARD PROCEDURE – BRAKE SHOE BURNISHING 137
REMOVAL 137
CLEANING 139
INSPECTION 139
INSTALLATION 140
DISC BRAKE CALIPER – FRONT 141
REMOVAL 141
DISASSEMBLY 142
ASSEMBLY 145
INSTALLATION 146
DISC BRAKE CALIPER – REAR 146
REMOVAL 146
DISASSEMBLY 147
ASSEMBLY 147
INSTALLATION 147
FLUID 148
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 148
STANDARD PROCEDURE – BRAKE FLUID LEVEL CHECKING 148
SPECIFICATIONS 148
BRAKE FLUID 148
MASTER CYLINDER 149
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 149
REMOVAL 149
INSTALLATION 150
PEDALS – ADJUSTABLE 150
DESCRIPTION 150
REMOVAL 150
INSTALLATION 152
POWER BRAKE BOOSTER 153
DESCRIPTION 153
DIAGNOSIS AND TESTING – POWER BRAKE BOOSTER 154
BASIC TEST 154
VACUUM LEAK TEST 154
REMOVAL 154
INSTALLATION 155
ROTOR 156
DIAGNOSIS AND TESTING – BRAKE ROTOR 156
BRAKING SURFACE INSPECTION 156
ROTOR MINIMUM THICKNESS 156
ROTOR THICKNESS VARIATION 156
ROTOR RUNOUT 157
STANDARD PROCEDURE – BRAKE ROTOR MACHINING 158
REMOVAL 159
REMOVAL – BRAKE ROTOR (FRONT) 159
REMOVAL – BRAKE ROTOR (REAR) 159
INSTALLATION 160
INSTALLATION – BRAKE ROTOR (FRONT) 160
INSTALLATION – BRAKE ROTOR (REAR) 160
SPECIFICATIONS 161
BRAKE ROTOR LIMITS/SPECIFICATIONS 161
PARKING BRAKE 161
DESCRIPTION 161
OPERATION 161
STANDARD PROCEDURE 162
STANDARD PROCEDURE – AUTOMATIC ADJUSTER LOCKING OUT 162
STANDARD PROCEDURE – AUTOMATIC ADJUSTER UNLOCKING 162
CABLE – PARKING BRAKE 162
REMOVAL 162
INSTALLATION 164
CALIPER – PARKING BRAKE 165
REMOVAL 165
DISASSEMBLY 166
ASSEMBLY 166
INSTALLATION 166
LEVER – PARKING BRAKE 168
REMOVAL 168
INSTALLATION 169
PADS/SHOES – PARKING BRAKE 169
REMOVAL 169
INSTALLATION 169
BRAKES – ABS 171
DESCRIPTION 171
DESCRIPTION – ANTILOCK BRAKE SYSTEM 171
DESCRIPTION – ELECTRONIC VARIABLE BRAKE PROPORTIONING 171
OPERATION 171
OPERATION – ANTILOCK BRAKE SYSTEM 171
NORMAL BRAKING 172
ABS BRAKING 172
NOISE AND BRAKE PEDAL FEEL 172
TIRE NOISE AND MARKS 172
START-UP CYCLE 172
DRIVE-OFF CYCLE 172
PREMATURE ABS CYCLING 172
OPERATION – ELECTRONIC VARIABLE BRAKE PROPORTIONING 173
CAUTION 173
DIAGNOSIS AND TESTING – INSPECTION AND ROAD TEST 174
STANDARD PROCEDURE – ANTILOCK BRAKE SYSTEM BLEEDING 174
SPECIFICATIONS 175
ANTILOCK BRAKE SYSTEM FASTENER TORQUE 175
TONE WHEEL RUNOUT 175
WHEEL SPEED SENSOR AIR GAP 175
TONE WHEEL 175
REMOVAL – FRONT TONE WHEEL 175
INSPECTION – TONE WHEEL 175
INSTALLATION – FRONT TONE WHEEL 176
WHEEL SPEED SENSOR – FRONT 176
REMOVAL 176
INSTALLATION 176
WHEEL SPEED SENSOR – REAR 177
REMOVAL 177
INSTALLATION 177
HCU (HYDRAULIC CONTROL UNIT) 178
DESCRIPTION – HYDRAULIC CONTROL UNIT (HCU) 178
VALVES AND SOLENOIDS 178
BRAKE FLUID ACCUMULATORS 178
PUMP/MOTOR 178
OPERATION – HYDRAULIC CIRCUITS AND VALVES 178
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION 179
ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION 180
ICU (INTEGRATED CONTROL UNIT) 181
DESCRIPTION 181
OPERATION 181
REMOVAL 181
DISASSEMBLY 182
ASSEMBLY 183
INSTALLATION 183
6-CLUTCH 184
CLUTCH 184
DESCRIPTION 184
OPERATION 185
WARNING 186
DIAGNOSIS AND TESTING – CLUTCH 186
ROAD TEST 186
CLUTCH CONTAMINATION 186
IMPROPER RELEASE OR CLUTCH ENGAGEMENT 186
CLUTCH MISALIGNMENT 186
PRESSURE PLATE 186
CLUTCH DISC 187
DIAGNOSIS CHART 187
STANDARD PROCEDURE – CLUTCH SYSTEM BLEED 189
LINKAGE BLEED 189
MASTER CYLINDER BLEED 190
SPECIFICATIONS 190
SPECIAL TOOLS 190
CLUTCH DISC 191
REMOVAL 191
CLEANING 191
INSTALLATION 191
CLUTCH RELEASE BEARING 192
REMOVAL 192
INSTALLATION 192
FLYWHEEL 192
DIAGNOSIS AND TESTING 192
LINKAGE 193
DESCRIPTION 193
OPERATION 193
MASTER CYLINDER 193
REMOVAL 193
INSTALLATION 193
CLUTCH PEDAL POSITION SWITCH 193
DESCRIPTION 193
OPERATION 193
DIAGNOSIS AND TESTING 194
REMOVAL 194
INSTALLATION 195
7-COOLING 196
COOLING 196
WARNING 196
COOLING SYSTEM WARNINGS 196
SPECIFICATIONS 196
TORQUE 196
SPECIAL TOOLS 197
COOLING 197
ACCESSORY DRIVE 198
ACCESSORY DRIVE BELT AND TENSIONER 198
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT DIAGNOSIS 198
REMOVAL 199
INSPECTION 199
INSTALLATION 200
8a-AUDIO/VIDEO 222
AUDIO 222
DESCRIPTION 222
OPERATION 222
DIAGNOSIS AND TESTING – AUDIO 222
AMPLIFIER 224
DESCRIPTION 224
OPERATION 224
REMOVAL 225
INSTALLATION 225
ANTENNA 225
DESCRIPTION 225
OPERATION 225
DIAGNOSIS AND TESTING – ANTENNA 225
REMOVAL 226
ANTENNA MODULE 226
DESCRIPTION 226
OPERATION 226
DIAGNOSIS AND TESTING – ANTENNA MODULE 226
REMOVAL 226
INSTALLATION 227
INSTRUMENT PANEL ANTENNA CABLE 227
REMOVAL 227
INSTALLATION 227
RADIO 227
DESCRIPTION 227
OPERATION 228
REMOVAL 228
INSTALLATION 228
RADIO NOISE SUPPRESSION COMPONENTS 228
DESCRIPTION 228
OPERATION 229
REMOVAL 229
SPEAKER 229
DESCRIPTION 229
OPERATION 229
DIAGNOSIS AND TESTING – SPEAKER 229
REMOVAL 231
DOOR SPEAKER 231
INSTRUMENT PANEL SPEAKER 231
REAR SPEAKER 231
SUB WOOFER 231
INSTALLATION 231
DOOR SPEAKER 231
INSTRUMENT PANEL SPEAKER 232
REAR SPEAKER 232
SUB WOOFER 232
8b-CHIME/BUZZER 234
CHIME/BUZZER 234
DESCRIPTION 234
OPERATION 234
AIRBAG WARNING 234
ANTILOCK BRAKE WARNING 234
CRITICAL COOLANT TEMPERATURE WARNING 234
CRITICAL OIL TEMPERATURE WARNING 234
DECK LID AJAR REMINDER 234
DOME LAMPS ON REMINDER 234
DOOR AJAR WARNING 234
ENHANCED SEAT BELT REMINDER 235
FASTEN SEAT BELT REMINDER 235
HEADLAMPS REMINDER 235
KEY IN IGNITION REMINDER 235
LOW FUEL REMINDER 235
PARK BRAKE/LOW BRAKE FLUID WARNING 235
SERVICE ENGINE SOON WARNING 236
TIRE PRESSURE SYSTEM WARNING 236
UNDER/OVER VOLTAGE WARNING 236
WARNING LAMP ANNOUNCEMENT 236
DIAGNOSIS AND TESTING – CHIME CONDITIONS 236
8e-ELECTRONIC CONTROL MODULES 238
BODY CONTROL MODULE 238
DESCRIPTION 238
BATTERY SAVE MODE 238
OPERATION 238
BATTERY SAVE MODE 239
REMOVAL 240
INSTALLATION 240
CONTROLLER ANTILOCK BRAKE 240
DESCRIPTION 240
OPERATION 240
CONTROLLER ANTILOCK BRAKE INPUTS 241
CONTROLLER ANTILOCK BRAKE OUTPUTS 241
REMOVAL 241
INSTALLATION 241
DATA LINK CONNECTOR 241
DESCRIPTION 241
OPERATION 241
POWERTRAIN CONTROL MODULE 241
DESCRIPTION 241
OPERATION – SENSOR RETURN – PCM INPUT 241
OPERATION – DATA BUS COMMUNICATION RECEIVE – PCM INPUT 242
OPERATION – IGNITION SENSE – PCM INPUT 242
OPERATION – PCM GROUND 242
OPERATION 242
OPERATION – 5 VOLT SUPPLY – PCM OUTPUT 243
STANDARD PROCEDURE – OBTAINING DIAGNOSTIC TROUBLE CODES 243
BULB CHECK 243
OBTAINING DTC’S USING DRB SCAN TOOL 243
REMOVAL 243
INSTALLATION 244
8f-ENGINE SYSTEMS 246
BATTERY SYSTEM 246
DESCRIPTION 246
OPERATION 246
WARNING 247
SAFETY PRECAUTIONS AND WARNINGS 247
DIAGNOSIS AND TESTING – BATTERY SYSTEM0 – 2 ZB (Continued) 247
MICRO 420 BATTERY TESTER 247
ABNORMAL BATTERY DISCHARGING 249
CLEANING 249
INSPECTION 250
SPECIFICATIONS 250
BATTERY SYSTEM SPECIFICATIONS 250
SPECIAL TOOLS 251
BATTERY SPECIAL TOOLS 251
BATTERY 251
DESCRIPTION 251
OPERATION 251
DIAGNOSIS AND TESTING – BATTERY 252
MICRO 420 BATTERY TESTER 252
STANDARD PROCEDURE 252
BATTERY CHARGING 252
CHARGING A COMPLETELY DISCHARGED BATTERY 253
CHARGING TIME REQUIRED 254
OPEN-CIRCUIT VOLTAGE TEST 254
IGNITION-OFF DRAW TEST 254
USING MICRO 420 BATTERY TESTER 256
BATTERY TESTING 256
REMOVAL 257
INSTALLATION 257
BATTERY HOLDDOWN 257
REMOVAL 257
INSTALLATION 257
BATTERY CABLES 257
DESCRIPTION 257
OPERATION 257
DIAGNOSIS AND TESTING – BATTERY CABLES 258
VOLTAGE DROP TEST 258
REMOVAL 259
INSTALLATION 259
BATTERY TRAY 260
DESCRIPTION 260
OPERATION 260
CHARGING 261
BATTERY TEMPERATURE SENSOR 261
OPERATION 261
REMOVAL 261
INSTALLATION 261
GENERATOR 261
DESCRIPTION 261
OPERATION 262
REMOVAL 262
INSTALLATION 263
VOLTAGE REGULATOR 263
DESCRIPTION 263
OPERATION 263
STARTING 264
DESCRIPTION 264
OPERATION 264
DIAGNOSIS AND TESTING 264
DIAGNOSIS AND TESTING – STARTING SYSTEM TEST 264
INSPECTION 264
DIAGNOSIS AND TESTING – CONTROL CIRCUIT TEST 266
STARTER SOLENOID 266
STARTER RELAY 266
RELAY TEST 267
RELAY CIRCUIT TEST 267
SAFETY SWITCHES 267
IGNITION SWITCH 267
STARTER BUTTON 267
BATTERY 267
ALL RELATED WIRING AND CONNECTORS 267
DIAGNOSIS AND TESTING – FEED CIRCUIT RESISTANCE TEST 268
DIAGNOSIS AND TESTING – CLUTCH PEDAL POSITION SWITCH 268
SPECIFICATIONS 268
STARTER 268
TORQUE 268
STARTER MOTOR 269
REMOVAL 269
INSTALLATION 269
STARTER MOTOR RELAY 269
DESCRIPTION 269
OPERATION 269
STARTER SOLENOID 269
DESCRIPTION 269
OPERATION 269
8g-HEATED SYSTEMS 270
HEATED GLASS 270
DESCRIPTION 270
OPERATION 270
DIAGNOSIS AND TESTING 271
ELECTRIC BACKLIGHT (EBL) SYSTEM 271
REAR WINDOW DEFOGGER RELAY 271
DESCRIPTION 271
OPERATION 272
REMOVAL 272
INSTALLATION 272
REAR WINDOW DEFOGGER SWITCH 273
DESCRIPTION 273
OPERATION 273
REAR WINDOW DEFOGGER GRID 273
STANDARD PROCEDURE 273
GRID LINE AND TERMINAL REPAIR 273
8h-HORN 276
HORN SYSTEM 276
DESCRIPTION 276
OPERATION 276
DIAGNOSIS AND TESTING – HORN SYSTEM 276
HORN 277
DIAGNOSIS AND TESTING – HORN 277
REMOVAL 277
INSTALLATION 277
HORN SWITCH 277
DESCRIPTION 277
8i-IGNITION CONTROL 278
IGNITION CONTROL 278
DESCRIPTION – IGNITION SYSTEM 278
OPERATION – IGNITION SYSTEM 278
SPECIFICATIONS 278
TORQUE 278
SPARK PLUG 279
CABLES RESISTANCE CHART 279
IGNITION COIL RESISTANCE – 8 3L 279
