2002 Jeep TJ Body Service Manual – PDF DOWNLOAD

Description

2002 Jeep TJ Body Service Manual – PDF DOWNLOAD

DESCRIPTION:

2002 Jeep TJ Body Service Manual – PDF DOWNLOAD

INTRODUCTION:

The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose body system problems. The diagnostics in this manual are based on the failure condition or symptom being present at time of diagnosis. Please follow the recommendations below when choosing your diagnostic path.

• When repairs are required, refer to the appropriate service manual for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added: carryover systems may be enhanced.
• READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE DIAGNOSTIC TROUBLE CODE. It is recommended that you review the entire manual to become familiar with all the new and changed diagnostic procedures. This book reflects many suggested changes from readers of past issues. After using this book, if you have any comments or suggestion, please fill out the form in the back of the book, and mail it back to us.

TABLE OF CONTENTS:

2002 Jeep TJ Body Service Manual – PDF DOWNLOAD

1 0 INTRODUCTION 1
1 1 SYSTEM COVERAGE 1
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 1
2 0 IDENTIFICATION OF SYSTEM 1
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1
3 1 AIRBAG SYSTEM 1
3 1 1 PASSENGER AIRBAG ON-OFF SWITCH 2
3 1 2 SPECIAL TOOLS 2
3 1 3 DIAGNOSTIC TROUBLE CODES 3
3 1 3 1 ACTIVE CODES 3
3 1 3 2 STORED CODES 3
3 2 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) 3
3 2 1 SMART CLUSTER FEATURES 3
3 2 1 1 NORMAL OPERATION 3
3 2 1 2 INSTRUMENT CLUSTER SELF TEST 3
3 2 1 3 DTC CAPABILITIES 4
3 2 2 VEHICLE STATUS MESSAGES DISPLAYED IN THE VF DISPLAY 4
3 2 2 1 ‘‘NO FUSE’’ IN VF DISPLAY 4
3 2 2 2 ‘‘NO BUS’’ IN VF DISPLAY 4
3 2 3 REAR WINDOW DEFOGGER 5
3 2 4 CHIME 5
3 2 4 1 PARK/HEADLAMPS ON REMINDER 5
3 2 4 2 KEY-IN IGNITION 5
3 2 4 3 SEAT BELT 5
3 2 4 4 DRIVER DOOR AJAR WARNING 5
3 2 4 5 PASSENGER DOOR AJAR WARNING 5
3 2 4 6 LOW OIL PRESSURE 5
3 2 4 7 ENGINE TEMPERATURE 5
3 2 4 8 LOW FUEL 5
3 2 4 9 BATTERY VOLTAGE 5
3 2 4 10 HIGH SPEED WARNING (GULF COAST VEHICLES ONLY) 6
3 2 4 11 TURN SIGNAL ON 6
3 2 4 12 SKIM (IF EQUIPPED) 6
3 2 4 13 PARK BRAKE REMINDER 6
3 2 4 14AIR BAG 6
3 2 5 HARDWIRED INDICATORS 6
3 2 5 1 SEAT BELT 6
3 2 5 2 PART TIME 6
3 2 5 3 BRAKE/PARK BRAKE 6
3 2 5 4 HIGH BEAM 6
3 2 5 5 TURN SIGNAL – LEFT 6
3 2 5 6 TURN SIGNAL – RIGHT 6
3 2 5 7 FRONT/REAR FOG 6
3 2 5 8 ABS 6
3 2 6 PANEL DIMMING ILLUMINATION 7
3 2 6 1 PANEL DIMMING FAULT 7
3 2 6 2 RADIO ILLUMINATION 7
3 2 6 3 DIMMABLE INDICATORS 7
3 2 7 PCI BUS INDICATORS 7
i
TABLE OF CONTENTS – Continued
3 2 7 1 AIR BAG WARNING INDICATOR 7
3 2 7 2 MALFUNCTION INDICATOR LAMP (ISO ENGINE ICON) 7
3 2 7 3 CHECK GAUGES 7
3 2 7 4 CRUISE 7
3 2 7 5 LOW FUEL 7
3 2 7 6 SKIM (IF EQUIPPED) 8
3 2 7 7 UPSHIFT (IF EQUIPPED) 8
3 2 8 INTERIOR/COURTESY LIGHTING 8
3 2 8 1 ILLUMINATED ENTRY 8
3 2 8 2 THEATER DIMMING 8
3 2 8 3 COURTESY LAMPS 8
3 2 8 4 IGNITION-OFF COURTESY LAMPS (ILLUMINATED EXIT) 8
3 2 9 ODOMETER/TRIP ODOMETER 8
3 2 9 1 TRIP SELECT BUTTON 8
3 2 9 2 ODOMETER ON WITH DOOR AJAR 8
3 2 10 BATTERY SAVER FEATURE 8
3 2 10 1 POWER – DOWN 9
3 2 10 2 POWER – UP 9
3 2 11 GAUGE POINTER PICK – UP AND ZERO SET 9
