2002 Jeep Wrangler TJ Gas Powertrain Service Manual – PDF DOWNLOAD

Description

2002 Jeep Wrangler TJ Gas Powertrain Service Manual – PDF DOWNLOAD

DESCRIPTION:

2002 Jeep Wrangler TJ Gas Powertrain Service Manual – PDF DOWNLOAD

INTRODUCTION:

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

• When repairs are required, refer to the appropriate service manual for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added; current systems may be enhanced. READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE DTC.
• It is recommended that you review the entire manual to become familiar with all new and enhanced diagnostic procedures. After using this book, if you have any comments or recommendations, please fill out the form at the back of the book and mail it back to us.

TABLE OF CONTENTS:

2002 Jeep Wrangler TJ Gas Powertrain Service Manual – PDF DOWNLOAD

1 0 INTRODUCTION 1
1 1 SYSTEM COVERAGE 1
1 2 SIX-STEP TROUBLE SHOOTING PROCEDURE 1
2 0 IDENTIFICATION OF SYSTEM 1
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1
3 1 GENERAL DESCRIPTION 1
3 2 FUNCTION OPERATION 1
3 2 1 FUEL CONTROL (GAS) 1
3 2 2 ON-BOARD DIAGNOSTICS 2
3 2 3 TRANSMISSION CONTROL 4
3 2 4 OTHER CONTROLS 4
3 2 5 NON-MONITORED CIRCUITS 9
3 2 6 SKIS OVERVIEW 9
3 2 7 SKIM ON-BOARD DIAGNOSTICS 9
3 2 8 SKIS OPERATION 9
3 2 9 PROGRAMMING THE POWERTRAIN CONTROL MODULE 10
3 2 10 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 10
3 2 11 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE 11
3 3 DIAGNOSTIC TROUBLE CODES 11
3 3 1 HARD CODE 11
3 3 2 INTERMITTENT CODE 11
3 3 3 STARTS SINCE SET COUNTER 11
3 3 4 HANDLING NO TROUBLE CODE PROBLEMS 12
3 3 5 NO START INFORMATION 13
3 4 USING THE DRBIIIT 13
3 5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 13
3 5 1 DRBIIIT DOES NOT POWER UP 13
3 5 2 DISPLAY IS NOT VISIBLE 14
4 0 DISCLAIMERS, SAFETY, WARNINGS 14
4 1 DISCLAIMERS 14
4 2 SAFETY 14
4 2 1 TECHNICIAN SAFETY INFORMATION 14
4 2 2 VEHICLE PREPARATION FOR TESTING 14
4 2 3 SERVICING SUB-ASSEMBLIES 14
4 2 4 DRBIIIT SAFETY INFORMATION 14
4 3 WARNINGS AND CAUTIONS 15
4 3 1 ROAD TEST WARNINGS 15
4 3 2 VEHICLE DAMAGE CAUTIONS 15
5 0 REQUIRED TOOLS AND EQUIPMENT 15
6 0 ACRONYMS 15
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 19
i
TABLE OF CONTENTS – Continued
CHARGING
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 20
P1492-AMBIENT/BATT TEMP SENSOR VOLTS TOO HIGH 23
P1493-AMBIENT/BATT TEMP SEN VOLTS TOO LOW 26
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 28
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 31
*CHECKING CHARGING SYSTEM OPERATION WITH NO DTCS 35
*CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR 38
COMMUNICATION
P0601-PCM INTERNAL CONTROLLER FAILURE 39
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM 40
P1686 NO SKIM BUS MESSAGE RECEIVED 42
P1687-NO CLUSTER BUS MESSAGE 44
P1696-PCM FAILURE EEPROM WRITE DENIED 46