8 3L – FIRING ORDER 279
CAMSHAFT POSITION SENSOR 280
OPERATION – 8 3L 280
REMOVAL 280
REPLACING WITH NEW SENSOR 280
REPLACING OLD SENSOR WITH ORIGINAL 281
INSTALLATION 281
INSTALLATION – WITH NEW SENSOR 281
REPLACING OLD SENSOR WITH ORIGINAL 281
IGNITION COIL 282
OPERATION 282
REMOVAL 282
INSTALLATION 283
SPARK PLUG 284
DESCRIPTION 284
OPERATION 284
REMOVAL 284
INSTALLATION 284
SPARK PLUG CABLE 284
DESCRIPTION 284
REMOVAL 284
INSTALLATION 285
STARTER BUTTON 286
REMOVAL 286
INSTALLATION 287
8j-INSTRUMENT CLUSTER 288
INSTRUMENT CLUSTER 288
DESCRIPTION 288
DESCRIPTION – EXPORT 288
OPERATION 289
OPERATION – EXPORT 290
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER WARNING/INDICATOR LAMPS 291
STANDARD PROCEDURE 291
STANDARD PROCEDURE – ENHANCED SEAT BELT REMINDER 291
STANDARD PROCEDURE – SELF-DIAGNOSTICS 291
REMOVAL 291
INSTALLATION 291
AIRBAG INDICATOR 292
DESCRIPTION 292
OPERATION 292
INSTRUMENT CLUSTER GAUGE PACK 292
REMOVAL 292
INSTALLATION 293
INSTRUMENT CLUSTER GAUGE PACK LENS 293
REMOVAL 293
INSTALLATION 293
INSTRUMENT CLUSTER LENS 293
REMOVAL 293
INSTALLATION 294
PASS AIRBAG OFF INDICATOR 294
DESCRIPTION 294
OPERATION 294
SEAT BELT WARNING INDICATOR 294
DESCRIPTION 294
OPERATION 294
8l-LAMPS 296
LAMPS/LIGHTING – EXTERIOR 297
WARNING 297
DIAGNOSIS AND TESTING – LAMPS/LIGHTING – EXTERIOR 297
SPECIFICATIONS 297
EXTERIOR LAMPS 297
EXTERIOR LAMPS – EXPORT 297
BACKUP LAMP 298
REMOVAL 298
INSTALLATION 298
BACK UP LAMP UNIT 298
REMOVAL 298
INSTALLATION 298
BRAKE LAMP SWITCH 299
DESCRIPTION 299
OPERATION 299
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCH 299
REMOVAL 300
INSTALLATION 300
CENTER HIGH MOUNTED STOP LAMP UNIT 301
REMOVAL 301
INSTALLATION 301
FOG LAMP – FRONT 301
REMOVAL 301
INSTALLATION 301
FOG LAMP UNIT – FRONT 301
REMOVAL 301
INSTALLATION 301
FOG LAMP – REAR (EXPORT) 302
DESCRIPTION 302
FOG LAMP UNIT – REAR (EXPORT) 302
REMOVAL 302
INSTALLATION 302
HEADLAMP 303
DESCRIPTION 303
OPERATION 303
DIAGNOSIS AND TESTING – HIGH INTENSITY DISCHARGE HEADLAMPS 304
REMOVAL 305
HIGH INTENSITY DISCHARGE (HID) HEADLAMPS – LOW BEAM 305
HIGH BEAM 305
INSTALLATION 305
HIGH INTENSITY DISCHARGE (HID) HEADLAMPS – LOW BEAM 305
HIGH BEAM 306
HEADLAMP UNIT 306
STANDARD PROCEDURE 306
STANDARD PROCEDURE – HEADLAMP UNIT AIMING 306
STANDARD PROCEDURE – HEADLAMP UNIT AIMING – EXPORT 306
REMOVAL 309
INSTALLATION 309
LICENSE PLATE LAMP 309
REMOVAL 309
INSTALLATION 309
LICENSE PLATE LAMP UNIT 310
REMOVAL 310
INSTALLATION 310
MULTI-FUNCTION SWITCH 310
DESCRIPTION 310
HAZARD WARNING SYSTEM 310
OPERATION 311
LIGHTING 311
WIPERS 312
HAZARD WARNING SYSTEM 312
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCH 312
FLASHER DIAGNOSIS 312
SWITCH DIAGNOSIS 314
REMOVAL 316
INSTALLATION 316
MULTI-FUNCTION SWITCH – EXPORT 318
DESCRIPTION 318
HAZARD WARNING SYSTEM 319
OPERATION 319
LIGHTING 319
WIPERS 320
HAZARD WARNING SYSTEM 320
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCH 320
FLASHER DIAGNOSIS 320
SWITCH DIAGNOSIS 322
REMOVAL 325
INSTALLATION 325
FRONT SIDE MARKER LAMP 326
REMOVAL 326
INSTALLATION 326
REAR SIDE MARKER LAMP 326
REMOVAL 326
INSTALLATION 326
REPEATER LAMP – EXPORT 326
REMOVAL 326
INSTALLATION 327
TAIL LAMP 327
REMOVAL 327
INSTALLATION 327
TAIL LAMP UNIT 327
REMOVAL 327
INSTALLATION 327
8n-POWER SYSTEMS 328
POWER LOCKS 328
DESCRIPTION 328
POWER LOCKS 328
DOOR ENTRY INHIBIT 328
DOOR EXIT 329
REMOTE KEYLESS ENTRY 329
OPERATION 329
DOOR ENTRY 329
DOOR EXIT 329
DOOR LOCK SWITCH 329
DOOR LOCK INHIBIT 329
AUTOMATIC DOOR LOCKS 329
KEY CYLINDER FUNCTION 329
REMOTE KEYLESS ENTRY 330
DIAGNOSIS AND TESTING – POWER LOCKS 330
DOOR CYLINDER UNLOCK SWITCH 330
DIAGNOSIS AND TESTING – DOOR CYLINDER UNLOCK SWITCH 330
EXTERIOR DOOR HANDLE SWITCH 330
DIAGNOSIS AND TESTING – EXTERIOR DOOR HANDLE SWITCH 330
INTERIOR DOOR HANDLE SWITCH 330
DIAGNOSIS AND TESTING – INTERIOR DOOR HANDLE SWITCH 330
POWER LOCK SWITCH 331
DIAGNOSIS AND TESTING – POWER LOCK SWITCH 331
REMOVAL 331
INSTALLATION 331
REMOTE KEYLESS ENTRY MODULE 331
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY MODULE 331
REMOVAL 331
INSTALLATION 332
REMOTE KEYLESS ENTRY TRANSMITTER 332
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY TRANSMITTER 332
STANDARD PROCEDURE 332
STANDARD PROCEDURE – RKE TRANSMITTER BATTERIES 332
STANDARD PROCEDURE – RKE TRANSMITTER CUSTOMER PREFERENCES 332
AUTOMATIC (ROLLING) LOCKS 332
HORN CHIRP DISABLING / ENABLING 332
OPTICAL CHIRP (FLASH) DISABLING / ENABLING 332
UNLOCK SEQUENCE 333
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMING 333
STANDARD PROCEDURE – TRANSMITTER SYNCHRONIZATION 333
SPECIFICATIONS – REMOTE KEYLESS ENTRY TRANSMITTER 333
RANGE 333
POWER MIRRORS 334
DESCRIPTION 334
OPERATION 334
DIAGNOSIS AND TESTING – POWER MIRRORS 334
POWER MIRROR SWITCH 334
DIAGNOSIS AND TESTING – POWER MIRROR SWITCH 334
REMOVAL 335
INSTALLATION 335
SIDEVIEW MIRROR 335
DESCRIPTION 335
OPERATION 335
POWER WINDOWS 336
DESCRIPTION 336
OPERATION 336
POWER WINDOWS 336
SMART GLASS FEATURE 336
DIAGNOSIS AND TESTING – POWER WINDOWS 336
POWER WINDOW SWITCH 337
DESCRIPTION 337
OPERATION 337
DIAGNOSIS AND TESTING – POWER WINDOW SWITCH 337
REMOVAL 337
INSTALLATION 337
WINDOW MOTOR 337
DESCRIPTION 337
OPERATION 338
DIAGNOSIS AND TESTING – WINDOW MOTOR 338
8o-RESTRAINTS 340
RESTRAINTS 341
WARNING 341
AIRBAG SYSTEM0 – 4 ZB (Continued) 341
CHILD RESTRAINTS 341
AIRBAG/TENSIONER DISPOSAL 341
DIAGNOSIS AND TESTING – AIRBAG SYSTEM 341
STANDARD PROCEDURE 342
STANDARD PROCEDURE – HANDLING AIRBAGS 342
DEPLOYED AIRBAG 342
UNDEPLOYED AIRBAG 342
STANDARD PROCEDURE – SERVICE AFTER AN AIRBAG DEPLOYMENT 342
DRIVER AIRBAG 342
PASSENGER AIRBAG 342
SEAT BELTS AND TENSIONERS 342
CLEAN UP PROCEDURE 342
CHILD TETHER 342
REMOVAL 342
INSTALLATION 343
CLOCKSPRING 343
DESCRIPTION 343
OPERATION 343
STANDARD PROCEDURE – CLOCK SPRING CENTERING 343
REMOVAL 344
INSTALLATION 344
DRIVER AIRBAG 345
DESCRIPTION 345
OPERATION 345
REMOVAL 345
INSTALLATION 345
OCCUPANT RESTRAINT CONTROLLER 345
DESCRIPTION 345
OPERATION 346
REMOVAL 346
INSTALLATION 347
PASSENGER AIRBAG 347
DESCRIPTION 347
OPERATION 347
REMOVAL 348
INSTALLATION 349
PASSENGER AIRBAG ON / OFF SWITCH 350
DESCRIPTION 350
OPERATION 350
REMOVAL 350
INSTALLATION 351
SEAT BELT & RETRACTOR 351
REMOVAL 351
INSTALLATION 351
SEAT BELT BUCKLE 352
REMOVAL 352
INSTALLATION 352
SEAT BELT SWITCH 353
DESCRIPTION 353
OPERATION 353
SEAT BELT TENSIONER 353
DESCRIPTION 353
OPERATION 353
8q-VEHICLE THEFT SECURITY 356
VEHICLE THEFT SECURITY 356
DESCRIPTION 356
OPERATION 356
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY 357
HOOD AJAR SWITCH 357
REMOVAL 357
INSTALLATION 357
VTSS DISARM SWITCH 357
DESCRIPTION 357
OPERATION 357
VTSS INDICATOR 357
DESCRIPTION 357
OPERATION 357
8r-WIPERS/WASHERS 358
WIPERS/WASHERS 358
DESCRIPTION 358
WIPER SYSTEM 358
WASHER SYSTEM 358
OPERATION 359
WIPER SYSTEM 359
WASHER SYSTEM 359
DIAGNOSIS AND TESTING – WIPERS/WASHERS 360
MOTOR WILL NOT OPERATE ALL SWITCH POSITIONS 360
MOTOR OPERATES SLOWLY AT ALL SPEEDS 360
WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION 360
WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION – WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION 361
WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION 361
WASHER SYSTEM DIAGNOSIS 361
WASHER HOSES / TUBES 362
REMOVAL 362
INSTALLATION 362
WASHER NOZZLE 362
REMOVAL 362
INSTALLATION 362
WASHER PUMP MOTOR 362
REMOVAL 362
INSTALLATION 362
WASHER RESERVOIR 362
REMOVAL 362
INSTALLATION 362
WIPER ARMS 362
REMOVAL 362
INSTALLATION 362
ADJUSTMENTS 363
ADJUSTMENT 363
WIPER BLADES 363
DESCRIPTION 363
OPERATION 363
REMOVAL 363
CLEANING 363
INSTALLATION 364
WIPER MODULE 364
REMOVAL 364
INSTALLATION 364
WIPER MOTOR 364
DIAGNOSIS AND TESTING – WIPER MOTOR 364
REMOVAL 365
INSTALLATION 365
WIPER/WASHER SWITCH 366
REMOVAL 366
INSTALLATION 366
HEADLAMP WASHERS – EXPORT 367
DESCRIPTION 367
OPERATION 367
DIAGNOSIS AND TESTING – HEADLAMP WASHERS – EXPORT 367
HEADLAMP WASHER HOSES / TUBES – EXPORT 369
REMOVAL 369
INSTALLATION 369
HEADLAMP WASHER NOZZLE – EXPORT 369
REMOVAL 369
REMOVAL – NOZZLE 369
REMOVAL – NOZZLE COVER 369
INSTALLATION 370
INSTALLATION – NOZZLE 370
INSTALLATION – NOZZLE COVER 370
HEADLAMP WASHER PUMP MOTOR – EXPORT 370
REMOVAL 370
INSTALLATION 370
WASHER PUMP MOTOR – EXPORT 371
REMOVAL 371
INSTALLATION 371
HEADLAMP WASHER RESERVOIR – EXPORT 371
REMOVAL 371
REMOVAL – LOWER RESERVOIR 371
REMOVAL – UPPER RESERVOIR 372
INSTALLATION 372
INSTALLATION – LOWER RESERVOIR 372
INSTALLATION – UPPER RESERVOIR 372
8w-WIRING 374
8W-01 WIRING DIAGRAM INFORMATION 376
WIRING DIAGRAM INFORMATION 376
DESCRIPTION 376
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 376
DESCRIPTION – CIRCUIT INFORMATION 380
DESCRIPTION – CIRCUIT FUNCTIONS 381
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 381
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 382
WARNINGS – GENERAL 382
DIAGNOSIS AND TESTING – WIRING HARNESS 382
STANDARD PROCEDURE 383
