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2007 Suzuki XL7 Service Manual JC636 – PDF DOWNLOAD
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Description
2007 Suzuki XL7 Service Manual JC636 – PDF DOWNLOAD
FILE DETAILS:
2007 Suzuki XL7 Service Manual JC636 – PDF DOWNLOAD
Language : English
Pages : 3159
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2007 Suzuki XL7 Service Manual JC636 – PDF DOWNLOAD
- This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair- Overhaul).
- The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
2007 Suzuki XL7 Service Manual JC636 – PDF DOWNLOAD
Top................................................................................................................................................ 0 Manual List........................................................................................................................................ 0 BOOKCOVER.......................................................................................................................................... 1 IMPORTANT.......................................................................................................................................... 2 FOREWORD........................................................................................................................................... 3 TABLE OF CONTENTS.................................................................................................................................. 5 Precautions........................................................................................................................................ 7 Precautions.................................................................................................................................... 8 Precautions................................................................................................................................ 8 Definition of Caution, Notice, and Important........................................................................................... 8 Approved Equipment for Collision Repair Caution........................................................................................ 8 Assistant Driving Caution.............................................................................................................. 8 Cleaning Solvent Caution............................................................................................................... 8 Eye Protection Caution................................................................................................................. 9 Foam Sound Deadeners Caution........................................................................................................... 9 Gasoline/Gasoline Vapors Caution....................................................................................................... 9 Glass and Sheet Metal Handling Caution................................................................................................. 9 Moving Parts and Hot Surfaces Caution.................................................................................................. 9 Protective Goggles and Glove Caution................................................................................................... 9 Road Test Caution...................................................................................................................... 9 Work Stall Test Caution................................................................................................................ 9 Belt Dressing Notice................................................................................................................... 10 Brake Fluid Effects on Paint and Electrical Components Notice.......................................................................... 10 Clean, Dry, Low Pressure Gas Source Notice............................................................................................. 10 Clearcoat/Ultraviolet Screeners Notice................................................................................................. 10 Component Fastener Tightening Notice................................................................................................... 10 Fastener Notice........................................................................................................................ 10 Machined Surface Damage Notice......................................................................................................... 10 OBDII Symbol Description Notice........................................................................................................ 11 Pipe Wrench Positioning Notice......................................................................................................... 11 Test Probe Notice...................................................................................................................... 11 General Information................................................................................................................................ 13 General Information............................................................................................................................ 14 General Description........................................................................................................................ 14 Abbreviations and Meanings............................................................................................................. 14 Registered and Non-Registered Trademarks............................................................................................... 19 Arrows and Symbols..................................................................................................................... 20 RPO Code List.......................................................................................................................... 20 US English/Metric Conversion........................................................................................................... 21 Decimal and Metric Equivalents......................................................................................................... 22 Fasteners.............................................................................................................................. 23 Thread Inserts......................................................................................................................... 26 Lifting and Jacking the Vehicle........................................................................................................ 27 Vehicle, Engine and Transmission, Transfer Case, Axle ID, and VIN Location, Derivative and Usage....................................... 28 Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label............................................................ 29 Vibration Theory and Terminology....................................................................................................... 31 Service Programming System (SPS)....................................................................................................... 39 DTC Symptom Description - Vehicle Diagnostic Information............................................................................... 40 Service Materials (Lubricants, Oil, Grease, Sealant, Adhesive, Cleaner, etc)........................................................... 42 Component Location......................................................................................................................... 45 Engine Identification.................................................................................................................. 45 Transmission Identification Information................................................................................................ 46 Diagnostic Information and Procedures...................................................................................................... 46 Diagnostic Procedure Instructions - Vehicle Diagnostic Information..................................................................... 46 Strategy Based Diagnosis - Vehicle Diagnostic Information.............................................................................. 49 Strategy Based Diagnosis............................................................................................................... 50 Vehicle-to-Vehicle Diagnostic Comparison............................................................................................... 51 Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information.................................................................... 52 Diagnostic Starting Point - Vehicle Diagnostic Information............................................................................. 68 Diagnostic Starting Point - Vibration Diagnosis and Correction......................................................................... 68 Diagnostic System Check - Vehicle Diagnostic Information............................................................................... 69 Diagnostic Repair Verification - Vehicle Diagnostic Information........................................................................ 71 Symptoms - Vehicle Diagnostic Information.............................................................................................. 71 Symptoms - Vibration Diagnosis and Correction.......................................................................................... 72 Squeaks and Rattles.................................................................................................................... 73 Vibration Analysis - Road Testing...................................................................................................... 74 Vibration Diagnostic Aids.............................................................................................................. 77 Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated................................................................... 77 Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified............................................................. 79 Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component............................................... 79 Vibration Diagnostic Aids - Vibration Duplicated, Appears to be Potential Operating Characteristic..................................... 