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Chrysler 2005 Crossfire SRT6 Service Manual

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GROUP TAB LOCATOR

Introduction

0

Lubrication & Maintenance

2

Suspension

3

Differential & Driveline

5

Brakes

6

Clutch

7

Cooling

8A

Audio/Video

8B

Chime/Buzzer

8E

Electronic Control Modules

8F

Engine Systems

8G

Heated Systems

8H

Horn

8I

Ignition Control

8J

Instrument Cluster

8L

Lamps

8M

Message Systems

8N

Power Systems

8O

Restraints

8P

Speed Control

8Q

Vehicle Theft Security

8R

Wipers/Washers

8W

Wiring

9

Engine

11

Exhaust System

13

Frame & Bumpers

14

Fuel System

19

Steering

21

Transmission

22

Tires/Wheels

23

Body

24

Heating & Air Conditioning

25

Emissions Control

Component and System Index

DTC Index

Service Manual Comment Forms

(Rear of Manual)

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Summary of Contents for Chrysler 2005 Crossfire SRT6

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System...
Page 3: Description
POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = Manufactured By DaimlerChrysler Corporation Make C = Chrysler Vehicle Type 3 = Passenger Car Other A = Restraint System Active Front And Side Air Bags Car Line N = Crossfire (LHD)
Page 4: Vehicle Safety Certification Label
INTRODUCTION VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label is attached to every DaimlerChrysler Corporation vehicle. The label certi- fies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label is located on the driver door shut-face. All communications or inquiries regarding the vehicle should include the Date of Manufacture, and the Vehi- cle Identification Number.
Page 5 INTRODUCTION INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8.
Page 6: Position
INTRODUCTION...
Page 7: Position
INTRODUCTION...
Page 8 INTRODUCTION FASTENER USAGE DESCRIPTION FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem- bly.
Page 9 INTRODUCTION...
Page 10 INTRODUCTION TORQUE REFERENCES DESCRIPTION Individual torque charts appear within many of the groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts.
Page 11: Lubrication & Maintenance
LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS LUBRICATION POINTS DESCRIPTION ......1 DESCRIPTION .
Page 12 0 - 2 LUBRICATION & MAINTENANCE PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE - PARTS AND LUBRICANT RECOMMENDATIONS Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI sym- bol on the label. At the bottom NLGI symbol is the usage and quality identification letters.
Page 13 LUBRICATION & MAINTENANCE 0 - 3 Use synthetic engine oils, approved to MB 229.3 or MB 229.5, such as Mopar part number 05127394AA. Synthetic SAE 0W-40 or SAE 5W-40 engine oils approved to API SL and/or GF-3 may be substituted. The FSS mat not alert for an oil change at the proper interval if an unapproved product is used;...
Page 14 0 - 4 LUBRICATION & MAINTENANCE CAUTION: Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MB 325.0) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protec- tion.
Page 15 LUBRICATION & MAINTENANCE 0 - 5 Manual Transmission Fluid No service is required or recommended for the manual transmission. If required, use fluid approved to MB 236.2. SAE 5W-20 meeting API SL or GF-3 Engine Oil, such as Mopar part number 04761872AB, may be subsituted. DESCRIPTION - DIFFERENTIAL LUBRICANT Note: Refer to the Owner’s Manual for the recommended differential lubricant change intervals for this axle.
Page 16 0 - 6 LUBRICATION & MAINTENANCE LUBRICATION POINTS DESCRIPTION Lubrication points are noted, and located in each of the applicable Service Information sections. MAINTENANCE SCHEDULES DESCRIPTION DESCRIPTION - FLEXIBLE SERVICE SYSTEM (FSS) The Flexible Service System (FSS) is a demand-acti- vated engine oil service system.
Page 17: Position
LUBRICATION & MAINTENANCE 0 - 7 This symbol represents Service A. The second symbol represents Service B. Depending on operating conditions throughout the year, the next service is calculated and displayed next to the this symbol in days remaining before the next service is required.
Page 18 0 - 8 LUBRICATION & MAINTENANCE The next service may be calculated and displayed next to this symbol as distance remaining before the next service is required. The counter can also be reset by any individual after the indicated service has been performed. Perform the following to reset the counter: 1.
Page 19 LUBRICATION & MAINTENANCE 0 - 9 Function Check • Horn, hazard warning flashers, turn signals, and indicator lamps • Headlamps and exterior lighting • Windshield wipers and washer system Inspection • Check front and rear brake pads for lining thickness •...
Page 20: Suspension
0 - 10 LUBRICATION & MAINTENANCE HOISTING STANDARD PROCEDURE - HOISTING WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN THE ENGINE, TRANSMISSION OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.
Page 21: Jump Starting
LUBRICATION & MAINTENANCE 0 - 11 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. WARNING: DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR.
Page 22: Emergency Tow Hooks
0 - 12 LUBRICATION & MAINTENANCE 7. Make final connection of the negative (-) jumper cable (2) to the ENGINE GROUND (1) of disabled vehicle, away from battery. CAUTION: Do not crank the starter motor on the disabled vehicle for more than 15 seconds, the starter will overheat and could fail.
Page 23: Ground Clearance
TOWING RECOMMENDATIONS Flat bed towing should be the only method used for the Chrysler Crossfire. The flat bed must have an approach angle less then 13.3° or something must be used (such as wood slats) to raise the overall height of the vehicle during loading.
Page 25 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page SUSPENSION WHEEL ALIGNMENT ..... . 3 DIAGNOSIS AND TESTING - SUSPENSION FRONT SUSPENSION .
Page 26 2 - 2 SUSPENSION CONDITION POSSIBLE CAUSES CORRECTION VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires. DRIFTS FROM STRAIGHT 2. Brakes dragging. 2. Repair brake as necessary. AHEAD DIRECTION ON UNCROWNED ROAD 3. Weak or broken spring. 3.
Page 27: Table Of Contents
WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT CHECKING AND ADJUSTING FRONT AXLE DESCRIPTION ......3 CAMBER AND CASTER .
Page 28: Operation
2 - 4 WHEEL ALIGNMENT OPERATION CASTER Caster is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle.
Page 29: Standard Procedure Standard Procedure - Wheel Alignment Inspection
WHEEL ALIGNMENT 2 - 5 WHEEL TOE POSITION Toe is the difference between the leading inside edges (1) and the trailing inside edges (2) of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment.
Page 30: Standard Procedure - Chassis Alignment Inspection
2 - 6 WHEEL ALIGNMENT • Perform a visual inspection for wear pattern, tread depth and any damage to the tires. 4. Inspect the wheel condition • Perform a visual inspection for any damage to the wheels. 5. Inspect the tire pressure. •...
Page 31: Inspecting And Adjusting Vehicle Level At Front And Rear Axles
WHEEL ALIGNMENT 2 - 7 INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES 1. Observe the general information on chassis alignment inspection. (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE). 2. Inspect the vehicle level at the front axle by performing the following: •...
Page 32 2 - 8 WHEEL ALIGNMENT 5. Check the caster and assign to tabular value. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICA- TIONS). ADJUSTING Note: Vehicles are delivered from the factory with pre-set caster, camber, and toe settings. When aligning a vehicle with factory settings, Eccentric Repair Bolts must be installed in order to adjust caster or camber.
Page 33: Standard Procedure - Checking And Adjusting Front Toe-In
WHEEL ALIGNMENT 2 - 9 Note: The vehicle level must correlate with the dimension established on the initial measurement. 11. Recheck the vehicle level at the front axle after adjusting the camber and caster. • Vehicle level at the front axle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE). •...
Page 34: Standard Procedure - Checking Toe-Out On Turns
2 - 10 WHEEL ALIGNMENT STANDARD PROCEDURE - CHECKING TOE-OUT ON TURNS 1. Check and adjust the toe-in at the front axle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE). 2. Check the toe-out on turns. To check steering geometry measure toe-out on turns. This is the difference in the wheel angle between the wheel on the outside of a curve and the wheel on the inside of a curve when the wheel on the inside of the curve is turned 20°.
Page 35: Standard Procedure - Checking And Adjusting Rear Axle Toe
WHEEL ALIGNMENT 2 - 11 3. Check the rear axle camber. (POS+) = Positive Camber, (NEG-) = Negative Camber. The camber on the rear axle is not adjustable. If substantial deviations in the rear axle camber are found, the cause may be one of the following: (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICA- TIONS).
Page 36: Specifications
2 - 12 WHEEL ALIGNMENT SPECIFICATIONS SPECIFICATIONS - WHEEL ALIGNMENT DESCRIPTION SPECIFICATION Vehicle level - front axle 1.4° (-2.1/+1.4) Vehicle level - rear axle 0.4° (±0.8) Ball point position 30,5±2 mm Front axle toe-in 0° 20’±10’ Toe-out on turns with wheel on the inside of the curve -1°...
Page 37 FRONT SUSPENSION 2 - 13 FRONT SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION LOWER CONTROL ARM STANDARD PROCEDURE - ADJUSTING REMOVAL ......32 FRONT WHEEL BEARINGS .
Page 38: Front Suspension
2 - 14 FRONT SUSPENSION 5. Loosen the hub nut bolt. Turn the hub nut (4) back until a slight end play is achieved. 6. Attach a dial indicator. CAUTION: Do not turn the wheel hub while taking the measurement. 7.
Page 39: Special Tools
FRONT SUSPENSION 2 - 15 SPECIAL TOOLS 9152 SPRING COMPRESSOR PLATES C-3894–A Tie Rod Puller 9168 Ball Joint Puller 9151 FRONT SPRING COMPRESSOR...
Page 40: Knuckle
2 - 16 FRONT SUSPENSION KNUCKLE DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. REMOVAL CAUTION: When removing the steering knuckle the shock absorber must remain installed.
Page 41 FRONT SUSPENSION 2 - 17 4. Remove the front disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL). 5. Remove the front wheel hub. (Refer to 2 - SUS- PENSION/FRONT/HUB / BEARING - REMOVAL). 6. Remove the disc brake dust shield by removing the three hex bolts (1).
Page 42 2 - 18 FRONT SUSPENSION Note: Check the ball joint rubber boot for any wear or damage. Repair as necessary. Note: An allen wrench may be required to hold the ball joint stud while removing the nut. CAUTION: Do not use pneumatic tools to tighten the bolt on the special tool.
Page 43 FRONT SUSPENSION 2 - 19 Note: An allen wrench may be required to hold the ball joint stud while removing the nut. 11. Remove the steering knuckle upper control arm nut (1) from the upper ball joint stud. CAUTION: Do not use pneumatic tools to tighten the bolt on the special tool.
Page 44: Installation
2 - 20 FRONT SUSPENSION INSTALLATION 1. Install the steering knuckle and nut (1) to the upper ball joint stud. Tighten to 45 N·m (33 ft. lbs.). 2. Install the steering knuckle and nut to the lower ball joint stud (1). Tighten to 105 N·m (77 ft. lbs.). 3.
Page 45 FRONT SUSPENSION 2 - 21 4. Install the Wheel Speed Sensor (WSS) and bolt. Tighten to 22 N·m (16 ft. lbs.). 5. Install the disc brake dust shield and three hex bolts (1). Tighten to 22 N·m (16 ft. lbs.). 6.
Page 46: Hub / Bearing
2 - 22 FRONT SUSPENSION 8. Install the front disc brake caliper (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 9. Install the front wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCE- DURE). 10. Lower the vehicle and check vehicle alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICATIONS).
Page 47: Removal
FRONT SUSPENSION 2 - 23 REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove and inspect the front disc brake caliper (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHAN- ICAL/DISC BRAKE CALIPERS REMOVAL). Inspect for any damage or wear. 4.
Page 48 2 - 24 FRONT SUSPENSION 5. Remove the front wheel hub dust cap (4). 6. Loosen the hub nut bolt then remove the hub nut (3) and then remove the tapered roller bearing (2). 7. Remove the front wheel hub (1) from the spindle. INSPECTING HUB AND BEARINGS 1.
Page 49: Installation
FRONT SUSPENSION 2 - 25 Note: Discoloration may be caused by generated heat due to incorrect bearing end play settings. CAUTION: Only replace the tapered roller bearing and bearing races in pairs. 2. Inspect the spindle for any discoloration or wear on the bearing seats or the contact surface of the radial seal ring.
Page 50 2 - 26 FRONT SUSPENSION 3. Install the front disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION). 4. Install the front disc brake caliper (6). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 5. Adjust the wheel bearing end play. (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING - DIAG- NOSIS AND TESTING).
Page 51: Lower Ball Joint
FRONT SUSPENSION 2 - 27 LOWER BALL JOINT REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the front disc brake caliper (1). (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). 4. Remove the front disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL).
Page 52 2 - 28 FRONT SUSPENSION 5. Remove the front dust shield by removing the three hex bolts (1). 6. Remove the front shock absorber bolt (1). (Refer to 2 - SUSPENSION/FRONT/SHOCK - REMOVAL). 7. Remove the front spring (1). (Refer to 2 - SUS- PENSION/FRONT/SPRING - REMOVAL).
Page 53 FRONT SUSPENSION 2 - 29 8. Remove the nuts (1 and 2) from the lower ball joint. CAUTION: Do not use pneumatic tools to tighten the bolt on the special tool. 9. Using Special Tool 9168 Ball Joint Puller (1) press out the outer ball joint stud from the steering knuckle.
Page 54: Installation
2 - 30 FRONT SUSPENSION INSTALLATION 1. Clean the ball joint tapered bolt and the mounting hole of the steering knuckle. 2. Install the lower ball joint onto the steering knuckle and the lower control arm. 3. Install both nuts (1 and 2). Tighten to 105 N·m (77 ft.
Page 55 FRONT SUSPENSION 2 - 31 5. Install the front disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION). 6. Install the front disc brake caliper (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 7. Install the compressed front spring (1). (Refer to 2 - SUSPENSION/FRONT/SPRING - INSTALLATION).
Page 56: Lower Control Arm
2 - 32 FRONT SUSPENSION 8. Install the front shock absorber bolt and nut (1). (Refer to 2 - SUSPENSION/FRONT/SHOCK - INSTALLATION). 9. Install the front wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCE- DURE). LOWER CONTROL ARM REMOVAL 1.
Page 57 FRONT SUSPENSION 2 - 33 4. Remove the shock absorber lower mounting nut and bolt (1). 5. Pull the shock absorber out of the mounting bracket. 6. Remove the sway bar from the lower control arm by removing the two nuts (1) then removing the clamp.
Page 58: Installation
2 - 34 FRONT SUSPENSION CAUTION: Do not use pneumatic tools to tighten the bolt on the special tool. 8. Using Special Tool 9168 Ball Joint Puller (1) press out the lower ball joint stud from the steering knuckle. CAUTION: Support the lower control arm before removing mounting bolts.
Page 59 FRONT SUSPENSION 2 - 35 3. Install the nut (2) attaching the lower control arm to the steering knuckle lower ball joint. Tighten to 45 N·m (33 ft. lbs.). 4. Install the sway bar clamp and bolts (1) to the lower control arm.
Page 60: Upper Control Arm
2 - 36 FRONT SUSPENSION 6. Install the front spring (1). (Refer to 2 - SUSPEN- SION/FRONT/SPRING - INSTALLATION). 7. Lower the vehicle and check vehicle alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE). 8. Install the front wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCE- DURE).
Page 61: Installation
FRONT SUSPENSION 2 - 37 INSTALLATION WARNING: TIGHTEN ALL NUTS AND BOLTS WITH THE VEHICLE AT NORMAL RIDE HEIGHT. 1. Install the upper control arm (2) and the bolt and nut (1) to the body. Tighten to 65 N·m (48 ft. lbs.) Note: Clean the ball joint tapered bolt and mount- ing hole of the steering knuckle.
Page 62: Installation
2 - 38 FRONT SUSPENSION 4. Remove the shock absorber nut and bolt (1) from the lower control arm. Then remove the shock from the vehicle by pulling it down and out of the vehi- cle. 5. Remove any mounting parts from the shock absorber.
Page 63: Spring Removal
FRONT SUSPENSION 2 - 39 SPRING REMOVAL 1. With the vehicle resting on its wheels remove the upper shock absorber nut (1). 2. Remove the washer and rubber mount. 3. Raise and support the vehicle then remove the lower shock absorber bolt and nut (1). Remove the shock from the vehicle.
Page 64: Installation
2 - 40 FRONT SUSPENSION 4. Support the lower control arm with a suitable sup- porting device. Raise the lower control arm up until it is almost level. WARNING: ONLY USE APPROVED CLAMPING DEVICES AND IF APPROPRIATE ALSO SCREEN OFF THE DANGER AREA. INSPECT SPECIAL TOOLS FOR DAMAGE AND FUNCTION.
Page 65 FRONT SUSPENSION 2 - 41 2. Swing the lower control arm up to its mounting position and install the bolts and nuts (1). Note: To avoid suspension preload, the vehicle must be at normal ride height before tightening lower control arm bolts to final specifications. 3.
Page 66: Stabilizer Bar
2 - 42 FRONT SUSPENSION STABILIZER BAR REMOVAL 1. Remove the stabilizer bar brackets (1) from the right and left lower control arms. 2. Remove the stabilizer bar bracket (4) from the retainer bracket. 3. Remove retainer bracket (4) and bracket mounting plate (if necessary). 4.
Page 67: Installation
FRONT SUSPENSION 2 - 43 INSTALLATION 1. Install both right and left stabilizer bar bushings (3 and 5) onto the stabilizer bar (6). Note: The lower control arms (2) may need to be raised to accept the stabilizer bar bushing (2) to its mating surface.
Page 68 2 - 44 REAR SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION KNUCKLE SPECIFICATIONS - TORQUE ....44 REMOVAL ......54 SPECIAL TOOLS .
Page 69: Special Tools
REAR SUSPENSION 2 - 45 SPECIAL TOOLS 9168 Ball Joint Puller C-3894–A Tie Rod Puller 9150 Rear Spring Compressor 9199 BEARING TOOL 9152 Spring Compressor Plates...
Page 70: Camber Strut
2 - 46 REAR SUSPENSION CAMBER STRUT REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the inner camber strut bolt (1) attaching the camber strut to the rear axle carrier. 4. Remove the outer camber strut bolt (2) attaching the camber strut to the wheel carrier.
Page 71: Trailing Link
REAR SUSPENSION 2 - 47 TRAILING LINK REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the inner trailing link bolt (1) attaching the trailing link to the rear axle carrier. 4. Remove the outer trailing link bolt (2) attaching the trailing link to the wheel carrier.
Page 72: Lateral Link
2 - 48 REAR SUSPENSION LATERAL LINK REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the inner lateral link bolt attaching the lat- eral link to the rear axle carrier. 4. Remove the lateral link ball joint nut (2). CAUTION: Do not use pneumatic tools to tighten the bolt on the tool.
Page 73: Track Bar
REAR SUSPENSION 2 - 49 TRACK BAR REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the inner track bar bolt attaching the track bar to the rear axle carrier. 4. Remove the outer track bar bolt attaching the track bar to the wheel carrier.
Page 74: Lower Control Arm
2 - 50 REAR SUSPENSION LOWER CONTROL ARM REMOVAL 1. Raise and support the vehicle. 2. Remove the rear tire and wheel assembly. 3. Remove the rear lower control arm plastic shield by removing the bolts (1) attaching the cover to the lower control arm.
Page 75 REAR SUSPENSION 2 - 51 5. Remove the rear shock absorber (1). (Refer to 2 - SUSPENSION/REAR/SHOCK - REMOVAL). 6. Remove the rear stabilizer bar link (1) from the rear lower control arm. 7. Remove the bolt attaching the rear lower control arm to the rear wheel carrier.
Page 76: Installation
2 - 52 REAR SUSPENSION INSTALLATION CAUTION: Vehicle must be at normal ride height before tightening components to specified torque. 1. Install the bolt attaching the rear lower control arm (4) to the rear wheel carrier. Tighten to 70 N·m (52 ft.
Page 77: Rear Suspension
REAR SUSPENSION 2 - 53 4. Install the rear lower control arm to the vehicle. Tighten to 70 N·m (52 ft. lbs.). 5. Install the rear stabilizer bar link (1) to the rear lower control arm. Tighten to 20 N·m (15 ft. lbs.). 6.
Page 78: Knuckle Removal
2 - 54 REAR SUSPENSION KNUCKLE REMOVAL 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Remove the rear disc brake caliper bolts (1). 4. Remove the rear disc brake caliper. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
Page 79 REAR SUSPENSION 2 - 55 5. Remove the disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL). 6. Remove the parking brake shoe assembly. (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - REMOVAL). 7. Remove the parking brake cable (2). (Refer to 5 - BRAKES/PARKING BRAKE/CABLES - REMOVAL).
Page 80 2 - 56 REAR SUSPENSION 8. Remove the rear Wheel Speed Sensor bolt (1). 9. Remove the rear Wheel Speed Sensor (2) from the knuckle. 10. Remove the rear axle halfshaft nut (1) from the rear hub assembly. 11. Remove the rear disc brake dust shield by remov- ing the hex bolts (1) from the rear hub assembly.
Page 81 REAR SUSPENSION 2 - 57 12. Remove the camber strut, nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/TOE LINK - REMOVAL). 13. Remove the trailing link, nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/TRAILING LINK - REMOVAL). 14. Remove the lateral link, nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/LATERAL LINK - REMOVAL).
Page 82 2 - 58 REAR SUSPENSION 15. Remove the track bar. (Refer to 2 - SUSPEN- SION/REAR/TRACK BAR - REMOVAL). 16. Remove the lower control arm. (Refer to 2 - SUS- PENSION/REAR/LOWER CONTROL REMOVAL). 17. Remove the knuckle (1) from the vehicle. 18.
Page 83: Installation
REAR SUSPENSION 2 - 59 INSTALLATION CAUTION: The rear axle halfshaft must be horizon- tal when tightening all nuts and bolts. 1. Install the knuckle to the vehicle. 2. Install the trailing link, nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/TOE LINK - INSTALLA- TION).
Page 84 2 - 60 REAR SUSPENSION 3. Install the trailing link nuts and bolts (1-2). (Refer to SUSPENSION/REAR/TRAILING LINK INSTALLATION). 4. Install the lateral link nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/LATERAL LINK - INSTAL- LATION). 5. Install the track bar nuts and bolts (1-2). (Refer to 2 - SUSPENSION/REAR/TRACK BAR - INSTALLA- TION).
Page 85 REAR SUSPENSION 2 - 61 7. Install the rear disc brake dust shield by installing the bolts (1) to the rear hub assembly. Tighten the bolts to 10 N·m (89 in. lbs.). 8. Install the rear axle halfshaft to the rear hub assembly.
Page 86 2 - 62 REAR SUSPENSION 11. Install the parking brake cable (2). (Refer to 5 - BRAKES/PARKING BRAKE/CABLES - INSTALLA- TION). 12. Install the parking brake shoe assembly (1-5). (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLATION). 13. Install the disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION).
Page 87: Hub / Bearing
REAR SUSPENSION 2 - 63 14. Install the rear disc brake caliper and bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANI- CAL/DISC BRAKE CALIPERS - INSTALLATION). 15. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). 16.
Page 88 2 - 64 REAR SUSPENSION 3. Remove the rear disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL). 4. Remove the parking brake shoes (1-5). (Refer to 5 BRAKES/PARKING BRAKE/SHOES REMOVAL). 5. Remove the rear axle halfshaft nut (1). 6.
Page 89 REAR SUSPENSION 2 - 65 7. Remove the snap ring (4) from the rear hub assembly housing. 8. Using the Special Tool 9181 Bearing Tool, remove the bearing (4) on the hub (1). CAUTION: Be sure not to mar or damage the rear axle halfshaft flange while in vise.
Page 90: Installation
2 - 66 REAR SUSPENSION INSTALLATION 1. Using the Special Tool 9199 Bearing Tool (1) install the bearing (2) by pulling it into the wheel carrier (3) until it touches the shoulder of the wheel carrier. Note: Insure that the snap ring is correctly fitted in the rear wheel carrier.
Page 91 REAR SUSPENSION 2 - 67 5. Install the disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION). 6. Install the rear disc brake caliper bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 7. Install the rear axle halfshaft. (Refer to 3 - DIFFER- ENTIAL &...
Page 92: Stabilizer Bar
2 - 68 REAR SUSPENSION STABILIZER BAR REMOVAL 1. Raise and support the vehicle. 2. Remove both wheel and tire assemblies. 3. Remove the right and left wheel speed sensors (2). (Refer BRAKES/ELECTRICAL/REAR WHEEL SPEED SENSOR - REMOVAL). 4. Remove the rear brake hoses (1) from the rear brake calipers.
Page 93 REAR SUSPENSION 2 - 69 5. Remove the rear springs (1). (Refer to 2 - SUS- PENSION/REAR/SPRING - REMOVAL). 6. Remove the rear shocks (1). (Refer to 2 - SUS- PENSION/REAR/SHOCK - REMOVAL). 7. Remove the rear parking brake cables (2) from the parking brake equalizer (1).
Page 94 2 - 70 REAR SUSPENSION 8. Remove the propeller shaft nuts (1) from the rear axle differential carrier. 9. Remove the propeller shaft (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/PROPELLER SHAFT - REMOVAL). 10. Remove the rear stabilizer bar links (2) from the stabilizer bar (1).
Page 95 REAR SUSPENSION 2 - 71 12. Remove the two bolts (1) attaching the rear axle carrier to the front portion of the frame. 13. Remove the two bolts (2) attaching the rear axle carrier to the rear portion of the frame. 14.
Page 96: Installation
2 - 72 REAR SUSPENSION INSTALLATION 1. Install the rear stabilizer bar into the vehicle. 2. Raise the rear differential housing and install the four bolts (1) attaching it to the vehicle. Tighten to 90 N·m (66 ft. lbs.). 3. Install the rear spring (1). (Refer to 2 - SUSPEN- SION/REAR/SPRING - INSTALLATION).
Page 97 REAR SUSPENSION 2 - 73 5. Loosely install the rear stabilizer clamps (1-3). 6. Install the rear stabilizer bar links (2) to the rear control arm. Tighten to 30 N·m (22 ft. lbs.). 7. Tighten the rear stabilizer clamp nuts (1). Tighten to 20 N·m (15 ft.
Page 98: Differential & Driveline
2 - 74 REAR SUSPENSION 8. Install the propeller shaft to the rear differential car- rier. (Refer to 3 - DIFFERENTIAL & DRIVELINE/ PROPELLER SHAFT - INSTALLATION). 9. Install the rear parking brake cables (2) to the park- ing brake equalizer (1). (Refer to 5 - BRAKES/ PARKING BRAKE/CABLES - INSTALLATION).
Page 99: Shock Removal
REAR SUSPENSION 2 - 75 11. Install the rear wheel speed sensors (2). (Refer to 5 - BRAKES/ELECTRICAL/REAR WHEEL SPEED SENSOR - INSTALLATION). 12. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). SHOCK REMOVAL Note: The vehicle must be resting on its wheels before removing the top shock absorber mounting hardware.
Page 100: Installation
2 - 76 REAR SUSPENSION 3. Remove the lower control arm plastic cover by removing the bolts (1) attaching the cover to the lower control arm. 4. Remove the shock absorber (1) from the lower control arm. 5. Inspect the shock absorber. INSTALLATION 1.
Page 101 REAR SUSPENSION 2 - 77 2. Install the lower control arm plastic cover and bolt (1). 3. Slowly lower the vehicle while guiding the top of the shock into the mounting hole in the frame. 4. Install the top shock absorber mounting hardware (1).
Page 102: Spring Removal
2 - 78 REAR SUSPENSION SPRING REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the control arm cover by removing the bolts (1) from the cover. 4. Remove the lower shock bolts (2) from the lower control arm.
Page 103 REAR SUSPENSION 2 - 79 5. Brace the rear suspension lower control arm with a suitable lifting device. 6. Raise the control arm until the halfshaft is horizon- tal. 7. Using Special Tool 9152 Compressor Plates and 9150 Spring Compressor (1) compress the rear spring.
Page 104: Installation
2 - 80 REAR SUSPENSION INSTALLATION 1. Install the spring into the spring pocket. 2. Swing the lower control arm (2) up and install the bolt attaching the control arm to the frame (1). 3. Carefully release the spring (1) insuring the spring properly aligns with the spring perch detents.
Page 105: Rear Axle Carrier
REAR SUSPENSION 2 - 81 5. Install the control arm cover and bolts (1). 6. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). 7. Check vehicle alignment. (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
Page 106 2 - 82 REAR SUSPENSION 4. Remove the left and right rear disc brake caliper bolts (1). 5. Remove the rear disc brake calipers. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). CAUTION: Supporting the weight of the caliper by the flexible brake hose can damage the hose.
Page 107 REAR SUSPENSION 2 - 83 9. Remove the right and left Wheel Speed Sensors (2). (Refer to 5 - BRAKES/ELECTRICAL/REAR WHEEL SPEED SENSOR - REMOVAL). 10. Remove the left and right rear axle halfshaft nuts (1). 11. Remove the rear axle halfshafts. (Refer to 3 - DIF- FERENTIAL &...
Page 108 2 - 84 REAR SUSPENSION 13. Remove the rear shock absorbers (1). (Refer to 2 - SUSPENSION/REAR/SHOCK - REMOVAL). CAUTION: Do not disconnect any of the fuel lines from the fuel pump assembly. 14. Remove the fuel pump mounting bolts.(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - REMOVAL).
Page 109 REAR SUSPENSION 2 - 85 19. Remove the rear two bolts (2) from the rear axle carrier attaching it to the frame. 20. Remove the rear axle carrier (1) from the vehicle by lowering it out of the vehicle with a suitable tool (2).
Page 110 2 - 86 REAR SUSPENSION 22. Remove the trailing link bolt (1). (Refer to 2 - SUSPENSION/REAR/TRAILING LINK REMOVAL). 23. Remove the lateral link bolt (1). (Refer to 2 - SUSPENSION/REAR/LATERAL LINK REMOVAL). 24. Remove the track bar bolt (inner). (Refer to 2 - SUSPENSION/REAR/TRACK BAR - REMOVAL).
Page 111: Installation
REAR SUSPENSION 2 - 87 25. Remove the stabilizer bar link (2). (Refer to 2 - SUSPENSION/REAR/STABILIZER REMOVAL). 26. Remove the lower control arm. (Refer to 2 - SUS- PENSION/REAR/LOWER CONTROL REMOVAL). INSTALLATION 1. Install the camber strut bolt (1). (Refer to 2 - SUS- PENSION/REAR/TOE LINK - INSTALLATION).
Page 112 2 - 88 REAR SUSPENSION 2. Install the trailing link bolt (1). (Refer to 2 - SUS- PENSION/REAR/TRAILING LINK INSTALLA- TION). 3. Install the lateral link bolt (1). (Refer to 2 - SUS- PENSION/REAR/LATERAL LINK INSTALLA- TION). 4. Install the track bar bolt. (Refer to 2 - SUSPEN- SION/REAR/TRACK BAR - INSTALLATION).
Page 113 REAR SUSPENSION 2 - 89 5. Install the stabilizer bar link (2). (Refer to 2 - SUS- PENSION/REAR/STABILIZER BAR - INSTALLA- TION). 6. Install the lower control arm. (Refer to 2 - SUS- PENSION/REAR/LOWER CONTROL INSTALLATION). 7. Install the rear axle carrier (1) by raising it up and installing the four bolts to the frame.
Page 114 2 - 90 REAR SUSPENSION 9. Install the propeller shaft assembly to the rear axle differential. (Refer to 3 - DIFFERENTIAL & DRIV- ELINE/PROPELLER SHAFT - INSTALLATION). 10. Install the fuel pump assembly. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - INSTALLATION).
Page 115 REAR SUSPENSION 2 - 91 13. Install the rear axle halfshafts. (Refer to 3 - DIF- FERENTIAL & DRIVELINE/HALF SHAFT INSTALLATION). 14. Install the right and left Wheel Speed Sensors (2). (Refer BRAKES/ELECTRICAL/REAR WHEEL SPEED SENSOR - INSTALLATION). 15. Install the parking brake rear cables (2) to the parking brake cable equalizer (1).
Page 116 2 - 92 REAR SUSPENSION 16. Install the rear portion of the exhaust system (Refer to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLATION). 17. Install the rear disc brake calipers and bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANI- CAL/DISC BRAKE CALIPERS - INSTALLATION). 18.
Page 117 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page HALFSHAFTS ......1 REAR DIFFERENTIAL .
Page 118: Halfshafts
3 - 2 HALFSHAFTS HALFSHAFTS DESCRIPTION Articulated halfshafts deliver power from the rear differential to the wheels through constant velocity (C/V) joints that minimize vibration.