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 383
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 384
STANDARD PROCEDURE – TESTING FOR CONTINUITY 384
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 384
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 385
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 385
SPECIAL TOOLS 385
WIRING/TERMINAL 385
CONNECTOR 386
REMOVAL 386
INSTALLATION 386
DIODE 389
REMOVAL 389
INSTALLATION 389
TERMINAL 389
REMOVAL 389
INSTALLATION 389
WIRE 390
STANDARD PROCEDURE – WIRE SPLICING 390
8W-02 COMPONENT INDEX 392
8W-10 POWER DISTRIBUTION 394
8W-15 GROUND DISTRIBUTION 414
8W-18 BUS COMMUNICATIONS 426
8W-20 CHARGING SYSTEM 430
8W-21 STARTING SYSTEM 434
8W-30 FUEL/IGNITION SYSTEM 438
8W-35 ANTILOCK BRAKES 454
8W-39 VEHICLE THEFT SECURITY SYSTEM 458
8W-40 INSTRUMENT CLUSTER 464
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 472
8W-42 AIR CONDITIONING/HEATER 476
8W-43 OCCUPANT RESTRAINT SYSTEM 484
8W-44 INTERIOR LIGHTING 488
8W-45 BODY CONTROL MODULE 494
8W-47 AUDIO SYSTEM 512
8W-48 REAR WINDOW DEFOGGER 518
8W-50 FRONT LIGHTING 520
8W-51 REAR LIGHTING 526
8W-52 TURN SIGNALS 532
8W-53 WIPERS 536
8W-56 CONVENIENCE SYSTEMS 540
8W-60 POWER WINDOWS 542
8W-61 POWER DOOR LOCKS 546
8W-62 POWER MIRRORS 552
8W-70 SPLICE INFORMATION 554
8W-80 CONNECTOR PIN-OUTS 558
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 626
CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION 626
8W-97 POWER DISTRIBUTION 660
POWER DISTRIBUTION 660
DESCRIPTION 660
OPERATION 660
CIGAR LIGHTER OUTLET 660
REMOVAL 660
INSTALLATION 660
POWER DISTRIBUTION CENTER 660
REMOVAL 660
INSTALLATION 660
POWER OUTLET 661
REMOVAL 661
INSTALLATION 661
9-ENGINE 662
ENGINE – 8 3L 664
DESCRIPTION 664
Vehicle Identification Number 664
Engine Serial Number 664
DIAGNOSIS AND TESTING 664
INTRODUCTION 664
ENGINE DIAGNOSIS – PERFORMANCE 665
ENGINE DIAGNOSIS – MECHANICAL 666
CYLINDER COMPRESSION PRESSURE TEST 668
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 668
CYLINDER HEAD GASKET FAILURE DIAGNOSIS 669
CYLINDER-TO-CYLINDER LEAKAGE TEST 669
CYLINDER-TO-WATER JACKET LEAKAGE TEST 669
INTAKE MANIFOLD LEAKS 669
HYDRAULIC TAPPET NOISE DIAGNOSIS 670
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS 670
OIL LEVEL TOO HIGH 670
OIL LEVEL TOO LOW 670
VALVE TRAIN NOISE DIAGNOSIS 670
ENGINE OIL LEAK INSPECTION 670
INSPECTION FOR REAR SEAL AREA LEAKS 671
STANDARD PROCEDURE 671
ENGINE CORE AND OIL GALLERY PLUGS 671
FORM-IN-PLACE GASKETS AND SEALERS 671
FORM-IN-PLACE GASKET AND SEALER APPLICATION 672
ENGINE GASKET SURFACE PREPARATION 673
HYDROSTATIC LOCKED ENGINE 673
REMOVAL – ENGINE ASSEMBLY 673
INSTALLATION – ENGINE ASSEMBLY 677
SPECIFICATIONS 678
ENGINE 678
TORQUE 681
SPECIAL TOOLS 682
ENGINE 682
AIR CLEANER ELEMENT 685
REMOVAL 685
INSTALLATION 685
AIR CLEANER HOUSING 686
REMOVAL 686
INSTALLATION 686
ENGINE MOUNTS 687
REMOVAL 687
INSTALLATION 687
INTAKE MANIFOLD 688
REMOVAL 688
INSPECTION 690
INSTALLATION 690
EXHAUST MANIFOLD 691
REMOVAL 691
INSPECTION 691
INSTALLATION 692
CYLINDER HEAD(S) 692
REMOVAL – CYLINDER HEAD(S) 692
CLEANING / INSPECTION 693
INSTALLATION – CYLINDER HEAD(S) 693
CYLINDER HEAD COVER(S) 694
REMOVAL 694
LEFT CYLINDER HEAD COVER 694
RIGHT CYLINDER HEAD COVER 694
INSTALLATION 695
LEFT CYLINDER HEAD COVER 695
RIGHT CYLINDER HEAD COVER 695
ROCKER ARMS 695
REMOVAL 695
INSTALLATION 696
VALVE SPRINGS/SEALS 696
DESCRIPTION 696
DIAGNOSIS AND TESTING 696
VALVE SPRING TESTING 696
STANDARD PROCEDURE – VALVE SPRING/SEAL SERVICE IN-CAR 697
REMOVAL 698
INSTALLATION 698
INTAKE/EXHAUST – VALVES/SEATS/GUIDES 699
STANDARD PROCEDURE – VALVE AND VALVE SEAT – REFACING 699
VALVE SEATS 699
INSPECTION 700
Valve 700
Valve Guide 700
INSTALLATION 782
FUEL RAIL 783
OPERATION 783
REMOVAL 783
INSTALLATION 785
FUEL TANK 785
OPERATION 785
STANDARD PROCEDURE – FUEL TANK CLOSEOUT PANEL 786
INSTALLATION 786
REMOVAL 786
INSTALLATION 794
FUEL FILLER TUBE 795
REMOVAL 795
INSTALLATION 795
FUEL PUMP INLET STRAINER 795
DESCRIPTION 795
QUICK CONNECT FITTING 795
STANDARD PROCEDURE – QUICK-CONNECT FITTINGS 795
REMOVAL 795
INSTALLATION 795
TWO-TAB TYPE FITTING 796
PLASTIC RETAINER RING TYPE FITTING 797
PRESSURE VACUUM FILLER CAP 797
DESCRIPTION 797
OPERATION 797
FUEL INJECTION 798
OPERATION 798
OPERATION – INJECTION SYSTEM 798
OPERATION – MODES OF OPERATION 799
IGNITION SWITCH ON (ZERO RPM) MODE 799
ENGINE START-UP MODE 799
ENGINE WARM-UP MODE 800
CRUISE OR IDLE MODE 800
ACCELERATION MODE 800
DECELERATION MODE 800
WIDE-OPEN-THROTTLE MODE 801
IGNITION SWITCH OFF MODE 801
FUEL CORRECTION or ADAPTIVE MEMORIES 801
DESCRIPTION 801
OPERATION 801
SPECIFICATIONS 802
TORQUE 802
SPECIAL TOOLS 803
FUEL 803
ACCELERATOR PEDAL 803
DESCRIPTION 803
REMOVAL 803
CRANKSHAFT POSITION SENSOR 804
DESCRIPTION 804
OPERATION 804
REMOVAL 804
INSTALLATION 804
FUEL INJECTORS 804
DESCRIPTION 804
OPERATION 805
REMOVAL 805
INSTALLATION 807
FUEL PUMP RELAY 807
DESCRIPTION 807
OPERATION 807
IDLE AIR CONTROL MOTOR 807
DESCRIPTION 807
OPERATION 808
REMOVAL 808
INSTALLATION 808
INLET AIR TEMPERATURE SENSOR 808
DESCRIPTION 808
REMOVAL 808
INSTALLATION 808
MAP SENSOR 809
DESCRIPTION 809
OPERATION 809
REMOVAL 810
INSTALLATION 810
O2 SENSOR 810
DESCRIPTION 810
OPERATION 810
UPSTREAM OXYGEN SENSOR 811
DOWNSTREAM OXYGEN SENSOR 811
REMOVAL 811
8 3L – UPSTREAM 1/1, 2/1 811
8 3L – DOWNSTREAM 1/2, 2/2 811
INSTALLATION 811
8 3L – UPSTREAM 1/1, 2/1 811
8 3L – DOWNSTREAM 1/2, 2/2 811
THROTTLE BODY 812
DESCRIPTION 812
OPERATION 812
REMOVAL 812
INSTALLATION 813
THROTTLE CABLE 813
REMOVAL 813
INSTALLATION 814
THROTTLE POSITION SENSOR 814
DESCRIPTION 814
OPERATION 814
REMOVAL 814
INSTALLATION 815
19-STEERING 816
STEERING 816
WARNINGS AND CAUTIONS 816
DIAGNOSIS AND TESTING 816
DIAGNOSIS AND TESTING – HYDRAULIC FLOW AND PRESSURE 816
FLOW AND PRESSURE TEST – AT POWER STEERING PUMP 816
FLOW AND PRESSURE TEST – AT POWER STEERING GEAR 817
DIAGNOSIS AND TESTING – STEERING SYSTEM DIAGNOSIS CHARTS 818
POWER STEERING NOISE 818
STEERING WHEEL FEEL 820
POWER STEERING FLUID 823
SPECIFICATIONS 823
POWER STEERING FASTENER TORQUE 823
SPECIAL TOOLS 824
POWER STEERING 824
COLUMN 825
WARNINGS AND CAUTIONS 825
REMOVAL 826
INSTALLATION 828
SPECIFICATIONS 830
STEERING COLUMN FASTENER TORQUE 830
IGNITION SWITCH 830
REMOVAL 830
INSTALLATION 831
START BUTTON 832
REMOVAL 832
INSTALLATION 832
INTERMEDIATE SHAFT 832
DIAGNOSIS AND TESTING – STEERING COLUMN INTERMEDIATE SHAFT 832
REMOVAL 832
INSTALLATION 833
INTERMEDIATE SHAFT – EXTENSION 833
DIAGNOSIS AND TESTING – STEERING COLUMN INTERMEDIATE SHAFT – EXTENSION 833
REMOVAL 833
INSTALLATION 833
STEERING WHEEL 834
REMOVAL 834
INSTALLATION 835
GEAR 837
REMOVAL 837
INSTALLATION 838
TIE ROD – OUTER 839
REMOVAL 839
INSTALLATION 840
21-TRANSMISSION/TRANSAXLE 852
MANUAL TRANSMISSION – T56 852
DESCRIPTION 852
IDENTIFICATION 852
OPERATION 853
NEUTRAL 853
1ST GEAR 853
2ND GEAR 853
3RD GEAR 853
4TH GEAR 853
5TH GEAR 853
6TH GEAR 853
REVERSE 854
DIAGNOSIS AND TESTING – MANUAL TRANSMISSION 854
LOW LUBRICANT LEVEL 854
HARD SHIFTING 855
TRANSMISSION NOISE 855
STANDARD PROCEDURE – DRAIN AND FILL 855
REMOVAL 855
DISASSEMBLY 856
MAINSHAFT 865
COUNTERSHAFT 868
INPUT SHAFT 868
EXTENSION HOUSING 869
TRANSMISSION CASE 870
TRANSMISSION ADAPTER 871
CLEANING 871
INSPECTION 871
ASSEMBLY 871
TRANSMISSION ADAPTER 871
TRANSMISSION CASE 872
EXTENSION HOUSING 873
INPUT SHAFT 873
COUNTERSHAFT 873
MAINSHAFT 875
TRANSMISSION HOUSING 877
INSTALLATION 885
ADJUSTMENTS 885
ADUSTMENTS 885
MAINSHAFT BEARINGS PRELOAD 885
COUNTERSHAFT BEARINGS PRELOAD 886
SPECIFICATIONS 887
SPECIAL TOOLS 887
EXTENSION HOUSING SEAL 887
REMOVAL 887
INSTALLATION 887
INPUT SHAFT 888
REMOVAL 888
INSTALLATION 889
REVERSE LOCKOUT SOLENOID 889
DESCRIPTION 889
OPERATION 889
SHIFT MECHANISM 890
REMOVAL0 – 8 ZB (Continued) 890
INSTALLATION 890
SKIP SHIFT SOLENOID 890
DESCRIPTION 890
OPERATION 890
22-TIRES/WHEELS 892
TIRES/WHEELS 892
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 892
METHOD 1 (RELOCATE WHEEL ON HUB) 892
METHOD 2 (RELOCATE TIRE ON WHEEL) 893
STANDARD PROCEDURE 894
TIRE AND WHEEL BALANCE 894
TIRE AND WHEEL MATCH MOUNTING 894
REMOVAL – TIRE AND WHEEL ASSEMBLY 897
INSTALLATION – TIRE AND WHEEL ASSEMBLY 897
TIRE PRESSURE MONITORING (TPM) 897
DESCRIPTION 897
OPERATION 897
POWER UP INITIALIZATION 897
TIRE DIAGNOSTIC FAULT 898
TIRE LOW PRESSURE 898
TIRE CRITICAL PRESSURE 898
DIAGNOSIS AND TESTING – TIRE PRESSURE MONITORING SYSTEM 898
SPECIFICATIONS 898
TIRE PRESSURE MONITORING SYSTEM 898
MODULE – TPM 898
DESCRIPTION 898
OPERATION 899
STANDARD PROCEDURE – TPM MODULE PROGRAMMING 899
REMOVAL 899
INSTALLATION 899
SENSOR – TPM 900
DESCRIPTION 900
VALVE STEM CORE AND CAP 900
OPERATION 900
REMOVAL 901
INSTALLATION 902
TIRES 903
DESCRIPTION – TIRES 903
DIAGNOSIS AND TESTING 904
TIRE NOISE AND VIBRATION 904
TIRE TREAD WEAR INDICATORS 904
TIRE TREAD WEAR PATTERNS 904
TIRE/VEHICLE LEAD 905
STANDARD PROCEDURE 907
TIRE INFLATION PRESSURES 907