79 Vibration in Service-Stall Test (Non-Torque Sensitive)................................................................................. 80 Vibration in Service-Stall Test (Torque Sensitive)..................................................................................... 80 Control Module References.............................................................................................................. 81 Special Tools and Equipment................................................................................................................ 83 Substitute Special Tool Table.......................................................................................................... 83 Electronic Vibration Analyzer (EVA) Description and Operation.......................................................................... 92 Vibrate Software Description and Operation............................................................................................. 94 Reed Tachometer Description............................................................................................................ 94 Special Tools - Squeaks and Rattles.................................................................................................... 94 Special Tools and Equipment - Vibration Diagnosis and Correction....................................................................... 94 Maintenance and Lubrication.................................................................................................................... 96 Scheduled Maintenance...................................................................................................................... 96 Maintenance Items...................................................................................................................... 96 Maintenance Schedule (North American Emissions)........................................................................................ 96 Oil Life System Resetting.............................................................................................................. 96 Specifications............................................................................................................................. 96 Approximate Fluid Capacities........................................................................................................... 96 Fluid and Lubricant Recommendations.................................................................................................... 96 Engine............................................................................................................................................. 97 Engine General Information and Diagnosis....................................................................................................... 106 General Description........................................................................................................................ 106 OBD System Description - Mode $06 Data Definitions..................................................................................... 106 Schematic and Routing Diagram.............................................................................................................. 109 Engine Controls Schematic Icons........................................................................................................ 109 Engine Controls Schematics............................................................................................................. 109 Engine Control Module Connector End Views.............................................................................................. 122 Engine Controls Connector End Views.................................................................................................... 124 Component Location......................................................................................................................... 135 Engine Controls Component Views........................................................................................................ 135 Diagnostic Information and Procedures...................................................................................................... 143 Diagnostic Starting Point - Engine Controls............................................................................................ 143 Diagnostic Starting Point - Engine Electrical.......................................................................................... 143 Scan Tool Output Controls - Engine Controls - 3.6L (LY7)............................................................................... 143 Scan Tool Output Controls - Engine Electrical.......................................................................................... 146 Scan Tool Data List - Engine Controls - 3.6L (LY7)..................................................................................... 146 Scan Tool Data List - Engine Electrical................................................................................................ 151 Scan Tool Data Definitions - Engine Controls - 3.6L (LY7).............................................................................. 153 Scan Tool Data Definitions - Engine Electrical......................................................................................... 159 Powertrain Diagnostic Trouble Code (DTC) Type Definitions.............................................................................. 160 DTC P0008 or P0009..................................................................................................................... 161 DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095.............................................. 162 DTC P0011, P0014, P0021, or P0024...................................................................................................... 164 DTC P0016, P0017, P0018, or P0019...................................................................................................... 166 DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058.............................................. 168 DTC P0100, P0102, or P0103............................................................................................................. 171 DTC P0101.............................................................................................................................. 173 DTC P0111, P0112 or P0113.............................................................................................................. 175 DTC P0116.............................................................................................................................. 177 DTC P0117 or P0118..................................................................................................................... 180 DTC P0119.............................................................................................................................. 182 DTC P0121, P0122, P0123, P0221, P0222, or P0223........................................................................................ 184 DTC P0125 or P0128..................................................................................................................... 187 DTC P0131 or P0151..................................................................................................................... 189 DTC P0132 or P0152..................................................................................................................... 191 DTC P0133 or P0153..................................................................................................................... 193 DTC P0134 or P0154..................................................................................................................... 195 DTC P0135, P0141, P0155, or P0161...................................................................................................... 197 DTC P0137, P0138, P0140, P0157, P0158, or P0160........................................................................................ 200 DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277.... 202 DTC P0300-P0306........................................................................................................................ 204 DTC P0324.............................................................................................................................. 207 DTC P0326, P0327, P0328, P0331, P0332, or P0333........................................................................................ 208 DTC P0335, P0336, or P0338............................................................................................................. 210 DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393.............................................. 212 DTC P0420 or P0430..................................................................................................................... 214 DTC P0442.............................................................................................................................. 216 DTC P0443, P0458, or P0459............................................................................................................. 218 DTC P0446.............................................................................................................................. 220 DTC P0449, P0498, or P0499............................................................................................................. 222 DTC P0451.............................................................................................................................. 224 DTC P0452 or P0453..................................................................................................................... 225 DTC P0455.............................................................................................................................. 227 DTC P0496.............................................................................................................................. 230 DTC P0506, P0507, or P050A............................................................................................................. 232 DTC P0560.............................................................................................................................. 233 DTC P0562.............................................................................................................................. 234 DTC P0563.............................................................................................................................. 