*NO RESPONSE FROM PCM (PCI BUS) 47
*NO RESPONSE FROM PCM (SCI ONLY) 48
*PCI BUS COMMUNICATION FAILURE 50
DRIVEABILITY – GAS
P0031-1/1 O2 SENSOR HEATER CIRCUIT LOW 52
P0032-1/1 O2 SENSOR HEATER CIRCUIT HIGH 52
P0037-1/2 O2 SENSOR HEATER CIRCUIT LOW 52
P0038-1/2 O2 SENSOR HEATER CIRCUIT HIGH 52
P0051-2/1 O2 SENSOR HEATER CIRCUIT LOW 52
P0052-2/1 O2 SENSOR HEATER CIRCUIT HIGH 52
P0071-BATTERY TEMP SENSOR PERFORMANCE 55
P0107-MAP SENSOR VOLTAGE TOO LOW 57
P0108-MAP SENSOR VOLTAGE TOO HIGH 60
P0111-INTAKE AIR TEMP PERFORMANCE 63
P0112-INTAKE AIR TEMP SENSOR VOLTAGE LOW 65
P0113-INTAKE AIR TEMP SENSOR VOLTAGE HIGH 67
P0117-ECT SENSOR VOLTAGE TOO LOW 69
P0118-ECT SENSOR VOLTAGE TOO HIGH 71
P0121-TPS VOLTAGE DOES NOT AGREE WITH MAP 73
P0122-TPS VOLTAGE LOW 78
P0123-THROTTLE POSITION SENSOR VOLTAGE HIGH 81
P0125-CLOSED LOOP TEMP NOT REACHED 84
P0131-1/1 O2 SENSOR SHORTED TO GROUND 86
P0137-1/2 O2 SENSOR SHORTED TO GROUND 86
P0151-2/1 O2 SENSOR SHORTED TO GROUND 86
P0157-2/2 O2 SENSOR SHORTED TO GROUND 86
P0132-1/1 O2 SENSOR SHORTED TO VOLTAGE 89
P0138-1/2 O2 SENSOR SHORTED TO VOLTAGE 89
P0152-2/1 O2 SENSOR SHORTED TO VOLTAGE 89
P0158-2/2 O2 SENSOR SHORTED TO VOLTAGE 89
P0133-1/1 O2 SENSOR SLOW RESPONSE 93
P0139-1/2 O2 SENSOR SLOW RESPONSE 93
P0153-2/1 O2 SENSOR SLOW RESPONSE 93
P0159-2/2 O2 SENSOR SLOW RESPONSE 93
P0135-1/1 O2 SENSOR HEATER FAILURE 96
P0141-1/2 O2 SENSOR HEATER FAILURE 96
P0155-2/1 O2 SENSOR HEATER FAILURE 96
ii
TABLE OF CONTENTS – Continued
P0161-2/2 O2 SENSOR HEATER FAILURE 96
P0136-1/2 O2 SENSOR HEATER CIRCUIT MALFUNCTION 99
P0171-1/1 FUEL SYSTEM LEAN 102
P0174-2/1 FUEL SYSTEM LEAN 102
P0172-1/1 FUEL SYSTEM RICH 108
P0175-2/1 FUEL SYSTEM RICH 108
P0201-INJECTOR #1 CONTROL CIRCUIT 113
P0202-INJECTOR #2 CONTROL CIRCUIT 113
P0203-INJECTOR #3 CONTROL CIRCUIT 113
P0204-INJECTOR #4 CONTROL CIRCUIT 113
P0205-INJECTOR #5 CONTROL CIRCUIT 113
P0206-INJECTOR #6 CONTROL CIRCUIT 113
P0300-MULTIPLE CYLINDER MIS-FIRE 116
P0301-CYLINDER #1 MISFIRE 116
P0302-CYLINDER #2 MISFIRE 116
P0303-CYLINDER #3 MISFIRE 116
P0304-CYLINDER #4 MISFIRE 116
P0305-CYLINDER #5 MISFIRE 116
P0306-CYLINDER #6 MISFIRE 116
P0320-NO CRANK REFERENCE SIGNAL AT PCM 120
P0340-NO CAM SIGNAL AT PCM 125
P0351-IGNITION COIL # 1 PRIMARY CIRCUIT 130
P0352-IGNITION COIL # 2 PRIMARY CIRCUIT 130
P0353-IGNITION COIL # 3 PRIMARY CIRCUIT 130
P0351-IGNITION COIL #1 PRIMARY CRICUIT 133
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 136
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY 136
P0441-EVAP PURGE FLOW MONITOR 139
P0442-EVAP LEAK MONITOR MEDIUM (0 040) LEAK DETECTED 142
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 142
P0456-EVAP LEAK MONITOR SMALL ( 020) LEAK DETECTED 142
P0443-EVAP PURGE SOLENOID CIRCUIT 146
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 148
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME 148