TIRE PRESSURE FOR HIGH SPEED OPERATION 907
TIRE LEAK REPAIRING 907
SPECIFICATIONS 908
TIRES 908
WHEELS 908
DESCRIPTION – WHEEL 908
DIAGNOSIS AND TESTING – WHEEL INSPECTION 908
CLEANING – ALUMINUM WHEEL CARE 909
SPECIFICATIONS 909
WHEELS 909
WHEEL MOUNTING STUDS – FRONT 909
REMOVAL 909
INSTALLATION 910
WHEEL MOUNTING STUDS – REAR 910
REMOVAL 910
INSTALLATION 910
23-BODY 912
BODY 912
WARNING 912
SAFETY PRECAUTIONS AND WARNINGS 912
DIAGNOSIS AND TESTING 912
WATER LEAKS 912
VISUAL INSPECTION BEFORE WATER LEAK TESTS 913
WATER LEAK TESTS 913
WATER LEAK DETECTION 913
WIND NOISE 913
VISUAL INSPECTION BEFORE TESTS 913
STANDARD PROCEDURE 914
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 914
Rigid Plastics: 914
Semi-Rigid Plastics: 914
Flexible Plastics: 914
Repair Procedure: 914
Adhesion Promoter/Surface Modifier: 914
SAFETY PRECAUTION AND WARNINGS 914
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 915
PANEL SECTIONING 917
PANEL REINFORCEMENT 917
VISUAL INSPECTION 918
PANEL SURFACE PREPARATION 918
PATCHING PANELS 918
PANEL PATCH FABRICATIONS 918
PANEL PATCH INSTALLATION 919
PATCHED PANEL SURFACING 921
STANDARD PROCEDURE – HEAT STAKING 921
SPECIFICATIONS 921
BODY PANELS AND MATERIALS 921
BODY LUBRICATION 921
LUBRICATION REQUIREMENTS 921
LUBRICANT APPLICATION 921
LUBRICANT USAGE – BODY 922
SPECIFICATIONS – TORQUE 922
SPECIAL TOOLS 923
BODY 923
CONVERTIBLE TOP 924
DESCRIPTION 924
FOLDING TOP COVER 926
REMOVAL 926
INSTALLATION 926
FOLDING TOP – ASSEMBLY 927
REMOVAL 927
INSTALLATION 927
REAR WINDOW 928
REMOVAL 928
INSTALLATION 928
STAY PADS – STRAPS 928
REMOVAL 928
INSTALLATION 929
BOW – CENTER/3 929
REMOVAL 929
INSTALLATION 929
BOW – REAR/4 929
REMOVAL 929
INSTALLATION 929
CLOTH SUPPORT PANEL 930
REMOVAL 930
INSTALLATION 930
HEADER ASSEMBLY 930
REMOVAL 930
INSTALLATION 930
TACK STRIP 930
REMOVAL 930
INSTALLATION 930
TENSION CABLE 931
REMOVAL 931
INSTALLATION 932
LATCH 932
REMOVAL 932
INSTALLATION 932
HINGE – SIDEARM/LINKAGE ASSEMBLY 932
REMOVAL 932
INSTALLATION 932
DECKLID 934
GAS PROP 934
REMOVAL 934
INSTALLATION 934
HINGE 934
REMOVAL 934
INSTALLATION 934
LATCH 936
REMOVAL 936
INSTALLATION 936
LATCH STRIKER 936
REMOVAL 936
INSTALLATION 936
LOCK CYLINDER 937
REMOVAL 937
INSTALLATION 937
SLAM BUMPER 937
REMOVAL 937
INSTALLATION 937
DOOR – FRONT 938
DOOR 938
REMOVAL 938
INSTALLATION 938
ADJUSTMENTS 939
ADJUSTMENT 939
FORE/AFT 939
UP/DOWN 939
IN/OUT 939
DOOR GLASS 940
REMOVAL 940
INSTALLATION 940
ADJUSTMENTS 940
ADJUSTMENT 940
940
UP/DOWN AND FORE/AFT ADJUSTMENTS 941
DOOR GLASS ALIGNMENT VERIFICATION 942
OUTSIDE DOOR HANDLE 942
REMOVAL 942
INSTALLATION 943
HINGE 943
REMOVAL 943
INSTALLATION 943
LOCK CYLINDER 944
REMOVAL 944
INSTALLATION 944
LATCH 944
REMOVAL 944
INSTALLATION 945
LATCH STRIKER 945
REMOVAL 945
INSTALLATION 945
TRIM PANEL 946
REMOVAL 946
INSTALLATION 946
WINDOW REGULATOR 948
REMOVAL 948
INSTALLATION 949
HINGE COVER – EXPORT 949
REMOVAL 949
INSTALLATION 949
EXTERIOR 950
BELLY PAN 950
REMOVAL 950
REMOVAL 950
REMOVAL – FRONT EXTENSION BELLY PAN 950
REMOVAL – REAR EXTENSION BELLY PAN 952
INSTALLATION 952
INSTALLATION – BELLY PAN 952
INSTALLATION – FRONT EXTENSION BELLY PAN 952
INSTALLATION – REAR EXTENSION BELLY PAN 952
COWL SCREEN PANEL 952
REMOVAL 952
INSTALLATION 952
FUEL FILL DOOR 953
REMOVAL 953
INSTALLATION 953
FUEL FILLER HOUSING 953
REMOVAL 953
INSTALLATION 953
FRONT WHEELHOUSE SPLASH SHIELD 953
REMOVAL 953
INSTALLATION 954
REAR QUARTER PANEL 954
REMOVAL 954
INSTALLATION 954
REAR WHEELHOUSE SPLASH SHIELD 957
REMOVAL 957
INSTALLATION 957
SILL PANEL 957
REMOVAL 957
INSTALLATION 958
SILL PANEL – EXPORT 959
REMOVAL 959
INSTALLATION 959
SIDE VIEW MIRROR 961
REMOVAL 961
INSTALLATION 961
GLASS-OUTSIDE REARVIEW MIRROR 961
REMOVAL 961
INSTALLATION 961
TRUNK PAN 962
REMOVAL 962
INSTALLATION 962
FRONT FENDER 963
REMOVAL 963
Fender 963
Fender Support 964
INSTALLATION 965
Fender Support 965
Fender 965
FRONT FENDER – EXPORT 966
REMOVAL 966
Fender 966
Fender Support 966
INSTALLATION 967
Fender Support 967
Fender 968
FRONT STRUT TOWER TO TOWER BRACE 968
REMOVAL 968
INSTALLATION 968
HOOD 970
ADJUSTMENT BUMPER 970
REMOVAL 970
INSTALLATION 970
HINGE 970
REMOVAL 970
INSTALLATION 970
REMOVAL 971
INSTALLATION 971
ADJUSTMENTS 971
ADJUSTMENT 971
HOOD AIR CLEANER SEAL 971
REMOVAL 971
INSTALLATION 971
HOOD LATCH AND SAFETY CATCH 971
REMOVAL 971
INSTALLATION 972
LATCH RELEASE HANDLE 972
REMOVAL 972
INSTALLATION 972
SILENCER PAD 973
REMOVAL 973
INSTALLATION 973
GAS PROP 974
REMOVAL 974
INSTALLATION 974
INSTRUMENT PANEL 975
CLUSTER BEZEL 975
REMOVAL 975
INSTALLATION 975
GLOVE BOX 975
REMOVAL 975
INSTALLATION 976
GLOVE BOX LATCH STRIKER 976
REMOVAL 976
INSTALLATION 976
INSTRUMENT PANEL RIGHT LOWER TRIM 976
REMOVAL 976
INSTALLATION 976
INSTRUMENT PANEL CENTER BEZEL 976
REMOVAL 976
INSTALLATION 977
INSTRUMENT PANEL STEERING COLUMN COVER 977
REMOVAL 977
INSTALLATION 977
INSTRUMENT PANEL & PAD ASSEMBLY 977
REMOVAL 977
INSTALLATION 980
INSTRUMENT PANEL COVER/PAD 982
REMOVAL 982
INSTALLATION 982
INTERIOR 983
A-PILLAR TRIM 983
REMOVAL 983
INSTALLATION 983
BULKHEAD QUARTER TRIM PANEL 983
REMOVAL 983
INSTALLATION 984
CARPETS 985
REMOVAL 985
Floor Carpets 985
Top Stack Carpet 985
INSTALLATION 985
Floor Carpets 985
Top Stack Carpet 985
CENTER CONSOLE BEZEL 986
REMOVAL 986
INSTALLATION 986
DOOR SURROUND PANEL 987
REMOVAL 987
INSTALLATION 987
REAR VIEW MIRROR 987
REMOVAL 987
INSTALLATION 987
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKET 987
SIDE COWL TRIM 988
REMOVAL 988
INSTALLATION 988
SPORT HOOP 988
REMOVAL 988
Sport Hoop 988
Sport Hoop Mounting Brackets 989
INSTALLATION 989
Sport Hoop Mounting Brackets 989
Sport Hoop 989
SUN VISOR 989
REMOVAL 989
INSTALLATION 990
FRONT TUNNEL CONSOLE 990
REMOVAL0 – 10 ZB (Continued) 990
INSTALLATION 990
PAINT 991
SPECIFICATIONS – PAINT CODES 991
PAINT CODE 991
DESCRIPTION 991
BASE COAT/CLEAR COAT FINISH 991
DESCRIPTION 991
PAINT TOUCH-UP 992
DESCRIPTION 992
TOUCH UP PROCEDURE 992
FINESSE SANDING/BUFFING & POLISHING 992
DESCRIPTION 992
SEATS 993
SEAT 993
REMOVAL 993
INSTALLATION 993
SEAT ADJUSTERS 994
REMOVAL 994
INSTALLATION 994
SEAT BACK 995
REMOVAL 995
INSTALLATION 995
SEAT BACK COVER 995
REMOVAL 995
INSTALLATION 996
SEAT BACK RECLINER 996
REMOVAL 996
INSTALLATION 997
SEAT CUSHION ASSEMBLY 997
REMOVAL 997
INSTALLATION 998
SEAT CUSHION COVER 998
REMOVAL 998
INSTALLATION 998
STATIONARY GLASS 999
WINDSHIELD 999
WARNING 999
WINDSHIELD SAFETY PRECAUTIONS 999
REMOVAL 999
INSTALLATION 1000
WEATHERSTRIP/SEALS 1002
DOOR INNER BELT WEATHERSTRIP 1002
REMOVAL 1002
INSTALLATION 1002
DOOR OPENING PRIMARY SEAL WEATHERSTRIP 1002
REMOVAL 1002
INSTALLATION 1002
DOOR OUTER BELT WEATHERSTRIP 1003
REMOVAL 1003
INSTALLATION 1003
DOOR SECONDARY SEAL WEATHERSTRIP 1003
REMOVAL 1003
INSTALLATION 1003
WINDSHIELD HEADER & A-PILLAR WEATHERSTRIP 1003
REMOVAL 1003
INSTALLATION 1003
SIDE RAIL WEATHERSTRIP 1003
REMOVAL 1003
INSTALLATION 1003
DECKLID OPENING WEATHERSTRIP 1004
REMOVAL 1004
INSTALLATION 1004
24-HEATING & AIR CONDITIONING 1030
HEATING & AIR CONDITIONING 1030
DESCRIPTION 1030
OPERATION 1031
DIAGNOSIS AND TESTING 1031
A/C PERFORMANCE 1031
A/C PERFORMANCE TEST 1032
HEATER PERFORMANCE 1035
SPECIFICATIONS 1036
HEATING-A/C SYSTEM 1036
CONTROLS 1038
A/C COMPRESSOR CLUTCH 1038
DESCRIPTION 1038
OPERATION 1038
DIAGNOSIS AND TESTING 1039
A/C COMPRESSOR CLUTCH COIL 1039
STANDARD PROCEDURE 1040
A/C CLUTCH INSPECTION 1040
A/C CLUTCH BREAK-IN 1040
REMOVAL 1040
INSTALLATION 1042
A/C COMPRESSOR CLUTCH RELAY 1043
DESCRIPTION 1043
OPERATION 1043
REMOVAL 1043
INSTALLATION 1043
A/C HEATER CONTROL 1044
DESCRIPTION 1044
REMOVAL 1044
INSTALLATION 1044
A/C LOW PRESSURE SWITCH 1045
DESCRIPTION 1045
OPERATION 1045
DIAGNOSIS AND TESTING 1045
A/C LOW PRESSURE SWITCH 1045
REMOVAL 1045
INSTALLATION 1046
A/C PRESSURE TRANSDUCER 1046
DESCRIPTION 1046
OPERATION 1046
DIAGNOSIS AND TESTING 1047
A/C PRESSURE TRANSDUCER 1047
REMOVAL 1047
INSTALLATION 1047
BLEND DOOR ACTUATOR 1048
DESCRIPTION 1048
OPERATION 1048
REMOVAL 1048
INSTALLATION 1049
BLOWER MOTOR RELAY 1049
DESCRIPTION 1049
OPERATION 1049
REMOVAL 1050
INSTALLATION 1050
BLOWER MOTOR RESISTOR BLOCK 1050
DESCRIPTION 1050
OPERATION 1050
DIAGNOSIS AND TESTING 1051
BLOWER MOTOR RESISTOR 1051
REMOVAL 1051
INSTALLATION 1052
MODE DOOR ACTUATORS 1052
DESCRIPTION 1052
OPERATION 1052
REMOVAL 1052
INSTALLATION 1053
RECIRCULATION DOOR ACTUATOR 1053
DESCRIPTION 1053
OPERATION 1053
REMOVAL 1054
INSTALLATION 1054
DISTRIBUTION 1055
AIR OUTLETS 1055
DESCRIPTION 1055
REMOVAL 1055
INSTALLATION 1055
BLOWER MOTOR 1056
DESCRIPTION 1056
OPERATION 1056
DIAGNOSIS AND TESTING 1056
BLOWER MOTOR 1056
REMOVAL 1057
INSTALLATION 1057
DEFROSTER DUCTS 1057
REMOVAL 1057
INSTALLATION 1058
FLOOR DISTRIBUTION DUCT 1059
REMOVAL 1059
INSTALLATION 1059
HVAC HOUSING 1059
REMOVAL 1059
DISASSEMBLY 1060
ASSEMBLY 1061
INSTALLATION 1061
INSTRUMENT PANEL DUCTS 1062
REMOVAL 1062
INSTALLATION 1062
25-EMISSIONS CONTROL 1090
EMISSIONS CONTROL 1090