235 DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610................................ 236 DTC P0627, P0628, or P0629............................................................................................................. 237 DTC P0638, P2100, P2101, or P2119...................................................................................................... 239 DTC P0642 or P0643..................................................................................................................... 241 DTC P0650.............................................................................................................................. 243 DTC P0652 or P0653..................................................................................................................... 244 DTC P0685, P0686, P0687, P0689, or P0690............................................................................................... 245 DTC P0698 or P0699..................................................................................................................... 248 DTC P0700.............................................................................................................................. 249 DTC P0864.............................................................................................................................. 249 DTC P1011-P1014........................................................................................................................ 250 DTC P1380.............................................................................................................................. 251 DTC P1551.............................................................................................................................. 252 DTC P167D.............................................................................................................................. 254 DTC P2096 or P2098..................................................................................................................... 255 DTC P2097 or P2099..................................................................................................................... 257 DTC P2105.............................................................................................................................. 259 DTC P2107.............................................................................................................................. 260 DTC P2122, P2123, P2127, P2128, or P2138............................................................................................... 261 DTC P2176.............................................................................................................................. 263 DTC P2177, P2179, P2187, or P2189...................................................................................................... 264 DTC P2178, 2180, P2188, or P2190....................................................................................................... 267 DTC P2227, P2228, or P2229............................................................................................................. 269 DTC P2231 or P2234..................................................................................................................... 270 DTC P2232 or P2235..................................................................................................................... 271 DTC P2270 or P2272..................................................................................................................... 273 DTC P2271 or P2273..................................................................................................................... 275 DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316.............................................. 277 DTC P2636.............................................................................................................................. 279 Symptoms - Engine Controls............................................................................................................. 280 Engine Cranks but Does Not Run......................................................................................................... 282 Inspection/Maintenance (I/M) System Check.............................................................................................. 284 Inspection/Maintenance (I/M) Complete System Set Procedure............................................................................. 286 Inspection/Maintenance (I/M) System DTC Table.......................................................................................... 287 Repair Instructions........................................................................................................................ 287 Idle Learn............................................................................................................................. 287 Specifications............................................................................................................................. 288 Temperature Versus Resistance - Engine Coolant Temperature Sensor...................................................................... 288 Temperature Versus Resistance - Intake Air Temperature Sensor.......................................................................... 288 Altitude Versus Barometric Pressure.................................................................................................... 288 Special Tools and Equipment................................................................................................................ 289 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 289 Aux. Emission Control Devices.................................................................................................................. 291 Precautions................................................................................................................................ 291 Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice..................................................................... 291 General Description........................................................................................................................ 291 Evaporative Emission Control System Description........................................................................................ 291 Crankcase Ventilation System Description............................................................................................... 292 Schematic and Routing Diagram.............................................................................................................. 293 Emission Hose Routing Diagram.......................................................................................................... 293 Evaporative Emissions Hose Routing Diagram............................................................................................. 294 Repair Instructions........................................................................................................................ 295 Evaporative Emission Canister Purge Solenoid Valve Replacement......................................................................... 295 Evaporative Emission Canister Vent Solenoid Valve Replacement.......................................................................... 296 Evaporative Emission Canister Vent Hose Replacement.................................................................................... 297 Evaporative Emission Pipe Replacement.................................................................................................. 298 Evaporative Emission Canister Replacement.............................................................................................. 302 Evaporative Emission Canister Filter Replacement....................................................................................... 304 Evaporative Emission System Cleaning................................................................................................... 305 Specifications............................................................................................................................. 306 Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...................................................................... 306 Special Tools and Equipment................................................................................................................ 306 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 306 Engine Electrical Devices...................................................................................................................... 307 Precautions................................................................................................................................ 307 Heated Oxygen and Oxygen Sensor Notice................................................................................................. 307 Heated Oxygen Sensor Resistance Learn Reset Notice..................................................................................... 307 Silicon Contamination of Heated Oxygen Sensors Notice.................................................................................. 307 General Description........................................................................................................................ 308 Air Intake System Description.......................................................................................................... 308 Camshaft Actuator System Description................................................................................................... 309 Engine Control Module Description...................................................................................................... 310 Knock Sensor (KS) System Description................................................................................................... 313 Throttle Actuator Control (TAC) System Description..................................................................................... 313 Repair Instructions........................................................................................................................ 315 Engine Coolant Temperature Sensor Replacement.......................................................................................... 