Page 119: Operation
HALFSHAFTS 3 - 3 OPERATION Halfshaft assemblies are designed to transmit power from the differential to the wheels, while allowing for powertrain and suspension flex. DIAGNOSIS AND TESTING - DRIVELINE HALFSHAFT VISUAL INSPECTION 1. Check for grease in the vicinity of the inboard and outboard C/V joint. If grease is present, this may be a sign that the inner or outer boots, or the retaining clamps are damaged.
Page 120: Removal
3 - 4 HALFSHAFTS 3. Improper wheel alignment. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, snow, etc. packed on the backside of the wheels). 2. Out of balance tires or wheels. 3. Improper tire and/or wheel runout. REMOVAL 1.
Page 121: Installation
HALFSHAFTS 3 - 5 CAUTION: When removing the halfshaft assembly, do not allow the snap ring to drag across the seal- ing lip of the differential oil seal. 6. Carefully pull the halfshaft (1) out of the differential housing, and remove the halfshaft from the vehicle. INSTALLATION 1.
Page 122: Specifications - Torque
3 - 6 HALFSHAFTS 6. Install the rear knuckle (1). (Refer to 2 - SUSPEN- SION/REAR/KNUCKLE - INSTALLATION). Note: A new halfshaft outer retaining nut must be used. 7. Install the rear wheels. (Refer to 22 - TIRES/ WHEELS - STANDARD PROCEDURE). SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION...
Page 123 HALFSHAFTS 3 - 7 2. Remove the inner C/V boot retaining clamp (1) from the axle halfshaft. 3. Remove the outer C/V boot retaining clamp (2) from the C/V joint housing. 4. Clamp the axle halfshaft in a vise. CAUTION: Insure to use a vise that is equipped with protective caps on the jaws of the vise to pre- vent any damage to the axle halfshaft.
Page 124: Installation
3 - 8 HALFSHAFTS 9. Slide the C/V boot off of the axle halfshaft. 10. Thoroughly clean and inspect the inner C/V joint assembly for any signs of excessive wear. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT/CV JOINT - INSPECTION) INSTALLATION 1.
Page 125 HALFSHAFTS 3 - 9 5. Align the splines on the axle halfshaft (1) with the splines on the C/V joint assembly (3). Note: The C/V joint assembly must be installed on axle halfshaft until the C/V joint assembly is seated against the circlip on the halfshaft. 6.
Page 126 3 - 10 HALFSHAFTS Note: The C/V boot must be positioned on the axle halfshaft so the raised bead on the inside of the C/V boot is in the groove on the axle halfshaft. 9. Install the C/V boot outer end into the sealing groove (1) of the C/V joint housing.
Page 127 HALFSHAFTS 3 - 11 Note: The jaws of the crimping tool must be closed completely for proper sealing. 13. Crimp the new C/V boot retaining clamp (3). 14. Install the half shaft to the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION).
Page 128: Cv Boot - Outer
3 - 12 HALFSHAFTS CV BOOT - OUTER REMOVAL 1. Remove the halfshaft from the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL). 2. Remove the outer C/V boot retaining clamp (2) from the axle halfshaft. 3. Remove the inner C/V boot retaining clamp (1) from the C/V joint housing.
Page 129 HALFSHAFTS 3 - 13 4. Clamp the axle halfshaft in a vise. CAUTION: Insure to use a vise that is equipped with protective caps on the jaws of the vise to pre- vent any damage to the axle halfshaft. 5. Remove the C/V boot from the outer C/V joint housing and slide it down the axle halfshaft.
Page 130: Installation
3 - 14 HALFSHAFTS INSTALLATION 1. Clean and inspect the C/V joint for wear and pit- ting. Replace as required. (Refer to 3 - DIFFEREN- TIAL & DRIVELINE/HALF SHAFT/C/V JOINT - INSPECTION). 2. Remove any road grime and debris from the axle shaft splines.
Page 131 HALFSHAFTS 3 - 15 5. Align the splines on the axle halfshaft (1) with the splines on the C/V joint assembly (3). 6. Install the outer C/V joint assembly onto the axle halfshaft by using a soft–faced hammer and tap- ping the end of the stub axle (with nut installed) until the outer C/V joint is fully seated on the axle halfshaft.
Page 132 3 - 16 HALFSHAFTS Note: The C/V boot must be positioned on the axle halfshaft so the raised bead on the inside of the C/V boot is in the groove on the axle halfshaft. 9. Install the C/V boot outer end into the sealing groove (1) of the C/V joint housing.
Page 133 HALFSHAFTS 3 - 17 Note: The jaws of the crimping tool must be closed completely for proper sealing. 13. Crimp the new C/V boot retaining clamp (3). 14. Install the half shaft to the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION).
Page 134: Cv Joint
3 - 18 HALFSHAFTS CV JOINT REMOVAL 1. Remove the halfshaft from the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL). 2. Remove the inner C/V boot retaining clamp (1) from the axle halfshaft. 3. Remove the outer C/V boot retaining clamp (2) from the C/V joint housing.
Page 135 HALFSHAFTS 3 - 19 4. Clamp the axle halfshaft in a vise. CAUTION: Insure to use a vise that is equipped with protective caps on the jaws of the vise to pre- vent any damage to the axle halfshaft. 5. Remove the C/V boot from the C/V joint housing and slide it down the axle halfshaft.
Page 136: Inspection
3 - 20 HALFSHAFTS INSPECTION DISASSEMBLING 1. Before disassembling the C/V joint assembly, mark the positions of joint ring, joint hub and the bearing cage with a suitable marking tool (1). 2. Rotate the bearing cage inside of the joint hub (arrow) and remove the bearing balls one at a time.
Page 137 HALFSHAFTS 3 - 21 4. Pivot the joint hub 90° relative to the bearing cage and remove it from the assembly. 5. Thoroughly clean all the parts. INSPECTION 1. Inspect the roller tracks in the C/V joint housing (1), bearing cage (2), and joint hub (4). Inspect the bearing balls (3) for signs of pitting or wear.
Page 138 3 - 22 HALFSHAFTS ASSEMBLING 1. Hold the joint hub vertically relative to the bearing cage, then guide it into place. 2. Insert one bearing ball, paying attention to the alignment marks on the joint hub and bearing cage. 3. Insert the joint hub with the bearing cage and the bearing ball in the joint ring while ensuring that the markings are properly aligned.
Page 139: Installation
HALFSHAFTS 3 - 23 4. Tilt the joint hub out with the bearing cage to allow the bearing balls to be inserted one after the other. 5. The C/V joint is now ready to be installed on the halfshaft. INSTALLATION 1.
Page 140 3 - 24 HALFSHAFTS 2. Install the C/V joint assembly onto the axle half- shaft by using a soft–faced hammer and tapping the end of the stub axle until the C/V joint is fully seated on the axle halfshaft. Note: The C/V joint assembly must be installed on axle halfshaft until the C/V joint assembly is seated against the circlip on the halfshaft.
Page 141 HALFSHAFTS 3 - 25 7. Position the inner C/V boot retaining clamp (1) and the outer C/V boot retaining clamp (2) into the seal- ing grooves on the C/V boot. 8. Position the crimping tool (1) on the C/V boot retaining clamp (3).
Page 142 3 - 26 PROPELLER SHAFT PROPELLER SHAFT TABLE OF CONTENTS page page PROPELLER SHAFT INSTALLATION ......35 DESCRIPTION .
Page 143 PROPELLER SHAFT 3 - 27 CAUTION: Propeller shafts are balanced by the manufacturer. Before undercoating a vehicle, the propeller shaft and universal joints should be covered. This will prevent the undercoating from causing an unbal- anced condition and vibration. CAUTION: Never allow the propeller shaft to drop or hang from the universal joint during removal. Suspend the shaft to the vehicles underside with wire to prevent damage to the universal joints.
Page 144: Propeller Shaft
3 - 28 PROPELLER SHAFT 8. Mark and number the propeller shaft six inches from the transmission end at four positions 90° apart. 9. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine.
Page 145: Shaft
PROPELLER SHAFT 3 - 29 14. If the additional clamp causes an additional vibra- tion, separate the clamps 0.5 inch (13 mm) above and below the mark. Repeat the vibration test. 15. Increase the distance between the clamps and repeat the test until the amount of vibration is at the lowest level.
Page 146 3 - 30 PROPELLER SHAFT 4. Remove the rear transmission tunnel support bracket bolts (1) and the bracket. 5. Support the transmission with a jack stand. 6. Remove the transmission mount bolts (1). 7. Remove the transmission crossmember bolts (2). 8.
Page 147: Installation
PROPELLER SHAFT 3 - 31 13. Remove the center bearing bracket bolts (1). 14. Carefully remove the propeller shaft from the vehicle. INSTALLATION Note: Align the marks of the front and rear propel- ler shaft flange to the transmission output flange and the rear axle pinion flange.
Page 148 3 - 32 PROPELLER SHAFT 8. Install the transmission tunnel support bracket. 9. Install the transmission tunnel support bracket bolts (1). Tighten the bolts to 20 N·m (15 ft. lbs.). 10. Position the transmission crossmember and trans- mission mount on the vehicle. 11.
Page 149: Specifications
PROPELLER SHAFT 3 - 33 SPECIFICATIONS SPECIFICATIONS - CENTERING SLEEVES CENTERING SLEEVE SPECIFICATIONS DESCRIPTION Automatic Transmission Front 1.13 28.8 Sleeve Automatic Transmission Rear 0.98 24.9 Sleeve Manual Transmission Front Sleeve 1.06 26.8 Manual Transmission Rear Sleeve 1.06 26.9 SPECIFICATION - RUNOUT Note: Measure front/rear runout approximately 3 inches (76 mm) from the weld seam at each end of the shaft tube for tube lengths over 30 inches.
Page 150: Center Bearing
3 - 34 PROPELLER SHAFT CENTER BEARING REMOVAL 1. Remove the propeller shaft. (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/PROPELLER SHAFT/CEN- TER BEARING - REMOVAL). 2. Separate the propeller shaft sections. 3. Use a jaw puller to remove the rubber mount and the bearing (2) from the propeller shaft (1).
Page 151: Installation
PROPELLER SHAFT 3 - 35 INSTALLATION 1. Press the bearing into the rubber mount. 2. Press the bearing and rubber mount onto the pro- peller shaft using a shop press and bearing adapter. 3. Grease the propeller shaft splines with Mopar heavy duty grease.
Page 152 3 - 36 PROPELLER SHAFT 6. Place a socket (2) with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press (1) the cap through the yoke to release the lower bearing cap. 7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap.
Page 153: Assembly
PROPELLER SHAFT 3 - 37 ASSEMBLY CAUTION: If the cross or bearing cap are not straight during assembly, the bearing cap will score the walls of the yoke bore and damage can occur. 1. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to the inside of the yoke bores.
Page 154: Centering And Fitted Sleeves
3 - 38 PROPELLER SHAFT 4. Press the bearing cap into the yoke bore enough to clear the snap ring groove. 5. Install a snap ring (1). Note: If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6.
Page 155: Removal - Fitted Sleeves
PROPELLER SHAFT 3 - 39 REMOVAL - FITTED SLEEVES 1. Raise and support the vehicle. 2. Remove the flange bolt and nut. 3. Use a drift punch (2) or extension to loosen the fit- ted sleeve (1). 4. Remove the fitted sleeve (1). INSTALLATION INSTALLATION - CENTERING SLEEVES 1.
Page 156 3 - 40 REAR DIFFERENTIAL REAR DIFFERENTIAL TABLE OF CONTENTS page page REAR DIFFERENTIAL SPECIAL TOOLS ......44 DESCRIPTION .
Page 157 REAR DIFFERENTIAL 3 - 41 Worn or damaged differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differential bearing noise is also constant and varies only with vehicle speed. Rear wheel hub bearings produce noise and vibration when worn or damaged.
Page 158 3 - 42 REAR DIFFERENTIAL DIAGNOSTIC CHART CONDITION POSSIBLE CAUSES CORRECTION WHEEL NOISE 1. Wheel loose. 1. Tighten loose wheel bolts. 2. Faulty wheel hub bearing. 2. Replace bearing. DIFFERENTIAL CRACKED 1. Improper adjustment of the 1. Replace differential. differential bearings. 2.
Page 159: Description
REAR DIFFERENTIAL 3 - 43 STANDARD PROCEDURE - DRAIN AND REFILL 1. Drive the vehicle until the differential lubricant is at the normal operating temperature. 2. Raise and support the vehicle. 3. Remove the differential housing fill plug (1). 4. Position a drain pan under the differential housing drain.
Page 160: Rear Differential
3 - 44 REAR DIFFERENTIAL SPECIAL TOOLS...
Page 161: Rear Differential Housing
REAR DIFFERENTIAL 3 - 45 REAR DIFFERENTIAL HOUSING REMOVAL 1. Raise and support the vehicle. 2. Remove the propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - REMOVAL). 3. Drain the rear differential housing. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR AXLE - STANDARD PRO- CEDURE).
Page 162: Installation
3 - 46 REAR DIFFERENTIAL INSTALLATION Note: Replace the self locking bolts and shims. Lightly oil the bolt at the thread and bolt head contact surfaces. 1. Position the differential housing in the vehicle and support it with a jack. 2.
Page 163: Pinion Flange Seal
REAR DIFFERENTIAL 3 - 47 PINION FLANGE SEAL REMOVAL 1. Raise and support the vehicle. 2. Drain the differential housing. (Refer to 3 - DIF- FERENTIAL & DRIVELINE/REAR AXLE - STAN- DARD PROCEDURE). 3. Remove the muffler. (Refer to 11 - EXHAUST SYS- TEM/MUFFLER - REMOVAL).
Page 164: Installation
3 - 48 REAR DIFFERENTIAL 10. Remove the pinion flange seal (1) with a suitable prying tool. INSTALLATION 1. Remove any burrs or nicks from the seal bore. 2. Drive in a new pinion flange seal (1) using Special Tool 9231 Drift and a mallet. 3.
Page 165: Axle Shaft Seals
REAR DIFFERENTIAL 3 - 49 9. Fill the differential housing to specification. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR AXLE - STAN- DARD PROCEDURE). 10. Lower the vehicle. AXLE SHAFT SEALS REMOVAL 1. Remove the halfshaft (1).(Refer to 3 - DIFFEREN- TIAL &...
Page 166: Installation
3 - 50 REAR DIFFERENTIAL INSTALLATION 1. Lubricate the new axle shaft seal with hypoid gear oil. 2. Using the Special Tool 9223 Drift (1), drive the new axle shaft seal (2) into the differential housing. 3. Install the halfshaft (1). (Refer to 3 - DIFFEREN- TIAL &...
Page 167 BRAKES - BASE 5 - 1 BRAKES - BASE TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS SERVICE INFORMATION .
Page 168 5 - 2 BRAKES - BASE DIAGNOSIS AND TESTING INSTALLATION MASTER CYLINDER/POWER BOOSTER ..44 INSTALLATION ..... . . 63 DIAGNOSIS AND TESTING - MASTER INSTALLATION - RHD .
Page 169: Brakes - Base
BRAKES - BASE 5 - 3 BRAKES - BASE DESCRIPTION 1 - BAS BRAKE BOOSTER 8 - BAS DIAPHRAGM TRAVEL SENSOR 2 - BAS SOLENOID VALVE 9 - COMPRESSION SPRING 3 - AIR FILTER 10 - OUTPUT ROD 4 - AIR FILTER 11 - CABLE CONNECTOR FOR RELEASE SWITCH AND SOLENOID VALVE 5 - POPPET VALVE...
Page 170: Warning
5 - 4 BRAKES - BASE Single piston brake calipers (3) are used on the front and on the rear. Ventilated disc brake rotors (2) are used on the front and solid disc brake rotors are used on the rear. The master cylinder has an aluminum body and a nylon reservoir with a single filler cap.
Page 171: Diagnosis And Testing - Base Brake System
BRAKES - BASE 5 - 5 CAUTION: Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing min- eral oil to clean the system components. These fluids damage rubber cups and seals. Use only fresh brake fluid or Mopar brake cleaner to clean or flush brake system components. These are the only cleaning mate- rials recommended.
Page 172: Cooling
5 - 6 BRAKES - BASE ROAD TESTING (1) If the complaint involved a low brake pedal, pump the pedal and note if it comes back up to the normal height. (2) Check the brake pedal response with the transmission in neutral and the engine running. The pedal should remain firm under constant foot pressure.
Page 173 BRAKES - BASE 5 - 7 A severe drag can char the brake pads all the way through. It can also distort and score the rotors to the point of replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the brake pads may generate smoke as it chars from over-heating.
Page 174: Standard Procedure Standard Procedure - Manual
5 - 8 BRAKES - BASE BRAKE LINING CONTAMINATION Brake pad contamination is mostly a product of leaking calipers or worn seals, driving through deep water puddles, or a pad that has become covered with grease or grit during repair. A contaminated pad should be replaced to avoid further brake concerns.
Page 175: Standard Procedure - Pressure Bleeding
BRAKES - BASE 5 - 9 3. Attach one end of the bleed hose (1) to the bleed screw and insert the opposite end in a glass con- tainer (2) partially filled with brake fluid. Be sure the end of the bleed hose is immersed in the brake fluid.
Page 176: Specifications
5 - 10 BRAKES - BASE SPECIFICATIONS BRAKE COMPONENTS SPECIFICATIONS DESCRIPTION SPECIFICATION Front Front Disc Brake Caliper Type Base Floating Fixed Front Disc Brake Caliper Piston Type Base Single 2-Piston (opposed) Front Disc Brake Rotor Type Base Ventilated Ventilated Disc Brake Rotor Diameter Base 300 mm (11.8 in.)
Page 177 BRAKES - BASE 5 - 11 DESCRIPTION SPECIFICATION Rear Rear Disc Brake Caliper Type Base Fixed Fixed Rear Disc Brake Caliper Piston Type Base 2-Piston (opposed) 2-Piston (opposed) Rear Disc Brake Rotor Type Base Solid Ventilated Disc Brake Rotor Diameter Base 278 mm (10.94 in.) 300 mm (11.8 in.)
Page 178: Brake Lines
5 - 12 BRAKES - BASE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Brake Booster Mounting Nuts Front Caliper Bracket Mounting Bolts 1020 Front Caliper Bleed Screw Front Caliper Slide Pins Master Cylinder Mounting Nuts Master Cylinder Primary Brake Line Master Cylinder Secondary Brake Line Rear Caliper Bracket Mounting Bolts Rear Caliper Bleed Screw...
Page 179: Standard Procedure - Iso Flaring
BRAKES - BASE 5 - 13 1. Cut off damaged tube with a Tubing Cutter. 2. Ream the cut edges of the tubing to ensure a proper flare. 3. Install the replacement tube nut on the tube. 4. Insert the tube in the flaring tool. 5.
Page 180: Removal
5 - 14 BRAKES - BASE REMOVAL FRONT BRAKE HOSE CAUTION: Do not spill brake fluid on any painted surface. Brake fluid can damage paint. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Disconnect the brake hose (4) from the caliper (3). 4.
Page 181: Rear Brake Hose
BRAKES - BASE 5 - 15 REAR BRAKE HOSE CAUTION: Do not spill brake fluid on any painted surface. Brake fluid can damage paint. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Disconnect the brake hose (1) from the brake line connection.
Page 182: Installation
5 - 16 BRAKES - BASE INSTALLATION FRONT BRAKE HOSE 1. Connect the brake hose (3) to the brake line con- nection (2). 2. Route the brake hose (1) behind the steering knuckle (2) and connect to the caliper.
Page 183: Installation - Rear Brake Hose
BRAKES - BASE 5 - 17 3. Connect the brake hose (4) at the caliper (3). 4. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). 5. Lower the vehicle. 6. Fill and bleed brake system. •...
Page 184: Brake Pads/Shoes
5 - 18 BRAKES - BASE 2. Route the brake hose (1) behind the rear shock (2) and connect to the caliper (3). 3. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). 4. Lower the vehicle. 5.
Page 185 BRAKES - BASE 5 - 19 6. Disconnect the brake pad wear indicator harness connector. 7. Remove the caliper slide pin caps (3) and then remove the caliper slide pins (2) from the caliper (1). CAUTION: Never allow the disc brake caliper to hang from the brake hose.
Page 186: Removal - Rear Disc Brake Pads
5 - 20 BRAKES - BASE 9. Remove the inboard (2) and outboard (3) brake pads from the caliper. REMOVAL - REAR DISC BRAKE PADS 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from the master cyl- inder brake reservoir with a clean suction gun.
Page 187 BRAKES - BASE 5 - 21 5. Remove the brake hose (1) from the caliper (2) by rotating the caliper while holding the brake hose with a line wrench. 6. Using a suitable punch (1) knock out the retaining pin (4) that holds the pads in place. 7.
Page 188: Installation
5 - 22 BRAKES - BASE INSTALLATION FRONT DISC BRAKE PADS Note: If the caliper piston is not completely bot- tomed out into the caliper, you must do so in order to install the caliper onto the rotor. Use a C-clamp to bottom out caliper.
Page 189 BRAKES - BASE 5 - 23 3. Install the caliper (1) on the caliper mounting bracket (2). 4. Install the caliper slide pins (2). Tighten the slide pins to 25 N·m (18 ft. lbs.). 5. Install the caliper slide pin caps (3). 6.
Page 190: Installation - Rear Disc Brake Pads
5 - 24 BRAKES - BASE 7. Install the caliper support spring (2) in the top end of the caliper under the caliper mounting bracket (1). Then install the other end into the lower caliper hole (3). Hold the spring (2) into the caliper (1) with your thumb while prying the end of the spring (2) out and down under the caliper mounting bracket with a screwdriver.
Page 191: Disc Brake Calipers
BRAKES - BASE 5 - 25 4. Install wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). 5. Lower the vehicle. 6. Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved.
Page 192: Brakes - Base
5 - 26 BRAKES - BASE The caliper piston seals (5) control the amount of pis- ton (1) extension needed to compensate for normal lining wear. During brake application the seals (6) are deflected outward by fluid pressure and piston (1) movement. When the brakes (and fluid pressure) are released, the seals (3) relax and retract the piston (1).
Page 193 BRAKES - BASE 5 - 27 5. Remove brake pad wear indicator (1) from caliper (2) by removing the retaining bolt. 6. Bottom the caliper piston into the caliper by prying the caliper over. 7. Remove the caliper support spring (2) by prying the spring out of the caliper (1).
Page 194 5 - 28 BRAKES - BASE 9. Remove the caliper (1) from the mounting bracket (2). CAUTION: DO NOT spill the brake fluid on any painted surfaces. Brake fluid can damage paint. 10. Remove the brake hose (4) from the caliper (3). 11.
Page 195: Removal - Rear Brake Caliper
BRAKES - BASE 5 - 29 REMOVAL - REAR BRAKE CALIPER 1. Raise and support the vehicle. 2. Remove the rear tire and wheel assembly. 3. Drain a small amount of fluid from the master cyl- inder brake reservoir with a clean suction gun. 4.
Page 196: Disassembly - Front Disc Brake Caliper
5 - 30 BRAKES - BASE DISASSEMBLY - FRONT DISC BRAKE CALIPER 1. Drain the brake fluid from the caliper. 2. Take a piece of wood and pad it with a one-inch thickness of shop towels. Place this piece (1) on the outboard side of the caliper (2) in front of the piston.
Page 197: Cleaning - Disc Brake Caliper
BRAKES - BASE 5 - 31 CLEANING - DISC BRAKE CALIPER CAUTION: DO NOT use gasoline, kerosene, paint thinner or similar solvents. These products may leave a residue that could damage the piston and seal. Clean the caliper components with clean brake fluid or Brake Clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.
Page 198: Installation
5 - 32 BRAKES - BASE 2. Install the new piston seal (2) into the seal groove. 3. Install the new dust boot (4) on the caliper piston (3) and seat the dust boot lip into the piston groove. 4. Stretch the dust boot (4) rearward to straighten the boot folds, then move the boot forward until the fold snaps into place.
Page 199 BRAKES - BASE 5 - 33 3. Install the caliper (1) on the mounting bracket (2). 4. Install the caliper slide pins (2). Tighten the slide pins to 25 N·m (18 ft. lbs.). 5. Install the caliper slide pin caps (3). 6.
Page 200 5 - 34 BRAKES - BASE 7. Connect the brake wear indicator to the brake pad. 8. Install one end of the caliper support spring (2) in the top end of the caliper and under the mounting bracket (1). 9. Install the other end into the lower caliper hole (3). 10.
Page 201: Installation - Rear Disc Brake Caliper
BRAKES - BASE 5 - 35 15. Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved. 16. Top off the brake fluid reservoir with new fluid if necessary, and check for leaks. INSTALLATION - REAR DISC BRAKE CALIPER 1.
Page 202: Rotors
5 - 36 BRAKES - BASE ROTORS DIAGNOSIS AND TESTING DISC BRAKE ROTORS REAR ROTOR MINIMUM THICKNESS Minimum usable thickness of the rear disc brake rotor is 0.299 in. (7.6 mm). The thickness specification is located on the center section of the rotor. Never resurface a rotor if at minimum thickness.
Page 203 BRAKES - BASE 5 - 37 FRONT ROTOR MINIMUM THICKNESS Rotor minimum thickness is 0.889 in. (22.6 mm). Do not resurface a rotor if at minimum thickness. Machining would cause thickness to fall below this limit. Measure rotor thickness at the center of the brake pad contact surface. Replace the rotor if worn below the mini- mum thickness, or if refinishing would reduce thickness below the allowable limit.
Page 204: Standard Procedure
5 - 38 BRAKES - BASE STANDARD PROCEDURE DISC BRAKE ROTOR MACHINING WARNING: BRAKE ROTORS THAT DO NOT MEET MINIMUM THICKNESS SPECIFICATIONS BEFORE OR AFTER MACHINING MUST BE REPLACED. Note: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles hub/bearing.
Page 205: Removal - Rear Disc Brake Rotor
BRAKES - BASE 5 - 39 CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose can result. Provide a suitable support to hang the caliper securely. 5. Remove the retaining bolt and then remove the brake rotor (1) from the wheel hub.
Page 206: Installation
5 - 40 BRAKES - BASE CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the hose can result. Provide a suitable support to hang the caliper securely. 4. Remove the rotor retaining bolt and remove the rotor (1) from the wheel hub.
Page 207 BRAKES - BASE 5 - 41 3. Install the caliper and bracket assembly (1) on the knuckle (2). 4. Install the caliper bracket mounting bolts (3). Tighten the mounting bolts to 115 N·m (85 ft. lbs.). 5. Connect the brake pad wear indicator. 6.
Page 208: Installation - Rear Disc Brake Rotor
5 - 42 BRAKES - BASE INSTALLATION - REAR DISC BRAKE ROTOR 1. Install the rotor (1) onto the wheel hub. 2. Install the rotor retaining bolt. Tighten to 10 N·m (7 ft. lbs.). 3. Install caliper assembly onto rotor. 4.
Page 209: Standard Procedure
BRAKES - BASE 5 - 43 STANDARD PROCEDURE MASTER CYLINDER FLUID LEVEL Always clean the master cylinder reservoir and cap before adding fluid. This will prevent dirt from falling in the reservoir and contaminating the brake fluid. The reservoir (2) has a MIN” and a “MAX” mark (1) on the side.
Page 210: Master Cylinder
5 - 44 BRAKES - BASE MASTER CYLINDER DESCRIPTION MASTER CYLINDER The master cylinder body is made of aluminum and contains a primary and secondary piston assembly. The cylinder body including the piston assemblies are not serviceable. If diagnosis indicates an internal prob- lem with the cylinder body, it must be replaced as an assembly.
Page 211: Diagnosis And Testing - Master Cylinder Fluid Loss
BRAKES - BASE 5 - 45 POWER BOOSTER VACUUM TEST 1. Connect the vacuum gauge (7) to the booster check valve (3) with the short length of hose (2) and the T-fitting (1). 2. Start and run the engine at a curb idle speed for one minute.
Page 212: Standard Procedure
5 - 46 BRAKES - BASE STANDARD PROCEDURE MASTER CYLINDER BLEEDING PROCEDURE A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1.
Page 213: Removal
BRAKES - BASE 5 - 47 REMOVAL REMOVAL CAUTION: Do not spill brake fluid on any painted surfaces. Brake fluid can damage paint. 1. Disconnect the brake fluid level sensor harness connector (2) from the reservoir (1). 2. Disconnect the master cylinder brake fluid pressure sensor (4) harness connectors. 3.
Page 214: Removal - Rhd
5 - 48 BRAKES - BASE REMOVAL - RHD CAUTION: Do not get brake fluid on any painted surfaces. Brake fluid can damage paint. 1. Disconnect the negative battery cable. 2. Disconnect the brake fluid level sensor harness connector (2) from the reservoir (1). 3.
Page 215: Installation
BRAKES - BASE 5 - 49 INSTALLATION INSTALLATION 1. Bleed the master cylinder on a bench. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - STANDARD PROCEDURE). 2. Install the O-ring (7) onto the master cylinder (5). 3. Install the master cylinder (5) to the booster (6). Install the mounting nuts. Tighten to 20 N·m (15 ft. lbs.). 4.
Page 216: Installation - Rhd
5 - 50 BRAKES - BASE INSTALLATION - RHD 1. Bleed the master cylinder on a bench. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - STANDARD PROCEDURE). 2. Install the master cylinder (5) to the booster (6). Install the mounting nuts and tighten to 20 N·m (15 ft. lbs.). 3.
Page 217: Power Brake Booster
BRAKES - BASE 5 - 51 POWER BRAKE BOOSTER DESCRIPTION 1 - BAS BRAKE BOOSTER 8 - BAS DIAPHRAGM TRAVEL SENSOR 2 - BAS SOLENOID VALVE 9 - COMPRESSION SPRING 3 - AIR FILTER 10 - OUTPUT ROD 4 - AIR FILTER 11 - CABLE CONNECTOR FOR RELEASE SWITCH AND SOLENOID VALVE 5 - POPPET VALVE...
Page 218: Operation
5 - 52 BRAKES - BASE OPERATION 1 - BAS BRAKE BOOSTER 8 - BAS DIAPHRAGM TRAVEL SENSOR 2 - BAS SOLENOID VALVE 9 - COMPRESSION SPRING 3 - AIR FILTER 10 - OUTPUT ROD 4 - AIR FILTER 11 - CABLE CONNECTOR FOR RELEASE SWITCH AND SOLENOID VALVE 5 - POPPET VALVE 12 - VACUUM CONNECTION...
Page 219: Removal
BRAKES - BASE 5 - 53 REMOVAL REMOVAL 1. Remove the master cylinder. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - REMOVAL). 2. Disconnect the vacuum hose (1) at the booster check valve (2). 3. Remove the brake rod pin retaining clip (4) that holds the boosters push rod (1) to the pedal (3).
Page 220: Removal - Rhd
5 - 54 BRAKES - BASE 4. Remove the booster retaining nuts (2) and the gas- ket (3) that attach the booster (1) to the dash panel. 5. Slide booster forward, tilt the booster upward slightly, then remove the booster from the engine compartment.
Page 221 BRAKES - BASE 5 - 55 5. Remove the brake rod pin retaining clip (4) that holds the boosters (1) push rod to the pedal (3). Then slide the push rod off the pin (2). 6. Remove the booster retaining nuts (2) that attach the booster (1) to the dash panel.
Page 222: Installation
5 - 56 BRAKES - BASE INSTALLATION INSTALLATION 1. Install a new booster gasket (3). 2. Align and position the booster (1) on the dash panel. 3. Lubricate the pedal pin with Mopar multi-mileage grease. 4. Install the booster retaining nuts (2). Tighten to 39 N·m (29 ft.
Page 223: Installation - Rhd
BRAKES - BASE 5 - 57 6. Check the condition of the grommet (2) that secures the check valve in the booster (3). Replace the grommet if it is worn or damaged. Install the vacuum hose (1) to booster check valve. 7.
Page 224 5 - 58 BRAKES - BASE 4. Align the brake booster (1) push rod to the holes on the brake pedal (3) then install the brake rod pin (2) and retaining clip (4) to the brake pedal (3). 5. Check the condition of the grommet that secures the check valve (1) in the booster.
Page 225: Pedal
BRAKES - BASE 5 - 59 PEDAL DESCRIPTION A suspended type brake pedal (5) is used, the pedal pivots on a shaft (3) mounted in the pedal support bracket. The bracket is attached to the bulkhead. OPERATION The brake pedal (3) is attached to the booster push rod (1).
Page 226: Removal
5 - 60 BRAKES - BASE REMOVAL REMOVAL 1. Remove the instrument panel lower cover (2) from the instrument panel. 2. Disconnect the stop lamp switch harness connector from the stop lamp switch (1).
Page 227: Removal - Rhd
BRAKES - BASE 5 - 61 3. Remove the return spring (7). 4. Remove the C-clip (1). 5. Remove the washer (2). 6. Remove the bushing (3). 7. Remove the brake pedal from the bracket (5). REMOVAL - RHD 1. Remove the two screws (2) from the lower I/P panel (1) then remove the lower panel from the I/P.
Page 228 5 - 62 BRAKES - BASE 2. Disconnect the stop lamp harness connector from the stop lamp switch (1). 3. Remove the return spring (7). 4. Remove the C-clip (1). 5. Remove the washer (2). 6. Remove the bushing (3). 7.
Page 229: Installation
BRAKES - BASE 5 - 63 INSTALLATION INSTALLATION 1. Install the brake pedal (5) to the bracket. 2. Install the bushing (3). 3. Install the washer (2). 4. Install the C-clip (1). 5. Install the return spring (7). 6. Install the stop lamp switch harness connector (1) to the stop lamp switch.
Page 230: Installation - Rhd
5 - 64 BRAKES - BASE 7. Install the instrument panel lower cover (2) to the instrument panel. INSTALLATION - RHD 1. Install the brake pedal (5) to the bracket. 2. Install the bushing (3). 3. Install the washer (2). 4.
Page 231 BRAKES - BASE 5 - 65 6. Install the stop lamp switch electrical connector (1) to the stop lamp switch. 7. Install the I/P lower panel (1) then install the two screws (2).