3 3 VEHICLE COMMUNICATION 9
3 4 USING THE DRBIIIT 10
3 4 1 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 10
3 4 2 DRBIIIT DOES NOT POWER UP 10
3 4 3 DISPLAY IS NOT VISIBLE 10
4 0 DISCLAIMERS, SAFETY, WARNING 11
4 1 DISCLAIMERS 11
4 2 SAFETY 11
4 2 1 TECHNICIAN SAFETY INFORMATION 11
4 2 2 VEHICLE PREPARATION FOR TESTING 11
4 2 3 SERVICING SUB-ASSEMBLIES 11
4 2 4 DRBIIIT SAFETY INFORMATION 11
4 3 WARNINGS 12
4 3 1 VEHICLE DAMAGE WARNINGS 12
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 12
5 0 REQUIRED TOOLS AND EQUIPMENT 12
6 0 GLOSSARY OF TERMS 12
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15
AIRBAG
ACM ACCELEROMETER – ACTIVE 16
ACM ACCELEROMETER – STORED 16
ACM STORED ENERGY FIRING 1 – ACTIVE 16
ACM STORED ENERGY FIRING 1 – STORED 16
INTERNAL 1 – ACTIVE 16
INTERNAL 1 – STORED 16
NO PCI TRANSMISSION – ACTIVE 16
OUTPUT DRIVER 1 – ACTIVE 16
OUTPUT DRIVER 1 – STORED 16
SAFING SENSOR – ACTIVE 16
ii
TABLE OF CONTENTS – Continued
SAFING SENSOR – STORED 16
STORED ENERGY LOGIC – ACTIVE 16
STORED ENERGY LOGIC – STORED 16
AIRBAG WARNING INDICATOR OPEN – ACTIVE 19
AIRBAG WARNING INDICATOR OPEN – STORED 20
AIRBAG WARNING INDICATOR SHORT – STORED 20
CLUSTER MESSAGE MISMATCH – STORED 20
DRIVER SQUIB 1 CIRCUIT OPEN – STORED 20
DRIVER SQUIB 1 CIRCUIT SHORT – STORED 20
DRIVER SQUIB 1 SHORT TO BATTERY – STORED 20
DRIVER SQUIB 1 SHORT TO GROUND – STORED 20
LOSS OF IGNITION RUN – START – STORED 20
NO CLUSTER MESSAGE – STORED 20
NO PCI TRANSMISSION – STORED 20
PASSENGER AIRBAG ON – OFF SWITCH CIRCUIT OPEN – STORED 20
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO BATTERY – STORED 20
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO GROUND – STORED 20
PASSENGER OFF INDICATOR SHORT TO BATTERY – STORED 20
PASSENGER OFF INDICATOR SHORT TO GROUND – STORED 20
PASSENGER SQUIB 1 CIRCUIT OPEN – STORED 20
PASSENGER SQUIB 1 CIRCUIT SHORT – STORED 20
PASSENGER SQUIB 1 SHORT TO BATTERY – STORED 20
PASSENGER SQUIB 1 SHORT TO GROUND – STORED 20
AIRBAG WARNING INDICATOR SHORT – ACTIVE 25
CLUSTER MESSAGE MISMATCH – ACTIVE 26
DRIVER SQUIB 1 CIRCUIT OPEN – ACTIVE 27
DRIVER SQUIB 1 CIRCUIT SHORT – ACTIVE 30
DRIVER SQUIB 1 SHORT TO BATTERY – ACTIVE 33
DRIVER SQUIB 1 SHORT TO GROUND – ACTIVE 36
LOSS OF IGNITION RUN ONLY – ACTIVE 39
LOSS OF IGNITION RUN-START – ACTIVE 41
NO CLUSTER MESSAGE – ACTIVE 43
PASSENGER AIRBAG ON – OFF SWITCH CIRCUIT OPEN – ACTIVE 44
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO BATTERY – ACTIVE 46
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO GROUND – ACTIVE 48
PASSENGER OFF INDICATOR SHORT TO BATTERY – ACTIVE 51
PASSENGER OFF INDICATOR SHORT TO GROUND – ACTIVE 53
PASSENGER SQUIB 1 CIRCUIT OPEN – ACTIVE 56
PASSENGER SQUIB 1 CIRCUIT SHORT – ACTIVE 59
PASSENGER SQUIB 1 SHORT TO BATTERY – ACTIVE 61
PASSENGER SQUIB 1 SHORT TO GROUND – ACTIVE 63
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 65
CHIME
*CHIME INOPERATIVE AT ALL TIMES 66
*CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED 67
*CHIME INOPERATIVE WITH EXTERIOR LAMPS ON AND DRIVER DOOR OPEN 68
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR OPEN 69
*CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED 72