315 Mass Airflow Sensor/Intake Air Temperature Sensor Replacement.......................................................................... 316 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1..................................................................................... 317 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2..................................................................................... 318 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1..................................................................................... 320 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2..................................................................................... 322 Heated Oxygen Sensor Wiring Repairs.................................................................................................... 324 Accelerator Pedal Position Sensor Replacement.......................................................................................... 324 Crankshaft Position Sensor Replacement................................................................................................. 326 Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust..................................................................... 327 Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake...................................................................... 328 Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust...................................................................... 329 Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake....................................................................... 330 Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake............................................ 331 Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust........................................... 332 Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake............................................. 333 Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust............................................ 334 Knock Sensor Replacement - Bank 1...................................................................................................... 335 Knock Sensor Replacement - Bank 2...................................................................................................... 336 Engine Control Module Replacement...................................................................................................... 337 Engine Control Module Programming and Setup............................................................................................ 339 Specifications............................................................................................................................. 340 Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...................................................................... 340 Special Tools and Equipment................................................................................................................ 340 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 340 Engine Mechanical.............................................................................................................................. 341 Precautions................................................................................................................................ 341 Torque Reaction Against Timing Drive Chain Notice...................................................................................... 341 General Description........................................................................................................................ 341 Drive Belt System Description.......................................................................................................... 341 Engine Component Description........................................................................................................... 341 Cleanliness and Care................................................................................................................... 343 Separating Parts....................................................................................................................... 343 Replacing Engine Gaskets............................................................................................................... 344 Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer......................................................................... 344 Schematic and Routing Diagram.............................................................................................................. 346 Camshaft Timing Drive Chain Alignment Diagram (Third Design)........................................................................... 346 Camshaft Timing Drive Chain Alignment Diagram (Fourth Design).......................................................................... 349 Component Location......................................................................................................................... 352 Disassembled Views..................................................................................................................... 352 Diagnostic Information and Procedures...................................................................................................... 366 Diagnostic Starting Point - Engine Mechanical.......................................................................................... 366 Symptoms - Engine Mechanical........................................................................................................... 366 Base Engine Misfire without Internal Engine Noises..................................................................................... 367 Base Engine Misfire with Abnormal Internal Lower Engine Noises......................................................................... 368 Base Engine Misfire with Abnormal Valve Train Noise.................................................................................... 369 Base Engine Misfire with Coolant Consumption........................................................................................... 369 Base Engine Misfire with Excessive Oil Consumption..................................................................................... 369 Engine Noise on Start-Up, but Only Lasting a Few Seconds............................................................................... 369 Upper Engine Noise, Regardless of Engine Speed......................................................................................... 370 Lower Engine Noise, Regardless of Engine Speed......................................................................................... 370 Engine Noise Under Load................................................................................................................ 371 Engine Will Not Crank - Crankshaft Will Not Rotate..................................................................................... 372 Coolant in Combustion Chamber.......................................................................................................... 373 Coolant in Engine Oil.................................................................................................................. 373 Engine Compression Test................................................................................................................ 374 Cylinder Leakage Test.................................................................................................................. 374 Crankcase Ventilation System Inspection/ Diagnosis..................................................................................... 375 Drive Belt Chirping, Squeal, and Whine Diagnosis....................................................................................... 375 Drive Belt Rumbling and Vibration Diagnosis............................................................................................ 378 Drive Belt Falls Off and Excessive Wear Diagnosis...................................................................................... 380 Drive Belt Tensioner Diagnosis......................................................................................................... 381 Vibration Analysis - Engine............................................................................................................ 382 Vibration Analysis - Engine/Accessory Isolation........................................................................................ 384 Vibration Analysis - Engine Balance.................................................................................................... 390 Engine Order Classification............................................................................................................ 395 Repair Instructions........................................................................................................................ 398 Air Cleaner Outlet Duct Replacement.................................................................................................... 398 Air Cleaner Element Replacement........................................................................................................ 399 Air Cleaner Assembly Replacement....................................................................................................... 400 Throttle Body Assembly Replacement..................................................................................................... 401 Throttle Body Service.................................................................................................................. 402 Drive Belt Replacement................................................................................................................. 402 Drive Belt Tensioner Replacement....................................................................................................... 403 Drive Belt Idler Pulley Replacement.................................................................................................... 404 Engine Mount Inspection................................................................................................................ 405 Engine Rear Mount Replacement.......................................................................................................... 