Page 232: Operation
5 - 66 BRAKES - BASE PARKING BRAKE OPERATION The parking brakes are operated by an automatic ten- sioner mechanism built into the hand lever (2) and cable system (1). The front cable (1) is connected to the hand lever and the equalizer. A set of drum type brake shoes are used for parking brakes.
Page 233 BRAKES - BASE 5 - 67 Parking brake cable (2) adjustment is controlled by the cable equalizer mechanism (1). The rear cables (2) are attached to the equalizer which uses a return spring to maintain tension and slides on the body. The front cable (5) is bolted to the equalizer (1) and the parking brake lever.
Page 234: Adjustments
5 - 68 BRAKES - BASE Excessive parking brake lever travel (sometimes described as a loose lever or too loose condition), is the result of worn brake shoes, improper brake shoe adjustment, or improperly assembled brake parts. A too loose condition can also be caused by inoperative or improperly assembled parking brake shoe parts. A condition where the parking brakes do not hold, will most probably be due to a wheel brake component.
Page 235 BRAKES - BASE 5 - 69 6. Tighten the parking brake cable tensioning bolt (3) until the parking brake cables (2) no longer sag. 7. Firmly apply the parking brake several times. 8. To fine adjust the parking brake. Tighten the park- ing brake tensioning bolt (3) until the parking brake lever can be moved one tooth with a moderate effort of approximately 90-120 N·m.
Page 236: Cables
5 - 70 BRAKES - BASE CABLES REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the rear caliper assembly bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). 4. Remove the rear brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL).
Page 237 BRAKES - BASE 5 - 71 5. Remove the parking brake shoe assembly (1-5). (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - REMOVAL). 6. Loosen the parking brake cable equalizer tensioner bolt (3). 7. Remove the front parking brake cable to the park- ing brake cable equalizer (1) retaining bolt (5).
Page 238: Installation
5 - 72 BRAKES - BASE 8. Remove the parking brake cables (2) from the parking brake cable equalizer (1). 9. Remove the parking brake shoe actuator arm by pulling the actuator arm (3) away from the rear wheel carrier assembly. 10.
Page 239 BRAKES - BASE 5 - 73 6. Install the parking brake cables (2) to the parking brake cable equalizer. 7. Install the parking brake cable equalizer to the front parking brake cable mounting bolt (5). 8. Install the parking brake shoe assembly (1-5). (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLATION).
Page 240: Lever
5 - 74 BRAKES - BASE 10. Install the rear caliper assembly bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 11. Adjust the parking brakes. (Refer to 5 - BRAKES/ PARKING BRAKE - ADJUSTMENTS). 12. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE).
Page 241 BRAKES - BASE 5 - 75 4. Remove the shifter bezel (1). (Refer to 23 - BODY/ INTERIOR/CENTER CONSOLE - REMOVAL). 5. Pull the rubber handle (1) off of the parking brake lever. Note: The rubber handle can only be removed from the parking brake lever with great force (suc- tion).
Page 242: Installation
5 - 76 BRAKES - BASE INSTALLATION 1. Install the front parking brake cable (1) through the hole in the floor. Then install the parking brake lever and bolts (2). Tighten to 20 N·m (15 ft. lbs.). 2. Connect parking brake switch harness...
Page 243 BRAKES - BASE 5 - 77 6. Install the parking brake cable equalizer (1) to the front parking brake cable mounting bolts (5). 7. Tighten the parking brake equalizer tensioning bolt (3). 8. Attach the return spring (4) from the equalizer (1) to the body frame.
Page 244: Shoes
5 - 78 BRAKES - BASE SHOES REMOVAL 1. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove the caliper assembly bolts (1). (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). 4. Remove the disc brake rotor (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL).
Page 245 BRAKES - BASE 5 - 79 5. Release the parking brake equalizer tensioning bolt (3). 6. Remove the parking brake shoe (1) return spring using a hooked pick (2). 7. Remove the parking brake shoe (1) hold down spring (3) using a pair of needle-nose pliers (2). 8.
Page 246: Installation
5 - 80 BRAKES - BASE 9. Remove the upper parking brake shoe return spring (2). 10. Remove the expanding lock (4). 11. The parking brake shoe assembly consists of the following components: • (1) Adjuster. • (2) Upper return spring. •...
Page 247 BRAKES - BASE 5 - 81 5. Install the return spring by using a hooked tool or needle-nose pliers (2). 6. Tighten the bolt (3) on the parking brake cable equalizer. (Refer to 5 - BRAKES/PARKING BRAKE/ CABLES - INSTALLATION). 7.
Page 248: Brake Fluid Level Sensor
5 - 82 BRAKES - BASE 8. Install the caliper assembly bolts (1). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). 9. Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). BRAKE FLUID LEVEL SENSOR REMOVAL CAUTION: Do not spill brake fluid on any painted surfaces.
Page 249: Installation
BRAKES - BASE 5 - 83 INSTALLATION 1. Install the fluid reservoir to the master cylinder. 2. Install the screw (1) attaching the fluid reservoir to the master cylinder. 3. Connect the brake fluid level sensor harness con- nector. 4. Fill the reservoir with MOPAR brake fluid to the proper level.
Page 250: Installation
5 - 84 BRAKES - BASE INSTALLATION 1. Install the brake pressure sensor (1). 2. Bleed the braking system. (Refer to 5 - BRAKES - STANDARD PROCEDURE). TRAVEL SENSOR REMOVAL WARNING: THE DIAPHRAGM TRAVEL SENSOR SEALING RING MAY BE SUCKED INTO THE BRAKE BOOSTER IF VACUUM IS PRESENT.
Page 251: Installation
BRAKES - BASE 5 - 85 INSTALLATION 1. Insert a new O-ring into the groove in the brake booster and ensure that it is correctly seated. 2. Rub some soapy water onto the front of the dia- phragm travel sensor so that the O-ring does not bind when inserted.
Page 252 5 - 86 BRAKES - ABS ELECTRICAL DIAGNOSTICS BRAKES - ABS ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page BRAKES - ABS ELECTRICAL DIAGNOSTICS 1038-ERROR MOTRONIC - CODING ..143 DIAGNOSIS AND TESTING 1040-NO CAN COMMUNICATIONS WITH 1000-CAB INTERNAL FAILURE - YAW RATE/ACCELERATION SENSOR .
Page 253: Diagnosis And Testing
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 87 1132-RIGHT REAR WHEEL SPEED SENSOR 1195-YAW RATE/ACCELERATION SENSOR - LOW SIGNAL ......213 CYCLE TOO LONG .
Page 254 5 - 88 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1000-CAB INTERNAL FAILURE - HARDWARE ERROR...
Page 255: 1000-Cab Internal Failure
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 89 1000-CAB INTERNAL FAILURE - HARDWARE ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 256: 1001-Cab Internal Failure - Signal Error
5 - 90 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1001-CAB INTERNAL FAILURE - SIGNAL ERROR...
Page 257 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 91 1001-CAB INTERNAL FAILURE - SIGNAL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 258: 1002-Cab Internal Failure - Left Front Inlet Valve
5 - 92 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1002-CAB INTERNAL FAILURE - LEFT FRONT INLET VALVE...
Page 259 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 93 1002-CAB INTERNAL FAILURE - LEFT FRONT INLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 260: 1003-Cab Internal Failure - Left Front Outlet Valve
5 - 94 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1003-CAB INTERNAL FAILURE - LEFT FRONT OUTLET VALVE...
Page 261 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 95 1003-CAB INTERNAL FAILURE - LEFT FRONT OUTLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 262: 1004-Cab Internal Failure - Right Front Inlet Valve
5 - 96 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1004-CAB INTERNAL FAILURE - RIGHT FRONT INLET VALVE...
Page 263 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 97 1004-CAB INTERNAL FAILURE - RIGHT FRONT INLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 264: 1005-Cab Internal Failure - Right Front Outlet Valve
5 - 98 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1005-CAB INTERNAL FAILURE - RIGHT FRONT OUTLET VALVE...
Page 265 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 99 1005-CAB INTERNAL FAILURE - RIGHT FRONT OUTLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 266: 1006-Cab Internal Failure - Left Rear Inlet Valve
5 - 100 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1006-CAB INTERNAL FAILURE - LEFT REAR INLET VALVE...
Page 267 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 101 1006-CAB INTERNAL FAILURE - LEFT REAR INLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 268: 1007-Cab Internal Failure - Left Rear Outlet Valve
5 - 102 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1007-CAB INTERNAL FAILURE - LEFT REAR OUTLET VALVE...
Page 269 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 103 1007-CAB INTERNAL FAILURE - LEFT REAR OUTLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 270: 1008-Cab Internal Failure - Right Rear Inlet Valve
5 - 104 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1008-CAB INTERNAL FAILURE - RIGHT REAR INLET VALVE...
Page 271 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 105 1008-CAB INTERNAL FAILURE - RIGHT REAR INLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 272: 1009-Cab Internal Failure - Right Rear Outlet Valve
5 - 106 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1009-CAB INTERNAL FAILURE - RIGHT REAR OUTLET VALVE...
Page 273 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 107 1009-CAB INTERNAL FAILURE - RIGHT REAR OUTLET VALVE (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 274 5 - 108 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1010-CAB INTERNAL FAILURE - LOW PRESSURE FEED VALVE 1...
Page 275: 1010-Cab Internal Failure - Low Pressure Feed Valve 1
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 109 1010-CAB INTERNAL FAILURE - LOW PRESSURE FEED VALVE 1 (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 276 5 - 110 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1011-CAB INTERNAL FAILURE - MASTER CYLINDER ISOLATION VALVE 1...
Page 277: 1011-Cab Internal Failure - Master Cylinder Isolation Valve 1
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 111 1011-CAB INTERNAL FAILURE - MASTER CYLINDER ISOLATION VALVE 1 (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 278 5 - 112 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1012-CAB INTERNAL FAILURE - LOW PRESSURE FEED VALVE 2...
Page 279: 1012-Cab Internal Failure - Low Pressure Feed Valve 2
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 113 1012-CAB INTERNAL FAILURE - LOW PRESSURE FEED VALVE 2 (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 280 5 - 114 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1013-CAB INTERNAL FAILURE - MASTER CYLINDER ISOLATION VALVE 2...
Page 281: 1013-Cab Internal Failure - Master Cylinder Isolation Valve 2
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 115 1013-CAB INTERNAL FAILURE - MASTER CYLINDER ISOLATION VALVE 2 (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 282: 1014-Valve Pml
5 - 116 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1014-VALVE PML This DTC is currently undefined.
Page 283: 1018-Cab Internal Failure - Internal Short
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 117 1018-CAB INTERNAL FAILURE - INTERNAL SHORT...
Page 284 5 - 118 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1018-CAB INTERNAL FAILURE - INTERNAL SHORT (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the internal functions of the CAB continously. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if an internal fault is detected. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 285: 1020-Can Bus Communication - General Malfunction
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 119 1020-CAN BUS COMMUNICATION - GENERAL MALFUNCTION...
Page 286 5 - 120 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1020-CAN BUS COMMUNICATION - GENERAL MALFUNCTION (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the CAN Bus network.
Page 287 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 121 1020-CAN BUS COMMUNICATION - GENERAL MALFUNCTION (CONTINUED) MEASURE THE RESISTANCE OF THE CAN C (-) BUS CIRCUIT With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the CAB har- ness connector to the harness connectors of the other modules on the CAN Bus network.
Page 288: 1022-No Can Communications With Pcm
5 - 122 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1022-NO CAN COMMUNICATIONS WITH PCM...
Page 289 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 123 1022-NO CAN COMMUNICATIONS WITH PCM (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the Power- train Control Module (PCM).
Page 290 5 - 124 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1022-NO CAN COMMUNICATIONS WITH PCM (CONTINUED) MEASURE THE RESISTANCE OF THE CAN C BUS (-) CIRCUIT With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the CAB har- ness connector to the PCM harness connector.
Page 291: 1023-Can Error Motronic - Timeout
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 125 1023-CAN ERROR MOTRONIC - TIMEOUT This DTC is currently undefined. 1024-ERROR MOTRONIC - ESP TORQUE INTERFACE LOCKED This DTC is currently undefined.
Page 292: 1025-Pcm Not Identified Or Incorrect
5 - 126 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1025-PCM NOT IDENTIFIED OR INCORRECT...
Page 293 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 127 1025-PCM NOT IDENTIFIED OR INCORRECT (CONTINUED) When Monitored and Set Condition • When Monitored: Continuous. • Set Condition: If the Controller Antilock Brake (CAB) cannot recognize the Powertrain Control Module (PCM) message, the DTC is set. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 294: 1026-No Can Communications With Tcm
5 - 128 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1026-NO CAN COMMUNICATIONS WITH TCM...
Page 295 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 129 1026-NO CAN COMMUNICATIONS WITH TCM (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the Trans- mission Control Module (TCM).
Page 296 5 - 130 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1026-NO CAN COMMUNICATIONS WITH TCM (CONTINUED) MEASURE THE RESISTANCE OF THE CAN C BUS (-) CIRCUIT With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the CAB har- ness connector to the TCM harness connector.
Page 297: 1027-Can Error Gearbox - Protocol
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 131 1027-CAN ERROR GEARBOX - PROTOCOL This DTC is currently undefined.
Page 298: 1028-Tcm Not Identified Or Incorrect
5 - 132 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1028-TCM NOT IDENTIFIED OR INCORRECT...
Page 299 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 133 1028-TCM NOT IDENTIFIED OR INCORRECT (CONTINUED) When Monitored and Set Condition • When Monitored: Continuous. • Set Condition: If the Controller Antilock Brake (CAB) cannot recognize the Transmission Control Module (TCM) message, the DTC is set. POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE (CAB) For a complete Antilock Brake System (ABS) Circuit Diagram (Refer to 5 - BRAKES/ELECTRICAL - SCHEMATICS...
Page 300: 1035-Can Communications - No Message From Steering Angle Sensor
5 - 134 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR...
Page 301 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 135 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the Steering Angle Sensor.
Page 302 5 - 136 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR (CONTINUED) Diagnostic Test CHECK STEERING ANGLE SENSOR SIGNAL VOLTAGE Note: Inspect Fuse 14 located in the Underhood Accessory Fuse Block. If the fuse is open, repair the cause of the open fuse before continuing.
Page 303 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 137 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR (CONTINUED) MEASURE STEERING ANGLE SENSOR FUSED IGNITION SWITCH OUTPUT CIRCUIT VOLTAGE With the ignition on. Measure the voltage of the Fused Ignition Switch Output circuit at the Steering Angle Sensor harness connector.
Page 304 5 - 138 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR (CONTINUED) MEASURE THE STEERING ANGLE SENSOR SIGNAL CIRCUIT RESISTANCE With the ignition off. Measure the resistance between ground and the Steering Angle Sen- sor Signal circuit.
Page 305 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 139 1035-CAN COMMUNICATIONS - NO MESSAGE FROM STEERING ANGLE SENSOR (CONTINUED) MEASURE THE STEERING ANGLE SENSOR GROUND CIRCUIT RESISTANCE Turn the ignition off. Measure the resistance between ground and the Sensor Ground cir- cuit.
Page 306: 1037-No Can Communications With Yaw Rate/Acceleration Sensor
5 - 140 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1037-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR...
Page 307 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 141 1037-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the Yaw Rate/ Acceleration Sensor.
Page 308 5 - 142 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1037-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) MEASURE THE RESISTANCE OF THE S-CAN (-) CIRCUIT With the ignition off. Measure the resistance of the S-CAN (-) circuit from the CAB harness connector to the Yaw Rate/Acceleration sensor harness connector.
Page 309: 1038-Error Motronic - Coding
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 143 1038-ERROR MOTRONIC - CODING This DTC is currently undefined.
Page 310: 1040-No Can Communications With Yaw Rate/Acceleration Sensor
5 - 144 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1040-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR...
Page 311 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 145 1040-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the Yaw Rate/ Acceleration Sensor.
Page 312 5 - 146 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1040-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) MEASURE THE RESISTANCE OF THE S-CAN (-) CIRCUIT With the ignition off. Measure the resistance of the S-CAN (-) circuit from the CAB harness connector to the Yaw Rate/Acceleration sensor harness connector.
Page 313: 1041-Esp Sensor Can - Protocol
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 147 1041-ESP SENSOR CAN - PROTOCOL This DTC is currently undefined.
Page 314: 1042-No Can Communications With Yaw Rate/Acceleration Sensor
5 - 148 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1042-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR...
Page 315 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 149 1042-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the Yaw Rate/ Acceleration Sensor.
Page 316 5 - 150 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1042-NO CAN COMMUNICATIONS WITH YAW RATE/ACCELERATION SENSOR (CONTINUED) MEASURE THE RESISTANCE OF THE S-CAN (-) CIRCUIT With the ignition off. Measure the resistance of the S-CAN (-) circuit from the CAB harness connector to the Yaw Rate/Acceleration sensor harness connector.
Page 317: 1045-Can Error Transfer Box - Timeout
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 151 1045-CAN ERROR TRANSFER BOX - TIMEOUT This DTC is currently undefined. 1046-CAN ERROR EAM - CODING/TIMEOUT This DTC is currently undefined. 1047-CAN ERROR VARIABLE STEERING TRANS RATIO - CODING This DTC is currently undefined.
Page 318: 1100-Left Front Wheel Speed Sensor Circuit
5 - 152 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT...
Page 319 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 153 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored (Supply circuit): Ignition on. The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). •...
Page 320 5 - 154 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) INSPECT THE LEFT FRONT WHEEL SPEED SENSOR Turn the ignition off. Inspect the Left Front Wheel Speed Sensor and connector. Is the Sensor or Connector damaged? >>...
Page 321 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 155 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) CHECK THE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary.
Page 322 5 - 156 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the Left Front Wheel Speed Sensor 12 Volt Supply circuit from the CAB harness connector to the Left Front Wheel Speed Sensor harness connector.
Page 323 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 157 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Measure the resistance between ground and the Left Front Wheel Speed Sensor Signal circuit.
Page 324 5 - 158 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE LEFT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Left Front Wheel Speed Sensor Signal circuit at the CAB harness connector.
Page 325 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 159 1100-LEFT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the related wiring harness and connectors. Look for any chafed, pierced, pinched, or partially bro- ken wires.
Page 326: 1101-Left Front Wheel Speed Sensor Erratic Signal
5 - 160 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1101-LEFT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL...
Page 327 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 161 1101-LEFT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 328: 1102-Left Front Wheel Speed Sensor Low Signal
5 - 162 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1102-LEFT FRONT WHEEL SPEED SENSOR LOW SIGNAL...
Page 329 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 163 1102-LEFT FRONT WHEEL SPEED SENSOR LOW SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 330: 1103-Left Front Wheel Speed Sensor Long Gap
5 - 164 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1103-LEFT FRONT WHEEL SPEED SENSOR LONG GAP...
Page 331 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 165 1103-LEFT FRONT WHEEL SPEED SENSOR LONG GAP (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or there is excessive time between signals.
Page 332: 1104-Left Front Wheel Speed Sensor Tone Wheel Error
5 - 166 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1104-LEFT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR...
Page 333 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 167 1104-LEFT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing and the CAB detects a defective tone wheel signal.
Page 334: 1105-Left Front Wheel Speed Sensor - Double Frequency
5 - 168 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1105-LEFT FRONT WHEEL SPEED SENSOR - DOUBLE FREQUENCY This DTC is currently undefined.
Page 335: 1110-Right Front Wheel Speed Sensor Circuit
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 169 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT...
Page 336 5 - 170 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored (Supply circuit): Ignition on. The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). •...
Page 337 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 171 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) INSPECT THE RIGHT FRONT WHEEL SPEED SENSOR Turn the ignition off. Inspect the Right Front Wheel Speed Sensor and connector. Is the Sensor or Connector damaged? >>...
Page 338 5 - 172 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) CHECK THE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary.
Page 339 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 173 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the Right Front Wheel Speed Sensor 12 Volt Supply circuit from the CAB harness connector to the Right Front Wheel Speed Sensor harness connector.
Page 340 5 - 174 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Measure the resistance between ground and the Right Front Wheel Speed Sensor Signal circuit.
Page 341 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 175 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE RIGHT FRONT WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Right Front Wheel Speed Sensor Signal circuit at the CAB harness connector.
Page 342 5 - 176 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1110-RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT (CONTINUED) VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the related wiring harness and connectors. Look for any chafed, pierced, pinched, or partially bro- ken wires.
Page 343: 1111-Right Front Wheel Speed Sensor Erratic Signal
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 177 1111-RIGHT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL...
Page 344 5 - 178 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1111-RIGHT FRONT WHEEL SPEED SENSOR ERRATIC SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 345: 1112-Right Front Wheel Speed Sensor Low Signal
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 179 1112-RIGHT FRONT WHEEL SPEED SENSOR LOW SIGNAL...
Page 346 5 - 180 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1112-RIGHT FRONT WHEEL SPEED SENSOR LOW SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 347: 1113-Right Front Wheel Speed Sensor Long Gap
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 181 1113-RIGHT FRONT WHEEL SPEED SENSOR LONG GAP...
Page 348 5 - 182 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1113-RIGHT FRONT WHEEL SPEED SENSOR LONG GAP (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or there is excessive time between signals.
Page 349: 1114-Right Front Wheel Speed Sensor Tone Wheel Error
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 183 1114-RIGHT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR...
Page 350 5 - 184 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1114-RIGHT FRONT WHEEL SPEED SENSOR TONE WHEEL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing and the CAB detects a defective tone wheel signal.
Page 351: 1115-Right Front Wheel Speed Sensor - Double Frequency
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 185 1115-RIGHT FRONT WHEEL SPEED SENSOR - DOUBLE FREQUENCY This DTC is currently undefined.
Page 352: 1120-Left Rear Wheel Speed Sensor Circuit
5 - 186 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT...
Page 353 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 187 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored (Supply circuit): Ignition on. The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). •...
Page 354 5 - 188 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) INSPECT THE LEFT REAR WHEEL SPEED SENSOR Turn the ignition off. Inspect the Left Rear Wheel Speed Sensor and connector. Is the Sensor or Connector damaged? >>...
Page 355 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 189 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) CHECK THE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary.
Page 356 5 - 190 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the Left Rear Wheel Speed Sensor 12 Volt Supply circuit from the CAB harness connector to the Left Rear Wheel Speed Sensor harness connector.
Page 357 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 191 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Measure the resistance between ground and the Left Rear Wheel Speed Sensor Signal circuit.
Page 358 5 - 192 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Left Rear Wheel Speed Sensor Signal circuit at the CAB harness connector.
Page 359 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 193 1120-LEFT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the related wiring harness and connectors. Look for any chafed, pierced, pinched, or partially bro- ken wires.
Page 360: 1121-Left Rear Wheel Speed Sensor Erratic Signal
5 - 194 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1121-LEFT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL...
Page 361 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 195 1121-LEFT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 362: 1122-Left Rear Wheel Speed Sensor Low Signal
5 - 196 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1122-LEFT REAR WHEEL SPEED SENSOR LOW SIGNAL...
Page 363 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 197 1122-LEFT REAR WHEEL SPEED SENSOR LOW SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 364: 1123-Left Rear Wheel Speed Sensor Long Gap
5 - 198 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1123-LEFT REAR WHEEL SPEED SENSOR LONG GAP...
Page 365 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 199 1123-LEFT REAR WHEEL SPEED SENSOR LONG GAP (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or there is excessive time between signals.
Page 366: 1124-Left Rear Wheel Speed Sensor Tone Wheel Error
5 - 200 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1124-LEFT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR...
Page 367 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 201 1124-LEFT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing and the CAB detects a defective tone wheel signal.
Page 368: 1125-Left Rear Wheel Speed Sensor - Double Frequency
5 - 202 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1125-LEFT REAR WHEEL SPEED SENSOR - DOUBLE FREQUENCY This DTC is currently undefined.
Page 369: 1130-Right Rear Wheel Speed Sensor Circuit
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 203 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT...
Page 370 5 - 204 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored (Supply circuit): Ignition on. The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). •...
Page 371 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 205 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) INSPECT THE RIGHT REAR WHEEL SPEED SENSOR Turn the ignition off. Inspect the Right Rear Wheel Speed Sensor and connector. Is the Sensor or Connector damaged? >>...
Page 372 5 - 206 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) CHECK THE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary.
Page 373 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 207 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the Right Rear Wheel Speed Sensor 12 Volt Supply circuit from the CAB harness connector to the Right Rear Wheel Speed Sensor harness connector.
Page 374 5 - 208 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Measure the resistance between ground and the Right Rear Wheel Speed Sensor Signal circuit.
Page 375 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 209 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE RIGHT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Right Rear Wheel Speed Sensor Signal circuit at the CAB harness connector.
Page 376 5 - 210 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1130-RIGHT REAR WHEEL SPEED SENSOR CIRCUIT (CONTINUED) VISUALLY INSPECT COMPONENTS FOR DAMAGE AND CORRECT INSTALLATION Visually inspect the related wiring harness and connectors. Look for any chafed, pierced, pinched, or partially bro- ken wires.
Page 377: 1131-Right Rear Wheel Speed Sensor Erratic Signal
BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 211 1131-RIGHT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL...
Page 378 5 - 212 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1131-RIGHT REAR WHEEL SPEED SENSOR ERRATIC SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 379 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 213 1132-RIGHT REAR WHEEL SPEED SENSOR LOW SIGNAL...
Page 380 5 - 214 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1132-RIGHT REAR WHEEL SPEED SENSOR LOW SIGNAL (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or erratic. POSSIBLE CAUSES DEFECTIVE WHEEL SPEED SENSOR MISSING SENSOR OR TONE WHEEL...
Page 381 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 215 1133-RIGHT REAR WHEEL SPEED SENSOR LONG GAP...
Page 382 5 - 216 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1133-RIGHT REAR WHEEL SPEED SENSOR LONG GAP (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing or there is excessive time between signals.