DESCRIPTION 1090
DESCRIPTION – MONITORED COMPONENT 1090
DESCRIPTION – VEHICLE EMISSION CONTROL INFORMATION LABEL 1093
DESCRIPTION – TRIP DEFINITION 1094
OPERATION – NON-MONITORED CIRCUITS 1094
DESCRIPTION – MONITORED SYSTEMS 1095
DESCRIPTION – HIGH AND LOW LIMITS 1097
OPERATION 1097
OPERATION – SYSTEM 1097
DRB III STATE DISPLAY TEST MODE 1098
OPERATION 1098
EVAPORATIVE EMISSIONS 1099
OPERATION – EVAPORATION CONTROL SYSTEM 1099
CCV SYSTEM 1099
DESCRIPTION 1099
OPERATION 1099
DIAGNOSIS AND TESTING – CRANKCASE VENTILATION SYSTEM 1100
TESTING/CLEANING 1100
EVAP/PURGE SOLENOID 1100
OPERATION 1100
REMOVAL 1101
INSTALLATION 1102
FUEL FILLER CAP 1102
DESCRIPTION 1102
OPERATION 1102
LEAK DETECTION PUMP 1102
REMOVAL 1102
INSTALLATION 1103
ORVR 1104
DESCRIPTION 1104
OPERATION 1104
VAPOR CANISTER 1105
DESCRIPTION 1105
OPERATION 1105
Purge Free Cells 1105
REMOVAL 1105
INSTALLATION 1106
INDEX 1112
COMMENTS 1114
2005-Viper Computer PCM pdf 1116
MAIN WELCOME PAGE 0
ZB SRT-10 BUX Service Manual 0
ZB SRT-10 BUX Body 0
ZB SRT-10 BUX Chassis 0
ZB SRT-10 BUX Powertrain 1116
TABLE OF CONTENTS 1116
1 0 INTRODUCTION 1122
1 1 SYSTEM COVERAGE 1122
1 2 SIX-STEP TROUBLE SHOOTING PROCEDURE 1122
2 0 IDENTIFICATION OF SYSTEM 1122
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1122
3 1 GENERAL DESCRIPTION 1122
3 2 FUNCTION OPERATION 1122
3 2 1 FUEL CONTROL 1122
3 2 2 ON-BOARD DIAGNOSTICS 1122
3 2 3 JTEC CONTROLLED REAR WHEEL DRIVE VEHICLES 1125
3 2 4 OTHER CONTROLS 1126
3 2 5 NON-MONITORED CIRCUITS 1130
3 3 DIAGNOSTIC TROUBLE CODES 1131
3 3 1 HARD CODE 1131
3 3 2 INTERMITTENT CODE 1131
3 3 3 STARTS SINCE SET COUNTER 1131
3 3 4 NO START INFORMATION 1131
3 4 USING THE DRBIII 1132
3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN 1132
3 5 1 DRBIII DOES NOT POWER UP 1132
3 5 2 DISPLAY IS NOT VISIBLE 1132
4 0 DISCLAIMERS, SAFETY, WARNINGS 1132
4 1 DISCLAIMERS 1132
4 2 SAFETY 1133
4 2 1 TECHNICIAN SAFETY INFORMATION 1133
4 2 2 VEHICLE PREPARATION FOR TESTING 1133
4 2 3 SERVICING SUB-ASSEMBLIES 1133
4 2 4 DRBIII SAFETY INFORMATION 1133
4 3 WARNINGS AND CAUTIONS 1133
4 3 1 ROAD TEST WARNINGS 1133
4 3 2 VEHICLE DAMAGE CAUTIONS 1134
5 0 REQUIRED TOOLS AND EQUIPMENT 1134
6 0 ACRONYMS 1134
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 1136
COMMUNICATION 1137
*NO RESPONSE FROM PCM (PCI BUS) 1137
*NO RESPONSE FROM PCM (SCI ONLY) 1138
*PCI BUS COMMUNICATION FAILURE 1141
DRIVEABILITY – GAS 1143
INTERMITTENT CONDITION 1143
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW 1144
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH 1144
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW 1144
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH 1144
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE 1147
P0107-MAP SENSOR VOLTAGE TOO LOW 1150
P0108-MAP SENSOR VOLTAGE TOO HIGH 1152
P0111-INTAKE AIR TEMP PERFORMANCE 1154
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW 1156
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH 1158
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW 1160
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH 1162
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP 1164
P0122-THROTTLE POSITION SENSOR #1 VOLTAGE TOO LOW 1169
P0123-THROTTLE POSITION SENSOR #1 VOLTAGE TOO HIGH 1172
P0125-CLOSED LOOP TEMP NOT REACHED 1175
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO LOW 1177
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO LOW 1177
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO LOW 1177
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO LOW 1177
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE TOO HIGH 1180
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE TOO HIGH 1180
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE TOO HIGH 1180
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE TOO HIGH 1180
P0133-O2 SENSOR 1/1 SLOW RESPONSE 1184
P0139-O2 SENSOR 1/2 SLOW RESPONSE 1184
P0153-O2 SENSOR 2/1 SLOW RESPONSE 1184
P0159-O2 SENSOR 2/2 SLOW RESPONSE 1184
P0135-O2 SENSOR 1/1 HEATER FAILURE 1187
P0141-O2 SENSOR 1/2 HEATER FAILURE 1187
P0155-O2 SENSOR 2/1 HEATER FAILURE 1187
P0161-O2 SENSOR 2/2 HEATER FAILURE 1187
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION 1190
P0171-1/1 FUEL SYSTEM LEAN 1192
P0174-2/1 FUEL SYSTEM LEAN 1192
P0172-1/1 FUEL SYSTEM RICH 1197
P0175-2/1 FUEL SYSTEM RICH 1197
P0197-ENGINE OIL TEMPERATURE SENSOR VOLTAGE TOO LOW 1202
P0198-ENGINE OIL TEMPERATURE SENSOR VOLTAGE TOO HIGH 1204
P0201-INJECTOR #1 CONTROL CIRCUIT 1206
P0202-INJECTOR #2 CONTROL CIRCUIT 1206
P0203-INJECTOR #3 CONTROL CIRCUIT 1206
P0204-INJECTOR #4 CONTROL CIRCUIT 1206
P0205-INJECTOR #5 CONTROL CIRCUIT 1206
P0206-INJECTOR #6 CONTROL CIRCUIT 1206
P0207-INJECTOR #7 CONTROL CIRCUIT 1206
P0208-INJECTOR #8 CONTROL CIRCUIT 1206
P0209-INJECTOR #9 CONTROL CIRCUIT 1206
P0210-INJECTOR #10 CONTROL CIRCUIT 1206
P0300-MULTIPLE CYLINDER MIS-FIRE 1210
P0301-CYLINDER #1 MISFIRE 1210
P0302-CYLINDER #2 MISFIRE 1210
P0303-CYLINDER #3 MISFIRE 1210
P0304-CYLINDER #4 MISFIRE 1210
P0305-CYLINDER #5 MISFIRE 1210
P0306-CYLINDER #6 MISFIRE 1210
P0307-CYLINDER #7 MISFIRE 1210
P0308-CYLINDER #8 MISFIRE 1210
P0309-CYLINDER #9 MISFIRE 1210
P0310-CYLINDER #10 MISFIRE 1210
P0320-NO CRANK REFERENCE SIGNAL AT PCM 1218
P0340-NO CAM REFERENCE SIGNAL AT PCM 1222
P0351-IGNITION COIL #1 PRIMARY CIRCUIT 1226
P0352-IGNITION COIL #2 PRIMARY CIRCUIT 1226
P0353-IGNITION COIL #3 PRIMARY CIRCUIT 1226
P0354-IGNITION COIL #4 PRIMARY CIRCUIT 1226
P0355-IGNITION COIL #5 PRIMARY CIRCUIT 1226
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 1229
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY 1229
P0441-EVAP PURGE FLOW MONITOR 1231
P0442-EVAP LEAK MONITOR MEDIUM (0 040) LEAK DETECTED 1233
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 1233
P0443-EVAP PURGE SOLENOID CIRCUIT 1236
P0460-FUEL LEVEL SENDING UNIT NO CHANGE OVER MILES 1238
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW 1239
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH 1241
P0500-NO VEHICLE SPEED SIGNAL 1243
P0505-IDLE AIR CONTROL MOTOR CIRCUITS 1245
P0522-OIL PRESSURE CIRCUIT LOW 1247
P0523-OIL PRESSURE CIRCUIT HIGH 1249
P0601-PCM INTERNAL CONTROLLER FAILURE 1251
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 1252
P0645-A/C CLUTCH RELAY CIRCUIT 1254
P0801-REVERSE GEAR LOCKOUT CIRCUIT OPEN OR SHORTED 1256
P1195-O2 SENSOR 1/1 SLOW DURING CATALYST MONITOR 1258
P1196-O2 SENSOR 2/1 SLOW DURING CATALYST MONITOR 1258
P1281-ENGINE IS COLD TOO LONG 1260
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT 1261
P1294-TARGET IDLE NOT REACHED 1263
P1296-NO 5-VOLTS TO MAP SENSOR 1265
P1297-NO CHANGE IN MAP FROM START TO RUN 1267
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 1270
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 1272
P1391-INTERMITTENT LOSS OF CMP OR CKP 1274
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 1277
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 1280
P1492-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH 1282
P1493-AMBIENT/BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW 1284
P1494-LEAK DETECTION PUMP SWITCH OR MECHANICAL FAULT 1286
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 1288
P1499-HYDRAULIC FAN SOLENOID CIRCUIT 1290
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 1292
P1598-A/C PRESSURE SENSOR VOLTAGE TOO HIGH 1294
P1599-A/C PRESSURE SENSOR VOLTAGE TOO LOW 1296
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 1298
P1687-NO CLUSTER BUS MESSAGE 1301
P1695-BUS MESSAGE FROM BODY CONTROL MODULE 1302
P1696-PCM FAILURE EEPROM WRITE DENIED 1303
P1719-SKIP SHIFT SOLENOID CIRCUIT OPEN OR SHORTED 1305
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIII 1307
*CANNOT SHIFT INTO 2ND AND 3RD GEARS 1309
*CANNOT SHIFT INTO REVERSE 1310
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS 1311
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS 1314
*CHECKING RADIATOR FAN OPERATION 1317
*CHECKING THE PCM POWER AND GROUNDS 1318
STARTING 1319
*CHECKING FUEL DELIVERY 1319
*CHECKING HARD START (FUEL SYSTEM) 1322
*ENGINE CRANKS BUT DOES NOT START 1324
*FUEL PRESSURE LEAK DOWN 1326
*NO CRANK CONDITION 1327
*NO RESPONSE FROM PCM WITH A NO START CONDITION 1331
*START AND STALL CONDITION 1334
VERIFICATION TESTS 1336
VERIFICATION TESTS 1336
8 0 COMPONENT LOCATIONS 1342
8 1 CONTROL MODULES AND PDC 1342
8 2 DATA LINK CONNECTOR 1342
8 3 SENSORS AND SOLENOIDS 1342
8 4 FUEL SYSTEM 1344
9 0 CONNECTOR PINOUTS 1346
A/C COMPRESSOR CLUTCH – BLACK 2 WAY 1346
A/C LOW PRESSURE SWITCH – DK GREEN 2 WAY 1346
A/C PRESSURE TRANSDUCER – BLACK 4 WAY 1346
BATTERY TEMPERATURE SENSOR – 2 WAY 1346
BRAKE LAMP SWITCH – BLACK 6 WAY 1347
CAMSHAFT POSITION SENSOR – GRAY 3 WAY 1347
CLOCKSPRING – WHITE 8 WAY 1347
CLUTCH INTERLOCK SWITCH – DK GREEN 2 WAY 1347
CRANKSHAFT POSITION SENSOR – BLACK 3 WAY 1347
DATA LINK CONNECTOR – BLACK 16 WAY 1348
ENGINE COOLANT TEMPERATURE SENSOR – BLACK 2 WAY 1348