406 Engine Mount Replacement - Right Side.................................................................................................. 406 Engine Mount Bracket Replacement - Right Side.......................................................................................... 408 Engine Mount Strut Replacement - Right Side............................................................................................ 410 Engine Mount Strut Bracket Replacement - Right Side.................................................................................... 411 Fuel Injector Sight Shield Replacement................................................................................................. 412 Crankcase Ventilation Hoses/Pipes Replacement (Front).................................................................................. 412 Crankcase Ventilation Hoses/Pipes Replacement (Rear)................................................................................... 413 Upper Intake Manifold Replacement...................................................................................................... 413 Lower Intake Manifold Replacement...................................................................................................... 417 Crankshaft Balancer Replacement........................................................................................................ 417 Crankshaft Front Oil Seal Replacement.................................................................................................. 419 Camshaft Cover Replacement - Left Side................................................................................................. 420 Camshaft Cover Replacement - Right Side................................................................................................ 422 Engine Front Cover Replacement......................................................................................................... 424 Secondary Camshaft Drive Chain Replacement - Left Side................................................................................. 428 Secondary Camshaft Drive Chain Replacement - Right Side................................................................................ 429 Secondary Camshaft Drive Chain Tensioner Replacement - Left Side....................................................................... 430 Secondary Camshaft Drive Chain Tensioner Replacement - Right Side...................................................................... 430 Secondary Camshaft Drive Chain Shoe Replacement - Left Side............................................................................ 431 Secondary Camshaft Drive Chain Shoe Replacement - Right Side........................................................................... 432 Secondary Camshaft Drive Chain Guide Replacement - Left Side........................................................................... 433 Secondary Camshaft Drive Chain Guide Replacement - Right Side.......................................................................... 434 Primary Camshaft Drive Chain and Sprockets Replacement................................................................................. 435 Camshaft Intermediate Drive Chain Idler Sprocket Replacement - Left Side............................................................... 437 Primary Camshaft Drive Chain Tensioner Replacement..................................................................................... 439 Primary Camshaft Drive Chain Guide Replacement - Lower................................................................................. 440 Primary Camshaft Drive Chain Guide Replacement - Upper................................................................................. 440 Camshaft Position Actuator Replacement - Bank 2 (Left Side) Exhaust.................................................................... 441 Camshaft Position Actuator Replacement - Bank 1 (Right Side) Exhaust................................................................... 444 Camshaft Position Actuator Replacement - Bank 2 (Left Side) Intake..................................................................... 444 Camshaft Position Actuator Replacement - Bank 1 (Right Side) Intake.................................................................... 445 Setting Camshaft Timing................................................................................................................ 445 Camshaft Replacement - Left Side....................................................................................................... 446 Camshaft Replacement - Right Side...................................................................................................... 448 Valve Rocker Arm Replacement - Left Side............................................................................................... 450 Valve Rocker Arm Replacement - Right Side.............................................................................................. 450 Valve Lifter Replacement - Left Side................................................................................................... 451 Valve Lifter Replacement - Right Side.................................................................................................. 451 Valve Stem Oil Seal and Valve Spring Replacement - Left Side........................................................................... 452 Valve Stem Oil Seal and Valve Spring Replacement - Right Side.......................................................................... 454 Cylinder Head Replacement - Left Side.................................................................................................. 457 Cylinder Head Replacement - Right Side................................................................................................. 458 Engine Flywheel Replacement............................................................................................................ 460 Crankshaft Rear Oil Seal and Housing Replacement....................................................................................... 460 Engine Replacement..................................................................................................................... 461 Drive Belt Tensioner Removal........................................................................................................... 470 Crankshaft Balancer Removal............................................................................................................ 470 Engine Flywheel Removal................................................................................................................ 471 Intake Manifold Removal................................................................................................................ 472 Camshaft Cover Removal - Left Side..................................................................................................... 475 Camshaft Cover Removal - Right Side.................................................................................................... 476 Engine Front Cover Removal (Third Design).............................................................................................. 477 Engine Front Cover Removal (Fourth Design)............................................................................................. 479 Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Third Design)........................................................... 481 Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Fourth Design).......................................................... 482 Secondary Camshaft Drive Chain Shoe Removal - Right Side (Third Design)................................................................ 482 Secondary Camshaft Drive Chain Shoe Removal - Right Side (Fourth Design)............................................................... 483 Secondary Camshaft Drive Chain Guide Removal - Right Side (Third Design)............................................................... 483 Secondary Camshaft Drive Chain Guide Removal - Right Side (Fourth Design).............................................................. 483 Secondary Camshaft Drive Chain Removal - Right Side (Third Design)..................................................................... 484 Secondary Camshaft Drive Chain Removal - Right Side (Fourth Design).................................................................... 484 Primary Camshaft Drive Chain Tensionser Removal (Third Design)......................................................................... 484 Primary Camshaft Drive Chain Tensionser Removal (Fourth Design)........................................................................ 485 Primary Camshaft Drive Chain Guide Removal - Upper (Third Design)...................................................................... 485 Primary Camshaft Drive Chain Guide Removal - Upper (Fourth Design)..................................................................... 485 Primary Camshaft Drive Chain Guide Removal - Lower (Third Design)...................................................................... 486 Primary Camshaft Drive Chain Guide Removal - Lower (Fourth Design)..................................................................... 486 Primary Camshaft Drive Chain Removal (Third Design).................................................................................... 486 Primary Camshaft Drive Chain Removal (Fourth Design)................................................................................... 486 Camshaft Intermediate Drive Chain Idler Removal - Right Side (Third Design)............................................................ 487 Camshaft Intermediate Drive Chain Idler Removal - Right Side (Fourth Design)........................................................... 487 Secondary Camshaft Drive Chain Tensioner Removal - Left Side (Third Design)............................................................ 487 Secondary Camshaft Drive Chain Tensioner Removal - Left Side (Fourth Design)........................................................... 488 Secondary Camshaft Drive Chain Shoe Removal - Left Side (Third Design)................................................................. 488 Secondary Camshaft Drive Chain Shoe Removal - Left Side (Fourth Design)................................................................ 489 Secondary Camshaft Drive Chain Guide Removal - Left Side (Third Design)................................................................ 489 Secondary Camshaft Drive Chain Guide Removal - Left Side (Fourth Design)............................................................... 