Page 383 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 217 1134-RIGHT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR...
Page 384 5 - 218 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1134-RIGHT REAR WHEEL SPEED SENSOR TONE WHEEL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: The Controller Antilock Brake (CAB) monitors the wheel speed circuit every 7 milliseconds (ms). • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the speed signal is missing and the CAB detects a defective tone wheel signal.
Page 385 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 219 1135-RIGHT REAR WHEEL SPEED SENSOR - DOUBLE FREQUENCY This DTC is currently undefined.
Page 386 5 - 220 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT...
Page 387 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 221 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects an Electronic Stability Program (ESP) Brake Pres- sure Sensor 1 malfunction.
Page 388 5 - 222 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN THE ESP BRAKE PRESSURE 1 SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY CIRCUIT Turn the ignition off. Measure the resistance between the ESP Brake Pressure Sensor 1 Signal circuit and the 5-Volt Supply circuit in the ESP Brake Pressure Sensor 1 harness connector.
Page 389 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 223 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE ESP BRAKE PRESSURE SENSOR 1 GROUND CIRCUIT With the ignition off. Measure the resistance of the Sensor Ground circuit from the CAB harness connector to the ESP Brake Pressure Sensor 1 harness con- nector.
Page 390 5 - 224 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE ESP BRAKE PRESSURE SENSOR 1 SIGNAL CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the ESP Brake Pressure Sensor 1 Signal circuit.
Page 391 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 225 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN THE ESP BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT AND THE SENSOR GROUND CIRCUIT Turn the ignition off. Measure the resistance between the 5-Volt Supply circuit and the Sen- sor Ground circuit.
Page 392 5 - 226 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1140-ESP BRAKE PRESSURE SENSOR 1 CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE ESP BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the 5-Volt Supply circuit from the ESP Brake Pressure Sensor 1 harness connector to the CAB harness con- nector.
Page 393 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 227 1141-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH RELEASE SWITCH...
Page 394 5 - 228 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1141-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH RELEASE SWITCH (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Brake Pressure Sensor.
Page 395 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 229 1142-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH TRAVEL SENSOR...
Page 396 5 - 230 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1142-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH TRAVEL SENSOR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Brake Pressure Sensor.
Page 397 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 231 1143-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH BOOSTER DISTANCE GRADIENT...
Page 398 5 - 232 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1143-ESP BRAKE PRESSURE SENSOR 1 - PLAUSIBILITY WITH BOOSTER DISTANCE GRADIENT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Brake Pressure Sensor.
Page 399 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 233 1145-ESP BRAKE PRESSURE SENSOR 1 - INVALID OFFSET...
Page 400 5 - 234 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1145-ESP BRAKE PRESSURE SENSOR 1 - INVALID OFFSET (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Brake Pressure Sensor.
Page 401 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 235 1150-LATERAL ACCELERATION CIRCUIT...
Page 402 5 - 236 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1150-LATERAL ACCELERATION CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. • Set Condition: The Controller Antilock Brake (CAB) will set this DTC if the ESP Yaw Rate/Lateral Acceleration Sensor has an internal malfunction.
Page 403 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 237 1151-YAW RATE/ACCELERATION SENSOR - PLAUSIBILITY ERROR...
Page 404 5 - 238 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1151-YAW RATE/ACCELERATION SENSOR - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 405 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 239 1152-YAW RATE/ACCELERATION SENSOR - INVALID OFFSET...
Page 406 5 - 240 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1152-YAW RATE/ACCELERATION SENSOR - INVALID OFFSET (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 407 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 241 1160-YAW RATE/ACCELERATION SENSOR - YAW MALFUNCTION...
Page 408 5 - 242 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1160-YAW RATE/ACCELERATION SENSOR - YAW MALFUNCTION (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 409 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 243 1161-YAW RATE/ACCELERATION SENSOR - PLAUSIBILITY ERROR...
Page 410 5 - 244 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1161-YAW RATE/ACCELERATION SENSOR - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 411 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 245 1162-YAW RATE/ACCELERATION SENSOR - INVALID OFFSET...
Page 412 5 - 246 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1162-YAW RATE/ACCELERATION SENSOR - INVALID OFFSET (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 413 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 247 1170-STEERING ANGLE SENSOR - INVALID OFFSET...
Page 414 5 - 248 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1170-STEERING ANGLE SENSOR - INVALID OFFSET (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the Steering Angle Sensor. •...
Page 415 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 249 1172-STEERING ANGLE SENSOR - INTERNAL ERROR...
Page 416 5 - 250 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1172-STEERING ANGLE SENSOR - INTERNAL ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the Steering Angle Sensor. •...
Page 417 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 251 1173-STEERING ANGLE SENSOR - PLAUSIBILITY ERROR...
Page 418 5 - 252 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1173-STEERING ANGLE SENSOR - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the Steering Angle Sensor. •...
Page 419 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 253 1174-STEERING ANGLE SENSOR - NOT INITIALIZED...
Page 420 5 - 254 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1174-STEERING ANGLE SENSOR - NOT INITIALIZED (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the Steering Angle Sensor. •...
Page 421 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 255 1174-STEERING ANGLE SENSOR - NOT INITIALIZED (CONTINUED) MEASURE STEERING ANGLE SENSOR FUSED IGNITION SWITCH OUTPUT CIRCUIT VOLTAGE With the ignition on. Measure the voltage of the Fused Ignition Switch Output circuit at the Steering Angle Sensor harness connector.
Page 422 5 - 256 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1175-STEERING ANGLE SENSOR - MOMENTARILY NOT INITIALIZED This DTC is currently undefined. 1179-STEERING ANGLE SENSOR - STEERING ANGLE OVERFLOW This DTC is currently undefined. 1181-STEERING ANGLE SENSOR - STEERING ANGLE GRADIENT ERROR This DTC is currently undefined.
Page 423 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 257 1185-BAS TRAVEL SENSOR CIRCUIT...
Page 424 5 - 258 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Travel Sensor mal- function.
Page 425 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 259 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN THE BAS TRAVEL SENSOR SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY CIRCUIT With the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between the BAS Travel Sensor Signal circuit and the 5-Volt supply circuit in the BAS Brake Booster C1 harness connector.
Page 426 5 - 260 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE BAS TRAVEL SENSOR GROUND CIRCUIT With the ignition off. Measure the resistance of the BAS Travel Sensor Ground circuit from the CAB harness connector to the BAS Brake Booster C1 harness connector.
Page 427 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 261 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS TRAVEL SENSOR SIGNAL CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Travel Sensor Signal circuit.
Page 428 5 - 262 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) CHECK THE BAS TRAVEL SENSOR 5-VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Turn the ignition on.
Page 429 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 263 1185-BAS TRAVEL SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS TRAVEL SENSOR 5-VOLT SUPPLY CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the 5-Volt Supply circuit.
Page 430 5 - 264 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1186-BAS TRAVEL SENSOR - PLAUSIBILITY ERROR...
Page 431 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 265 1186-BAS TRAVEL SENSOR - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the BAS Travel Sensor. •...
Page 432 5 - 266 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1187-BAS TRAVEL SENSOR - PLAUSIBILITY ERROR...
Page 433 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 267 1187-BAS TRAVEL SENSOR - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition On. The Controller Antilock Brake (CAB) monitors the status of the BAS Travel Sensor. •...
Page 434 5 - 268 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1188-BAS TRAVEL SENSOR - PLAUSIBILITY WITH PRESSURE GRADIENT This DTC is currently undefined.
Page 435 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 269 1190-YAW RATE/ACCELERATION SENSOR - INVALID CALIBRATION VALUES...
Page 436 5 - 270 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1190-YAW RATE/ACCELERATION SENSOR - INVALID CALIBRATION VALUES (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor.
Page 437 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 271 1195-YAW RATE/ACCELERATION SENSOR - CYCLE TOO LONG...
Page 438 5 - 272 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1195-YAW RATE/ACCELERATION SENSOR - CYCLE TOO LONG (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor.
Page 439 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 273 1201-BAS RELEASE SWITCH CIRCUIT...
Page 440 5 - 274 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Release Switch mal- function.
Page 441 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 275 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE VOLTAGE OF THE SENSOR (APPLIED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the BAS Release Switch Sensor (Applied) cir- cuit at the BAS Brake Booster C2 harness connector.
Page 442 5 - 276 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE VOLTAGE OF THE BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT With the ignition on. Measure the voltage of the BAS Release Switch 12 Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 443 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 277 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE 12 VOLT SUPPLY CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch 12 Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 444 5 - 278 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (RELEASED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch Sensor (Released) circuit at the BAS Brake Booster C2 harness con- nector.
Page 445 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 279 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (APPLIED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch Sensor (Applied) circuit at the BAS Brake Booster C2 harness connec- tor.
Page 446 5 - 280 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1201-BAS RELEASE SWITCH CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (APPLIED) CIRCUIT WITH CAB CONNECTED With the ignition off. Reconnect the CAB harness connector. Measure the resistance between ground and the BAS Release Switch Sensor (Applied) circuit at the BAS Brake Booster C2 harness connec- tor.
Page 447 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 281 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR...
Page 448 5 - 282 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Release Switch mal- function.
Page 449 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 283 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE VOLTAGE OF THE SENSOR (APPLIED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the BAS Release Switch Sensor (Applied) cir- cuit at the BAS Brake Booster C2 harness connector.
Page 450 5 - 284 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE VOLTAGE OF THE BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT With the ignition on. Measure the voltage of the BAS Release Switch 12 Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 451 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 285 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE 12 VOLT SUPPLY CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch 12 Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 452 5 - 286 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (RELEASED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch Sensor (Released) circuit at the BAS Brake Booster C2 harness con- nector.
Page 453 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 287 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (APPLIED) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the BAS Release Switch Sensor (Applied) circuit at the BAS Brake Booster C2 harness connec- tor.
Page 454 5 - 288 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1202-BAS RELEASE SWITCH - PLAUSIBILITY ERROR (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS RELEASE SWITCH SENSOR (APPLIED) CIRCUIT WITH CAB CONNECTED With the ignition off. Reconnect the CAB harness connector. Measure the resistance between ground and the BAS Release Switch Sensor (Applied) circuit at the BAS Brake Booster C2 harness connec- tor.
Page 455 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 289 1210-CAB SYSTEM UNDERVOLTAGE...
Page 456 5 - 290 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1210-CAB SYSTEM UNDERVOLTAGE (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit voltage above 10 km/h (6 MPH) every 7 milliseconds for proper system voltage. •...
Page 457 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 291 1210-CAB SYSTEM UNDERVOLTAGE (CONTINUED) MEASURE THE VOLTAGE OF THE FUSED B(+) CIRCUIT Turn the ignition off. Disconnect the CAB harness connector. Note: Check connectors - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B(+) circuit at the CAB harness con- nector.
Page 458 5 - 292 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1212-CAB SYSTEM OVERVOLTAGE...
Page 459 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 293 1212-CAB SYSTEM OVERVOLTAGE (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit at all times for proper system voltage. • Set Condition: If the voltage is above 16 volts for greater than 500 milliseconds (ms), the Diagnostic Trouble Code (DTC) is set.
Page 460 5 - 294 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1212-CAB SYSTEM OVERVOLTAGE (CONTINUED) MEASURE THE RESISTANCE OF THE GROUND CIRCUIT Turn the ignition off. Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Measure the resistance between ground and the Ground circuit at the CAB harness connector.
Page 461 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 295 1310-POWER SUPPLY OR RETURN PUMP This DTC is currently undefined.
Page 462 5 - 296 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1330-BAS SOLENOID VALVE CIRCUIT...
Page 463 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 297 1330-BAS SOLENOID VALVE CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a BAS Solenoid Valve malfunction. POSSIBLE CAUSES BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE BAS SOLENOID VALVE CONTROL CIRCUIT SHORT TO VOLTAGE BAS SOLENOID VALVE CIRCUITS SHORT TO EACH OTHER...
Page 464 5 - 298 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1330-BAS SOLENOID VALVE CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off. Measure the resistance of the BAS Solenoid Valve Control circuit from the CAB harness connector to the BAS Brake Booster C2 harness connector.
Page 465 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 299 1330-BAS SOLENOID VALVE CIRCUIT (CONTINUED) MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT Turn the ignition on. Measure the voltage of the BAS Solenoid Valve 5-Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 466 5 - 300 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1330-BAS SOLENOID VALVE CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT Turn the ignition off. Measure the resistance between ground and the BAS Solenoid Valve 5-Volt Supply circuit. Is the resistance above 100k ohms? >>...
Page 467 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 301 1330-BAS SOLENOID VALVE CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off. Reconnect the CAB harness connector. Measure the resistance between ground and the BAS Solenoid Valve Control circuit.
Page 468 5 - 302 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH...
Page 469 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 303 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Solenoid Valve mal- function.
Page 470 5 - 304 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off. Measure the resistance of the BAS Solenoid Valve Control circuit from the CAB harness connector to the BAS Brake Booster C2 harness connector.
Page 471 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 305 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH (CONTINUED) MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT Turn the ignition on. Measure the voltage of the BAS Solenoid Valve 5-Volt Supply circuit at the BAS Brake Booster C2 harness connector.
Page 472 5 - 306 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT Turn the ignition off. Measure the resistance between ground and the BAS Solenoid Valve 5-Volt Supply circuit.
Page 473 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 307 1331-BAS SOLENOID VALVE - RESISTANCE TOO HIGH (CONTINUED) MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE CONTROL CIRCUIT With the ignition off. Reconnect the CAB harness connector. Measure the resistance between ground and the BAS Solenoid Valve Control circuit.
Page 474 5 - 308 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1350-YAW RATE/ACCELERATION SENSOR - HARDWARE ERROR...
Page 475 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 309 1350-YAW RATE/ACCELERATION SENSOR - HARDWARE ERROR (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the ESP Yaw Rate/Lateral Acceleration Sensor. •...
Page 476 5 - 310 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1351-YAW RATE/ACCELERATION SENSOR - UNDERVOLTAGE...
Page 477 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 311 1351-YAW RATE/ACCELERATION SENSOR - UNDERVOLTAGE (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a ESP Yaw Rate/Lateral Acceleration Sensor Und- ervoltage condition.
Page 478 5 - 312 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1351-YAW RATE/ACCELERATION SENSOR - UNDERVOLTAGE (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE YAW RATE/ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT With the ignition off. Disconnect the Controller Antilock Brake (CAB) harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the 5-Volt Supply circuit.
Page 479 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 313 1351-YAW RATE/ACCELERATION SENSOR - UNDERVOLTAGE (CONTINUED) MEASURE THE RESISTANCE OF THE YAW RATE/ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT With the ignition off. Measure the resistance of the 5-Volt Supply circuit from the Yaw Rate/ Acceleration Sensor harness connector to the CAB harness connector.
Page 480 5 - 314 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1352-YAW RATE/ACCELERATION SENSOR - OVERVOLTAGE...
Page 481 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 315 1352-YAW RATE/ACCELERATION SENSOR - OVERVOLTAGE (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a Yaw Rate/Acceleration Sensor Overvoltage con- dition. POSSIBLE CAUSES ESP YAW RATE/LATERAL ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE ESP YAW RATE/LATERAL ACCELERATION SENSOR...
Page 482 5 - 316 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1352-YAW RATE/ACCELERATION SENSOR - OVERVOLTAGE (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE YAW RATE/ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT With the ignition off. Disconnect the Controller Antilock Brake (CAB) harness connector. Note: Check connectors - Clean/repair as necessary. Measure the voltage of the Yaw Rate/Acceleration Sensor 5 Volt Sup- ply circuit at the Yaw Rate/Acceleration Sensor harness connector.
Page 483 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 317 1353-YAW RATE/ACCELERATION SENSOR - INITIALIZATION TO RUN TIME This DTC is currently undefined. 1354-YAW RATE/ACCELERATION SENSOR - WRONG VERSION This DTC is currently undefined.
Page 484 5 - 318 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1355-YAW RATE/ACCELERATION SENSOR - SHORT TO VOLTAGE...
Page 485 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 319 1355-YAW RATE/ACCELERATION SENSOR - SHORT TO VOLTAGE (CONTINUED) When Monitored and Set Condition • When Monitored: Ignition on. • Set Condition: The Controller Antilock Brake (CAB) detects a ESP Yaw Rate/Lateral Acceleration Sensor Over- voltage condition.
Page 486 5 - 320 BRAKES - ABS ELECTRICAL DIAGNOSTICS 1355-YAW RATE/ACCELERATION SENSOR - SHORT TO VOLTAGE (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE YAW RATE/ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT With the ignition off. Disconnect the Controller Antilock Brake (CAB) harness connector. Note: Check connectors - Clean/repair as necessary.
Page 487 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 321 1400-DRIVE TEST- LWS FAULT This DTC is currently undefined. 1401-DRIVE TEST- DRS FAULT This DTC is currently undefined. 1402-DRIVE TEST- SENSOR CLUSTER AY FAULT This DTC is currently undefined. 1403-DRIVE TEST- INSTALLATION POSITION CLUSTER This DTC is currently undefined.
Page 488 5 - 322 BRAKES - ABS ELECTRICAL DIAGNOSTICS ABS VERIFICATION TEST ABS VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. With the DRB III , erase all Diagnostic Trouble Codes (DTCs) from ALL modules. Start the engine and allow it to run for 2 minutes.
Page 489 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 323 SCHEMATICS AND DIAGRAMS...
Page 490 5 - 324 BRAKES - ABS ELECTRICAL DIAGNOSTICS...
Page 491 BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 325...
Page 492 5 - 326 BRAKES - ABS SERVICE INFORMATION BRAKES - ABS SERVICE INFORMATION TABLE OF CONTENTS page page BRAKES - ESP SERVICE INFORMATION OPERATION ......344 DESCRIPTION .
Page 493: Description
BRAKES - ABS SERVICE INFORMATION 5 - 327 BRAKES - ESP SERVICE INFORMATION DESCRIPTION This section covers the physical and operational descriptions and the on-car service procedures for Electronic Sta- bility Program (ESP). The purpose of this four-channel design ESP is to prevent wheel lockup under braking conditions on virtually any type of road surface.
Page 494: Operation - Electronic Stability Program (Esp)
5 - 328 BRAKES - ABS SERVICE INFORMATION OPERATION - ELECTRONIC STABILITY PROGRAM (ESP) NORMAL BRAKING Under normal braking conditions, the ABS functions are the same as a standard base brake system with a diago- nally split master cylinder and conventional vacuum assist. ABS BRAKING ABS operation is available at vehicle speeds above 5 mph (8 km/h).
Page 495: Drive Mode
BRAKES - ABS SERVICE INFORMATION 5 - 329 TIRE NOISE AND MARKS Although the ABS system prevents complete wheel lockup, some wheel slip is desired in order to achieve optimum braking performance. Wheel slip is defined as follows: “0” percent slip means the wheel is rolling freely. “100” per- cent slip means the wheel is fully locked.
Page 496: Diagnosis And Testing - Inspection And Road Test
5 - 330 BRAKES - ABS SERVICE INFORMATION PREMATURE ABS CYCLING Symptoms of premature ABS cycling include: clicking sounds from the solenoid valves, pump/motor running, and pulsations in the brake pedal. Premature ABS cycling can occur at any braking rate of the vehicle and on any type of road surface.
Page 497: Specifications - Torque Chart
BRAKES - ABS SERVICE INFORMATION 5 - 331 7. If the amber antilock warning indicator lamp stays on, drive the car to a speed of approximately 15 mph (25 km/h) to complete the “ABS Start-Up” and “Drive-Off Cycle. (Refer to 5 - BRAKES/HYDRAU- LIC/MECHANICAL/MASTER CYLINDER - OPERA- TION).
Page 498: Front Wheel Speed Sensor
5 - 332 BRAKES - ABS SERVICE INFORMATION FRONT WHEEL SPEED SENSOR DESCRIPTION A wheel speed sensor is used at each wheel. The front sensors are mounted to the steering knuckles. Tone wheels are mounted to the outboard ends of the front axle shafts. The gear type tone wheel serves as the trigger mech- anism for each sensor.
Page 499: Removal
BRAKES - ABS SERVICE INFORMATION 5 - 333 REMOVAL 1. Remove the bolts (2) attaching the flange to the steering knuckle. 2. Remove the wheel speed sensor (1) from the steering knuckle. 3. Disconnect the wheel speed / brake wear indicator wire harness connector (2) from the body mount connector (1).
Page 500: Installation
5 - 334 BRAKES - ABS SERVICE INFORMATION INSTALLATION 1. Connect the wheel speed sensor / brake wear indi- cator wire harness connector (2) to the body mount connector (1). 2. Install the wheel speed sensor (1) to the steering knuckle.
Page 501: Rear Wheel Speed Sensor
BRAKES - ABS SERVICE INFORMATION 5 - 335 REAR WHEEL SPEED SENSOR DESCRIPTION A wheel speed sensor is used at each rear wheel. The gear type tone wheel serves as the trigger mechanism for each of the front wheel speed sensors. OPERATION The sensors convert wheel speed into a digital signal.
Page 502: Removal
5 - 336 BRAKES - ABS SERVICE INFORMATION REMOVAL 1. Remove the bolt (1) attaching the wheel speed sensor to the rear knuckle. 2. Remove the rear wheel speed sensor (2) from the knuckle. 3. Pull the rubber grommet (1) out of the body. Unhook the wheel speed sensor wire harness from the mount (2).
Page 503: Installation
BRAKES - ABS SERVICE INFORMATION 5 - 337 4. Disconnect the wheel speed sensor harness con- nector (1). INSTALLATION 1. Connect the wheel speed sensor wire harness con- nector (1).
Page 504 5 - 338 BRAKES - ABS SERVICE INFORMATION 2. Install the rubber grommet (1) to the body and then hook the wheel speed sensor wire harness to the mount (2). 3. Install the wheel speed sensor (2) to the knuckle. 4.
Page 505: Steering Angle Sensor
BRAKES - ABS SERVICE INFORMATION 5 - 339 STEERING ANGLE SENSOR DESCRIPTION An optical steering angle sensor is used to sense the steering angle specified by the driver’s actions. The steering angle sensor consists of two micro-computers which work together with a signal measuring ring to form one unit.
Page 506: Removal
5 - 340 BRAKES - ABS SERVICE INFORMATION REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SIDE IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE BATTERY NEGATIVE...
Page 507: Installation
BRAKES - ABS SERVICE INFORMATION 5 - 341 INSTALLATION 1. Locate and align the alignment points on the com- ponent housings (1). 2. Install the steering angle sensor to the clockspring. 3. Snap the steering angle sensor retaining tabs (1) onto the clockspring.
Page 508: Yaw Rate/Lateral Acceleration Sensor
5 - 342 BRAKES - ABS SERVICE INFORMATION 4. Install the clockspring onto the steering column. (Refer to 8 - ELECTRICAL/RESTRAINTS/CLOCK- SPRING - INSTALLATION). YAW RATE/LATERAL ACCELERATION SENSOR DESCRIPTION The Mark 25 Braking System uses a combined Yaw Rate and Acceleration Sensor. The Yaw Rate/Lateral Accel- eration Sensor is a combined sensor and is located under the center console behind the gear shifter assembly.
Page 509: Operation
BRAKES - ABS SERVICE INFORMATION 5 - 343 The lateral acceleration portion of the sensor is used to inform the ESP control module of the amount of lateral acceleration forces during cornering. OPERATION The Yaw Rate/Lateral Acceleration Sensor is a combined sensor. The yaw rate portion of the sensor is used to measure the yaw rate of the vehicle.
Page 510: Installation
5 - 344 BRAKES - ABS SERVICE INFORMATION INSTALLATION 1. Install the yaw rate/lateral acceleration sensor (1). Tighten the nuts to 10 N·m (89 in. lbs.). 2. Connect the yaw rate/lateral acceleration harness connector. 3. Install the rear center console. (Refer to 23 - BODY/INTERIOR/CENTER CONSOLE INSTALLATION).
Page 511: Installation
BRAKES - ABS SERVICE INFORMATION 5 - 345 INSTALLATION (Refer to 5 - BRAKES/ELECTRICAL/BRAKE PRESSURE SWITCH - INSTALLATION) TRAVEL SENSOR DESCRIPTION The BAS travel sensor (2) is a device used to detect an emergency stop. The BAS travel sensor is located on the power brake booster (1).
Page 512: Operation
5 - 346 BRAKES - ABS SERVICE INFORMATION OPERATION The BAS travel sensor (3) reports the position of the brake booster diaphragm plate to the Controller Antilock Brake (CAB). The BAS travel sensor rod is attached to the brake booster diaphragm plate (2). The diaphragm plate is located internal to the brake booster (1), and the sensor rod moves proportionally to the travel of the brake pedal.
Page 513: Solenoid Valve
BRAKES - ABS SERVICE INFORMATION 5 - 347 SOLENOID VALVE DESCRIPTION The BAS solenoid valve (2) is an electrically activated device used to increase brake assist. The BAS solenoid valve (2) cannot be serviced. The power brake booster must be replaced in the event of a BAS solenoid valve failure.
Page 514: Release Switch Description
5 - 348 BRAKES - ABS SERVICE INFORMATION RELEASE SWITCH DESCRIPTION The BAS release switch (2) is a device used to signal the Controller Antilock Brake (CAB) module that the brake is released. The BAS release switch (2) cannot be serviced. The power brake booster must be replaced in the event of a BAS release switch failure.
Page 515: Hcu (Hydraulic Control Unit)
BRAKES - ABS SERVICE INFORMATION 5 - 349 HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The CAB (Mark 20 or Mark 25 ) is a microprocessor- based device which monitors the Antilock Brake Sys- tem (ABS), and the Electronic Stability Program (ESP) during normal braking and driving functions.
Page 516: Removal
5 - 350 BRAKES - ABS SERVICE INFORMATION REMOVAL 1. Clean off the top of the HCU, especially around the hydraulic lines (1-6). Be sure there is not any debris that could fall into the brake line holes. Note: To aid in reassembly, insure the hydraulic brake lines and corresponding connections at the HCU are clearly marked before disassembly.
Page 517: Installation
BRAKES - ABS SERVICE INFORMATION 5 - 351 INSTALLATION 1. Inspect the seating and condition of the rubber grommets and replace if necessary. CAUTION: caution when re-connecting hydraulic lines. Refer to markings for proper installation. If necessary, trace the line routing to the corresponding wheel.
Page 519 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH INSTALLATION ......17 DESCRIPTION ......1 RELEASE BEARING/SLAVE CYLINDER OPERATION .
Page 520: Clutch