ENGINE OIL PRESSURE SENSOR – BLACK 3 WAY 1348
ENGINE OIL TEMPERATURE SENSOR – BLACK 2 WAY 1349
EVAP/PURGE SOLENOID – BLACK 2 WAY 1349
FUEL INJECTOR NO 1 – BLACK 2 WAY 1349
FUEL INJECTOR NO 2 – BLACK 2 WAY 1349
FUEL INJECTOR NO 3 – BLACK 2 WAY 1349
FUEL INJECTOR NO 4 – BLACK 2 WAY 1350
FUEL INJECTOR NO 5 – BLACK 2 WAY 1350
FUEL INJECTOR NO 6 – BLACK 2 WAY 1350
FUEL INJECTOR NO 7 – BLACK 2 WAY 1350
FUEL INJECTOR NO 8 – BLACK 2 WAY 1350
FUEL INJECTOR NO 9 – BLACK 2 WAY 1351
FUEL INJECTOR NO 10 – BLACK 2 WAY 1351
FUEL TANK MODULE – GRAY 4 WAY 1351
GENERATOR – GRAY 2 WAY 1351
HYDRAULIC COOLING MODULE – BLACK 3 WAY 1351
IDLE AIR CONTROL MOTOR – BLACK 4 WAY 1352
IGNITION COIL PACK-LEFT – BLACK 4 WAY 1352
IGNITION COIL PACK-RIGHT – BLACK 3 WAY 1352
IGNITION SWITCH – BLACK 5 WAY 1352
INTAKE AIR TEMPERATURE SENSOR – BLACK 2 WAY 1352
LEAK DETECTION PUMP – BLACK 4 WAY 1353
MANIFOLD ABSOLUTE PRESSURE SENSOR – BLACK 3 WAY 1353
MULTI-FUNCTION SWITCH – GRAY 20 WAY 1353
OXYGEN SENSOR 1/1 LEFT BANK UP – BLACK 4 WAY 1354
OXYGEN SENSOR 1/2 LEFT BANK DOWN – BLACK 4 WAY 1354
OXYGEN SENSOR 2/1 RIGHT BANK UP – BLACK 4 WAY 1354
OXYGEN SENSOR 2/2 RIGHT BANK DOWN – BLACK 4 WAY 1354
FUSES (PDC) 1356
A/C COMPRESSOR CLUTCH RELAY 1356
AUTO SHUT DOWN RELAY 1356
FUEL PUMP RELAY 1356
OXYGEN SENSOR HEATER RELAY 1357
RUN/ACC RELAY 1357
STARTER MOTOR RELAY 1357
POWERTRAIN CONTROL MODULE C1 – BLACK/BLACK 32 WAY 1358
POWERTRAIN CONTROL MODULE C2 – BLACK/WHITE 32 WAY 1359
POWERTRAIN CONTROL MODULE C3 – BLACK/GRAY 32 WAY 1360
PUSH-BUTTON STARTER SWITCH – NATURAL 6 WAY 1360
REVERSE LOCK-OUT SOLENOID – WHITE 2 WAY 1361
SKIP SHIFT SOLENOID – WHITE 2 WAY 1361
THROTTLE POSITION SENSOR – BLACK 3 WAY 1361
TIRE PRESSURE MONITOR MODULE – BLUE 6 WAY 1361
VTSS LED – BLACK 2 WAY 1361
10 0 SCHEMATIC DIAGRAMS 1362
11 0 CHARTS AND GRAPHS 1366
11 1 O2 SENSOR CONFIGURATION 1366
11 2 VACUUM READINGS 1367
11 3 CAM AND CRANK SENSORS PATTERNS 1367
11 4 EELD 1368
2005-Viper Body Systems pdf 1372
MAIN WELCOME PAGE 0
ZB SRT-10 BUX Service Manual 0
ZB SRT-10 BUX Powertrain 0
ZB SRT-10 BUX Chassis 0
ZB BUX Body 1372
TABLE OF CONTENTS 1372
1 0 INTRODUCTION 1382
1 1 SYSTEM COVERAGE 1382
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 1382
2 0 IDENTIFICATION OF SYSTEM 1382
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1382
3 1 AIRBAG SYSTEM 1383
3 1 1 DRIVER AIRBAG 1383
3 1 2 CLOCKSPRING 1385
3 1 3 PASSENGER AIRBAGS 1385
3 1 4 PASSENGER AIRBAG ON-OFF SWITCH 1386
3 1 5 SEAT BELT TENSIONER (SBT) 1386
3 1 6 SEAT BELT SWITCHES (SBS) 1386
3 1 7 SPECIAL TOOLS 1387
3 1 8 DIAGNOSTIC TROUBLE CODES 1387
3 1 8 1 ACTIVE CODES 1387
3 1 8 2 STORED CODES 1387
3 2 AUDIO SYSTEM 1388
3 2 1 REMOTE RADIO CONTROLS (IF EQUIPPED) 1388
3 3 BODY CONTROL MODULE 1388
3 3 1 BATTERY SAVE FEATURE 1389
3 3 1 1 CUSTOMER NORMAL OPERATING MODE 1389
3 3 1 2 SHIPPING OPERATING MODE 1389
3 4 CHIME WARNING SYSTEM 1389
3 4 1 CHIME PRIORITY 1390
3 4 2 CHIME ON CONDITIONS 1390
3 4 3 WARNING LAMP ANNOUNCEMENT 1390
3 4 4 OTHER CHIME ON CONDITIONS 1391
3 5 COMMUNICATION 1391
3 6 DOOR AJAR SYSTEM 1392
3 7 EXTERIOR LIGHTING SYSTEM 1392
3 7 1 HEADLAMP POWER 1392
3 7 2 HEADLAMP SWITCH 1392
3 7 3 PARK LAMP 1392
1392
3 7 5 FOG LAMPS 1392
3 7 6 EXTERIOR LIGHTING BATTERY SAVER 1392
3 8 RELAYS CONTROLLED BY THE BCM 1392
3 9 HEATING & A/C SYSTEM 1393
3 9 1 SYSTEM AVAILABILITY 1393
3 9 2 SYSTEM CONTROLS 1393
3 9 3 SYSTEM REVISIONS 1394
3 9 4 SYSTEM DIAGNOSTICS 1394
3 10 INSTRUMENT CLUSTER / GAUGE CLUSTER 1394
3 11 INTERIOR LIGHTING 1397
3 11 1 COURTESY LAMP CONTROL 1397
3 11 2 ILLUMINATED ENTRY 1397
3 11 3 INTERIOR LIGHTING BATTERY SAVER 1397
3 12 TIRE PRESSURE MONITORING SYSTEM (TPMS) 1398
3 12 1 TIRE PRESSURE MONITOR MODULE 1398
3 12 2 TIRE PRESSURE MONITOR MODULE MODES 1400
3 13 POWER DOOR ENTRY SYSTEM 1401
3 13 1 UNLATCH OUTPUT 1401
3 13 2 NEUTRAL RETURN OUTPUT 1401
3 13 3 DOOR LOCK INHIBIT 1401
3 13 4 AUTOMATIC DOOR LOCKS 1402
3 13 5 REMOTE KEYLESS ENTRY (RKE) 1402
3 14 POWER WINDOWS 1402
3 14 1 DRIVER WINDOW 1402
3 14 2 PASSENGER WINDOW 1402
3 15 ELECTRICALLY HEATED SYSTEMS 1403
3 16 VEHICLE THEFT SECURITY SYSTEM 1403
3 17 USING THE DRBIII 1403
3 18 DRBIII ERROR MESSAGES 1403
3 19 DRBIII DOES NOT POWER UP (BLANK SCREEN) 1403
3 20 DISPLAY IS NOT VISIBLE 1404
4 0 DISCLAIMERS, SAFETY, WARNINGS 1404
4 1 DISCLAIMERS 1404
4 2 SAFETY 1404
4 2 1 TECHNICIAN SAFETY INFORMATION 1404
4 2 2 VEHICLE PREPARATION FOR TESTING 1404
4 2 3 SERVICING SUB-ASSEMBLIES 1404
4 2 4 DRBIII SAFETY INFORMATION 1404
4 3 WARNINGS 1405
4 3 1 VEHICLE DAMAGE WARNINGS 1405
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 1405
5 0 REQUIRED TOOLS AND EQUIPMENT 1405
6 0 GLOSSARY OF TERMS 1405
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 1408
AIRBAG 1409
ACCELEROMETER 1 1409
ACCELEROMETER 2 1409
INTERNAL 1 1409
OUTPUT DRIVER 1 1409
STORED ENERGY FIRING 1 1409
AIRBAG WARNING INDICATOR OPEN 1411
AIRBAG WARNING INDICATOR SHORT 1411
CLUSTER MESSAGE MISMATCH 1413
DRIVER SEAT BELT SWITCH CIRCUIT OPEN 1415
DRIVER SEAT BELT SWITCH SHORT TO BATTERY 1417
DRIVER SEAT BELT SWITCH SHORT TO GROUND 1419
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN 1421
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT 1423
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY 1425
DRIVER SEAT BELT TENSIONER SHORT TO GROUND 1428
DRIVER SQUIB 1 CIRCUIT OPEN 1430
DRIVER SQUIB 1 CIRCUIT SHORT 1433
DRIVER SQUIB 1 SHORT TO BATTERY 1436
DRIVER SQUIB 1 SHORT TO GROUND 1439
DRIVER SQUIB 2 CIRCUIT OPEN 1442
DRIVER SQUIB 2 CIRCUIT SHORT 1445
DRIVER SQUIB 2 SHORT TO BATTERY 1448
DRIVER SQUIB 2 SHORT TO GROUND 1451
LOSS OF IGNITION RUN – START 1454
LOSS OF IGNITION RUN ONLY 1457
NO CLUSTER MESSAGE 1460
NO PCI TRANSMISSION 1462
PASSENGER AIRBAG ON – OFF SWITCH OPEN 1464
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO BATTERY 1466
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO GROUND 1469
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY 1472
PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND 1474
PASSENGER SEAT BELT SWITCH CIRCUIT OPEN 1478
PASSENGER SEAT BELT SWITCH SHORT TO BATTERY 1480
PASSENGER SEAT BELT SWITCH SHORT TO GROUND 1482
PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN 1484
PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT 1487
PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY 1489
PASSENGER SEAT BELT TENSIONER SHORT TO GROUND 1491
PASSENGER SQUIB 1 CIRCUIT OPEN 1493
PASSENGER SQUIB 1 CIRCUIT SHORT 1496
PASSENGER SQUIB 1 SHORT TO BATTERY 1499
PASSENGER SQUIB 1 SHORT TO GROUND 1502
PASSENGER SQUIB 2 CIRCUIT OPEN 1505
PASSENGER SQUIB 2 CIRCUIT SHORT 1508
PASSENGER SQUIB 2 SHORT TO BATTERY 1510
PASSENGER SQUIB 2 SHORT TO GROUND 1512
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 1514
AUDIO 1515
ALL OUTPUTS SHORT 1515
CD MECHANICAL FAILURE 1517
NO PCI TRANSMISSION 1517
*AM/FM SWITCH INOPERATIVE 1517
*ANY STATION PRESET SWITCH INOPERATIVE 1517
*BALANCE INOPERATIVE 1517
*CD EJECT SWITCH INOPERATIVE 1517
*EQUALIZER INOPERATIVE 1517
*FADER INOPERATIVE 1517
*FF/RW SWITCH INOPERATIVE 1517
*HOUR/MINUTE SWITCHES INOPERATIVE 1517
*PAUSE/PLAY SWITCH INOPERATIVE 1517
*PWR SWITCH INOPERATIVE 1517
*SCAN SWITCH INOPERATIVE 1517
*SEEK SWITCH INOPERATIVE 1517
*SET SWITCH INOPERATIVE 1517
*TAPE EJECT SWITCH INOPERATIVE 1517
*TIME SWITCH INOPERATIVE 1517
*TUNE SWITCH INOPERATIVE 1517
CD PLAY FAILURE 1518
CD READ FAILURE 1519
CD TEMPERATURE HIGH 1520
LOW VOLTAGE LEVEL 1521
NO ANTENNA CONNECTION 1522
NO COMMUNICATION WITH BCM 1523
CHIME 1524
*CHIME INOPERATIVE 1524
*KEY IN IGNITION AND DRIVER’S DOOR OPEN CHIME NOT OPERATING PROPERLY 1526
COMMUNICATION 1527
ACM MESSAGES NOT RECEIVED 1527
AUDIO MESSAGES NOT RECEIVED 1528
COUNTRY CODE NOT PROGRAMMED 1529
INTERNAL BCM FAILURE 1530
MIC MESSAGES NOT RECEIVED 1531
PCI BUS SHORTED TO BATTERY 1532
PCI BUS SHORTED TO GROUND 1532
PCI INTERNAL FAULT 1533
PCM MESSAGES NOT RECEIVED 1534
*NO RESPONSE FROM AIRBAG CONTROL MODULE 1535
*NO RESPONSE FROM BODY CONTROL MODULE 1537
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 1539
*NO RESPONSE FROM HVAC 1541
*NO RESPONSE FROM INSTRUMENT CLUSTER 1543
*NO RESPONSE FROM PCM (PCI BUS) 1546
*NO RESPONSE FROM PCM (SCI ONLY) 1547
*NO RESPONSE FROM RADIO 1550
*NO RESPONSE FROM TIRE PRESSURE MONITOR MODULE 1552
*PCI BUS COMMUNICATION FAILURE 1554
DOOR AJAR 1556
*DECKLID AJAR CIRCUIT OPEN 1556
*DECKLID AJAR CIRCUIT SHORTED TO GROUND 1557
*DRIVER DOOR AJAR CIRCUIT OPEN 1558
*DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND 1559
*HOOD AJAR CIRCUIT OPEN 1560
*HOOD AJAR CIRCUIT SHORTED TO GROUND 1561
*PASSENGER DOOR AJAR CIRCUIT OPEN 1562
*PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND 1563
ELECTRICALLY HEATED SYSTEMS 1564
DEFOG RELAY CONTROL CKT SHORTED TO BATT 1564
EXTERIOR LIGHTING 1566
LEFT FOG LAMP OUTPUT OPEN 1566
LEFT FOG LAMP OUTPUT SHORTED 1567
LEFT HIGH BEAM OUTPUT OPEN 1568
LEFT HIGH BEAM OUTPUT SHORT 1570