489 Secondary Camshaft Drive Chain Removal - Left Side (Third Design)...................................................................... 490 Secondary Camshaft Drive Chain Removal - Left Side (Fourth Design)..................................................................... 490 Camshaft Intermediate Drive Chain Idler Removal - Left Side (Third Design)............................................................. 490 Camshaft Intermediate Drive Chain Idler Removal - Left Side (Fourth Design)............................................................ 490 Crankshaft Sprocket Removal (Third Design)............................................................................................. 491 Crankshaft Sprocket Removal (Fourth Design)............................................................................................ 491 Camshaft Position Actuator Removal - Left Side Exhaust (Third Design).................................................................. 491 Camshaft Position Actuator Removal - Left Side Exhaust (Fourth Design)................................................................. 492 Camshaft Position Actuator Removal - Left Side Intake (Third Design)................................................................... 492 Camshaft Position Actuator Removal - Left Side Intake (Fourth Design).................................................................. 492 Camshaft Position Actuator Removal - Right Side Exhaust (Third Design)................................................................. 493 Camshaft Position Actuator Removal - Right Side Exhaust (Fourth Design)................................................................ 493 Camshaft Position Actuator Removal - Right Side Intake (Third Design).................................................................. 493 Camshaft Position Actuator Removal - Right Side Intake (Fourth Design)................................................................. 494 Camshaft Removal - Left Side........................................................................................................... 494 Valve Rocker Arm Removal - Left Side................................................................................................... 495 Valve Lifter Removal - Left Side....................................................................................................... 495 Cylinder Head Removal - Left Side...................................................................................................... 496 Camshaft Removal - Right Side.......................................................................................................... 496 Valve Rocker Arm Removal - Right Side.................................................................................................. 497 Valve Lifter Removal - Right Side...................................................................................................... 497 Cylinder Head Removal - Right Side..................................................................................................... 498 Crankshaft Rear Oil Seal and Housing Removal........................................................................................... 498 Piston, Connecting Rod, and Bearing Removal............................................................................................ 499 Crankshaft and Bearings Removal........................................................................................................ 501 Engine Block Disassemble............................................................................................................... 503 Engine Block Cleaning and Inspection................................................................................................... 505 Crankshaft and Bearings Cleaning and Inspection........................................................................................ 507 Crankshaft Balancer Cleaning and Inspection............................................................................................ 510 Engine Flywheel Cleaning and Inspection................................................................................................ 510 Piston and Connecting Rod Disassemble.................................................................................................. 511 Piston, Connecting Rod, and Bearings Cleaning and Inspection........................................................................... 512 Piston and Connecting Rod Assemble..................................................................................................... 515 Cylinder Head Disassemble.............................................................................................................. 517 Cylinder Head Cleaning and Inspection.................................................................................................. 519 Valve Spring Inspection and Measurement................................................................................................ 522 Valve and Seat Grinding................................................................................................................ 522 Cylinder Head Assemble................................................................................................................. 526 Camshaft Cleaning and Inspection....................................................................................................... 528 Valve Lifters Cleaning and Inspection.................................................................................................. 530 Valve Rocker Arms Cleaning and Inspection.............................................................................................. 531 Camshaft Timing Drive Components Cleaning and Inspection (Third Design)................................................................ 531 Camshaft Timing Drive Components Cleaning and Inspection (Fourth Design)............................................................... 537 Engine Front Cover Disassemble......................................................................................................... 544 Engine Front Cover Cleaning and Inspection............................................................................................. 545 Engine Front Cover Assemble............................................................................................................ 546 Camshaft Cover Disassemble............................................................................................................. 547 Camshaft Cover Cleaning and Inspection................................................................................................. 549 Camshaft Cover Assemble................................................................................................................ 551 Intake Manifold Disassemble............................................................................................................ 553 Intake Manifold Cleaning and Inspection................................................................................................ 556 Intake Manifold Assemble............................................................................................................... 558 Thread Repair.......................................................................................................................... 561 Service Prior to Assembly.............................................................................................................. 588 Engine Block Assemble.................................................................................................................. 588 Crankshaft and Bearings Installation................................................................................................... 591 Piston, Connecting Rod, and Bearing Installation....................................................................................... 597 Crankshaft Rear Oil Seal and Housing Installation...................................................................................... 601 Cylinder Head Installation - Right Side................................................................................................ 603 Valve Lifter Installation - Right Side................................................................................................. 604 Valve Rocker Arm Installation - Right Side............................................................................................. 605 Camshaft Installation - Right Side..................................................................................................... 605 Cylinder Head Installation - Left Side................................................................................................. 607 Valve Lifter Installation - Left Side.................................................................................................. 608 Valve Rocker Arm Installation - Left Side.............................................................................................. 609 Camshaft Installation - Left Side...................................................................................................... 610 Camshaft Position Actuator Installation - Right Side Intake (Third Design)............................................................. 612 Camshaft Position Actuator Installation - Right Side Intake (Fourth Design)............................................................ 613 Camshaft Position Actuator Installation - Right Side Exhaust (Third Design)............................................................ 614 Camshaft Position Actuator Installation - Right Side Exhaust (Fourth Design)........................................................... 615 Camshaft Position Actuator Installation - Left Side Intake (Third Design).............................................................. 616 Camshaft Position Actuator Installation - Left Side Intake (Fourth Design)............................................................. 616 Camshaft Position Actuator Installation - Left Side Exhaust (Third Design)............................................................. 618 Camshaft Position Actuator Installation - Left Side Exhaust (Fourth Design)............................................................ 618 Crankshaft Sprocket Installation (Third Design)........................................................................................ 