P0462-FUEL LEVEL SENDING UNIT VOLTS TOO LOW 149
P0463-FUEL LEVEL SENDING UNIT VOLTS TOO HIGH 151
P0500-NO VEHICLE SPEED SENSOR SIGNAL 154
P0505-IDLE AIR CONTROL MOTOR CIRCUITS 157
P0522-OIL PRESSURE SENSOR VOLTS LOW 160
P0523-OIL PRESSURE SENSOR VOLTS HIGH 162
P0551-POWER STEERING SWITCH FAILURE 164
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR 166
P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR 166
P1281-ENGINE IS COLD TOO LONG 169
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT 170
P1294-TARGET IDLE NOT REACHED 172
P1296-NO 5 VOLTS TO MAP SENSOR 175
P1297-NO CHANGE IN MAP FROM START TO RUN 177
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 180
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 182
P1391-INTERMITTENT LOSS OF CMP OR CKP 185
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 189
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 192
iii
TABLE OF CONTENTS – Continued
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT 194
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 196
P1899-P/N SWITCH PERFORMANCE 199
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS 201
*CHECKING FUEL DELIVERY 203
*CHECKING IAC MOTOR 206
*CHECKING MAP SENSOR OPERATION WITH NO DTC’S 207
*CHECKING MINIMUM AIRFLOW 208
*CHECKING RADIATOR FAN OPERATION WITH NO DTCS 210
*CHECKING RADIATOR FAN RELAY OUTPUT 212
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR 214
*CHECKING THE INTAKE AIR TEMPERATURE SENSOR 215
*CHECKING THE PCM POWER AND GROUNDS 216
*CHECKING THROTTLE POSITION SENSOR OPERATION WITH NO DTCS 217
HEATING & A/C
P0645-A/C CLUTCH RELAY CIRCUIT 218
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS 221
SPEED CONTROL
P1595-SPEED CONTROL SOLENOID CIRCUITS 224
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT 224
P1596-SPEED CONTROL SWITCH ALWAYS HIGH 229
P1597-SPEED CONTROL SWITCH ALWAYS LOW 232
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIT 235
STARTING
*ENGINE CRANKS DOES NOT START 238
*NO CRANK CONDITION 241
*NO RESPONSE FROM PCM WITH A NO START CONDITION 244
*START AND STALL CONDITION 247
TRANSMISSION
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT 249
P0743-TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS 253
VEHICLE THEFT/SECURITY
ANTENNA FAILURE 258
COP FAILURE 258
EEPROM FAILURE 258
INTERNAL FAULT 258
RAM FAILURE 258
SERIAL LINK INTERNAL FAULT 258
STACK OVERFLOW FAILURE 258
PCM STATUS FAILURE 260
SERIAL LINK EXTERNAL FAULT 260
ROLLING CODE FAILURE 262
VIN MISMATCH 262
TRANSPONDER COMMUNICATION FAILURE 264
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE 264
TRANSPONDER ID MISMATCH 264
TRANSPONDER RESPONSE MISMATCH 264
iv
TABLE OF CONTENTS – Continued
VERIFICATION TESTS
VERIFICATION TESTS 267
8 0 COMPONENT LOCATIONS 275
8 1 CONTROL MODULES AND PDC 275
8 2 CONTROLS AND SOLENOIDS 275
8 3 DATA LINK CONNECTOR 277
8 4 SENSORS 277
8 5 FUEL SYSTEM 280