LOW BEAM RELAY COIL OUTPUT OPEN/SHORT TO GROUND 1572
LOW BEAM RELAY COIL SHORT TO VOLTAGE 1574
PARK LAMP OUTPUT SHORT 1575
REAR FOG RELAY OPEN/SHORT TO GROUND (EXPORT ONLY) 1576
REAR FOG RELAY SHORT TO BATTERY (EXPORT ONLY) 1578
RIGHT FOG LAMP OUTPUT OPEN 1579
RIGHT FOG LAMP OUTPUT SHORTED 1580
RIGHT HIGH BEAM OUTPUT OPEN 1581
RIGHT HIGH BEAM OUTPUT SHORT 1583
HEATING & A/C 1585
A/C SWITCH FAULT (ACTIVE) 1585
CHECKSUM FAILURE (ACTIVE) 1585
DEFOG SWITCH FAULT (ACTIVE) 1585
A/C SWITCH FAULT (STORED) 1586
BACKLIGHT DIMMING RX FAILURE (STORED) 1586
BLEND OVERCURRENT (STORED) 1586
CHECKSUM FAILURE (STORED) 1586
DEFOG SWITCH FAULT (STORED) 1586
LOOPBACK TEST FAILURE (STORED) 1586
MODE 1 OVERCURRENT (STORED) 1586
MODE 2 OVERCURRENT (STORED) 1586
RECIRC OVERCURRENT (STORED) 1586
REFRIGERANT PRESS RX FAILURE (STORED) 1586
TX FAILURE (STORED) 1586
VIN RX FAILURE (STORED) 1586
ACT CKT TEST PASSED, OVERCURRENT DTCS ACTIVE 1589
BLEND CIRCUIT SHORTED TO GROUND 1589
BLEND CIRCUIT SHORTED TO IGN OR BATT 1589
COMMON DRIVER SHORTED TO GROUND 1589
COMMON DRIVER SHORTED TO IGN OR BATT 1589
MODE 1 CIRCUIT SHORTED TO GROUND 1589
MODE 1 CIRCUIT SHORTED TO IGN OR BATT 1589
MODE 2 CIRCUIT SHORTED TO GROUND 1589
MODE 2 CIRCUIT SHORTED TO IGN OR BATT 1589
RECIRC CIRCUIT SHORTED TO GROUND 1589
RECIRC CIRCUIT SHORTED TO IGN OR BATT 1589
SHORT TOO COMPLEX 1589
BACKLIGHT DIMMING RX FAILURE (ACTIVE) 1595
BLEND CALIBRATION FAULT 1596
MODE 1 CALIBRATION FAULT 1596
MODE 2 CALIBRATION FAULT 1596
RECIRCULATION CALIBRATION FAULT 1596
BLEND OVERCURRENT (ACTIVE) 1599
MODE 1 OVERCURRENT (ACTIVE) 1599
MODE 2 OVERCURRENT (ACTIVE) 1599
RECIRC OVERCURRENT (ACTIVE) 1599
DEFOG RELAY CONTROL CKT SHORTED TO BATT 1601
LOOPBACK TEST FAILURE (ACTIVE) 1602
REFRIGERANT PRESSURE RX FAILURE (ACTIVE) 1603
VIN RX FAILURE (ACTIVE) 1603
TX FAILURE (ACTIVE) 1605
*A/C – HEATER CONTROL ILLUMINATION INOPERATIVE 1607
*BLEND/MODE/RECIRC DOOR OPERATION IMPROPER 1609
TIMING CHAIN COVER 701
REMOVAL 701
INSTALLATION 701
TIMING CHAIN AND SPROCKETS 703
REMOVAL 703
TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL 703
CRANKSHAFT SPROCKET REMOVAL 703
INSTALLATION 704
CRANKSHAFT SPROCKET INSTALLATION 704
TIMING CHAIN AND CAMSHAFT SPROCKET INSTALLATION 704
LUBRICATION 704
DESCRIPTION 704
OPERATION 704
DIAGNOSIS AND TESTING 705
CHECKING ENGINE OIL PRESSURE 705
ENGINE OIL LEAK 705
Air Leak Detection Test Method 705
INSPECTION FOR REAR SEAL AREA LEAKS 705
OIL 706
STANDARD PROCEDURE 706
CHECKING ENGINE OIL LEVEL 706
ENGINE OIL AND FILTER CHANGE 707
OIL FILTER SPECIFICATION 707
USED ENGINE OIL DISPOSAL 707
OIL COOLER & LINES 707
DESCRIPTION 707
OPERATION 707
STANDARD PROCEDURE – OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY 707
DISASSEMBLY 707
ASSEMBLY 708
REMOVAL 709
INSTALLATION 709
OIL PAN 710
REMOVAL 710
INSTALLATION 710
OIL PUMP 711
REMOVAL 711
DISASSEMBLY 711
CLEANING 712
INSPECTION 712
ASSEMBLY 713
INSTALLATION 714
OIL PRESSURE SENSOR 714
REMOVAL 714
INSTALLATION 714
SENSOR-OIL TEMPERATURE 714
REMOVAL 714
INSTALLATION 714
ENGINE BLOCK 714
DESCRIPTION 714
STANDARD PROCEDURE – CYLINDER BORE HONING 714
CLEANING 715
INSPECTION 715
HYDRAULIC TAPPETS 716
DESCRIPTION 716
REMOVAL 716
INSTALLATION 716
CAMSHAFT 717
REMOVAL 717
INSTALLATION 717
PISTON & CONNECTING ROD 718
DESCRIPTION 718
STANDARD PROCEDURE 718
PISTON FITTING 718
MEASURING CONNECTING ROD SIDE CLEARANCE 718
REMOVAL 719
INSPECTION 720
CONNECTING ROD 720
PISTON PIN 720
PISTON 720
INSTALLATION 720
PISTON RINGS 721
STANDARD PROCEDURE – MEASURING PISTON RING CLEARANCES 721
REMOVAL 721
INSTALLATION 721
CONNECTING ROD BEARINGS 722
DESCRIPTION 722
STANDARD PROCEDURE 722
CONNECTING ROD BEARING – FITTING 722
MEASURING CONNECTING ROD BEARING CLEARANCE 723
CRANKSHAFT DAMPER 723
REMOVAL 723
INSTALLATION 725
CRANKSHAFT OIL SEAL – FRONT 725
REMOVAL 725
INSTALLATION 725
CRANKSHAFT OIL SEAL AND RETAINER – REAR 726
REMOVAL 726
INSTALLATION 726
CRANKSHAFT MAIN BEARINGS 727
DESCRIPTION 727
STANDARD PROCEDURE 727
MEASURING CRANKSHAFT MAIN BEARING CLEARANCE IN-CAR 727
PLASTIGAGE METHOD 727
PREFERRED METHOD 727
ALTERNATIVE METHOD 727
CRANKSHAFT 728
STANDARD PROCEDURE 728
MEASURING CRANKSHAFT END PLAY 728
CRANKSHAFT END PLAY CHECK – OPTIONAL 728
CRANKSHAFT JOURNAL MEASUREMENT 728
REMOVAL 729
INSPECTION 730
INSTALLATION 731
CRANKSHAFT PILOT BEARING 733
REMOVAL 733
INSTALLATION 733
11-EXHAUST SYSTEM 734
EXHAUST SYSTEM 734
DESCRIPTION – EXPORT 734
OPERATION – EXPORT 734
DIAGNOSIS AND TESTING – EXHAUST SYSTEM RESTRICTION CHECK 735
INSPECTION 736
EXHAUST SYSTEM INSPECTION 736
ADJUSTMENTS 736
EXHAUST SYSTEM ALIGNMENT 736
SPECIFICATIONS0 – 6 ZB (Continued) 737
TORQUE 737
SPECIAL TOOLS 737
EXHAUST SYSTEM 737
PIPE CLAMPS 737
DESCRIPTION 737
HEAT SHIELDS 738
DESCRIPTION 738
CATALYTIC CONVERTER(S) 738
OPERATION 738
REMOVAL 738
INSPECTION 741
INSTALLATION 741
RESONATOR(S) 741
REMOVAL 741
INSTALLATION 741
SPOUT ASSEMBLY – LEFT/RIGHT 742
REMOVAL 742
INSTALLATION 742
H-PIPE 744
REMOVAL 744
INSTALLATION 744
HEAT SHIELDS – EXPORT 744
REMOVAL – AUXILIARY RESONATOR HEAT SHEILD 744
INSTALLATION – AUXILIARY RESONATOR HEAT SHIELD 744
RESONATOR(S) – EXPORT 745
REMOVAL 745
INSTALLATION 745
SPOUT ASSEMBLY – EXPORT 745
REMOVAL 745
INSTALLATION 745
H-PIPE – EXPORT 746
REMOVAL 746
REMOVAL – H-PIPE 746
REMOVAL – H-PIPE EXTENSION PIPES 747
INSTALLATION 747
INSTALLATION – H-PIPE 747
INSTALLATION – H-PIPE EXTENSION PIPES 747
EXHAUST PIPE – EXPORT 748
REMOVAL – DIVERTER PIPE 748
INSTALLATION – DIVERTER PIPE 748
SUPPORT BRACKET AND ISOLATOR – EXPORT 749
REMOVAL 749
REMOVAL – AUXILIARY RESONATOR – UPPER LEFT 749
REMOVAL – AUXILIARY RESONATOR – LOWER LEFT HANGER 749
INSTALLATION 749
INSTALLATION – AUXILIARY RESONATOR – UPPER LEFT 749
INSTALLATION – AUXILIARY RESONATOR – LOWER LEFT HANGER 749
EXHAUST SOLENOID – EXPORT 750
REMOVAL 750
INSTALLATION 750
13-FRAME & BUMPERS 752
FRAME & BUMPERS 752
SPECIFICATIONS – TORQUE 752
FRONT FASCIA 752
REMOVAL 752
INSTALLATION 754
FRONT FASCIA – EXPORT 754
REMOVAL – EXPORT 754
INSTALLATION – EXPORT 754
FRONT BUMPER REINFORCEMENT 755
REMOVAL 755
INSTALLATION 755
FRONT BUMPER REINFORCEMENT – EXPORT 756
REMOVAL – EXPORT 756
INSTALLATION – EXPORT 756
REAR FASCIA 756
REMOVAL 756
INSTALLATION 756
REAR BUMPER FOAM 758
REMOVAL 758
INSTALLATION 758
REAR BUMPER 758
REMOVAL 758
INSTALLATION 758
FRONT TOW EYE BRACKET – EXPORT 759
REMOVAL – EXPORT 759
INSTALLATION – EXPORT 759
BRACKET – REAR LICENSE PLATE EXPORT 759
REMOVAL – EXPORT 759
INSTALLATION – EXPORT 759
FRAME 760
WARNING 760
STANDARD PROCEDURE 760
FRAME DAMAGE REPAIR 760
FRONT FRAME ASSEMBLY 761
WARNINGS AND CAUTIONS 761
Removal 761
Installation 761
FRONT UPPER FRAME RAIL ASSEMBLY 761
WARNINGS AND CAUTIONS 761
Removal 761
Installation 762
FRAME SIDE SILL ASSEMBLY 762
WARNINGS AND CAUTIONS 762
Removal 762
Installation 762
REAR UPPER FRAME RAIL ASSEMBLY 762
WARNINGS AND CAUTIONS 762
Removal 762
Installation 762
SPECIFICATIONS 763
FRAME DIMENSIONS 763
VEHICLE PREPARATION 763
SPECIFICATIONS – WELDING 771
REAR TRANSMISSION CROSSMEMBER 772
REMOVAL 772
INSTALLATION 772
14-FUEL SYSTEM 774
FUEL DELIVERY 774
DESCRIPTION 775
FUEL DELIVERY SYSTEM 775
LONG-TERM STORAGE 775
OPERATION – FUEL DELIVERY SYSTEM 775
STANDARD PROCEDURE 775
FUEL SYSTEM PRESSURE RELEASE PROCEDURE 775
DRAINING FUEL TANK 775
SPECIFICATIONS 775
FUEL SYSTEM PRESSURE 775
TORQUE 775
SPECIAL TOOLS 776
FUEL 776
FUEL FILTER 776
DESCRIPTION 776
REMOVAL 776
INSTALLATION 776
FUEL LEVEL SENSOR 777
DESCRIPTION 777
OPERATION 777
REMOVAL 777
INSTALLATION 777
FUEL TUBES/LINES/HOSES AND CLAMPS 778
DESCRIPTION – FUEL TUBES/LINES/HOSES AND CLAMPS 778
STANDARD PROCEDURE – HOSES AND CLAMPS 779
FUEL PRESSURE REGULATOR 779
DESCRIPTION 779
OPERATION 779
REMOVAL 779
INSTALLATION 780
ELECTRIC FUEL PUMP 780
DESCRIPTION 780
OPERATION 780
FUEL PUMP ELECTRICAL CONTROL 780
STANDARD PROCEDURE – FUEL PUMP REPLACEMENT 780
FUEL PUMP MODULE 780
DESCRIPTION 780
REMOVAL 780
*BLOWER MOTOR INOPERATIVE 1611
*BLOWER MOTOR SPEEDS INCORRECT 1614
*EBL STATUS INDICATOR FLASHING 1616
*HVAC SYSTEM TEST 1617
IGNITION, POWER, ACCESSORY 1619
BCM – ACCESSORY RELAY CONTROL CIRCUIT OPEN 1619
BCM – ACCESSORY RELAY CONTROL CIRCUIT SHORT TO GROUND 1621
BCM – IGNITION MUX SWITCH INPUT MISMATCH 1623
BCM – IGNITION MUX SWITCH INPUT OPEN 1625
BCM – IGNITION MUX SWITCH INPUT SHORT 1627
BCM – IGNITION RUN 1 SHORT 1628
BCM – IGNITION RUN 2 SHORT 1630
BCM – IOD OUTPUT CIRCUIT SHORT TO GROUND 1632
BCM – IOD WAKE UP CLUSTER OUTPUT OPEN / SHORT TO GROUND 1634
BCM – IOD WAKE UP CLUSTER OUTPUT SHORT TO VOLTAGE 1636
BCM – RUN/START HARDWIRE INPUT MISMATCH 1637
EXHAUST RELAY OPEN/SHORT TO GROUND (EXPORT ONLY) 1639
EXHAUST RELAY SHORT TO BATTERY (EXPORT ONLY) 1641
HORN RELAY COIL OPEN/SHORT TO GROUND 1642
HORN RELAY COIL SHORT TO BATTERY 1644
HORN SWITCH STUCK 1646
*HORNS INOPERATIVE 1648
INSTRUMENT CLUSTER 1651
ABS LAMP CIRCUIT OPEN 1651
ABS LAMP CIRCUIT SHORTED 1651
AIRBAG LAMP CIRCUIT OPEN 1651
AIRBAG LAMP CIRCUIT SHORTED 1651