619 Crankshaft Sprocket Installation (Fourth Design)....................................................................................... 620 Camshaft Intermediate Drive Chain Idler Installation - Left Side (Third Design)........................................................ 620 Camshaft Intermediate Drive Chain Idler Installation - Left Side (Fourth Design)....................................................... 621 Secondary Camshaft Drive Chain Installation - Left Side (Third Design)................................................................. 622 Secondary Camshaft Drive Chain Installation - Left Side (Fourth Design)................................................................ 624 Secondary Camshaft Drive Chain Guide Installation - Left Side (Third Design)........................................................... 626 Secondary Camshaft Drive Chain Guide Installation - Left Side (Fourth Design).......................................................... 626 Secondary Camshaft Drive Chain Shoe Installation - Left Side (Third Design)............................................................ 627 Secondary Camshaft Drive Chain Shoe Installation - Left Side (Fourth Design)........................................................... 627 Secondary Camshaft Drive Chain Tensioner Installation - Left Side (Third Design)....................................................... 628 Secondary Camshaft Drive Chain Tensioner Installation - Left Side (Fourth Design)...................................................... 630 Camshaft Intermediate Drive Chain Idler Installation - Right Side (Third Design)....................................................... 633 Camshaft Intermediate Drive Chain Idler Installation - Right Side (Fourth Design)...................................................... 633 Primary Camshaft Drive Chain Installation (Third Design)............................................................................... 634 Primary Camshaft Drive Chain Installation (Fourth Design).............................................................................. 635 Primary Camshaft Drive Chain Guide Installation - Lower (Third Design)................................................................. 637 Primary Camshaft Drive Chain Guide Installation - Lower (Fourth Design)................................................................ 637 Primary Camshaft Drive Chain Guide Installation - Upper (Third Design)................................................................. 638 Primary Camshaft Drive Chain Guide Installation - Upper (Fourth Design)................................................................ 638 Primary Camshaft Drive Chain Tensionser Installation (Third Design).................................................................... 639 Primary Camshaft Drive Chain Tensionser Installation (Fourth Design)................................................................... 642 Secondary Camshaft Drive Chain Installation - Right Side (Third Design)................................................................ 645 Secondary Camshaft Drive Chain Installation - Right Side (Fourth Design)............................................................... 647 Secondary Camshaft Drive Chain Guide Installation - Right Side (Third Design).......................................................... 649 Secondary Camshaft Drive Chain Guide Installation - Right Side (Fourth Design)......................................................... 649 Secondary Camshaft Drive Chain Shoe Installation - Right Side (Third Design)........................................................... 650 Secondary Camshaft Drive Chain Shoe Installation - Right Side (Fourth Design).......................................................... 650 Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design)...................................................... 651 Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Fourth Design)..................................................... 654 Engine Front Cover Installation (Third Design)......................................................................................... 656 Engine Front Cover Installation (Fourth Design)........................................................................................ 658 Camshaft Cover Installation - Left Side................................................................................................ 661 Camshaft Cover Installation - Right Side............................................................................................... 664 Intake Manifold Installation........................................................................................................... 666 Engine Flywheel Installation........................................................................................................... 669 Crankshaft Balancer Installation....................................................................................................... 670 Drive Belt Tensioner Installation...................................................................................................... 671 Engine Prelubing....................................................................................................................... 672 Specifications............................................................................................................................. 674 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 674 Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...................................................................... 675 Engine Mechanical Specifications....................................................................................................... 675 Sealers, Adhesives, and Lubricants..................................................................................................... 678 Thread Repair Specifications........................................................................................................... 679 Special Tools and Equipment................................................................................................................ 705 Engine Support Fixture................................................................................................................. 705 Tools and Equipment.................................................................................................................... 708 Special Tools - Engine Mechanical - 3.6L (LY7)......................................................................................... 708 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 713 Engine Lubrication System...................................................................................................................... 714 General Description........................................................................................................................ 714 Lubrication Description................................................................................................................ 714 Diagnostic Information and Procedures...................................................................................................... 715 Oil Consumption Diagnosis.............................................................................................................. 715 Oil Pressure Diagnosis and Testing..................................................................................................... 715 Oil Leak Diagnosis..................................................................................................................... 717 Repair Instructions........................................................................................................................ 718 Oil Level Indicator and Tube Replacement............................................................................................... 718 Engine Oil and Oil Filter Replacement.................................................................................................. 719 Oil Filter Adapter Replacement......................................................................................................... 719 Engine Oil Pressure Sensor and/or Switch Replacement................................................................................... 721 Oil Pan Replacement.................................................................................................................... 721 Oil Pump Replacement................................................................................................................... 723 Oil Pump Suction Pipe and Screen Assembly Replacement.................................................................................. 724 Oil Level Indicator and Tube Removal................................................................................................... 725 Oil Filter Adapter Removal............................................................................................................. 726 Oil Pan Removal........................................................................................................................ 727 Oil Pump Removal....................................................................................................................... 728 Oil Pump Disassemble................................................................................................................... 728 Oil Pump Cleaning and Inspection....................................................................................................... 730 Oil Pump Assemble...................................................................................................................... 732 Oil Filter Adapter Disassemble......................................................................................................... 733 Oil Filter Adapter Cleaning and Inspection............................................................................................. 733 Oil Filter Adapter Assemble............................................................................................................ 734 Oil Pan Disassemble.................................................................................................................... 735 Oil Pan Cleaning and Inspection........................................................................................................ 736 Oil Pump Pipe and Screen Cleaning and Inspection....................................................................................... 