6 - 2 CLUTCH OPERATION The clutch operates with leverage, clamping force, and friction. The disc serves as the friction element, the dia- phragm-style clutch cover provides the clamping force. The clutch pedal, hydraulic linkage, and the release bearing provide the leverage. A shared reservoir for the brake system and clutch system is mounted to the dash panel.
Page 521 CLUTCH 6 - 3 CLUTCH MISALIGNMENT Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch release. CLUTCH COVER AND DISC RUNOUT Check the clutch disc before installation.
Page 522 6 - 4 CLUTCH DIAGNOSIS CHART The diagnosis chart describes common clutch problems, causes and correction. Conditions, causes and corrective action are outlined in the indicated columns. CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT 1. Normal wear. 1. Replace cover and disc. 2.
Page 523 CLUTCH 6 - 5 CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON INPUT 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub SHAFT SPLINES. during installation. splines if possible. Replace disc if necessary. 2. Input shaft splines rough, 2.
Page 524: Standard Procedure
6 - 6 CLUTCH CONDITION POSSIBLE CAUSES CORRECTION CONTACT SURFACE OF 1. Clutch cover incorrect or release 1. Replace clutch cover and release RELEASE BEARING DAMAGED. fingers bent or distorted. bearing/slave cylinder. 2. Release bearing defective or 2. Replace the release bearing/ damaged.
Page 525: Specifications - Torque
CLUTCH 6 - 7 3. Raise and support the vehicle. 4. Remove the bleeder screw rubber access plug (1). 5. Remove the bleeder screw rubber cap. 6. Open the bleeder screw (1) on the slave cylinder. 7. Allow the brake fluid to flow until there are no bub- bles and fluid is clear.
Page 526: Special Tools
6 - 8 CLUTCH SPECIAL TOOLS 9102 FLYWHEEL LOCKING TOOL...
Page 527: Clutch Disc
CLUTCH 6 - 9 CLUTCH DISC REMOVAL 1. Remove the transmission (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL - REMOVAL). Note: Gradually remove the clutch cover bolts 1 to 1 1/2 turns at a time. 2. Loosen the bolts (1) on the clutch cover. 3.
Page 528: Installation
6 - 10 CLUTCH INSTALLATION 1. If the clutch cover is to be reused, adjustment is required on the clutch disc. Use an old release bearing or a length of pipe to release diaphragm pressure. Set the adjusting ring to the mark as shown.
Page 529 CLUTCH 6 - 11 4. Install a universal clutch alignment tool (1). 5. Align the clutch disc to the flywheel. Note: Gradually tighten the clutch cover bolts 1 to 1 1/2 turns at a time. 6. Tighten the clutch cover bolts (1) until all bolts are fully seated.
Page 530: Clutch Cover
6 - 12 CLUTCH CLUTCH COVER DESCRIPTION The clutch cover assembly (1), sometimes referred to as a pressure plate, is a diaphragm type with a one- piece spring and multiple release fingers (2). The clutch cover is attached to the engine flywheel (3) with eight bolts.
Page 531 CLUTCH 6 - 13 2. Loosen the bolts (1) on the clutch cover. 3. Mark the relation of the clutch cover to the fly- wheel. Note: Gradually remove the clutch cover bolts 1 to 1 1/2 turns at a time. 4.
Page 532: Installation
6 - 14 CLUTCH INSTALLATION 1. If the clutch cover is to be reused, adjustment is required. Use an old release bearing or a length of pipe to release diaphragm pressure. Set the adjust- ing ring to the mark as shown. 2.
Page 533 CLUTCH 6 - 15 4. Install a universal clutch alignment tool (1). 5. Align the clutch disc. Note: Gradually tighten the clutch cover bolts 1 to 1 1/2 turns at a time. 6. Tighten the clutch cover bolts (1) until all bolts are fully seated.
Page 534: Master Cylinder - Clutch
6 - 16 CLUTCH MASTER CYLINDER - CLUTCH REMOVAL WARNING: RISK OF POISONING DUE TO SWAL- LOWING BRAKE FLUID. RISK OF INJURY DUE TO BRAKE FLUID COMING INTO CONTACT WITH THE SKIN AND EYES. Note: Only pour brake fluid into suitable, appropri- ately marked containers.
Page 535: Installation
CLUTCH 6 - 17 5. Disconnect the clutch master cylinder pressure line (1) at the clutch master cylinder and cap the line. 6. Remove the clutch pedal spring (3), circlip (1), and retaining nuts (2). 7. Rotate the clutch master cylinder counter-clockwise and remove from the vehicle.
Page 536 6 - 18 CLUTCH 5. Connect the clutch master cylinder fluid pressure line (1). 6. Connect the clutch master cylinder fluid supply hose (1). 7. Remove the clamp from the clutch master cylinder supply hose. 8. Install the illumination control module (4). 9.
Page 537: Release Bearing/Slave Cylinder
CLUTCH 6 - 19 RELEASE BEARING/SLAVE CYLINDER DESCRIPTION The clutch release bearing is integrated with the clutch slave cylinder for smooth operation. By eliminating the clutch release fork, less effort is required to release the clutch. Even pressure application to the release bearing increases the life of the bearing.
Page 538: Removal
6 - 20 CLUTCH REMOVAL WARNING: RISK OF POISONING DUE TO SWAL- LOWING BRAKE FLUID. RISK OF INJURY DUE TO BRAKE FLUID COMING INTO CONTACT WITH THE SKIN AND EYES. Note: Only pour brake fluid into suitable, appropri- ately marked containers. Wear protective clothing and safety glasses when handling brake fluid.
Page 539: Diagnosis And Testing
CLUTCH 6 - 21 DIAGNOSIS AND TESTING Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Common causes of runout are: •...
Page 540: Installation
6 - 22 CLUTCH INSTALLATION Note: If a new flywheel is installed, perform the First Initialization Reset function in the Powertrain Control Module with the DRB III . Refer to the Reset Adaptives menu selection on the DRB III . Note: Align flywheel on straight pin in crankshaft.
Page 541: Clutch Pedal
CLUTCH 6 - 23 CLUTCH PEDAL REMOVAL 1. Remove the driver side lower instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL ASSEMBLY - REMOVAL). 2. Remove the driver side upper instrument panel (1) (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL ASSEMBLY - REMOVAL).
Page 542: Installation
6 - 24 CLUTCH 4. Disconnect the clutch pedal position switch. 5. Remove the circlip (2) and the return spring (3). 6. Remove the clutch pedal from the pivot (1). INSTALLATION 1. Install the clutch pedal on the pivot (1). 2.
Page 543 CLUTCH 6 - 25 4. Install the driver side upper instrument panel (1) (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL ASSEMBLY - INSTALLATION). 5. Install the driver side lower instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRU- MENT PANEL ASSEMBLY - INSTALLATION).
Page 545 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING - ELECTRICAL DIAGNOSTICS ..1 COOLING - SERVICE INFORMATION ..12 COOLING - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page...
Page 546 7 - 2 COOLING - ELECTRICAL DIAGNOSTICS *RADIATOR COOLING FAN INOPERATIVE...
Page 547 COOLING - ELECTRICAL DIAGNOSTICS 7 - 3 *RADIATOR COOLING FAN INOPERATIVE (CONTINUED) POSSIBLE CAUSES FUSED B(+) CIRCUIT OPEN GROUND CIRCUIT OPEN RADIATOR FAN CONTROL MODULE OUTPUT CIRCUIT OPEN RADIATOR FAN CONTROL MODULE GROUND CIRCUIT OPEN RADIATOR FAN CONTROL CIRCUIT OPEN RADIATOR FAN CONTROL MODULE RADIATOR FAN MOTOR POWERTRAIN CONTROL MODULE...
Page 548 7 - 4 COOLING - ELECTRICAL DIAGNOSTICS *RADIATOR COOLING FAN INOPERATIVE (CONTINUED) CHECKING THE FUSED B(+) CIRCUIT Turn the ignition off. Disconnect the Radiator Fan Control Module harness connector. Note: Check connectors — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B(+) circuit at the Radiator Fan Control Module harness connector.
Page 549 COOLING - ELECTRICAL DIAGNOSTICS 7 - 5 *RADIATOR COOLING FAN INOPERATIVE (CONTINUED) CHECKING THE RADIATOR FAN CONTROL CIRCUIT With the ignition off. Disconnect the Powertrain Control Module (PCM) C4 harness connec- tor. Note: Check connectors — Clean/repair as necessary. Measure the resistance of the Radiator Fan Control circuit from the Radiator Fan Control Module harness connector to the PCM harness connector.
Page 550 7 - 6 COOLING - ELECTRICAL DIAGNOSTICS *RADIATOR COOLING FAN INOPERATIVE (CONTINUED) CHECKING THE RADIATOR FAN CONTROL MODULE GROUND CIRCUIT With the ignition off. Measure the resistance of the Radiator Fan Control Module Ground circuit from the Radiator Fan Control Module harness connector to the Radiator Fan Motor harness connector.
Page 551 COOLING - ELECTRICAL DIAGNOSTICS 7 - 7 *RADIATOR COOLING FAN ALWAYS ON...
Page 552 7 - 8 COOLING - ELECTRICAL DIAGNOSTICS *RADIATOR COOLING FAN ALWAYS ON (CONTINUED) POSSIBLE CAUSES RADIATOR FAN CONTROL CIRCUIT SHORTED TO GROUND RADIATOR FAN CONTROL MODULE OUTPUT CIRCUIT SHORTED TO VOLTAGE RADIATOR FAN CONTROL MODULE A/C SWITCH CIRCUIT MALFUNCTION POWERTRAIN CONTROL MODULE For a complete Radiator Cooling Fan Circuit Diagram, (Refer to 7 - COOLING - SCHEMATICS AND DIAGRAMS).
Page 553 COOLING - ELECTRICAL DIAGNOSTICS 7 - 9 *RADIATOR COOLING FAN ALWAYS ON (CONTINUED) CHECKING THE RADIATOR FAN CONTROL CIRCUIT Turn the ignition off. Disconnect the Powertrain Control Module (PCM) C4 harness connec- tor. Note: Check connectors — Clean/repair as necessary. Measure the resistance between ground and the Radiator Fan Control circuit.
Page 554 7 - 10 COOLING - ELECTRICAL DIAGNOSTICS POWERTRAIN VERIFICATION TEST – VER 3 POWERTRAIN VERIFICATION TEST – VER 3 Note: If the PCM has been replaced, the PCM version coding must be updated with the DRB III . Inspect the vehicle to ensure that all components related to the repair are connected properly. With the DRB III , clear DTCs and Reset Memory for all engine values.
Page 555 COOLING - ELECTRICAL DIAGNOSTICS 7 - 11 SCHEMATICS AND DIAGRAMS...
Page 556 7 - 12 COOLING - SERVICE INFORMATION COOLING - SERVICE INFORMATION TABLE OF CONTENTS page page COOLING - SERVICE INFORMATION INSPECTION ......16 DESCRIPTION .
Page 557: Operation
COOLING - SERVICE INFORMATION 7 - 13 On vehicles equipped with a Supercharger, there are additional cooling system components. The Charge Air Cooler, Charge Air Cooler Radiator, Charge Air Cooler Circulation Pump, and all related hoses are also part of the cooling system.
Page 558 7 - 14 COOLING - SERVICE INFORMATION • When engine is cold: Thermostat (6) is closed, cooling system has no flow through the radiator (7). The cool- ant flows through the engine, heater core (3), coolant recovery reservoir (1) and an internal engine by-pass. •...
Page 559: Diagnosis And Testing
COOLING - SERVICE INFORMATION 7 - 15 Supercharged vehicles (if equipped) have additional cooling system components. The Charge Air Cooler (2), Charge Air Cooler Radiator (3), Charge Air Cooler Circulation Pump (4), and all related hoses make up the charge air cooler cooling system.
Page 560: Cooling System Leak
7 - 16 COOLING - SERVICE INFORMATION • Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system). COOLING SYSTEM LEAK With the engine not running, wipe the coolant recovery reservoir neck sealing area clean. Attach a radiator pressure tester (1) to the coolant recovery reservoir with Special Tool 9107 Pressure Tester Adaptor (2).
Page 561: Specifications
COOLING - SERVICE INFORMATION 7 - 17 SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Belt Tensioner Bolts — Condensor Bolts — Coolant Recovery — Reservoir Nuts Idler Pulley Screw — Transmission Cooler Line — Nuts Transmission Cooler Line —...
Page 562: Special Tools
7 - 18 COOLING - SERVICE INFORMATION SPECIAL TOOLS PRESSURE TESTER ADAPTER 9107 REFRACTOMETER 8286...
Page 563 ENGINE 7 - 19 ENGINE TABLE OF CONTENTS page page COOLANT REMOVAL - SRT ..... . 40 DESCRIPTION ......20 INSTALLATION OPERATION .
Page 564: Engine
7 - 20 ENGINE COOLANT DESCRIPTION WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS.
Page 565: Operation
ENGINE 7 - 21 COOLANT SELECTION AND ADDITIVES CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere.
Page 566: Standard Procedure
7 - 22 ENGINE CAUTION: Do not mix different types of coolant—corrosion protection will be severely reduced. STANDARD PROCEDURE DRAINING WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN- COCK WITH THE COOLING SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 567: Reverse Flushing
ENGINE 7 - 23 Note: The engine cooling system will push any remaining air into the coolant recovery reservoir within about an hour of normal driving. As a result, a drop in coolant level in the coolant recovery reservoir may occur.
Page 568: Coolant Level Sensor
7 - 24 ENGINE COOLANT LEVEL SENSOR REMOVAL 1. Partially drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PRO- CEDURE). 2. Disconnect the coolant level sensor harness con- nector (2). 3. Depress the locking tabs and pull the coolant level sensor (1) from the coolant recovery reservoir.
Page 569: Operation
ENGINE 7 - 25 thermostat allows engine coolant to flow to the radiator. This provides quick engine warm up and overall tempera- ture control. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing.
Page 570: Diagnosis And Testing
7 - 26 ENGINE DIAGNOSIS AND TESTING THERMOSTAT 1. Remove the thermostat from the engine. (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL). 2. Suspend the thermostat in a container of water. CAUTION: Never use a welding torch or soldering torch as the sudden introduction of heat alters the struc- ture of the metal! 3.
Page 571: Removal
ENGINE 7 - 27 REMOVAL 1. Remove the air cleaner housing. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL). 2. Partially drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE). 3. Disconnect the upper radiator hose. Note: The thermostat housing and the thermostat are serviced as an assembly.
Page 572: Coolant Recovery Reservoir
7 - 28 ENGINE COOLANT RECOVERY RESERVOIR OPERATION The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling losses.
Page 573: Removal - Srt
ENGINE 7 - 29 REMOVAL - SRT 1. Disconnect the negative battery cable. 2. Partially drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PRO- CEDURE). 3. Disconnect the small coolant hose at the coolant recovery reservoir (4). 4.
Page 574: Installation
7 - 30 ENGINE 7. Disconnect the coolant overflow hose (1). 8. Remove the two retaining nuts (2) and lift the cool- recovery reservoir from engine compartment. INSTALLATION INSTALLATION 1. Position the coolant recovery reservoir in the engine compartment. 2. Install the two retaining nuts (2). Tighten the nuts to 5 N·m (44 in.
Page 575: Installation - Srt
ENGINE 7 - 31 4. Connect the coolant level sensor harness connec- tor (2). 5. Connect the small coolant hose (4) from the radia- tor to the top of the coolant recovery reservoir. 6. Connect the large coolant hose (3) to the bottom of the coolant recovery reservoir.
Page 576 7 - 32 ENGINE 4. Connect the coolant level sensor harness connec- tor (2). 5. Connect the small coolant hose (4) from the radia- tor to the top of the coolant recovery reservoir. 6. Connect the large coolant hose (3) to the bottom of the coolant recovery reservoir.
Page 577: Radiator Fan
ENGINE 7 - 33 RADIATOR FAN REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the radiator fan harness connector (1). 3. Remove the coolant return hose (1) from the mounting bracket (2).
Page 578 7 - 34 ENGINE 4. Using a suitable tool, grasp the radiator fan hold down clamps (2) and pull up to remove the clamps from the mounting holes. 5. Carefully pry the upper radiator hose and return hoses away from the cooling fan. 6.
Page 579: Installation
ENGINE 7 - 35 INSTALLATION Note: Lightly lubricate the two locating studs on the bottom of the radiator fan prior to installation. 1. Gently lower the radiator fan into the vehicle. 2. Carefully pry the upper radiator hose and return hoses away from the cooling fan.
Page 580 7 - 36 ENGINE 4. Install the radiator fan hold down clamps (1). . 5. Route the coolant return hose (1) through the bracket (2) on the radiator fan. 6. Connect the radiator fan harness connector (1). 7. Connect the negative battery cable.
Page 581: Radiator Fan Control Module
ENGINE 7 - 37 RADIATOR FAN CONTROL MODULE REMOVAL REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the radiator fan control module harness connector (2). 3. Remove the retaining nuts at the top and bottom of the cooling fan module (1). 4.
Page 582: Installation
7 - 38 ENGINE INSTALLATION INSTALLATION 1. Position the radiator fan control module on the inner fender well studs. 2. Install the upper and lower retaining nuts. Tighten the nuts to 10 N·m (89 in. lbs.). 3. Connect the radiator fan control module harness connector.
Page 583: Engine Coolant Temperature Sensor
ENGINE 7 - 39 ENGINE COOLANT TEMPERATURE SENSOR OPERATION The engine coolant temperature sensor provides an input to the powertrain control module (PCM). As coolant tem- perature varies, the engine coolant temperature sensor resistance changes, resulting in a variable input voltage to the PCM.
Page 584 7 - 40 ENGINE 5. Pull up on the engine coolant temperature sensor retaining clip (1) and slide the engine coolant tem- perature sensor out of the housing. 6. Remove the engine coolant temperature sensor from the engine. REMOVAL - SRT 1.
Page 585 ENGINE 7 - 41 4. Remove the air pump tube retaining bolts (2). 5. Remove the air pump tube assembly from the engine (1). (Refer to 25 - EMISSIONS CONTROL/ INJECTION/AIR PUMP INLET TUBE REMOVAL). 6. Release the tension on the accessory drive belt. 7.
Page 586 7 - 42 ENGINE 8. Remove the supercharger idler pulley upper retain- ing bolt (1) and lower retaining bolt (2). 9. Remove the supercharger idler pulley. 10. Remove the accessory drive belt idler pulley (2) to gain access to the engine coolant temperature sensor (1).
Page 587: Installation
ENGINE 7 - 43 12. Pull up on the engine coolant temperature sensor retaining clip (1) and slide the engine coolant tem- perature sensor out of the housing. 13. Remove the engine coolant temperature sensor from the engine. INSTALLATION INSTALLATION 1.
Page 588 7 - 44 ENGINE 4. Connect the engine coolant temperature sensor harness connector (1). 5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 589 ENGINE 7 - 45 INSTALLATION - SRT 1. Clean any debris or corrosion from the engine cool- ant temperature sensor mounting surface. 2. Use a small amount of petroleum jelly to lubricate the sensor seal. 3. Install the engine coolant temperature sensor and retaining clip (1).
Page 590 7 - 46 ENGINE 5. Install the accessory drive belt idler pulley. Tighten the accessory drive belt idler pulley bolt (2) to 20 N·m (15 ft. lbs.). 6. Install the supercharger idler pulley upper mounting bolt (1) and the lower mounting bolt (2). Tighten the mounting bolts to 20 N·m (15 ft.
Page 591 ENGINE 7 - 47 7. Install the accessory drive belt to the accessory drive belt pulley. (Refer to 7 - COOLING/ACCES- SORY DRIVE - OPERATION). 8. Install the air pump tube assembly (1) and install the retaining bolts (2). (Refer to 25 - EMISSIONS CONTROL/AIR INJECTION/AIR PUMP...
Page 592: Description
7 - 48 ENGINE 9. Install the engine cover (1). Align the engine cover retaining clips to the engine rubber mounts, and push down firmly to connect engine cover to the rubber mounts. Note: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
Page 593: Removal
ENGINE 7 - 49 Note: Handle the radiator with care, plastic tanks while stronger than brass, are subject to damage. REMOVAL 1. Disconnect the negative battery cable. 2. Remove the radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL). 3.
Page 594 7 - 50 ENGINE 6. Disconnect the lower radiator hose (2). 7. Disconnect the coolant recovery reservoir hose (1). 8. Disconnect the transmission cooler line (3) located on the right side of the radiator (automatic trans- mission only). (Refer to 7 - COOLING/TRANSMIS- SION/TRANS COOLER LINES - REMOVAL).
Page 595 ENGINE 7 - 51 Using a suitable tool, grasp the radiator hold down clamps (2) and pull up to remove the clamps from the mounting holes. 10. Remove the condenser retaining bolts (1) from the radiator support. 11. Carefully lean the radiator back toward the engine. 12.
Page 596: Installation
7 - 52 ENGINE INSTALLATION 1. Carefully lower the radiator into the vehicle. 2. Connect the lower radiator hose (2). 3. Connect the coolant recovery reservoir hose (1). 4. Install the transmission cooler line (3) (automatic transmission only). Tighten the line to 10 N·m (89 in.
Page 597 ENGINE 7 - 53 6. Connect the transmission cooler line (1) located in the middle front of the vehicle (automatic transmis- sion only). (Refer to 7 - COOLING/TRANSMIS- SION/TRANS COOLER LINES - INSTALLATION). 7. Using a suitable tool (1) install the radiator retain- ing clamps (2).
Page 598 7 - 54 ENGINE 8. Install the two condenser retainer bolts (1) into the radiator support. Tighten the bolts to 10 N·m (89 in. lbs.). 9. Install the radiator fan. (Refer to 7 - COOLING/EN- GINE/RADIATOR FAN - INSTALLATION). 10. Install the air inlet tubes. 11.
Page 599: Radiator Pressure Cap
ENGINE 7 - 55 RADIATOR PRESSURE CAP DESCRIPTION The pressure cap is located on the coolant reservoir. The pressure cap is made of high strength plastic, and screws onto the coolant reservoir tank. The cap con- tains a springloaded pressure relief valve, and a spring loaded vacuum relief valve.
Page 600: Water Pump
7 - 56 ENGINE CLEANING Clean the radiator pressure cap using a mild soap and water only. WATER PUMP DESCRIPTION The water pump is a die cast aluminum housing with a swept vane impeller. It attaches directly to the timing chain cover.
Page 601 ENGINE 7 - 57 5. Remove the radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL). 6. Remove the accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). 7. Remove the belt tensioner. (Refer to 7 - COOLING/ ACCESSORY DRIVE/BELT TENSIONERS...
Page 602 7 - 58 ENGINE 8. Disconnect the lower radiator hose (2). 9. Disconnect the coolant by-pass hose (1). 10. Remove the generator. (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - REMOVAL). 11. Remove the water pump pulley (2). 12. Remove the accessory drive belt idler pulley (1). 13.
Page 603 ENGINE 7 - 59 REMOVAL - SRT 1. Remove the engine cover. Grasp both corners of the engine cover and pull up firmly. 2. Drain the cooling system. (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). 3. Remove the radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL).
Page 604 7 - 60 ENGINE 4. Remove the air pump tube retaining bolts (2). 5. Remove the air pump tube assembly from the engine (1). (Refer to 25 - EMISSIONS CONTROL/ INJECTION/AIR PUMP INLET TUBE REMOVAL). 6. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
Page 605 ENGINE 7 - 61 9. Remove the supercharger idler pulley upper retain- ing bolt (1) and lower retaining bolt (2). 10. Remove the supercharger idler pulley. 11. Remove the accessory drive belt from the engine. 12. Remove the belt tensioner pulley and the belt ten- sioner.
Page 606 7 - 62 ENGINE 13. Disconnect the lower radiator hose (2). 14. Disconnect the coolant by-pass hose (1). 15. Remove the generator. (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - REMOVAL). 16. Remove the water pump pulley (2). 17. Remove the accessory drive belt idler pulley (1). 18.
Page 607 ENGINE 7 - 63 INSPECTION Note: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the weep hole.
Page 608: Installation
7 - 64 ENGINE INSTALLATION INSTALLATION 1. Clean all gasket surfaces. 2. Position the water pump with a new gasket on the timing chain cover. 3. Install the water pump bolts in the correct positions. Tighten the bolts to 35 N·m (26 ft. lbs.). 4.
Page 609 ENGINE 7 - 65 6. Install the water pump pulley (2) and bolts. Tighten the water pump pulley bolts to 10 N·m (89 in. lbs.). 7. Install the idler pulley (1) and bolt. Tighten the idler pulley bolt to 10 N·m (89 in. lbs.). 8.
Page 610 7 - 66 ENGINE 9. Rotate the belt tensioner counterclockwise and install the accessory drive belt. 10. Release the belt tensioner and remove the wrench. 11. Install the radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - INSTALLATION). 12. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 611: Installation - Srt
ENGINE 7 - 67 INSTALLATION - SRT 1. Clean all gasket surfaces. 2. Position the water pump with a new gasket on the timing chain cover. 3. Install the water pump bolts in the correct positions. Tighten the bolts to 35 N·m (26 ft. lbs.). 4.
Page 612 7 - 68 ENGINE 8. Connect the lower radiator hose (2) and coolant by-pass hose (1). 9. Install the generator. (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION). 10. Rotate the belt tensioner counterclockwise and install the accessory drive belt. 11.
Page 613 ENGINE 7 - 69 12. Install the air pump tube assembly (1) to the engine. (Refer to 25 - EMISSIONS CONTROL/ AIR INJECTION/AIR PUMP INLET TUBE - INSTALLATION). 13. Install the radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - INSTALLATION).
Page 614: Radiator - Charge Air Cooler
7 - 70 ENGINE 14. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. Note: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
Page 615: Operation
ENGINE 7 - 71 charge air cooler located beneath the supercharger. The charge air cooler radiator operates independently of the engine cooling system. The only common link is the coolant reservoir. Both systems use the coolant reservoir as their source of coolant. OPERATION The charge air cooler radiator operates similarily to the engine radiator.
Page 616 7 - 72 ENGINE 6. Allow the charge air cooler radiator (2) to hang from the cooling hoses (1). 7. Remove the drain plug (1) from the charge air cooler radiator. 8. Drain the coolant out of the charge air cooler cool- ing system.
Page 617: Installation
ENGINE 7 - 73 9. Disconnect the inlet coolant hose (2) and the outlet coolant hose (1) from the charge air cooler radiator. 10. Remove the charge air cooler radiator from the vehicle. INSTALLATION 1. Locate the upper mounting studs (1), and the lower rubber mounts (2) for the charge air cooler radiator.
Page 618 7 - 74 ENGINE 2. Carefully install the charge air cooler radiator, and seat the radiator into the lower rubber mounts. 3. Tilt the charge air cooler radiator inward, and install the radiator onto the upper mounting studs. 4. Install the left and right charge air cooler radiator retaining nuts.
Page 619: Charge Air Cooler
ENGINE 7 - 75 CHARGE AIR COOLER DESCRIPTION The charge air cooler is used to reduce the temperature of the engines incoming air supply. The charge air cooler is mounted to the bottom of the supercharger, and is located between the cylinder banks. The charge air cooler is constructed of aluminum, and is detachable from the supercharger.
Page 620: Removal
7 - 76 ENGINE REMOVAL 1. Remove the engine supercharger (3).(Refer to 9 - ENGINE/MANIFOLDS/SUPERCHARGER REMOVAL). 2. Remove the four charge air cooler flange bolts (2) from the supercharger housing. 3. Remove the two mounting bolts (4) from the super- charger housing.
Page 621: Installation
ENGINE 7 - 77 6. Remove the MAP sensor (1) from the charge air cooler. INSTALLATION 1. Install the MAP sensor to the charge air cooler.
Page 622 7 - 78 ENGINE 2. Install a new charge air cooler flange gasket (1). 3. Install the charge air cooler (3) to the supercharger. Tighten the charge air cooler mounting bolts (2) to 25 N·m (18 ft. lbs.). 4. Install the charge air cooler rear mounting bolts. Tighten the charge air cooler rear mounting bolts (4) to 20 N·m (15 ft.
Page 623: Charge Air Cooler Circulation Pump
ENGINE 7 - 79 CHARGE AIR COOLER CIRCULATION PUMP DESCRIPTION The charge air cooler circulation pump is mounted to the side of the charge air cooler radiator. The pump is used to circulate coolant between the charge air cooler radiator and the charge air cooler. The pump is a positive dis- placement pump, that operates on a pulsed 12 volt signal.
Page 624: Removal
7 - 80 ENGINE REMOVAL 1. Remove the right front inner fender lining in order to gain access to the charge air cooler circulation pump. 2. Remove the charge air cooler circulation pump inlet hose (2). 3. Remove the charge air cooler circulation pump out- let hose (1).
Page 625: Installation
ENGINE 7 - 81 INSTALLATION 1. Install the charge air cooler circulation pump to the mounting bracket. 2. Install the charge air cooler circulation pump mounting bolt (1). Tighten the mounting bolt to 20 N·m (15 ft. lbs.). 3. Reconnect the charge air cooler circulation pump harness connector (2).
Page 626 7 - 82 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE REMOVAL - SRT ..... . 92 DESCRIPTION .
Page 627: Operation - Srt
ACCESSORY DRIVE 7 - 83 OPERATION - SRT The accessory drive belt provides the link between the engine crankshaft and the engine accessories. Ten- sion on the accessory drive belt is maintained by an automatic belt tensioner. 1. Supercharger 2. Power Steering Pump 3.
Page 628: Belt Tensioner
7 - 84 ACCESSORY DRIVE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Idler Pulley Bolt — Belt Tensioner Bolts — BELT TENSIONER REMOVAL REMOVAL 1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly. 2.
Page 629: Removal - Srt
ACCESSORY DRIVE 7 - 85 4. Remove the belt tensioner retaining bolts (1) and the belt tensioner (2). REMOVAL - SRT 1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
Page 630 7 - 86 ACCESSORY DRIVE 2. Remove the air pump tube assembly retaining bolts (2). 3. Disconnect the air pump tube assembly (1) from the switchover valves. 4. Remove the air pump tube assembly (1) from the engine. 5. Release the tension on the accessory drive belt by attaching a wrench and pulling up on the tensioner and relocating the accessory drive belt.
Page 631 ACCESSORY DRIVE 7 - 87 7. Remove the accessory drive belt tensioner bolts (1). 8. Remove the accessory drive belt tensioner from the engine. INSTALLATION INSTALLATION 1. Position the belt tensioner (2) on the timing chain cover. 2. Install the belt tensioner bolts (1). Tighten the bolts to 20 N·m (15 ft.
Page 632 7 - 88 ACCESSORY DRIVE 3. Install the wrench on the tensioner and remove the tensioner locking pin (1). 4. Install the accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). 5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 633: Installation - Srt
ACCESSORY DRIVE 7 - 89 INSTALLATION - SRT 1. Install the accessory drive belt tensioner with the mounting bolts (1). Tighten the mounting bolts to 20 N·m (15 ft. lbs.). 2. Install the accessory drive belt tensioner pulley to the stud. Tighten the pulley nut to 20 N·m (15 ft. lbs.).
Page 634 7 - 90 ACCESSORY DRIVE 4. Install the air pump tube assembly (1) to the engine. (Refer to 25 - EMISSIONS CONTROL/AIR INJECTION/AIR PUMP INLET TUBE INSTALLATION). 5. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 635: Drive Belt Removal Removal
ACCESSORY DRIVE 7 - 91 DRIVE BELT REMOVAL REMOVAL 1. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly. 2. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt. 3.
Page 636: Removal - Srt
7 - 92 ACCESSORY DRIVE REMOVAL - SRT 1. Remove the engine cover (1). Grasp both corners of the engine cover and pull up firmly. 2. Remove the air pump tube retaining bolts (2). 3. Remove the air pump tube assembly from the engine (1).
Page 637: Cleaning
ACCESSORY DRIVE 7 - 93 4. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt. 5. Remove the accessory drive belt from the pulleys. 6. Carefully release the wrench tension on the belt tensioner. 7. Remove the supercharger idler pulley upper retain- ing bolt (1) and lower retaining bolt (2).
Page 638: Inspection
7 - 94 ACCESSORY DRIVE INSPECTION Belt replacement is necessary for any or all of the fol- lowing conditions: • Excessive wear • Frayed cords • Severe glazing The accessory drive belt may develop minor cracks across the ribbed side (1) due to reverse bending. These minor cracks are considered normal and acceptable.
Page 639 ACCESSORY DRIVE 7 - 95 2. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the tensioner pulley. 3. Release the belt tensioner and remove the wrench. 4. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 640: Installation - Srt
7 - 96 ACCESSORY DRIVE INSTALLATION - SRT 1. Route the accessory drive belt onto the engine pulleys. 2. Install the supercharger idler pulley upper mounting bolt (1) and the lower mounting bolt (2). Tighten the bolts to 20 N·m (15 ft. lbs.).
Page 641 ACCESSORY DRIVE 7 - 97 3. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the tensioner pulley. 4. Release the belt tensioner and remove the wrench. 5. Install the air pump tube assembly (1) to the engine.