ABS MESSAGES NOT RECEIVED 1653
BCM – FUEL LEVEL SENDING UNIT INPUT OPEN / SHORTED TO VOLTAGE 1654
BCM – FUEL LEVEL SENDING UNIT INPUT SHORT TO GROUND 1656
BCM – PWM DIMMING OUTPUT SHORT 1658
BCM MESSAGES NOT RECEIVED 1660
EEPROM CHECKSUM FAILURE 1661
ORC MESSAGES NOT RECEIVED 1662
PCM MESSAGES NOT RECEIVED 1663
*GAUGE CLUSTER DIAGNOSTIC TEST 1664
*INSTRUMENT CLUSTER DIAGNOSTIC TEST 1667
INTERIOR LIGHTING 1668
COURTESY LAMP OUTPUT SHORT 1668
DOME SWITCH INPUT OPEN 1669
DOME SWITCH INPUT SHORT 1670
READING LAMP OUTPUT SHORT 1671
POWER DOOR LOCKS/RKE 1672
DECKLID RELEASE OUTPUT OPEN 1672
DECKLID RELEASE OUTPUT SHORT TO GROUND 1674
DRIVER CYLINDER UNLOCK SWITCH OPEN OR SHORT TO VOLTAGE 1676
DRIVER CYLINDER UNLOCK SWITCH SHORT TO GROUND 1678
DRIVER CYLINDER UNLOCK SWITCH STUCK 1680
DRIVER DOOR LOCK CIRCUIT SHORT TO GROUND 1682
DRIVER DOOR LOCK SWITCH STUCK 1684
DRIVER DOOR UNLATCH CIRCUIT SHORT TO GROUND 1686
DRIVER EXTERIOR DOOR HANDLE SWITCH STUCK 1687
DRIVER INTERIOR DOOR HANDLE SWITCH STUCK 1689
PASSENGER DOOR LOCK CIRCUIT SHORT TO GROUND 1691
PASSENGER DOOR LOCK SWITCH STUCK 1693
PASSENGER DOOR UNLATCH CIRCUIT SHORT TO GROUND 1695
PASSENGER EXTERIOR DOOR HANDLE SWITCH STUCK 1696
PASSENGER INTERIOR DOOR HANDLE SWITCH STUCK 1698
PASSENGER/DRIVER DOOR UNLATCH RETURN SHORT TO GROUND 1700
RKE PROGRAM LINE OUTPUT OPEN/SHORT TO GROUND 1702
RKE PROGRAM LINE OUTPUT SHORT TO BATTERY 1704
*ALL DOOR SWITCHES INOPERATIVE 1705
*DRIVER DOOR SWITCH OR SWITCHES INOPERATIVE 1706
*DRIVER DOOR UNLATCH INOPERATIVE 1709
*PASSENGER DOOR SWITCH OR SWITCHES INOPERATIVE 1711
*PASSENGER DOOR UNLATCH INOPERATIVE 1714
*REMOTE KEYLESS ENTRY PROBLEM 1716
POWER WINDOWS 1718
DRIVER WINDOW DOWN OUTPUT SHORT TO GROUND 1718
DRIVER WINDOW HALL EFFECT FAILURE 1720
DRIVER WINDOW SWITCH OPEN/SHORT TO VOLTAGE 1723
DRIVER WINDOW SWITCH SHORT TO GROUND 1725
DRIVER WINDOW SWITCH STUCK DOWN 1726
DRIVER WINDOW SWITCH STUCK UP 1727
DRIVER WINDOW UP OUTPUT SHORT TO GROUND 1728
PASSENGER WINDOW DOWN RELAY COIL OPEN/SHORT TO GROUND 1730
PASSENGER WINDOW DOWN RELAY COIL SHORT TO BATTERY 1732
PASSENGER WINDOW HALL EFFECT FAILURE 1734
PASSENGER WINDOW SWITCH OPEN/SHORT TO VOLTAGE 1738
PASSENGER WINDOW SWITCH SHORT TO GROUND 1740
PASSENGER WINDOW SWITCH STUCK DOWN 1742
PASSENGER WINDOW SWITCH STUCK UP 1743
PASSENGER WINDOW UP SHORT TO GROUND 1744
*DRIVER WINDOW INOPERATIVE 1746
*PASSENGER WINDOW INOPERATIVE 1748
TIRE PRESSURE MONITORING 1752
CRITICAL TIRE PRESSURE – BCM 1752
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER – TPM 1753
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER – TPM 1753
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER – TPM 1753
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER – TPM 1753
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY – TPM 1756
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY – TPM 1756
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY – TPM 1756
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY – TPM 1756
TIRE PRESSURE LOW – BCM 1758
TIRE PRESSURE MONITOR MODULE FAILURE – TPM 1759
TPM DIAGNOSTIC – BCM 1760
TPM MODULE INITIALIZED – BCM 1763
*LO TIRE LCD MESSAGE FLASHING 1766
VEHICLE THEFT/SECURITY 1767
VTSS INDICATOR OUTPUT OPEN 1767
VTSS INDICATOR OUTPUT SHORT 1769
*ALARM TRIPS ON ITS OWN 1771
*DECKLID DOES NOT TRIP VTSS 1772
*DRIVER DOOR DOES NOT TRIP VTSS 1773
*EXTERIOR LAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED 1774
*HOOD DOES NOT TRIP VTSS 1775
*HORN FAILS TO SOUND WHEN ALARM IS TRIPPED 1776
*PASSENGER DOOR DOES NOT TRIP VTSS 1777
*VTSS LAMP ON STEADY DURING ARMING 1778
*VTSS WILL NOT ARM 1779
WINDSHIELD WIPER & WASHER 1780
HEADLAMP WASHER RELAY OPEN/SHORT TO GROUND (EXPORT ONLY) 1780
HEADLAMP WASHER RELAY SHORT TO BATTERY (EXPORT ONLY) 1782
WIPER PUMP SWITCH STUCK (EXPORT ONLY) 1784
VERIFICATION TESTS 1785
VERIFICATION TESTS 1785
8 0 COMPONENT LOCATIONS 1790
8 1 AIRBAG SYSTEM 1790
8 2 BODY CONTROL MODULE 1791
8 3 HEATING & A/C SYSTEM 1791
8 4 INSTRUMENT PANEL 1792
8 5 POWER WINDOW MOTOR 1792
8 6 POWER DOOR LOCKS 1792
8 6 1 DRIVER CYLINDER UNLOCK SWITCH 1792
8 6 2 DOOR LATCH ASSEMBLY 1793
8 6 3 RKE MODULE 1793
8 7 TIRE PRESSURE MONITOR MODULE (TPM) 1793
8 8 VEHICLE THEFT SECURITY SYSTEM (VTSS) 1794
8 8 1 DRIVER CYLINDER UNLOCK SWITCH 1794
8 8 2 VEHICLE THEFT SECURITY SYSTEM INDICATOR 1794
9 0 CONNECTOR PINOUTS 1796
BODY CONTROL MODULE C3 – BLACK/WHITE 34 WAY 1796
BODY CONTROL MODULE C4 – BLACK/GRAY 34 WAY 1797
C108 (EXPORT) – DK GRAY (HEADLAMP AND DASH SIDE) 1797
C108 (EXPORT) – LT GRAY (RELAY HARNESS SIDE) 1798
C304 (EXPORT) – BLACK (BODY SIDE) 1798
C304 (EXPORT) – BLACK (REAR FOG LAMP SIDE) 1798
EXHAUST SOLENOID (EXPORT) – BLACK 2 WAY 1798
EXHAUST SOLENOID RELAY (EXPORT) – 5 WAY 1799
EXPORT ACCESSORY FUSE 1799
FOG LAMP-LEFT REAR (EXPORT) – 2 WAY 1799
FOG LAMP-RIGHT REAR (EXPORT) – 2 WAY 1799
HEADLAMP WASHER PUMP MOTOR (EXPORT) – BLACK 2 WAY 1800
HEADLAMP WASHER PUMP RELAY (EXPORT) – 5 WAY 1800
MULTI-FUNCTION SWITCH – GRAY 20 WAY 1800
REAR FOG LAMP RELAY (EXPORT) – 5 WAY 1801
SIDE REPEATER LAMP-LEFT (EXPORT) – BLACK 2 WAY 1801
SIDE REPEATER LAMP-RIGHT (EXPORT) – BLACK 2 WAY 1801
10 0 SCHEMATIC DIAGRAMS 1802
10 1 AIRBAG SYSTEM 1802
10 2 AUDIO SYSTEM 1803
10 3 CHIME SYSTEM 1804
10 4 COMMUNICATION 1805
10 5 DOOR AJAR SYSTEM 1806
10 6 ELECTRICALLY HEATED SYSTEMS 1806
10 6 1 REAR WINDOW DEFOGGER SYSTEM 1806
10 7 EXTERIOR LIGHTING 1807
10 7 1 FRONT LAMPS 1807
10 7 2 REAR FOG LAMPS (EXPORT ONLY) 1808
10 8 HEATING & A/C SYSTEM 1809
10 9 IGNITION, POWER, ACCESSORY 1810
10 9 1 HORN SYSTEM 1810
10 9 2 EXHAUST CONTROL SYSTEM (EXPORT ONLY) 1811
10 10 INSTRUMENT CLUSTER/GAUGE CLUSTER 1812
10 11 INTERIOR LIGHTING 1813
10 12 POWER DOOR LOCKS/RKE 1814
10 13 POWER WINDOW SYSTEM 1815
10 14 TIRE PRESSURE MONITOR MODULE (TPM) 1816
10 15 VEHICLE THEFT SECURITY SYSTEM 1817
10 16 WIPER SYSTEM 1818
10 16 1 HEADLAMP WASHERS (EXPORT ONLY) 1818
2005-Viper ABS Systems pdf 1820
MAIN WELCOME PAGE 0
ZB SRT-10 BUX Service Manual 0
ZB SRT-10 BUX Powertrain 0
ZB SRT-10 BUX Body 0
ZB Chassis 1820
TABLE OF CONTENTS 1820
1 0 INTRODUCTION 1822
1 1 SYSTEM COVERAGE 1822
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 1822
2 0 IDENTIFICATION OF SYSTEM 1822
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1822
3 1 TEVES MARK 20e SYSTEM DESCRIPTION 1822
3 1 1 PEDAL FEEL/VEHICLES CHARACTERISTICS 1823
3 1 2 SYSTEM COMPONENTS 1823
3 1 3 ABS AND RED BRAKE WARNING INDICATOR 1823
3 1 4 CONTROLLER ANTILOCK BRAKE (CAB) 1823
3 1 5 HYDRAULIC CONTROL UNIT 1824
3 1 6 SENSORS 1824
3 2 DIAGNOSTIC TROUBLE CODES 1824
3 2 1 ABS INITIALIZATION 1825
3 2 2 DIAGNOSTIC MODE 1825
3 2 3 INTERMITTENT DIAGNOSTIC TROUBLE CODES 1825
3 3 FREEZE FRAME 1825
3 4 USING THE DRBIII 1825
3 5 DRBIII ERROR MESSAGES 1825
3 5 1 DRBIII DOES NOT POWER UP (BLANK SCREEN) 1825
3 5 2 DISPLAY IS NOT VISIBLE 1826
4 0 DISCLAIMERS, SAFETY, WARNINGS 1826
4 1 DISCLAIMERS 1826
4 2 SAFETY 1826
4 2 1 TECHNICIAN SAFETY INFORMATION 1826
4 2 2 VEHICLE PREPARATION FOR TESTING 1826
4 2 3 SERVICING SUB-ASSEMBLIES 1826
4 2 4 DRBIII SAFETY INFORMATION 1826
4 3 WARNING 1827
4 3 1 VEHICLE DAMAGE WARNINGS 1827
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 1827
4 4 DIAGNOSIS 1827
5 0 REQUIRED TOOLS AND EQUIPMENT 1828
6 0 GLOSSARY OF TERMS 1828
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 1830
BRAKES (CAB) 1831
BUS SYSTEM COMMUNICATION 1831
CAB INTERNAL FAILURE 1833
CLUSTER LAMP FAILURE 1835
INCORRECT TONE WHEEL FAILURE 1837
LEFT FRONT SENSOR CIRCUIT FAILURE 1838
LEFT REAR SENSOR CIRCUIT FAILURE 1838
RIGHT FRONT SENSOR CIRCUIT FAILURE 1838
RIGHT REAR SENSOR CIRCUIT FAILURE 1838
LEFT FRONT WHEEL SPEED SIGNAL FAILURE 1843
LEFT REAR WHEEL SPEED SIGNAL FAILURE 1843
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE 1843
RIGHT REAR WHEEL SPEED SIGNAL FAILURE 1843
PUMP CIRCUIT FAILURE 1846
SYSTEM OVER VOLTAGE 1850
SYSTEM UNDER VOLTAGE 1853
VALVE POWER FEED FAILURE 1855
*BRAKE LAMP SWITCH INOPERATIVE 1858
COMMUNICATION 1859
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 1859
VERIFICATION TESTS 1861
VERIFICATION TESTS 1861
8 0 COMPONENT LOCATIONS 1862
8 1 CONTROLLER ANTILOCK BRAKE (CAB) 1862
8 2 DATA LINK CONNECTOR 1862
8 3 HYDRAULIC CONTROL UNIT (HCU) 1862
8 4 POWER DISTRIBUTION CENTER 1863
8 5 MESSAGE CENTERS 1863
8 6 WHEEL SPEED SENSORS 1863
8 7 WHEEL SPEED SENSOR CONNECTORS 1864
8 8 BRAKE LAMP SWITCH 1865
8 9 ABS PUMP MOTOR 1865
9 0 CONNECTOR PINOUTS 1866
ABS PUMP MOTOR (CONNECTOR SIDE) – 2 WAY 1866
BRAKE LAMP SWITCH – BLACK 6 WAY 1866
CONTROLLER ANTILOCK BRAKE – BLACK 24 WAY 1866
DATA LINK CONNECTOR – BLACK 16 WAY 1867
FUSES (PDC) 1869
WHEEL SPEED SENSOR-LEFT FRONT – LT GRAY 2 WAY 1869
WHEEL SPEED SENSOR-LEFT REAR – GRAY 2 WAY 1869
WHEEL SPEED SENSOR-RIGHT FRONT – LT GRAY 2 WAY 1870
WHEEL SPEED SENSOR-RIGHT REAR – GRAY 2 WAY 1870
10 0 SCHEMATIC DIAGRAMS 1872
VIDEO PREVIEW OF THE MANUAL:
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S.V