8 6 SWITCHES 280
9 0 CONNECTOR PINOUTS 283
A/C COMPRESSOR CLUTCH – BLACK 2 WAY 283
A/C HIGH PRESSURE SWITCH – 2 WAY 283
A/C LOW PRESSURE SWITCH – 2 WAY 283
BACK-UP LAMP SWITCH (M/T) – BLACK 2 WAY 283
BATTERY TEMPERATURE SENSOR – BLACK 2 WAY 283
BRAKE LAMP SWITCH – GRAY 6 WAY 284
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID – WHITE 2 WAY 284
CAMSHAFT POSITION SENSOR – 3 WAY 284
CLOCKSPRING C1 – NATURAL 4 WAY 284
CLOCKSPRING C2 – YELLOW 2 WAY 284
CLUTCH PEDAL POSITION SWITCH (M/T) – BLACK 2 WAY 285
CRANKSHAFT POSITION SENSOR – 3 WAY 285
DATA LINK CONNECTOR – BLACK 16 WAY 285
ENGINE COOLANT TEMPERATURE SENSOR – BLACK 2 WAY 285
ENGINE OIL PRESSURE SENSOR – BLACK 3 WAY 286
EVAP/PURGE SOLENOID – BLACK 2 WAY 286
FUEL INJECTOR NO 1 (2 5L) – 2 WAY 286
FUEL INJECTOR NO 1 (4 0L) – 2 WAY 286
FUEL INJECTOR NO 2 (2 5L) – 2 WAY 286
FUEL INJECTOR NO 2 (4 0L) – 2 WAY 287
FUEL INJECTOR NO 3 (2 5L) – 2 WAY 287
FUEL INJECTOR NO 3 (4 0L) – 2 WAY 287
FUEL INJECTOR NO 4 (2 5L) – 2 WAY 287
FUEL INJECTOR NO 4 (4 0L) – 2 WAY 287
FUEL INJECTOR NO 5 (4 0L) – 2 WAY 287
FUEL INJECTOR NO 6 (4 0L) – 2 WAY 288
FUEL PUMP MODULE – BLACK 6 WAY 288
FUSES (FUSE/RELAY BLOCK) 290
GENERATOR – 3 WAY 291
GENERATOR – BLACK 2 WAY 291
IDLE AIR CONTROL MOTOR – BLACK 4 WAY 291
IGNITION COIL (2 5L) – GRAY 2 WAY 291
IGNITION COIL PACK (4 0L) – BLACK 4 WAY 292
IGNITION SWITCH – 10 WAY 292
INTAKE AIR TEMPERATURE SENSOR – GRAY 2 WAY 292
LEAK DETECTION PUMP – 4 WAY 292
MANIFOLD ABSOLUTE PRESSURE SENSOR – 3 WAY 293
OXYGEN SENSOR 1/1 UPSTREAM – 4 WAY 293
OXYGEN SENSOR 1/2 DOWNSTREAM – BLACK 4 WAY 293
v
TABLE OF CONTENTS – Continued
OXYGEN SENSOR 2/1 UPSTREAM (4 0L CALIFORNIA/EUROPEAN III)
– 4 WAY 293
OXYGEN SENSOR 2/2 DOWNSTREAM (4 0L CALIFORNIA/EUROPEAN III) – 4
WAY 293
OXYGEN SENSOR CONNECTOR (COMPONENT SIDE) – 4 WAY 294
PARK/NEUTRAL POSITION SWITCH (A/T) – 3 WAY 294
FUSES (PDC) 296
A/C COMPRESSOR CLUTCH RELAY 296
AUTOMATIC SHUT DOWN RELAY 296
ENGINE STARTER MOTOR RELAY 297
FUEL PUMP RELAY 297
OXYGEN SENSOR DOWNSTREAM HEATER RELAY 297
POWER STEERING PRESSURE SWITCH (2 5L) – BLACK 2 WAY 298
POWERTRAIN CONTROL MODULE C1 – BLACK 32 WAY 298
POWERTRAIN CONTROL MODULE C2 – WHITE 32 WAY 299
POWERTRAIN CONTROL MODULE C3 – GRAY 32 WAY 300
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 300
SPEED CONTROL SERVO – BLACK 4 WAY 301
THROTTLE POSITION SENSOR – 3 WAY 301
TORQUE CONVERTER CLUTCH SOLENOID – BLACK 2 WAY 301
TRANSFER CASE SWITCH – BLACK 2 WAY 301
TRANSMISSION RANGE INDICATOR ILLUMINATION (PRNDL) – BLACK 2 WAY 301
VEHICLE SPEED SENSOR – BLACK 3 WAY 302
10 0 SCHEMATIC DIAGRAMS 303
10 1 2001 JEEP TJ 2 5L JTEC SYSTEM 303
10 2 2001 JEEP TJ 4 0L JTEC SYSTEM 304
10 3 2001 JEEP TJ 4 0L JTEC SYSTEM 305
11 0 CHARTS AND GRAPHS 307

2002 JEEP WRANGLER TJ GAS POWERTRAIN SERVICE MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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