Page 642: Idler Pulley
7 - 98 ACCESSORY DRIVE 6. Install the engine cover (1). Align engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. Note: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
Page 643 ACCESSORY DRIVE 7 - 99 2. Relocate the accessory drive belt away from the idler pulley (4). 3. Remove the idler pulley bolt cover (1). 4. Remove the bolt (1) and the idler pulley (2) from the engine. 5. Check the pulley bearing for any wear, looseness or noise.
Page 644: Removal - Idler Pulley (Srt)
7 - 100 ACCESSORY DRIVE REMOVAL - IDLER PULLEY (SRT) Note: A small dowel rod can be inserted into the accessory drive belt tensioner to hold the ten- sioner in place while performing repairs. 1. Rotate the belt tensioner counterclockwise and release the tension on the accessory drive belt.
Page 645: Removal - Supercharger Idler (Srt)
ACCESSORY DRIVE 7 - 101 3. Remove the bolt (1) and the idler pulley from the engine. 4. Check the pulley bearing for looseness and noise. Replace if necessary. REMOVAL - SUPERCHARGER IDLER (SRT) 1. Remove the engine cover (1). Grasp both corners of the engine cover and pull up firmly.
Page 646 7 - 102 ACCESSORY DRIVE 2. Remove the air tube assembly (1) by removing the retaining bolts (2). 3. Release the tension on the accessory drive belt. 4. Remove the supercharger idler pulley retainer bolts (1) and (2) and the pulley assembly.
Page 647: Installation
ACCESSORY DRIVE 7 - 103 INSTALLATION INSTALLATION 1. Position the idler pulley (2) on the engine. 2. Install the idler pulley bolt (1). Tighten to 20 N·m (15 ft. lbs.). 3. Install the bolt cover (1) on the idler pulley.
Page 648 7 - 104 ACCESSORY DRIVE Note: If a dowel rod was inserted into the acces- sory drive belt tensioner, remove rod. 4. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley. 5. Carefully release the belt tensioner and remove the wrench.
Page 649: Installation - Idler Pulley (Srt)
ACCESSORY DRIVE 7 - 105 INSTALLATION - IDLER PULLEY (SRT) 1. Position the idler pulley on the engine. 2. Install the idler pulley bolt (1). Tighten the idler pul- ley bolt to 20 N·m (15 ft. lbs.). 3. Rotate the belt tensioner counterclockwise and install the accessory drive belt over the idler pulley.
Page 650: Installation - Supercharger Idler (Srt)
7 - 106 ACCESSORY DRIVE 5. Install and properly route the accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE - OPERATION). INSTALLATION - SUPERCHARGER IDLER (SRT) 1. Install the supercharger idler pulley retainer bolts (1) and (2), and the pulley assembly. Tighten bolts to 20 N·m (15 ft.
Page 651 ACCESSORY DRIVE 7 - 107 3. Install the air tube assembly (1) by installing the retaining bolts (2). 4. Install the engine cover (1). Align engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 652 7 - 108 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION COOLER LINES INSTALLATION ......109 REMOVAL .
Page 653 TRANSMISSION 7 - 109 INSTALLATION 1. Position the cooler line(s) and loosely connect the fittings. 2. Install the retainers and bolts for the cooler line(s). Note: Replace the copper washers if the banjo bolts are removed. 3. Tighten the cooler line fittings or banjo bolts to 20 N·m (15 ft. lbs.). 4.
Page 655 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO - ELECTRICAL DIAGNOSTICS... 1 AUDIO - SERVICE INFORMATION ... . 20 AUDIO - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page...
Page 656: Audio - Electrical Diagnostics
8A - 2 AUDIO - ELECTRICAL DIAGNOSTICS *RADIO INOPERATIVE...
Page 657 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 3 *RADIO INOPERATIVE (CONTINUED) POSSIBLE CAUSES FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN FUSED B(+) CIRCUIT OPEN GROUND CIRCUIT OPEN RADIO For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 658 8A - 4 AUDIO - ELECTRICAL DIAGNOSTICS *RADIO INOPERATIVE (CONTINUED) MEASURE RADIO GROUND CIRCUIT RESISTANCE Turn the ignition off. Measure the resistance between ground and the Ground circuit at cav- ity 8 (connector A) of the Radio harness connector. Is the resistance below 5.0 ohms? >>...
Page 659: No Sound From All Speakers
AUDIO - ELECTRICAL DIAGNOSTICS 8A - 5 *NO SOUND FROM ALL SPEAKERS...
Page 660 8A - 6 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM ALL SPEAKERS (CONTINUED) POSSIBLE CAUSES FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN POWER AMPLIFIER For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 661 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 7 *NO SOUND FROM ALL SPEAKERS (CONTINUED) MEASURE POWER AMPLIFIER GROUND CIRCUIT RESISTANCE Turn the ignition off. Measure the resistance between ground and the Ground circuit at cav- ity 11 (connector A) of the Power Amplifier harness connector. Is the resistance below 5.0 ohms? >>...
Page 662: No Sound From Left Door Speakers
8A - 8 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM LEFT DOOR SPEAKERS...
Page 663 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 9 *NO SOUND FROM LEFT DOOR SPEAKERS (CONTINUED) POSSIBLE CAUSES AMPLIFIED LEFT DOOR SPEAKER (+) CIRCUIT OPEN AMPLIFIED LEFT DOOR SPEAKER (-) CIRCUIT OPEN POWER AMPLIFIER For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 664: No Sound From Right Door Speakers
8A - 10 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM RIGHT DOOR SPEAKERS...
Page 665 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 11 *NO SOUND FROM RIGHT DOOR SPEAKERS (CONTINUED) POSSIBLE CAUSES AMPLIFIED RIGHT DOOR SPEAKER (+) CIRCUIT OPEN AMPLIFIED RIGHT DOOR SPEAKER (-) CIRCUIT OPEN POWER AMPLIFIER For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 666: No Sound From Left Rear Speaker
8A - 12 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM LEFT REAR SPEAKER...
Page 667 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 13 *NO SOUND FROM LEFT REAR SPEAKER (CONTINUED) POSSIBLE CAUSES AMPLIFIED LEFT REAR SPEAKER (+) CIRCUIT OPEN AMPLIFIED LEFT REAR SPEAKER (-) CIRCUIT OPEN LEFT REAR SPEAKER SUPPLY VOLTAGE CIRCUIT OPEN LEFT REAR SPEAKER GROUND CIRCUIT OPEN LEFT REAR SPEAKER For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 668 8A - 14 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM LEFT REAR SPEAKER (CONTINUED) MEASURE LEFT REAR SPEAKER CIRCUIT RESISTANCE With the ignition off. Connect a jumper wire between cavity 3 and cavity 4 of the Left Rear Speaker harness connector. Measure the resistance between cavity 12 (connector B) and cavity 4 (connector B) of the Power Amplifier harness connector.
Page 669: No Sound From Right Rear Speaker
AUDIO - ELECTRICAL DIAGNOSTICS 8A - 15 *NO SOUND FROM RIGHT REAR SPEAKER...
Page 670 8A - 16 AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM RIGHT REAR SPEAKER (CONTINUED) POSSIBLE CAUSES AMPLIFIED RIGHT REAR SPEAKER (+) CIRCUIT OPEN AMPLIFIED RIGHT REAR SPEAKER (-) CIRCUIT OPEN RIGHT REAR SPEAKER SUPPLY VOLTAGE CIRCUIT OPEN RIGHT REAR SPEAKER GROUND CIRCUIT OPEN RIGHT REAR SPEAKER For a complete Audio System Circuit Diagram, (Refer to 8 - ELECTRICAL/AUDIO - SCHEMATICS AND DIA- GRAMS).
Page 671 AUDIO - ELECTRICAL DIAGNOSTICS 8A - 17 *NO SOUND FROM RIGHT REAR SPEAKER (CONTINUED) MEASURE RIGHT REAR SPEAKER CIRCUIT RESISTANCE With the ignition off. Connect a jumper wire between cavity 3 and cavity 4 of the Right Rear Speaker harness connector. Measure the resistance between cavity 14 (connector B) and cavity 13 (connector B) of the Power Amplifier harness connector.
Page 672: Body Verification Test
8A - 18 AUDIO - ELECTRICAL DIAGNOSTICS BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 673: Schematics And Diagrams
AUDIO - ELECTRICAL DIAGNOSTICS 8A - 19 SCHEMATICS AND DIAGRAMS...
Page 674 8A - 20 AUDIO - SERVICE INFORMATION AUDIO - SERVICE INFORMATION TABLE OF CONTENTS page page AUDIO - SERVICE INFORMATION INSTALLATION ......32 DESCRIPTION .
Page 675: Audio - Service Information Description
AUDIO - SERVICE INFORMATION 8A - 21 AUDIO - SERVICE INFORMATION DESCRIPTION The audio system is standard factory-installed equipment. The system uses an ignition switched source of battery current so that the system will only operate when the ignition switch is in the ON/RUN or START positions. The audio system includes the following components: •...
Page 676: Special Tools
8A - 22 AUDIO - SERVICE INFORMATION SPECIAL TOOLS Radio Removal Tool 9241...
Page 677: Amplifier Removal Removal
AUDIO - SERVICE INFORMATION 8A - 23 AMPLIFIER REMOVAL REMOVAL 1. Un-snap and remove the carpeted floor mat from the passenger footwell. 2. Un-tuck the carpeting in the passenger footwell, and fold the carpet down to expose the foam insu- lation.
Page 678: Removal - Rhd
8A - 24 AUDIO - SERVICE INFORMATION 5. Remove the four amplifier retaining screws (1) from the base plate, and disconnect the amplifier har- ness connector. 6. Remove the amplifier from the base plate. REMOVAL - RHD 1. Un-snap and remove the carpeted floor mat from the passenger footwell.
Page 679 AUDIO - SERVICE INFORMATION 8A - 25 Note: It is not necessary to remove the harness connectors to rotate the base plate in the passen- ger footwell. 4. Remove the plastic retaining nuts (1) from the floor panel and rotate the base plate exposing the amplifier.
Page 680: Installation
8A - 26 AUDIO - SERVICE INFORMATION INSTALLATION INSTALLATION 1. Connect the amplifier harness connector and attach the amplifier to the base plate with the four retaining screws (1). 2. Rotate the base plate and install it over the mount- ing studs on the floor panel.
Page 681 AUDIO - SERVICE INFORMATION 8A - 27 4. Install the foam insulating panel. 5. Install the carpeting in the passenger footwell. 6. Install the floor mat to the carpet. INSTALLATION - RHD 1. Connect the amplifier harness connector and attach the amplifier to the base plate with the four retaining screws (1).
Page 682: Antenna Body & Cable - Convertible
8A - 28 AUDIO - SERVICE INFORMATION 2. Rotate the base plate and install it over the mount- ing studs on the floor panel. Note: Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to the floor mounting studs.
Page 683: Operation
AUDIO - SERVICE INFORMATION 8A - 29 OPERATION The antenna body and cable connects the antenna mast to the radio. The radio antenna is an electromag- netic circuit component used to capture radio fre- quency signals that are broadcast by local commercial radio stations in both the Amplitude Modulating (AM) and Frequency Modulating (FM) frequency ranges.
Page 684 8A - 30 AUDIO - SERVICE INFORMATION 4. There should be no continuity. The ohmmeter should register an open circuit. Low resistance indicates a dam- aged or shorted antenna conductor. If OK, go to Test 2. If not OK, replace the faulty antenna cable component. TEST 2 Test 2 checks the antenna conductor components for an open circuit.
Page 685: Removal
AUDIO - SERVICE INFORMATION 8A - 31 REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the left side trunk liner aside. 3. Remove antenna mast (1) by unscrewing mast from antenna body. 4. Remove the retaining nut from the underside of the mounting bracket.
Page 686: Rear Window Antenna Module
8A - 32 AUDIO - SERVICE INFORMATION REAR WINDOW ANTENNA MODULE REMOVAL 1. Disconnect the negative battery cable. 2. Remove the liftgate interior trim panel. (Refer to 23 BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/ TRIM PANEL - REMOVAL). 3. Disconnect the antenna module harness connec- tors.
Page 687: Rear Window Antenna
AUDIO - SERVICE INFORMATION 8A - 33 REAR WINDOW ANTENNA DESCRIPTION The liftgate glass contains the audio antenna (4) attached to the inside surface. Grid lines running hor- izontally form the antenna, which terminates to bus bars (1) at either side. Blade type terminals, also attached to the inside glass surface at the bus bars, form the beginning connection point for the radio fre- quency signal.
Page 688: Removal
8A - 34 AUDIO - SERVICE INFORMATION 6. For a rear glass antenna terminal replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent bus bar. Apply a thin layer of epoxy to the area where the terminal was previously fastened and onto the adjacent bus bar line.
Page 689: Installation
AUDIO - SERVICE INFORMATION 8A - 35 INSTALLATION 1. Install the liftgate glass. 2. Connect the rear window defogger (3) and the rear window antenna (1) harness connectors to the lift- gate glass terminals. 3. Install the center high mount stop lamp (CHMSL) assembly to the liftgate (2), and connect the CHMSL harness connector.
Page 690: Installation
8A - 36 AUDIO - SERVICE INFORMATION 6. To remove the radio tools, depress the flexible metal tabs on each side of the radio. INSTALLATION 1. Connect the radio harness connectors. 2. Align and gently guide the radio into the radio opening.
Page 691: Removal - Rear Panel Speaker
AUDIO - SERVICE INFORMATION 8A - 37 1. Disconnect the negative battery cable. 2. Remove the door interior trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL). 3. Disconnect the lower door speaker harness connector. 4. Remove the lower door speaker retaining screws (1).
Page 692: Removal - Tweeter Speaker
8A - 38 AUDIO - SERVICE INFORMATION 7. Disconnect the rear panel speaker harness con- nector (2). 8. Remove the inner mounting frame (1) together with the left or right rear panel speaker from the vehicle. REMOVAL - TWEETER SPEAKER WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 693: Lower Door Speaker
AUDIO - SERVICE INFORMATION 8A - 39 3. Disconnect the tweeter speaker harness connector (2). 4. Release the retaining tabs and remove the tweeter speaker (1) from the door interior trim panel. INSTALLATION LOWER DOOR SPEAKER WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 694: Installation - Rear Panel Speaker
8A - 40 AUDIO - SERVICE INFORMATION INSTALLATION - REAR PANEL SPEAKER 1. Install the inner mounting frame (4) together with the left or right rear panel speaker into the opening of the rear panel. 2. Connect the rear panel speaker harness connector (3). 3.
Page 695 AUDIO - SERVICE INFORMATION 8A - 41 1. Install the tweeter speaker (1) into the door interior trim panel (2). 2. Connect the tweeter speaker harness connector (3). 3. Install the door interior trim panel (2). (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION).
Page 697 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER - ELECTRICAL DIAGNOSTICS . . . 1 CHIME/BUZZER - SERVICE INFORMATION ..3 CHIME/BUZZER - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page CHIME/BUZZER - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS .
Page 698 8B - 2 CHIME/BUZZER - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS...
Page 699 CHIME/BUZZER - SERVICE INFORMATION 8B - 3 CHIME/BUZZER - SERVICE INFORMATION TABLE OF CONTENTS page page CHIME TONE GENERATOR DIAGNOSIS AND TESTING - CHIME DESCRIPTION WARNING SYSTEM ..... 4 DESCRIPTION .
Page 700 8B - 4 CHIME/BUZZER - SERVICE INFORMATION Hard wired circuitry connects many of the chime warning system components to each other through the electrical system of the vehicle. If the Instrument Cluster or the chime tone generator is damaged or faulty, the Instrument Cluster assembly must be replaced.
Page 701 CHIME/BUZZER - SERVICE INFORMATION 8B - 5 CONDITION POSSIBLE CAUSES CORRECTION NO KEY IN IGNITION OR 1. Faulty door ajar switch or 1. Check that interior lights illuminate with the HEADLAMPS-ON WARNING circuits. driver door open. If not OK, repair the interior CHIME WITH DRIVER SIDE lighting system as required.
Page 702 8B - 6 CHIME/BUZZER - SERVICE INFORMATION • Warning Beep Support - The Instrument Cluster chime tone generator will generate a short series of beeps to provide an audible alert to the vehicle operator of certain visual warning indications displayed by the Instru- ment Cluster.
Page 703: Electrical Diagnostics
ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES - ELECTRONIC CONTROL MODULES - SERVICE ELECTRICAL DIAGNOSTICS....1 INFORMATION .
Page 704: Electronic Control Modules - Electrical Diagnostics
8E - 2 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *DRB III DOES NOT POWER UP...
Page 705 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 3 *DRB III DOES NOT POWER UP (CONTINUED) POSSIBLE CAUSES FUSED B(+) CIRCUIT OPEN GROUND CIRCUIT OPEN For a complete Data Link Connector Circuit Diagram, (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES - SCHEMATICS AND DIAGRAMS).
Page 706: No Response From All Modules
8E - 4 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM ALL MODULES...
Page 707 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 5 *NO RESPONSE FROM ALL MODULES (CONTINUED) POSSIBLE CAUSES SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND CIRCUIT OPEN FUEL TANK PRESSURE SENSOR POWERTRAIN CONTROL MODULE For a complete Data Link Connector Circuit Diagram, (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES - SCHEMATICS AND DIAGRAMS).
Page 708 8E - 6 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM ALL MODULES (CONTINUED) MEASURE THE PCM SENSOR GROUND CIRCUIT VOLTAGE With the ignition on. Measure the voltage of the Sensor Ground circuit at DLC cavity 5. Is the voltage below 0.5 volts? >>...
Page 709 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 7 *NO RESPONSE FROM ALL MODULES (CONTINUED) MEASURE THE PCM SENSOR GROUND CIRCUIT VOLTAGE WITH THE PCM DISCONNECTED Turn the ignition off. Disconnect the PCM C4 harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on.
Page 710: No Response From Powertrain Control Module
8E - 8 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM POWERTRAIN CONTROL MODULE...
Page 711 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 9 *NO RESPONSE FROM POWERTRAIN CONTROL MODULE (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT OPEN FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN PCM GROUND CIRCUITS SCI RECEIVE CIRCUIT OPEN SCI RECEIVE CIRCUIT SHORTED TO GROUND SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND...
Page 712 8E - 10 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM POWERTRAIN CONTROL MODULE (CONTINUED) FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN With the ignition on. Measure the voltage of the Fused Engine Control Relay Output circuit at the PCM C5 harness connector. Is the voltage above 10 volts? >>...
Page 713 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 11 *NO RESPONSE FROM POWERTRAIN CONTROL MODULE (CONTINUED) SCI RECEIVE CIRCUIT OPEN With the ignition off. Disconnect the PCM C4 harness connector. Note: Check connector — Clean/repair as necessary. Measure the resistance of the PCM SCI Receive circuit from the PCM C4 harness connector to the DLC.
Page 714 8E - 12 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM POWERTRAIN CONTROL MODULE (CONTINUED) SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE Turn the ignition on. Measure the voltage of the PCM SCI Receive circuit at the DLC. Is the voltage below 0.5 volt? >>...
Page 715 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 13 *NO RESPONSE FROM POWERTRAIN CONTROL MODULE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND With the ignition off. Measure the resistance between ground and the PCM SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 716: No Response From Occupant Restraint Controller
8E - 14 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER...
Page 717 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 15 *NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER (CONTINUED) POSSIBLE CAUSES FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN ORC GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE OCCUPANT RESTRAINT CONTROLLER For a complete Data Link Connector Circuit Diagram, (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES - SCHEMATICS AND DIAGRAMS).
Page 718 8E - 16 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER (CONTINUED) ORC GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance of the Ground circuit from the ORC harness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 719 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 17 *NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ignition on. Measure the voltage of the SCI Transmit circuit at the ORC connector. Is the voltage below 0.5 volt? >>...
Page 720: No Response From Instrument Cluster
8E - 18 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM INSTRUMENT CLUSTER...
Page 721 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 19 *NO RESPONSE FROM INSTRUMENT CLUSTER (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT(S) OPEN IC GROUND CIRCUIT(S) OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR A/C HEATER CONTROL MODULE...
Page 722 8E - 20 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM INSTRUMENT CLUSTER (CONTINUED) FUSED B+ CIRCUIT OPEN Turn the ignition off. Disconnect the IC C1 harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B+ circuit at the IC C1 harness con- nector.
Page 723 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 21 *NO RESPONSE FROM INSTRUMENT CLUSTER (CONTINUED) GROUND CIRCUIT(S) OPEN Turn the ignition off. Measure the resistance of the Ground circuits from the IC C1 harness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 724 8E - 22 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM INSTRUMENT CLUSTER (CONTINUED) DISCONNECT MODULES Note: The Instrument Cluster, Universal Garage Door Opener/Tire Pressure Monitor, A/C Heater Control Module and Power Top Con- trol Module (if equipped) all use the SCI Transmit circuit at DLC cavity 15 to communicate with the DRB III .
Page 725 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 23 *NO RESPONSE FROM INSTRUMENT CLUSTER (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 726: No Response From Universal Garage Door Opener/Tire Pressure Monitor
8E - 24 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR...
Page 727 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 25 *NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE A/C HEATER CONTROL MODULE INSTRUMENT CLUSTER...
Page 728 8E - 26 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR (CONTINUED) FUSED B+ CIRCUIT OPEN Turn the ignition off. Disconnect the UGDO/TPM harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B+ circuit at the UGDO/TPM har- ness connector.
Page 729 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 27 *NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR (CONTINUED) SCI TRANSMIT CIRCUIT OPEN With the ignition off. Measure the resistance of the SCI Transmit circuit from the UGDO/ TPM harness connector to the DLC. Is the resistance below 5.0 ohms? >>...
Page 730 8E - 28 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ignition off. Disconnect the harness connectors for the IC, UGDO/TPM, A/C Heater Control Module, and Power Top Control Module (if equipped). Turn the ignition on.
Page 731: No Response From A/C Heater Control Module
ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 29 *NO RESPONSE FROM A/C HEATER CONTROL MODULE...
Page 732: Electronic Control Modules - Electrical Diagnostics
8E - 30 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM A/C HEATER CONTROL MODULE (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT(S) OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR INSTRUMENT CLUSTER...
Page 733 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 31 *NO RESPONSE FROM A/C HEATER CONTROL MODULE (CONTINUED) FUSED B+ CIRCUIT OPEN Turn the ignition off. Disconnect the A/C Heater Control Module harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on.
Page 734 8E - 32 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM A/C HEATER CONTROL MODULE (CONTINUED) GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance of the Ground circuit from the A/C Heater Con- trol Module harness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 735 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 33 *NO RESPONSE FROM A/C HEATER CONTROL MODULE (CONTINUED) DISCONNECT MODULES Note: The Instrument Cluster, Universal Garage Door Opener/Tire Pressure Monitor, A/C Heater Control Module, and Power Top Control Module (if equipped) all use the SCI Transmit circuit at DLC cavity 15 to communicate with the DRB III .
Page 736 8E - 34 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM A/C HEATER CONTROL MODULE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 737 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 35 *NO RESPONSE FROM POWER TOP CONTROL MODULE...
Page 738: No Response From Power Top
8E - 36 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM POWER TOP CONTROL MODULE (CONTINUED) POSSIBLE CAUSES FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE POWER TOP CONTROL MODULE For a complete Data Link Connector Circuit Diagram, (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES - SCHEMATICS AND DIAGRAMS).
Page 739 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 37 *NO RESPONSE FROM POWER TOP CONTROL MODULE (CONTINUED) FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN Turn the ignition off. Disconnect the Power Top Control Module harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on.
Page 740 8E - 38 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM POWER TOP CONTROL MODULE (CONTINUED) SCI TRANSMIT CIRCUIT OPEN With the ignition off. Measure the resistance of the SCI Transmit circuit from the Power Top Control Module harness connector to the DLC. Is the resistance below 5.0 ohms? >>...
Page 741: No Response From Controller Antilock Brake
ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 39 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE...
Page 742 8E - 40 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT(S) OPEN TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN GROUND CIRCUIT(S) OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE SHIFT LEVER ASSEMBLY CONTROLLER ANTILOCK BRAKE MODULE...
Page 743 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 41 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE (CONTINUED) FUSED B+ CIRCUIT(S) OPEN Turn the ignition off. Disconnect the CAB harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B+ circuits at the CAB harness con- nector.
Page 744 8E - 42 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE (CONTINUED) GROUND CIRCUIT(S) OPEN Turn the ignition off. Measure the resistance of the Ground circuits from the CAB harness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 745 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 43 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE (CONTINUED) DISCONNECT MODULES Note: The Controller Antilock Brake and Shift Lever Assembly both use the SCI Transmit circuit at DLC cavity 9 to communicate with the DRB III . If one of these modules keeps the SCI Transmit circuit artificially high or low, the DRB III will not be able to com- municate with either of the modules.
Page 746 8E - 44 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 747: No Response From Shift Lever Assembly
ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 45 *NO RESPONSE FROM SHIFT LEVER ASSEMBLY...
Page 748 8E - 46 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM SHIFT LEVER ASSEMBLY (CONTINUED) POSSIBLE CAUSES TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE CONTROLLER ANTILOCK BRAKE SHIFT LEVER ASSEMBLY...
Page 749 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 47 *NO RESPONSE FROM SHIFT LEVER ASSEMBLY (CONTINUED) TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN Turn the ignition off. Disconnect the SLA harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Traction System Relay Output circuit at the SLA harness connector.
Page 750 8E - 48 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM SHIFT LEVER ASSEMBLY (CONTINUED) SCI TRANSMIT CIRCUIT OPEN With the ignition off. Measure the resistance of the SCI Transmit circuit from the SLA har- ness connector to the DLC. Is the resistance below 5.0 ohms? >>...
Page 751 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 49 *NO RESPONSE FROM SHIFT LEVER ASSEMBLY (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE Turn the ignition off. Disconnect the harness connectors for the Controller Antilock Brake and Shift Lever Assembly. Turn the ignition on. Measure the voltage of the SCI Transmit circuit at the SLA harness connector.
Page 752: No Response From Transmission Control Module
8E - 50 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM TRANSMISSION CONTROL MODULE...
Page 753 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 51 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE (CONTINUED) POSSIBLE CAUSES TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE TRANSMISSION CONTROL MODULE For a complete Data Link Connector Circuit Diagram, (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES - SCHEMATICS AND DIAGRAMS).
Page 754 8E - 52 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM TRANSMISSION CONTROL MODULE (CONTINUED) GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance of the Ground circuit from the TCM harness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 755 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 53 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND With the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 756: No Response From Body Control Module
8E - 54 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM BODY CONTROL MODULE...
Page 757 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 55 *NO RESPONSE FROM BODY CONTROL MODULE (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT(S) OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT(S) OPEN GROUND CIRCUIT(S) OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE SENTRY KEY REMOTE ENTRY MODULE BODY CONTROL MODULE...
Page 758 8E - 56 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM BODY CONTROL MODULE (CONTINUED) FUSED B+ CIRCUIT(S) OPEN Turn the ignition off. Disconnect the BCM harness connectors. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B+ circuits at the BCM C4 harness connector.
Page 759 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 57 *NO RESPONSE FROM BODY CONTROL MODULE (CONTINUED) GROUND CIRCUIT(S) OPEN Turn the ignition off. Measure the resistance of the Ground circuits from the BCM C4 har- ness connector to ground. Is the resistance below 5.0 ohms? >>...
Page 760 8E - 58 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM BODY CONTROL MODULE (CONTINUED) DISCONNECT MODULES Note: The Body Control Module and Sentry Key Remote Entry Module both use the SCI Transmit circuit at DLC cavity 1 to com- municate with the DRB III .
Page 761 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 59 *NO RESPONSE FROM BODY CONTROL MODULE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 762: No Response From Sentry Key Remote Entry Module
8E - 60 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE...
Page 763 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 61 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE (CONTINUED) POSSIBLE CAUSES FUSED B+ CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE BODY CONTROL MODULE SENTRY KEY REMOTE ENTRY MODULE...
Page 764 8E - 62 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE (CONTINUED) FUSED B+ CIRCUIT OPEN Turn the ignition off. Disconnect the SKREEM C1 harness connector. Note: Check connector — Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Fused B+ circuit at the SKREEM C1 har- ness connector.
Page 765 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 63 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE (CONTINUED) GROUND CIRCUIT OPEN Turn the ignition off. Measure the resistance of the Ground circuit from the SKREEM C1 harness connector. Is the resistance below 5.0 ohms? >>...
Page 766 8E - 64 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE (CONTINUED) DISCONNECT MODULES Note: The Body Control Module and Sentry Key Remote Entry Module both use the SCI Transmit circuit at DLC cavity 1 to com- municate with the DRB III .