*CHIME SOUNDS WITH DRIVER’S DOOR OPEN, KEY REMOVED 74
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM INSTRUMENT CLUSTER 75
iii
TABLE OF CONTENTS – Continued
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM SENTRY KEY IMMOBILIZER
MODULE 77
*NO RESPONSE FROM AIRBAG CONTROL MODULE 79
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 81
*NO RESPONSE FROM PCM (PCI BUS) 83
*NO RESPONSE FROM PCM (SCI ONLY) 84
*PCI BUS COMMUNICATION FAILURE 86
ELECTRICALLY HEATED SYSTEMS
*REAR DEFFOGER RELAY OPEN 88
*REAR DEFOGGER RELAY SHORT TO VOLTAGE 90
*REAR DEFOGGER SWITCH INDICATOR INOPERATIVE 91
*REAR WINDOW DEFOGGER GRID INOPERATIVE 92
INSTRUMENT CLUSTER
ACM MESSAGE NOT REC’D BY MIC 96
AIR BAG LAMP CIRCUIT OPEN 97
AIR BAG LAMP CIRCUIT SHORT 98
CHECKSUM FAILURE 99
PANEL DIMMER OPEN 100
PCM MESSAGE NOT REC’D BY MIC 102
SKIM MESSAGE NOT REC’D BY MIC 103
*4WD INDICATOR INOPERATIVE 104
*ABS INDICATOR INOPERATIVE 106
*AIR BAG INDICATOR INOPERATIVE 107
*ALL GAUGES INOPERATIVE 108
*ANY PCI BUS INDICATOR INOPERATIVE 110
*BRAKE WARNING INDICATOR ALWAYS ON 111
*BRAKE WARNING INDICATOR INOPERATIVE 112
*FOG LAMP INDICATOR INOPERATIVE – DOMESTIC 114
*HIGH BEAM INDICATOR INOPERATIVE 115
*NO BUS IN VF DISPLAY 116
*NO FUSE IN VF DISPLAY 117
*ONE GAUGE INOPERATIVE 118
*PANEL DIMMNG INOPERATIVE 119
*REAR FOG LAMP INDICATOR INOPERATIVE – BUX ONLY 120
*SEAT BELT INDICATOR NOT OPERATING PROPERLY 121
*VF DISPLAY INOPERATIVE 123
*VF ODOMETER INOPERATIVE WITH DOOR OPEN 124
INTERIOR LIGHTING
*COURTESY LAMPS INOPERATIVE – ALL LAMPS 126
*COURTESY LAMPS ON AT ALL TIMES 127
*ILLUMINATED ENTRY INOPERATIVE 129
VERIFICATION TESTS
VERIFICATION TESTS 130
8 0 SYSTEM COMPONENT LOCATIONS 133
8 1 DATA LINK CONNECTOR 133
8 2 AIRBAG 133
8 2 1 DRIVER AIRBAG MODULE & CLOCKSPRING 133
iv
TABLE OF CONTENTS – Continued
8 2 2 DRIVER/PASSENGER AIRBAG MODULES & MECHANICAL
INSTRUMENT CLUSTER 134
8 2 3 AIRBAG CONTROL MODULE AND PASSENGER AIRBAG ON/OFF
SWITCH 134
8 3 FUSE BLOCK 135
8 4 INSTRUMENT CLUSTER 135
8 4 1 FRONT VIEW 135
8 4 2 REAR VIEW 136
8 5 POWER DISTRIBUTION CENTER (PDC) 136
8 6 POWERTRAIN CONTROL MODULE 137
9 0 CONNECTOR PINOUTS 139
AIRBAG CONTROL MODULE – YELLOW 22 WAY 139
CLOCKSPRING C2 – YELLOW 2 WAY 139
CONTROLLER ANTILOCK BRAKE – 25 WAY 140
DATA LINK CONNECTOR – BLACK 16 WAY 140
DRIVER AIRBAG – YELLOW 2 WAY 140
FUSES (FUSE/RELAY BLOCK) 142
IGNITION SWITCH – 10 WAY 142
INSTRUMENT CLUSTER C1 – 8 WAY 143
INSTRUMENT CLUSTER C2 – 16 WAY 143
MULTI-FUNCTION SWITCH – GRAY 20 WAY 143
PASSENGER AIRBAG – YELLOW 2 WAY 144
PASSENGER AIRBAG ON/OFF SWITCH – 6 WAY 144
FUSES (PDC) 146
REAR WINDOW DEFOGGER RELAY 146
POWERTRAIN CONTROL MODULE C1 – BLACK 32 WAY 147
POWERTRAIN CONTROL MODULE C2 – WHITE 32 WAY 148
POWERTRAIN CONTROL MODULE C3 – GRAY 32 WAY 149
REAR WINDOW DEFOGGER SWITCH (HARD TOP) – 4 WAY 149
SEAT BELT SWITCH (RHD BUILT-UP-EXPORT) – BLACK 2 WAY 150
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 150
10 0 SCHEMATIC DIAGRAMS 151
10 1 AIRBAG SYSTEM 151
10 2 CHIME SYSTEM 151
10 3 INSTRUMENT CLUSTER SYSTEM 152
10 4 INTERIOR LIGHTING 153
10 5 REAR DEFOGGER 154
10 6 VEHICLE COMMUNICATIONS 155

2002 JEEP TJ BODY SERVICE MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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