Page 767 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 65 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE (CONTINUED) SCI TRANSMIT CIRCUIT SHORTED TO GROUND OR OPEN Turn the ignition off. Measure the resistance between ground and the SCI Transmit circuit. Is the resistance above 100 kohms? >>...
Page 768: Body Verification Test
8E - 66 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 769: Schematics And Diagrams
ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 67 SCHEMATICS AND DIAGRAMS...
Page 770 8E - 68 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS...
Page 771 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 69...
Page 772 8E - 70 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS...
Page 773 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 71...
Page 774 8E - 72 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS...
Page 775 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 73...
Page 776 8E - 74 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION ELECTRONIC CONTROL MODULES - SERVICE INFORMATION TABLE OF CONTENTS page page COMMUNICATION OPERATION ......91 DESCRIPTION .
Page 777: Data Link Connector
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 75 OPERATION Data exchange between modules is achieved by serial transmission of encoded data over a broadcast network. The Controller Area Network (CAN) data bus messages are carried over the bus in the form of variable pulse width modulated signals.
Page 778: Description
8E - 76 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION The Powertrain Control Module (1) is concealed in the engine compartment inside the Control Module Box (2) located next to the Battery (3). The Powertrain Control Module utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehi- cle.
Page 779: Description - Rhd
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 77 DESCRIPTION - RHD The Powertrain Control Module (1) is concealed in the engine compartment inside the Control Module Box (3) located next to the Battery (2). The Powertrain Control Module utilizes integrated cir- cuitry and information carried on the Controller Area Network (CAN) data bus along with many hard wired inputs to monitor many sensor and switch inputs...
Page 780: Removal
8E - 78 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION PROGRAMMING THE PCM The Sentry Key Remote Entry System Secret Key is an ID code that is unique to each Sentry Key Remote Entry Module. This code is programmed and stored in the Sentry Key Remote Entry Module, the PCM, and the ignition key transponder chip(s).
Page 781 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 79 3. Holding the metal powertrain control module retain- ing clip (1) back, pull the powertrain control module up and out of the control module box. 4. Disconnect the electrical connectors (1) and remove the powertrain control module (2).
Page 782: Removal - Rhd
8E - 80 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION REMOVAL - RHD 1. Disconnect the negative battery cable. 2. Slide the clips forward to remove the plastic control module box cover (1). 3. Holding the metal powertrain control module retaining clip back, pull the powertrain control module (2) up and out of the control module box (5).
Page 783: Installation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 81 INSTALLATION INSTALLATION 1. Connect the electrical connectors (1) to the power- train control module (2). 2. Install the powertrain control module into the con- trol module box. 3. Push the powertrain control module into the metal powertrain control module retaining clip (1).
Page 784: Installation - Rhd
8E - 82 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 4. Install the plastic control module box cover (1) and slide the clips rearward to lock the cover. 5. Connect the negative battery cable (2). INSTALLATION - RHD 1. Connect the PCM harness electrical connector to the powertrain control module (2). 2.
Page 785: Transmission Control Module
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 83 TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module (1) is located in the interior passenger compartment on the passenger side. It is mounted behind a base plate (3) in the passenger side footwell next to the Radio Amplifier (2). The carpet must be pulled pack and the base plate unfastened and flipped down in order to access the Transmission Control Module.
Page 786: Standard Procedure - Tcm Quick Learn
8E - 84 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION • 1-2/4-5 Solenoid • 2-3 Solenoid • 3-4 Solenoid • TCC Solenoid • Modulation Pressure Solenoid • Shift Pressure Solenoid • DRB III Scan Tool Communication • Sensor Supply Voltage • Solenoid Supply Voltage Some examples of Transmission Control Module indirect outputs are: •...
Page 787: Removal
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 85 • The shift lever position must stay in Drive after the Shift to Drive prompt until the DRB III indicates the pro- cedure is complete • The calculated oil temperature must be above 15.6°C (60°F) and below 93.3°C (200°F) REMOVAL REMOVAL 1.
Page 788 8E - 86 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 6. Remove the two retaining screws (1) from the base plate, and disconnect the TCM harness connectors. 7. Remove the TCM (2) from the base plate. REMOVAL 1. Un-snap and remove the carpet floor mat. 2.
Page 789 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 87 Note: It is not necessary to remove the electrical connectors to rotate the base plate in the passen- ger footwell. 4. Remove the three plastic retaining nuts (1) from the floor panel studs. 5.
Page 790: Installation
8E - 88 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION INSTALLATION INSTALLATION 1. Connect the TCM harness connectors and attach the TCM (2) to the base plate with the two retaining screws (1). 2. Rotate the base plate and install it over the mount- ing studs on the floor panel.
Page 791 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 89 4. Install the foam insulation panel. Note: Make sure the aligning tabs of the base plate are positioned correctly in the foam insulat- ing panel. 5. Install the carpeting in the passenger footwell. 6.
Page 792 8E - 90 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 2. Rotate the base plate and install it over the mount- ing studs on the floor panel. Note: Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to the floor mounting studs.
Page 793: Controller Antilock Brake Description
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 91 CONTROLLER ANTILOCK BRAKE DESCRIPTION The Controller Antilock Brake (CAB) (1) is located in the engine compartment in front of the Underhood Accessory Fuse Block (2). The CAB is a microprocessor-based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when the vehicle is in an ABS stop.
Page 794: Removal
8E - 92 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the Antilock Brake System for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory.
Page 795: Installation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 93 4. Disconnect the Controller Antilock Brake (CAB) harness connector (1). 5. Remove the retaining screws (2) from the Inte- grated Control Unit (ICU) retaining bracket. 6. Pull the ICU upwards, carefully pushing the hydrau- lic brake lines to one side.
Page 796: Security System Module
8E - 94 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 5. Reconnect the CAB harness connector (1). 6. Connect the negative battery cable. 7. Bleed the brake system. (Refer to 5 - BRAKES - STANDARD PROCEDURE). 8. Read the fault memory and erase. SECURITY SYSTEM MODULE DESCRIPTION The Central Locking Pump/Security System Module (3) uses a combination of electrical wires (2) and air pressure/...
Page 797: Operation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 95 The Central Locking Pump/Security System Module controls the air and vacuum lines that handle the locking and unlocking of the vehicle doors, the liftgate, and the fuel tank door. OPERATION VEHICLE LOCKING / UNLOCKING To unlock, the SKREEM module sends a signal to the Body Control Module.
Page 798: Removal
8E - 96 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION SIREN The vehicle theft system alarm Siren contains a built in rechargeable battery back up and can sound if its electrical circuits are disconnected or if the vehicle battery cables are disconnected. The Siren can also sound if the electrical circuits between it and the CLP/SSM are disconnected.
Page 799: Installation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 97 8. Disconnect the air lines (2) and the electrical har- ness (1) from the central locking pump/security system module (3) and remove the module. INSTALLATION 1. Install the central locking pump/security system module (3) into the trunk and connect the air lines (2) and the electrical harness (1).
Page 800: Sentry Key Remote Entry Module
8E - 98 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 3. Install the right half of the trunk floor covering (3). 4. Install the rear interior trim panel (2). 5. Install the right side interior trim panel (4). 6. Install the right upper trim panel (1). 7.
Page 801: Operation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 99 The SKREEM is also the primary component of the sentry key system. The SKREEM has a halo-like Antenna Ring that connects by wires to the SKREEM and is mounted around the Ignition Lock Cylinder. The SKREEM cannot be adjusted or repaired.
Page 802: Removal
8E - 100 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION REMOVAL 1. Disconnect the negative battery cable. 2. Remove the Instrument Cluster. (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER REMOVAL). 3. Disconnect the 2-pin CAN BUS harness connector (1) from the SKREEM module. 4.
Page 803: Body Control Module
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 101 BODY CONTROL MODULE DESCRIPTION DESCRIPTION BODY CONTROL MODULE The Body Control Module (BCM) (1) is concealed in the engine compartment inside of the Control Module Box (2) located next to the battery (3). The BCM utilizes integrated circuitry and information carried on the Controller Area Network (CAN) bus along with many hardwired inputs to monitor many sensor and switch inputs throughout the vehicle.
Page 804: Description - Rhd
8E - 102 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION DESCRIPTION - RHD BODY CONTROL MODULE The Body Control Module (BCM) (2) is concealed in the engine compartment inside of the Control Module Box (1) located next to the battery (3). The BCM utilizes integrated circuitry and information carried on the Controller Area Network (CAN) bus along with many hardwired inputs to monitor many...
Page 805: Removal
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 103 REMOVAL REMOVAL 1. Disconnect the negative battery cable (2). 2. Slide the clips forward to remove the plastic control module box cover (1). 3. Holding the metal body control module retaining clip (1) back, pull the body control module up and out of the control module box.
Page 806: Removal - Rhd
8E - 104 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 4. Disconnect the electrical connectors (1) by first sliding the grey windshield wiper connector lock to the right and removing the windshield wiper electri- cal connector. Then, pull the metal body control module connector lock up to unlock and disconnect the rest of the body control module electrical con- nectors.
Page 807: Installation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 105 4. Disconnect the BCM harness connectors by first sliding the grey motor harness wiper connector lock to the right and disconnecting the windshield wiper harness connector. Then, pull the metal body control module connector lock up to unlock and disconnect the rest of the body control module harness connectors.
Page 808: Installation - Rhd
8E - 106 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 3. Install the plastic control module box cover (1) and slide the clips rearward to lock the cover. 4. Connect the negative battery cable (2). INSTALLATION - RHD 1. Connect the harness connectors to the body control module (6) and push the metal body control module con- nector lock down to lock the connector assembly.
Page 809: Power Top Control Module
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 107 POWER TOP CONTROL MODULE DESCRIPTION The Power Top Control Module (PTCM) (1) is located in the trunk below the left rear tail light assembly and next to the power top hydraulic assembly. The PTCM is mounted to an attaching bracket at the power top hydraulic assembly.
Page 810: Removal
8E - 108 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION REMOVAL 1. Disconnect the negative battery cable. 2. Remove the left trunk trim panel (1), by removing the plastic retainers (2) and lifting the left trunk trim panel out of the trunk. 3.
Page 811: Installation
ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 109 INSTALLATION 1. Install the power top control module to the hydrau- lic pump bracket (4). 2. Install the power top control module retaining screw (1). 3. Connect the power top control module harness connectors (2) and (3).
Page 813 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING SYSTEM .
Page 814: Battery System
8F - 2 BATTERY SYSTEM • Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery hold-down hardware. For battery system maintenance schedules and jump starting procedure, see the owner’s manual in the vehicle glove box.
Page 815 BATTERY SYSTEM 8F - 3 CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 816 8F - 4 BATTERY SYSTEM CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications. Replace an incorrect MAINTAINED. this vehicle.
Page 817: Cleaning
BATTERY SYSTEM 8F - 5 CLEANING The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. 1.
Page 818: Inspection
8F - 6 BATTERY SYSTEM 4. Clean any corrosion from the battery (3) and the battery terminal posts and battery cables (2) with a wire brush or a post and terminal cleaner (1), and a sodium bicarbonate (baking soda) and warm water cleaning solution.
Page 819: Special Tools
BATTERY SYSTEM 8F - 7 SPECIAL TOOLS Micro 420 Battery Tester...
Page 820: Description
8F - 8 BATTERY SYSTEM BATTERY DESCRIPTION A large capacity, low-maintenance storage battery (3) is standard factory-installed equipment on this model. Male post type terminals made of a soft lead material protrude from the top of the molded plastic battery case to provide the means for connecting the battery to the vehicle electrical system.
Page 821: Standard Procedure
BATTERY SYSTEM 8F - 9 As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the battery discharging process is reversed.
Page 822 8F - 10 BATTERY SYSTEM • Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected specific gravity of the battery electrolyte. • Open-circuit voltage of the battery is 12.4 volts or above. WARNING: NEVER EXCEED TWENTY AMPERES WHEN CHARGING A COLD (-1° C [30° F] OR LOWER) BAT- TERY.
Page 823 BATTERY SYSTEM 8F - 11 1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the read- ing is below ten volts, the battery charging current will be low. It could take some time before the bat- tery accepts a current greater than a few milliam- peres.
Page 824: Standard Procedure - Using Micro 420 Battery Tester
8F - 12 BATTERY SYSTEM BATTERY CHARGING TIME Charging 5 Amps Amperage Amps Amps Open Circuit Hours Charging @ 21° C (70° F) Voltage 12.25 to 12.49 6 hours 3 hours hours 12.00 to 12.24 10 hours 5 hours hours 10.00 to 11.99 14 hours 7 hours...
Page 825: Standard Procedure - Open-Circuit Voltage Test
BATTERY SYSTEM 8F - 13 6. While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit.
Page 826 8F - 14 BATTERY SYSTEM • Faulty or shorted electronic modules and components. • An internally shorted generator. • Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been cor- rected.
Page 827: Standard Procedure - Checking Battery Electrolyte Level
BATTERY SYSTEM 8F - 15 each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diag- nosis and testing procedures (Refer to 8 - ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING).
Page 828 8F - 16 BATTERY SYSTEM 2. Look through the battery cap holes (1) to determine the level of the electrolyte in the battery. The elec- trolyte should be approximately 1 centimeter above the battery plates or until the lip (2) inside the bat- tery cap holes is covered.
Page 829: Removal - Battery
BATTERY SYSTEM 8F - 17 REMOVAL REMOVAL - BATTERY WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOV- ING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES. 1.
Page 830: Removal - Rhd
8F - 18 BATTERY SYSTEM REMOVAL - RHD WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOV- ING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES. 1.
Page 831: Installation - Battery
BATTERY SYSTEM 8F - 19 INSTALLATION INSTALLATION - BATTERY 1. Clean and inspect the battery. Refer to the procedures in this section. CAUTION: The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables. 2. Position the battery (5) onto the battery tray. Ensure that the battery positive and negative terminal posts are correctly positioned.
Page 832: Installation - Rhd
8F - 20 BATTERY SYSTEM INSTALLATION - RHD 1. Clean and inspect the battery. Refer to the procedures in this section. CAUTION: The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables. 2. Position the battery (4) onto the battery tray. Ensure that the battery positive and negative terminal posts are correctly positioned.
Page 833: Operation
BATTERY SYSTEM 8F - 21 The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components.
Page 834 8F - 22 BATTERY SYSTEM 1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position.
Page 835: Description
BATTERY SYSTEM 8F - 23 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter (1).
Page 836: Description - Rhd
8F - 24 BATTERY SYSTEM DESCRIPTION - RHD The battery is mounted in a battery tray (1) located in the left rear corner of the engine compartment. The battery tray and support unit is secured at the front with a bolt (2) on the front wheelhouse inner panel, and at the rear with a bolt (2) on a bracket from the bulkhead.
Page 837: Removal
BATTERY SYSTEM 8F - 25 REMOVAL REMOVAL 1. Remove the battery. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL). 2. Remove the battery tray (1) retaining bolts (2). 3. Remove the battery tray (1). REMOVAL - RHD 1. Remove the battery. (Refer to 8 - ELECTRICAL/ BATTERY SYSTEM/BATTERY - REMOVAL).
Page 838: Installation
8F - 26 BATTERY SYSTEM INSTALLATION INSTALLATION 1. Install the battery tray (1). 2. Install the battery tray (1) retaining bolts (2). Tighten the bolts to 15 N·m (11 ft. lbs.). 3. Install the battery. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION). INSTALLATION - RHD 1.
Page 839 CHARGING SYSTEM 8F - 27 CHARGING SYSTEM TABLE OF CONTENTS page page CHARGING SYSTEM OPERATION ......30 DESCRIPTION .
Page 840: Charging System
8F - 28 CHARGING SYSTEM 2. Inspect condition of battery cable terminals, battery posts, connections at engine block, and starter solenoid. They should be clean and tight. Repair as required. 3. Inspect all fuses in the Underhood Accessory Fuse Block for tightness in receptacles. They should be properly installed and tight.
Page 841 CHARGING SYSTEM 8F - 29 SCHEMATICS AND DIAGRAMS...
Page 842: Description
8F - 30 CHARGING SYSTEM SPECIFICATIONS SPECIFICATIONS - GENERATOR TYPE PART NUMBER RATED SAE AMPS ENGINE MINIMUM TEST AMPS BOSCH 05097756AA 3.2L V-6 120@2200RPM SPECIFICATIONS - TORQUE DESCRIPTION Ft. Lbs. In. Lbs. Generator Mounting Bolts — Generator B+ Terminal Nut —...
Page 843 CHARGING SYSTEM 8F - 31 REMOVAL 1. Disconnect the negative battery cable. 2. Remove the right side air inlet tube. CAUTION: The accessory drive belt tensioner pulley is spring loaded and can cause damage to hands and fingers if allowed to spring back. 3.
Page 844 8F - 32 CHARGING SYSTEM INSTALLATION 1. Connect the generator B+ cable with the retaining nut and connect the generator harness connector (4). Tighten the generator B+ cable retaining nut to 15 N·m (11 ft. lbs.). 2. Install the protective plastic cap on the generator B+ cable nut (5). 3.
Page 845: Description
CHARGING SYSTEM 8F - 33 VOLTAGE REGULATOR DESCRIPTION The voltage regulator (2) is a separate component attached to the rear of the generator assembly (1). If replacement is necessary, the voltage regulator can be replaced separately from the generator. OPERATION OPERATION The amount of DC current produced by the generator is controlled by the voltage regulator circuitry.
Page 846: Removal
8F - 34 CHARGING SYSTEM REMOVAL 1. Remove the generator (1). (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOVAL). 2. Unclip the plastic voltage regulator cover (4) and remove. 3. Remove the screws (3) attaching the voltage regulator to the generator. 4.
Page 847 STARTING SYSTEM 8F - 35 STARTING SYSTEM TABLE OF CONTENTS page page STARTING SYSTEM TORQUE SPECIFICATIONS ....43 DESCRIPTION ......35 STARTER MOTOR OPERATION .
Page 848: Starting System
8F - 36 STARTING SYSTEM OPERATION The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes, and a low-amperage control circuit that operates on less than 20 amperes. The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the starter solenoid, and the starter motor.
Page 849 STARTING SYSTEM 8F - 37 CONDITION POSSIBLE CAUSE CORRECTION 6. Starter motor faulty. 6. If all other starting system components and circuits test OK, replace the starter motor assembly. STARTER ENGAGES, 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of FAILS TO TURN faulty.
Page 850 8F - 38 STARTING SYSTEM TESTING COLD CRANKING TEST For complete wiring diagrams, refer to Starting System in the Contents of Group 8W - Wiring Diagrams. The bat- tery must be fully-charged and load-tested before proceeding. Refer to Battery in the Diagnosis and Testing section of Group 8F - Engine Systems for the procedures.
Page 851 STARTING SYSTEM 8F - 39 • Battery is fully-charged and load-tested. Refer to Battery in the Diagnosis and Testing section of Group 8F - Engine Systems for the procedures. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - DIAGNOSIS AND TESTING). • Fully engage the parking brake. •...
Page 852 8F - 40 STARTING SYSTEM 3. Connect the voltmeter (2) to measure between the battery (1) positive terminal post and the starter (3) solenoid battery terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery cable connection at the solenoid.
Page 853 STARTING SYSTEM 8F - 41 If the resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing section of this Group 8F - Engine Systems. (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - DIAGNOSIS AND TESTING).
Page 854: Schematics And Diagrams
8F - 42 STARTING SYSTEM SCHEMATICS AND DIAGRAMS...
Page 855: Specifications
STARTING SYSTEM 8F - 43 SPECIFICATIONS STARTER MOTOR Starter Motor and Solenoid Manufacturer Engine Application 3.2L Power Rating Voltage 12 Volts Number of Fields Number of Poles Number of Brushes Drive Type Free Running Test Voltage Free Running Test Maximum Amperage Draw Free Running Test Minimum Speed Solenoid Closing Maximum Voltage Required *Cranking Amperage Draw Test...
Page 856: Diagnosis And Testing - Starter Motor
8F - 44 STARTING SYSTEM OPERATION The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft.
Page 857 STARTING SYSTEM 8F - 45 3. Check the solenoid (1) for continuity between the solenoid terminal (2) and the solenoid field coil ter- minal (4) with a continuity tester (3). There should be continuity. If OK, go to Step 4. If not OK, replace the faulty starter motor assembly.
Page 858: Removal
8F - 46 STARTING SYSTEM REMOVAL 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the lower engine panel. 4. Disconnect the right O2 sensor electrical connector. 5. Remove the right side exhaust pipe from the exhaust manifold to the rear exhaust system. (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - REMOVAL) 6.
Page 859: Installation
STARTING SYSTEM 8F - 47 INSTALLATION 1. Install the starter (4). 2. Connect the starter cable and the ground cable with the nuts. Tighten the starter positive cable nut to 14 N·m (10 ft. lbs.). Tighten the starter ground cable nut (2) to 6 N·m (52 in. lbs.) 3.
Page 861 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS - ELECTRICAL DIAGNOSTICS . . . 1 HEATED MIRRORS - SERVICE INFORMATION . . 25 HEATED GLASS - SERVICE INFORMATION ..12 HEATED SEATS - ELECTRICAL DIAGNOSTICS.
Page 862: Heated Glass - Electrical Diagnostics
8G - 2 HEATED GLASS - ELECTRICAL DIAGNOSTICS REAR DEFOGGER SWITCH SENSE CIRCUIT...
Page 863 HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 3 REAR DEFOGGER SWITCH SENSE CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: The Body Control Module (BCM) detects a short to power, ground, or an open on the Rear Defogger Switch Sense circuit.
Page 864: Diagnostics
8G - 4 HEATED GLASS - ELECTRICAL DIAGNOSTICS REAR DEFOGGER SWITCH SENSE CIRCUIT (CONTINUED) BODY CONTROL MODULE With the ignition on. Measure the voltage of the Rear Defogger Switch Sense circuit at the BCM C3 harness connector.Press and hold the Rear Defogger Switch. Is the voltage above 10.0 volts? >>...
Page 865 HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 5 REAR DEFOGGER SWITCH SENSE CIRCUIT (CONTINUED) REAR DEFOGGER SWITCH SENSE CIRCUIT SHORT TO GROUND With the ignition off. Measure the resistance between ground and the Rear Defogger Switch Sense circuit. Is the resistance below 100k ohms? >>...
Page 866: Heated Glass - Electrical Diagnostics
8G - 6 HEATED GLASS - ELECTRICAL DIAGNOSTICS *REAR WINDOW DEFOGGER INOPERATIVE...
Page 867 HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 7 *REAR WINDOW DEFOGGER INOPERATIVE (CONTINUED) POSSIBLE CAUSES REAR WINDOW DEFOGGER FUSED B(+) CIRCUIT OPEN REAR WINDOW DEFOGGER GRID OPEN REAR WINDOW DEFOGGER GRID GROUND CIRCUIT OPEN CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE For a complete Heated Glass Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED GLASS - SCHEMATICS AND DIAGRAMS).
Page 868: Heated Glass - Electrical Diagnostics
8G - 8 HEATED GLASS - ELECTRICAL DIAGNOSTICS *REAR WINDOW DEFOGGER INOPERATIVE (CONTINUED) MEASURE REAR WINDOW DEFOGGER GRID VOLTAGE Turn the ignition off. Reconnect the CLP/SSM C2 harness connector. Disconnect the Rear Window Defogger Grid harness connector termi- nal 1. Note: Check connector - Clean/repair as necessary.
Page 869 HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 9 *REAR WINDOW DEFOGGER INOPERATIVE (CONTINUED) MEASURE REAR WINDOW DEFOGGER SUPPLY CIRCUIT RESISTANCE Turn the ignition off. Disconnect the CLP/SSM C2 harness connector. Measure the resistance of the Rear Window Defogger Grid Supply cir- cuit from the CLP/SSM C2 harness connector to the Rear Window Defogger Grid harness connector terminal 2.
Page 870: Heated Glass - Electrical Diagnostics
8G - 10 HEATED GLASS - ELECTRICAL DIAGNOSTICS BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 871: Schematics And Diagrams
HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 11 SCHEMATICS AND DIAGRAMS...
Page 872 8G - 12 HEATED GLASS - SERVICE INFORMATION HEATED GLASS - SERVICE INFORMATION TABLE OF CONTENTS page page HEATED GLASS - SERVICE INFORMATION INSTALLATION ......15 DESCRIPTION .
Page 873: Operation
HEATED GLASS - SERVICE INFORMATION 8G - 13 OPERATION When the Rear Window Defogger Switch (2) is pressed with the Ignition Switch turned to the ON/RUN position, electrical current from Fuses 25 and 26 in the Underhood Accessory Fuse Block is applied to the rear window defogger grid.
Page 874: Diagnosis And Testing - Rear Window Defogger System
8G - 14 HEATED GLASS - SERVICE INFORMATION On the Roadster model, the rear defogger grid is com- prised of horizontal silver-ceramic grid lines (1) through the two vertical bus bars (2) on the glass inside surface. When the circuit is operating, the grid lines provide heat in the form of resistance.
Page 875: Rear Window Defogger Switch
HEATED GLASS - SERVICE INFORMATION 8G - 15 REAR WINDOW DEFOGGER SWITCH REMOVAL WARNING: REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR, SEAT, STEERING WHEEL, STEER- ING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER- SONAL INJURY.
Page 876: Standard Procedure - Rear Glass Heating Grid Repair
8G - 16 HEATED GLASS - SERVICE INFORMATION 2. Using a 12-volt DC voltmeter, contact a good body ground point with the negative lead. With the posi- tive lead, contact the vertical bus bar (1) on the left side of the vehicle. The voltmeter should read bat- tery voltage.
Page 877 HEATED GLASS - SERVICE INFORMATION 8G - 17 5. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch). 6. For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar.
Page 878 8G - 18 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS HEATED MIRRORS - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page HEATED MIRRORS - ELECTRICAL *RIGHT HEATED MIRROR INOPERATIVE . . . 21 DIAGNOSTICS BODY VERIFICATION TEST ... . . 23 DIAGNOSIS AND TESTING SCHEMATICS AND DIAGRAMS .
Page 879: Left Heated Mirror Inoperative
HEATED MIRRORS - ELECTRICAL DIAGNOSTICS 8G - 19 *LEFT HEATED MIRROR INOPERATIVE...
Page 880: Heated Mirrors - Electrical Diagnostics
8G - 20 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS *LEFT HEATED MIRROR INOPERATIVE (CONTINUED) POSSIBLE CAUSES LEFT MIRROR HEATER ELEMENT FUSED HEATED MIRROR SUPPLY CIRCUIT OPEN LEFT MIRROR HEATER ELEMENT GROUND CIRCUIT OPEN LEFT MIRROR HEATER ELEMENT For a complete Heated Mirrors Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED MIRRORS - SCHEMATICS AND DIAGRAMS).
Page 881: Right Heated Mirror Inoperative
HEATED MIRRORS - ELECTRICAL DIAGNOSTICS 8G - 21 *RIGHT HEATED MIRROR INOPERATIVE...
Page 882 8G - 22 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS *RIGHT HEATED MIRROR INOPERATIVE (CONTINUED) POSSIBLE CAUSES RIGHT MIRROR HEATER ELEMENT FUSED HEATED MIRROR SUPPLY CIRCUIT OPEN RIGHT MIRROR HEATER ELEMENT GROUND CIRCUIT OPEN RIGHT MIRROR HEATER ELEMENT For a complete Heated Mirrors Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED MIRRORS - SCHEMATICS AND DIAGRAMS).
Page 883: Body Verification Test
HEATED MIRRORS - ELECTRICAL DIAGNOSTICS 8G - 23 BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 884: Schematics And Diagrams
8G - 24 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS...
Page 885 HEATED MIRRORS - SERVICE INFORMATION 8G - 25 HEATED MIRRORS - SERVICE INFORMATION TABLE OF CONTENTS page page HEATED MIRRORS - SERVICE INFORMATION DIAGNOSIS AND TESTING ....26 DESCRIPTION .
Page 886 8G - 26 HEATED MIRRORS - SERVICE INFORMATION DIAGNOSIS AND TESTING The operation of the heated mirror system is similar to the rear window defogger and can be confirmed in the fol- lowing manner: • Turn the Ignition Switch to the ON/RUN position and activate the Rear Window Defogger.
Page 887 HEATED MIRRORS - SERVICE INFORMATION 8G - 27 The heated mirror grid is attached to the back of the sideview mirror glass and cannot be adjusted or repaired. If faulty or damaged, the entire sideview mir- ror assembly must be replaced as a unit. For com- plete sideview mirror...
Page 888 8G - 28 HEATED SEATS - ELECTRICAL DIAGNOSTICS HEATED SEATS - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page page HEATED SEATS - ELECTRICAL DIAGNOSTICS *BOTH HEATED SEATS INOPERATIVE ..35 DIAGNOSIS AND TESTING BODY VERIFICATION TEST ... . . 37 *LEFT HEATED SEAT INOPERATIVE .
Page 889: Left Heated Seat Inoperative
HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 29 *LEFT HEATED SEAT INOPERATIVE...
Page 890 8G - 30 HEATED SEATS - ELECTRICAL DIAGNOSTICS *LEFT HEATED SEAT INOPERATIVE (CONTINUED) POSSIBLE CAUSES LEFT SEAT BACK/CUSHION HEATER ELEMENT LEFT HEATED SEAT OUTPUT CIRCUIT OPEN LEFT HEATED SEAT GROUND CIRCUIT OPEN HEATED SEAT MODULE For a complete Heated Seats Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED SEATS - SCHEMATICS AND DIAGRAMS).
Page 891 HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 31 *LEFT HEATED SEAT INOPERATIVE (CONTINUED) MEASURE LEFT HEATED SEAT OUTPUT CIRCUIT RESISTANCE Disconnect the Left Heated Seat Back/Heated Seat Cushion harness connector. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Left Heated Seat Output circuit from the Heated Seat Module harness connector to the Left Heated Seat Back/ Heated Seat Cushion harness connector.
Page 892: Right Heated Seat Inoperative
8G - 32 HEATED SEATS - ELECTRICAL DIAGNOSTICS *RIGHT HEATED SEAT INOPERATIVE...
Page 893 HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 33 *RIGHT HEATED SEAT INOPERATIVE (CONTINUED) POSSIBLE CAUSES RIGHT SEAT BACK/CUSHION HEATER ELEMENT RIGHT HEATED SEAT OUTPUT CIRCUIT OPEN RIGHT HEATED SEAT GROUND CIRCUIT OPEN HEATED SEAT MODULE For a complete Heated Seats Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED SEATS - SCHEMATICS AND DIAGRAMS).
Page 894 8G - 34 HEATED SEATS - ELECTRICAL DIAGNOSTICS *RIGHT HEATED SEAT INOPERATIVE (CONTINUED) MEASURE RIGHT HEATED SEAT OUTPUT CIRCUIT RESISTANCE Disconnect the Right Heated Seat Back/Heated Seat Cushion harness connector. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Right Heated Seat Output circuit between the Heated Seat Module harness connector and the Right Heated Seat Back/Heated Seat Cushion harness connector.
Page 895: Both Heated Seats Inoperative
HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 35 *BOTH HEATED SEATS INOPERATIVE...
Page 896 8G - 36 HEATED SEATS - ELECTRICAL DIAGNOSTICS *BOTH HEATED SEATS INOPERATIVE (CONTINUED) POSSIBLE CAUSES FUSED B(+) CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN HEATED SEAT MODULE For a complete Heated Seats Circuit Diagram (Refer to 8 - ELECTRICAL/HEATED SEATS - SCHEMATICS AND DIAGRAMS).
Page 897: Body Verification Test
HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 37 BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 898: Schematics And Diagrams
8G - 38 HEATED SEATS - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS...
Page 899 HEATED SEATS - SERVICE INFORMATION 8G - 39 HEATED SEATS - SERVICE INFORMATION TABLE OF CONTENTS page page HEATED SEATS - SERVICE INFORMATION REMOVAL - HEATED SEAT BACK ELEMENT . 43 DESCRIPTION ......39 INSTALLATION OPERATION .
Page 900: Operation
8G - 40 HEATED SEATS - SERVICE INFORMATION OPERATION The Heated Seat System will operate only when the Ignition Switch is in the ACC or ON/RUN position. The Heated Seat Module receives switched power through Fuse 1 and non-switched power through Fuse 24 in the Underhood Accessory Fuse Block.
Page 901: Installation
HEATED SEATS - SERVICE INFORMATION 8G - 41 Note: The Heated Seat Switches and the Heated Seat Control Module are integral and serviced together. 1. Disconnect the negative battery cable. 2. Remove the center console interior trim panel. (Refer to 23 - BODY/INTERIOR/CENTER CON- SOLE - REMOVAL).
Page 902: Heated Seat Element
8G - 42 HEATED SEATS - SERVICE INFORMATION HEATED SEAT ELEMENT DESCRIPTION The Heated Seat Elements (1 and 5) are an integrated part of the seat cushion (4) or seat back cushion (2). The heated seat elements are only serviced with the cushion assemblies. The seat covers (6) are serviced separately and are attached to the seat frame (3).
Page 903: Heated Seat Cushion Element
HEATED SEATS - SERVICE INFORMATION 8G - 43 REMOVAL HEATED SEAT CUSHION ELEMENT Note: Disconnect the negative battery cable before removing the seat or attempting seat electrical repair. The heated seat cushion element (2) is part of the seat cushion assembly (3). To access the element, the seat must be removed and the seat cover (1) disas- sembled.
Page 904: Heated Seat Cushion Element
8G - 44 HEATED SEATS - SERVICE INFORMATION INSTALLATION HEATED SEAT CUSHION ELEMENT The heated seat cushion element (2) is an integral part of the seat cushion (3). For complete seat cush- ion installation procedures, see seat cushion installa- tion in the body section. (Refer to 23 - BODY/SEATS/ SEAT CUSHION - INSTALLATION).
Page 905 HEATED SEATS - SERVICE INFORMATION 8G - 45 The Heated Seat Control Module (1) is integrated within the Heated Seat Switch (2) assembly. For com- plete Heated Seat Control Module removal proce- dures, see Heated Seat Switch removal in this section.
Page 907 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN - ELECTRICAL DIAGNOSTICS ... 1 HORN - SERVICE INFORMATION ....9 HORN - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page...
Page 908: Horn - Electrical Diagnostics
8H - 2 HORN - ELECTRICAL DIAGNOSTICS *HORNS INOPERATIVE...
Page 909 HORN - ELECTRICAL DIAGNOSTICS 8H - 3 *HORNS INOPERATIVE (CONTINUED) POSSIBLE CAUSES HORN SWITCH CIRCUIT OPEN RELAY CONTROL MODULE GROUND CIRCUIT OPEN HORN(S) For a complete Horn Circuit Diagram, (Refer to 8 - ELECTRICAL/HORN - SCHEMATICS AND DIAGRAMS). Diagnostic Test TEST THE HORNS Note: Inspect the Horn Fuse (F6) located in the Relay Control Module.
Page 910: Horn - Electrical Diagnostics
8H - 4 HORN - ELECTRICAL DIAGNOSTICS *HORNS INOPERATIVE (CONTINUED) MEASURE THE HORN CIRCUIT RESISTANCE Disconnect the left Horn harness connector (Horn No.2). Note: Check connectors - Clean/repair as necessary. Measure the resistance between cavity 1 of the Relay Control Module harness connector “E”...
Page 911: Horns Always On
HORN - ELECTRICAL DIAGNOSTICS 8H - 5 *HORNS ALWAYS ON...
Page 912 8H - 6 HORN - ELECTRICAL DIAGNOSTICS *HORNS ALWAYS ON (CONTINUED) POSSIBLE CAUSES HORN CIRCUIT SHORT TO BATTERY HORN SWITCH CIRCUIT SHORT TO GROUND RELAY CONTROL MODULE For a complete Horn Circuit Diagram, (Refer to 8 - ELECTRICAL/HORN - SCHEMATICS AND DIAGRAMS). Diagnostic Test TEST THE HORN CIRCUIT Turn the ignition off.
Page 913: Body Verification Test
HORN - ELECTRICAL DIAGNOSTICS 8H - 7 BODY VERIFICATION TEST BODY VERIFICATION TEST Turn the ignition off. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. Note: If the SKREEM or the PCM was replaced, refer to the service information for proper programming procedures.
Page 914: Schematics And Diagrams
8H - 8 HORN - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS...
Page 915 HORN - SERVICE INFORMATION 8H - 9 HORN - SERVICE INFORMATION TABLE OF CONTENTS page page HORN - SERVICE INFORMATION REMOVAL ......14 DESCRIPTION .
Page 916: Description
8H - 10 HORN - SERVICE INFORMATION OPERATION The Horn circuit feed is from the fuse to the horn relay within the Relay Control Module (3), both of which are located inside the Control Module Box (5). When the Horn Switch is depressed, it completes the ground circuit to the horn relay.
Page 917: Removal
HORN - SERVICE INFORMATION 8H - 11 HORN REMOVAL 1. Disconnect the negative battery cable. 2. Remove the front grille. (Refer to 23 - BODY/EX- TERIOR/GRILLE - REMOVAL). 3. Disconnect the horn harness connector (1).
Page 918: Installation
8H - 12 HORN - SERVICE INFORMATION Note: Do not disconnect the horn from the horn mounting bracket. 4. Remove the horn bracket mounting bolt (2) from the core support brace (1). 5. Remove the horn from the vehicle. INSTALLATION 1.
Page 919: Horn Switch
HORN - SERVICE INFORMATION 8H - 13 4. Connect the negative battery cable. HORN SWITCH DIAGNOSIS AND TESTING WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 920: Removal
8H - 14 HORN - SERVICE INFORMATION Note: For complete horn system diagnostics, see Horn Electrical Diagnostics in this section. REMOVAL WARNING: REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR, SEAT, STEERING WHEEL, STEER- ING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER- SONAL INJURY.
Page 921 HORN - SERVICE INFORMATION 8H - 15 1. Install the horn switch into the steering wheel, then route the driver airbag harness and connector (3) through the opening in the horn switch. Note: Be sure the horn switch preload springs are centered over the mounting studs (2).
Page 922: Horn Relay
8H - 16 HORN - SERVICE INFORMATION HORN RELAY DESCRIPTION The horn relay is housed within the Relay Control Module (1) located inside the Control Module Box (3) on the passenger side of the engine compartment. The Relay Control Module also contains the Fuse (2) for the horn relay circuitry.
Page 923: Removal
HORN - SERVICE INFORMATION 8H - 17 REMOVAL 1. Remove the relay control module. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/RELAY REMOVAL). INSTALLATION 1. Install the relay control module. (Refer to 8 - ELEC- TRICAL/POWER DISTRIBUTION/RELAY INSTALLATION).
Page 925 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION SYSTEM - ELECTRICAL IGNITION SYSTEM - SERVICE INFORMATION..3 DIAGNOSTICS ......1 IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS TABLE OF CONTENTS page...
Page 926 8I - 2 IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS SCHEMATICS AND DIAGRAMS...
Page 927 IGNITION SYSTEM - SERVICE INFORMATION 8I - 3 IGNITION SYSTEM - SERVICE INFORMATION TABLE OF CONTENTS page page IGNITION SYSTEM - SERVICE INFORMATION INSTALLATION - SRT ....15 DESCRIPTION .
Page 928: Ignition System - Service Information Description
8I - 4 IGNITION SYSTEM - SERVICE INFORMATION IGNITION SYSTEM - SERVICE INFORMATION DESCRIPTION The High Energy Ignition (HEI) system uses one coil and two spark plugs per cylinder. Individual coils for each cylinder ensure consistent performance at high rpms and allow individual cylinder spark control. Dual spark plugs provide more complete combustion, particularly near the cylinder walls, thus decreasing emissions.
Page 929: Specifications
IGNITION SYSTEM - SERVICE INFORMATION 8I - 5 The following components make up the Ignition System: Spark Plugs Each cylinder utilizes two spark plugs. The spark plugs use a platinum tip design for extended service life. The spark plugs are mounted directly across from each other in the cylinder head. Ignition Coil Packs Each cylinder has its own coil pack.
Page 930: Camshaft Position Sensor
8I - 6 IGNITION SYSTEM - SERVICE INFORMATION CAMSHAFT POSITION SENSOR DESCRIPTION The Camshaft Position Sensor is a hall effect type sensor (3 wire). The Camshaft Position Sensor is mounted on the front of the right cylinder head. OPERATION The Camshaft Position Sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses.
Page 931: Removal
IGNITION SYSTEM - SERVICE INFORMATION 8I - 7 REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the camshaft position sensor harness connector (1). 3. Remove the retaining bolt (2). 4. Remove the camshaft position sensor from the cyl- inder head. INSTALLATION Note: Lubricate the camshaft position sensor O-ring with engine oil.
Page 932: Ignition Coil
8I - 8 IGNITION SYSTEM - SERVICE INFORMATION 3. Position the camshaft position sensor on the cylin- der head. 4. Install the retaining bolt (2). Tighten the retaining bolt to 8 N·m (71 in. lbs.). 5. Connect the camshaft position sensor harness con- nector (1).
Page 933: Operation
IGNITION SYSTEM - SERVICE INFORMATION 8I - 9 OPERATION The Ignition Coils are powered by Fuse 11 in the Underhood Accessory Fuse Block. The Powertrain Control Module (PCM) controls the current flow through the primary side of the coils by toggling the control circuits.
Page 934: Removal
8I - 10 IGNITION SYSTEM - SERVICE INFORMATION REMOVAL REMOVAL 1. Disconnect the negative battery cable (2). 2. Remove the air cleaner inlet tubes (2). 3. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly.
Page 935: Removal - Srt
IGNITION SYSTEM - SERVICE INFORMATION 8I - 11 4. Disconnect the ignition coil wire harness connector (1). 5. Disconnect the spark plug cables (4) from the spark plugs. 6. Remove the ignition coil retaining bolt (2). 7. Remove the ignition coil (3) from the cylinder head cover.
Page 936 8I - 12 IGNITION SYSTEM - SERVICE INFORMATION 2. Remove the engine cover (1). Grasp both corners of the engine cover, and pull up firmly. 3. Remove the upper air cleaner housing by removing the inlet tube (2) and the retaining screws (1). (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL).
Page 937: Installation
IGNITION SYSTEM - SERVICE INFORMATION 8I - 13 4. Disconnect the ignition coil harness connector (2). 5. Disconnect both the spark plug cables from the spark plugs (3). 6. Remove the ignition coil mounting bolt (1). 7. Remove the ignition coil from the engine. INSTALLATION INSTALLATION 1.
Page 938 8I - 14 IGNITION SYSTEM - SERVICE INFORMATION Note: When installing the spark plug cables, route the cables correctly. Failure to route the cables properly can cause improper spark plug phase- shift. 4. Install the spark plug cables to the appropriate coil tower (A &...
Page 939: Installation - Srt
IGNITION SYSTEM - SERVICE INFORMATION 8I - 15 7. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts. Note: To ease the installation of the engine cover, apply a small amount of lubricant to the engine cover rubber mounts.
Page 940 8I - 16 IGNITION SYSTEM - SERVICE INFORMATION Note: When installing the spark plug cables, route the cables correctly. Failure to route the cables properly can cause improper spark plug phase- shift. 4. Install the spark plug cables to the appropriate coil tower (A &...
Page 941 IGNITION SYSTEM - SERVICE INFORMATION 8I - 17 7. Install the upper air cleaner housing. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION). 8. Install the engine cover (1). Align the engine cover retaining clips to the rubber mounts, and push down firmly to connect engine cover to rubber mounts.
Page 942: Knock Sensor
8I - 18 IGNITION SYSTEM - SERVICE INFORMATION KNOCK SENSOR DESCRIPTION The 3.2L engine is equipped with two knock sensors. The knock sensors bolt onto the cylinder block below the intake manifold in the engine valley. They are designed to detect engine vibration that is caused by detonation. OPERATION Two knock sensors are used on the 3.2L V-6.
Page 943: Removal
IGNITION SYSTEM - SERVICE INFORMATION 8I - 19 Note: Over tightening or under tightening the knock sensor mounting bolts will affect knock sensor perfor- mance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. REMOVAL 1.
Page 944: Spark Plug
8I - 20 IGNITION SYSTEM - SERVICE INFORMATION SPARK PLUG DESCRIPTION The engine uses platinum tip resistor spark plugs. Platinum-tip spark plugs allow 100,000-mile (161,000-km) replacement intervals in normal service. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Page 945: Operation
IGNITION SYSTEM - SERVICE INFORMATION 8I - 21 Spark plugs using either a single or double platinum tips have a recommended service life of 100,000 miles for normal driving conditions per schedule A in this manual. The spark plugs have a recommended ser- vice life of 75,000 miles for severe driving conditions.
Page 946: Diagnosis And Testing - Spark Plug Conditions
8I - 22 IGNITION SYSTEM - SERVICE INFORMATION DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS NORMAL OPERATING The few deposits present on the spark plug will prob- ably be light tan or slightly gray in color. This is evi- dent with most grades of commercial gasoline. There will not be evidence of electrode burning.
Page 947 IGNITION SYSTEM - SERVICE INFORMATION 8I - 23 OIL OR ASH ENCRUSTED If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. ELECTRODE GAP BRIDGING Electrode gap bridging may be traced to loose depos- its in the combustion chamber.
Page 948 8I - 24 IGNITION SYSTEM - SERVICE INFORMATION SCAVENGER DEPOSITS Fuel scavenger deposits may be either white or yel- low. They may appear to be harmful, but this is a nor- mal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies.
Page 949 IGNITION SYSTEM - SERVICE INFORMATION 8I - 25 PREIGNITION DAMAGE Preignition damage is usually caused by excessive combustion chamber temperature. The center elec- trode (2) dissolves first and the ground electrode (1) dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plug has the cor- rect heat range rating for the engine.
Page 950: Removal
8I - 26 IGNITION SYSTEM - SERVICE INFORMATION REMOVAL CAUTION: When disconnecting a high tension cable from a spark plug or from the ignition coil, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force.
Page 951: Installation
IGNITION SYSTEM - SERVICE INFORMATION 8I - 27 INSTALLATION 1. Using a spark plug gap gauge (1), gap the spark plugs to 1.02 mm (.040 in.) before installation. 2. Start the spark plugs into the cylinder head by hand to avoid cross threading. 3.
Page 952: Spark Plug Cable
8I - 28 IGNITION SYSTEM - SERVICE INFORMATION Note: When installing spark plug cables, insure a positive connection is made. A snap should be felt when a good connection is made between the spark plug cable and the spark plug. 5.
Page 953: Operation
IGNITION SYSTEM - SERVICE INFORMATION 8I - 29 Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced.
Page 954 8I - 30 IGNITION SYSTEM - SERVICE INFORMATION Note: Refer to the reference pad cast into the cylinder head cover to identify proper spark plug/spark plug cable orientation. Note: When installing spark plug cables, insure a positive connection is made. A snap should be felt when a good connection is made between the spark plug cable and the spark plug.
Page 955 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER - ELECTRICAL INSTRUMENT CLUSTER - SERVICE DIAGNOSTICS ......1 INFORMATION .
Page 956: Instrument Cluster - Electrical Diagnostics
8J - 2 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT...
Page 957 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 3 COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: Coolant Level Sensor/Washer Fluid Level Switch circuit failure. POSSIBLE CAUSES INDICATOR CIRCUIT OPEN COOLANT LEVEL SENSOR MALFUNCTION WASHER FLUID LEVEL SWITCH MALFUNCTION...
Page 958: Instrument Cluster - Electrical Diagnostics
8J - 4 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT (CONTINUED) MEASURE WASHER FLUID LEVEL SWITCH RESISTANCE With the ignition off. Disconnect the Washer Fluid Level Switch harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between cavity 1 and cavity 2 of the Washer Fluid Level Switch connector.
Page 959: Lamp Outage Indicator Circuit
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 5 LAMP OUTAGE INDICATOR CIRCUIT...
Page 960 8J - 6 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS LAMP OUTAGE INDICATOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: Lamp Outage Indicator circuit failure between the Illumination Control Module and the Instru- ment Cluster.
Page 961 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 7 LAMP OUTAGE INDICATOR CIRCUIT (CONTINUED) MEASURE LAMP OUTAGE INDICATOR CIRCUIT RESISTANCE Turn the ignition off. Disconnect the Illumination Control Module harness connector. Note: Check connectors — Clean/repair as necessary. Measure the resistance of the Lamp Outage Indicator circuit from the Illumination Control Module D harness connector to the Instrument Cluster C1 harness connector.
Page 962: Fuel Level Sensor Circuit
8J - 8 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS FUEL LEVEL SENSOR CIRCUIT...
Page 963 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 9 FUEL LEVEL SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: Fuel Level Sensor circuit failure between the Fuel Level Sensor and the Instrument Cluster. POSSIBLE CAUSES FUEL LEVEL SENSOR CIRCUIT(S) OPEN FUEL LEVEL SENSOR...
Page 964 8J - 10 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS FUEL LEVEL SENSOR CIRCUIT (CONTINUED) MEASURE FUEL LEVEL SENSOR CIRCUIT RESISTANCE Turn the ignition off. Disconnect the Instrument Cluster C2 harness connector. Note: Check connectors - Clean/repair as necessary. Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Level Sensor harness connector.
Page 965: Ambient Temperature Sensor Circuit
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 11 AMBIENT TEMPERATURE SENSOR CIRCUIT...
Page 966 8J - 12 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS AMBIENT TEMPERATURE SENSOR CIRCUIT (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: The Instrument Cluster reports an abnormally high or low voltage that is detected on the Ambi- ent Temperature Sensor Signal circuit.
Page 967 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 13 AMBIENT TEMPERATURE SENSOR CIRCUIT (CONTINUED) READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB III Turn the ignition off. Connect a jumper wire between the Ambient Temperature Sensor Sig- nal circuit and the Sensor Ground circuit. Turn the ignition on.
Page 968 8J - 14 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS AMBIENT TEMPERATURE SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT With the ignition off. Measure the resistance of the Sensor Ground circuit from the Instru- ment Cluster harness connector to the Ambient Temperature Sensor harness connector.
Page 969 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 15 AMBIENT TEMPERATURE SENSOR CIRCUIT (CONTINUED) READ A/C HEATER CONTROL MODULE DTC’S WITH DRB III Turn the ignition off. Reconnect the Ambient Temperature Sensor connector. Turn the ignition on. With the DRB III , read A/C Heater Control Module DTC’s. Wait two minutes.
Page 970 8J - 16 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS AMBIENT TEMPERATURE SENSOR CIRCUIT (CONTINUED) MEASURE THE RESISTANCE BETWEEN GROUND AND THE AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT Turn the ignition off. Disconnect the Instrument Cluster harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Ambient Temperature Signal circuit.
Page 971: No Communication From Instrument Cluster
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 17 NO COMMUNICATION FROM INSTRUMENT CLUSTER...
Page 972 8J - 18 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO COMMUNICATION FROM INSTRUMENT CLUSTER (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: Serial Communication K1 failure between the A/C Heater Control Module and the Instrument Cluster.
Page 973: No Communication To Instrument Cluster
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 19 NO COMMUNICATION TO INSTRUMENT CLUSTER...
Page 974 8J - 20 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO COMMUNICATION TO INSTRUMENT CLUSTER (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: Serial Communication K2 failure between the A/C Heater Control Module and the Instrument Cluster.
Page 975: No Can Communications With Pcm
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 21 NO CAN COMMUNICATIONS WITH PCM...
Page 976 8J - 22 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH PCM (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: This DTC is set when a CAN ID was not received in the required time from the Powertrain Control Module (PCM).
Page 977 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 23 NO CAN COMMUNICATIONS WITH PCM (CONTINUED) PCM AND SKREEM CAN C BUS TERMINATION Turn the ignition off. Measure the resistance of the PCM CAN C Bus termination by back probing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the PCM C4 harness connector.
Page 978 8J - 24 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH PCM (CONTINUED) CAN C BUS (-) CIRCUIT OPEN With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the SKREEM C2 harness connector to the PCM C4 harness connector. Is the resistance below 5.0 ohms? >>...
Page 979 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 25 NO CAN COMMUNICATIONS WITH PCM (CONTINUED) CAN C BUS (+) CIRCUIT SHORTED TO VOLTAGE Turn the ignition on. Measure the voltage of the CAN C Bus (+) circuit at the PCM C4 har- ness connector.
Page 980 8J - 26 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH PCM (CONTINUED) CAN C BUS (-) CIRCUIT SHORT TO GROUND Turn the ignition off. Measure the resistance between ground and the CAN C Bus (-) cir- cuit. Is the resistance below 100 ohms? >>...
Page 981 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 27 NO CAN COMMUNICATIONS WITH PCM (CONTINUED) INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time. Note: Check connectors — Clean/repair as necessary. Poor pin to terminal connections can set DTCs. Note: Check for any Technical Service Bulletins that may apply.
Page 982: No Can Communications With Cab
8J - 28 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH CAB...
Page 983 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 29 NO CAN COMMUNICATIONS WITH CAB (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: This DTC is set when a CAN ID was not received in the required time from the Controller Antilock Brake (CAB).
Page 984 8J - 30 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH CAB (CONTINUED) PCM AND SKREEM CAN C BUS TERMINATION Turn the ignition off. Measure the resistance of the PCM CAN C Bus termination by back probing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the PCM C4 harness connector.
Page 985 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 31 NO CAN COMMUNICATIONS WITH CAB (CONTINUED) CAN C BUS (-) CIRCUIT OPEN With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the SKREEM C2 harness connector to the PCM C4 harness connector. Is the resistance below 5.0 ohms? >>...
Page 986 8J - 32 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH CAB (CONTINUED) CAN C BUS (+) CIRCUIT SHORTED TO VOLTAGE Turn the ignition on. Measure the voltage of the CAN C Bus (+) circuit at the PCM C4 har- ness connector.
Page 987 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 33 NO CAN COMMUNICATIONS WITH CAB (CONTINUED) CAN C BUS (-) CIRCUIT SHORT TO GROUND Turn the ignition off. Measure the resistance between ground and the CAN C Bus (-) cir- cuit. Is the resistance below 100 ohms? >>...
Page 988 8J - 34 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH CAB (CONTINUED) INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time. Note: Check connectors — Clean/repair as necessary. Poor pin to terminal connections can set DTCs. Note: Check for any Technical Service Bulletins that may apply.
Page 989: No Can Communications With Tcm
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 35 NO CAN COMMUNICATIONS WITH TCM...
Page 990: Instrument Cluster - Electrical Diagnostics
8J - 36 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH TCM (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: This DTC is set when a CAN ID was not received in the required time from the Transmission Control Module (TCM).
Page 991 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 37 NO CAN COMMUNICATIONS WITH TCM (CONTINUED) PCM AND SKREEM CAN C BUS TERMINATION Turn the ignition off. Measure the resistance of the PCM CAN C Bus termination by back probing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the PCM C4 harness connector.
Page 992 8J - 38 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH TCM (CONTINUED) CAN C BUS (-) CIRCUIT OPEN With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the SKREEM C2 harness connector to the PCM C4 harness connector. Is the resistance below 5.0 ohms? >>...
Page 993 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 39 NO CAN COMMUNICATIONS WITH TCM (CONTINUED) CAN C BUS (+) CIRCUIT SHORTED TO VOLTAGE Turn the ignition on. Measure the voltage of the CAN C Bus (+) circuit at the PCM C4 har- ness connector.
Page 994 8J - 40 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS NO CAN COMMUNICATIONS WITH TCM (CONTINUED) CAN C BUS (-) CIRCUIT SHORT TO GROUND Turn the ignition off. Measure the resistance between ground and the CAN C Bus (-) cir- cuit. Is the resistance below 100 ohms? >>...
Page 995 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 41 NO CAN COMMUNICATIONS WITH TCM (CONTINUED) INTERMITTENT WIRING AND CONNECTORS The conditions necessary to set this DTC are not present at this time. Note: Check connectors — Clean/repair as necessary. Poor pin to terminal connections can set DTCs. Note: Check for any Technical Service Bulletins that may apply.
Page 996 8J - 42 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS CAN BUS COMMUNICATION GENERAL MALFUNCTION...
Page 997: Can Bus Communication General
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 43 CAN BUS COMMUNICATION GENERAL MALFUNCTION (CONTINUED) When Monitored and Set Condition • When Monitored: With the ignition on. • Set Condition: CAN Bus communication failure between the Instrument Cluster and the CAN Bus network. POSSIBLE CAUSES CAN BUS CIRCUIT(S) OPEN INSTRUMENT CLUSTER...
Page 998 8J - 44 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS CAN BUS COMMUNICATION GENERAL MALFUNCTION (CONTINUED) MEASURE THE RESISTANCE OF THE CAN C BUS (-) CIRCUIT With the ignition off. Measure the resistance of the CAN C Bus (-) circuit from the Instru- ment Cluster harness connector to the harness connectors of the other modules on the CAN Bus network.
Page 999 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 45 *LEFT TURN SIGNAL INDICATOR INOPERATIVE...
Page 1000: Left Turn Signal Indicator
8J - 46 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *LEFT TURN SIGNAL INDICATOR INOPERATIVE (CONTINUED) POSSIBLE CAUSES INDICATOR CIRCUIT OPEN INDICATOR LAMP INSTRUMENT CLUSTER For a complete Instrument Cluster Circuit Diagram,(Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHE- MATICS AND DIAGRAMS). Diagnostic Test INSPECT THE LEFT TURN SIGNAL INDICATOR LAMP Turn the ignition off.
Page 1001: Right Turn Signal Indicator Inoperative
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 47 *RIGHT TURN SIGNAL INDICATOR INOPERATIVE...
Page 1002 8J - 48 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *RIGHT TURN SIGNAL INDICATOR INOPERATIVE (CONTINUED) POSSIBLE CAUSES INDICATOR CIRCUIT OPEN INDICATOR LAMP INSTRUMENT CLUSTER For a complete Instrument Cluster Circuit Diagram,(Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHE- MATICS AND DIAGRAMS). Diagnostic Test INSPECT THE RIGHT TURN SIGNAL INDICATOR LAMP Turn the ignition off.
Page 1003: High Beam Indicator Inoperative
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 49 *HIGH BEAM INDICATOR INOPERATIVE...
Page 1004 8J - 50 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *HIGH BEAM INDICATOR INOPERATIVE (CONTINUED) POSSIBLE CAUSES INDICATOR CIRCUIT OPEN INDICATOR LAMP INSTRUMENT CLUSTER For a complete Instrument Cluster Circuit Diagram, (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHE- MATICS AND DIAGRAMS). Diagnostic Test HIGH BEAM INDICATOR LAMP Turn the ignition off.
Page 1005 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 51 *HIGH BEAM INDICATOR INOPERATIVE (CONTINUED) MEASURE HIGH BEAM INDICATOR CIRCUIT RESISTANCE Turn the ignition off. Disconnect the Illumination Control Module harness connector. Measure the resistance of the High Beam Indicator circuit from the Illu- mination Control Module harness connector cavity 7 to the Instrument Cluster C1 harness connector cavity A2.
Page 1006: Brake Warning Indicator Inoperative
8J - 52 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *BRAKE WARNING INDICATOR INOPERATIVE...
Page 1007 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 53 *BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED) POSSIBLE CAUSES INDICATOR CIRCUIT OPEN BRAKE FLUID LEVEL SWITCH INDICATOR LAMP INSTRUMENT CLUSTER For a complete Instrument Cluster Circuit Diagram, (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHE- MATICS AND DIAGRAMS).
Page 1008 8J - 54 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED) MEASURE BRAKE WARNING INDICATOR CIRCUIT RESISTANCE Turn the ignition off. Disconnect the Instrument Cluster C1 harness connector. Note: Check connectors - Clean/repair as necessary. Connect a jumper wire between cavity 1 and cavity 2 of the Brake Fluid Level Switch harness connector.
Page 1009: Battery Voltage Indicator Inoperative
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 55 *BATTERY VOLTAGE INDICATOR INOPERATIVE...
Page 1010 8J - 56 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS *BATTERY VOLTAGE INDICATOR INOPERATIVE (CONTINUED) POSSIBLE CAUSES INDICATOR CIRCUIT OPEN INDICATOR LAMP GENERATOR INSTRUMENT CLUSTER For a complete Instrument Cluster Circuit Diagram, (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHE- MATICS AND DIAGRAMS). Diagnostic Test GENERATOR OUTPUT Turn the ignition off.

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