737 Oil Pan Assemble....................................................................................................................... 737 Oil Pump Installation.................................................................................................................. 738 Oil Pan Installation................................................................................................................... 739 Oil Filter Adapter Installation........................................................................................................ 740 Oil Level Indicator and Tube Installation.............................................................................................. 741 Specifications............................................................................................................................. 742 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 742 Special Tools and Equipment................................................................................................................ 743 Tools and Equipment.................................................................................................................... 743 Special Tools - Engine Mechanical - 3.6L (LY7)......................................................................................... 743 Engine Cooling System.......................................................................................................................... 744 General Description........................................................................................................................ 744 Cooling System Description and Operation............................................................................................... 744 Schematic and Routing Diagram.............................................................................................................. 746 Engine Cooling Schematics.............................................................................................................. 747 Cooling System Connector End Views..................................................................................................... 748 Component Location......................................................................................................................... 749 Cooling System Component Views......................................................................................................... 749 Diagnostic Information and Procedures...................................................................................................... 750 Diagnostic Starting Point - Engine Cooling............................................................................................. 750 Scan Tool Output Controls (3.6L) - Engine Cooling...................................................................................... 750 Scan Tool Data List (3.6L) - Engine Cooling............................................................................................ 751 Scan Tool Data Definitions (3.6L) - Engine Cooling..................................................................................... 751 DTC P0480, P0481, P0691, P0692, P0693, or P0694........................................................................................ 752 Symptoms - Engine Cooling.............................................................................................................. 754 Cooling Fan Always On.................................................................................................................. 755 Cooling Fan Inoperative................................................................................................................ 756 Engine Overheating..................................................................................................................... 758 Loss of Coolant........................................................................................................................ 759 Thermostat Diagnosis................................................................................................................... 761 Engine Fails To Reach Normal Operating Temperature..................................................................................... 762 Pressure Cap Testing................................................................................................................... 762 Cooling System Leak Testing............................................................................................................ 763 Repair Instructions........................................................................................................................ 764 Radiator Drain Cock Replacement........................................................................................................ 764 Draining and Filling Cooling System (LY7 GE 47716 Fill)................................................................................ 764 Draining and Filling Cooling System (LY7 Static Fill).................................................................................. 769 Coolant System Flushing................................................................................................................ 770 Heater Inlet Pipe Replacement.......................................................................................................... 770 Heater Outlet Pipe Replacement......................................................................................................... 771 Heater Outlet Hose Replacement......................................................................................................... 773 Radiator Surge Tank Inlet Hose/Pipe Replacement........................................................................................ 774 Surge Tank Replacement................................................................................................................. 775 Radiator Inlet Hose Replacement........................................................................................................ 776 Radiator Outlet Hose Replacement....................................................................................................... 777 Cooling Fan and Shroud Replacement..................................................................................................... 778 Engine Coolant Fan Motor Replacement................................................................................................... 781 Radiator Replacement................................................................................................................... 784 Engine Coolant Thermostat Housing Replacement.......................................................................................... 785 Thermostat Replacement................................................................................................................. 785 Coolant Air Bleed Pipe Assembly Replacement............................................................................................ 786 Water Outlet Housing Replacement....................................................................................................... 787 Water Pump Replacement................................................................................................................. 787 Coolant Heater Replacement............................................................................................................. 789 Coolant Heater Cord Replacement........................................................................................................ 789 Water Outlet Removal................................................................................................................... 790 Engine Coolant Thermostat Housing Removal.............................................................................................. 791 Water Pump Removal..................................................................................................................... 793 Water Pump Cleaning and Inspection..................................................................................................... 794 Water Pump Installation................................................................................................................ 795 Engine Coolant Thermostat Housing Installation......................................................................................... 795 Water Outlet Installation.............................................................................................................. 798 Specifications............................................................................................................................. 799 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 799 Fastener Tightening Specifications - Engine Cooling.................................................................................... 799 Special Tools and Equipment................................................................................................................ 799 Tools and Equipment.................................................................................................................... 799 Special Tools - Engine Mechanical - 3.6L (LY7)......................................................................................... 800 Special Tools - Engine Cooling......................................................................................................... 800 Fuel System.................................................................................................................................... 801 Precautions................................................................................................................................ 801 Fuel Pipe Fitting Caution.............................................................................................................. 801 Relieving Fuel Pressure Caution........................................................................................................ 801 Fuel Rail Notice....................................................................................................................... 801 General Description........................................................................................................................ 802 Fuel System Description................................................................................................................ 802 Diagnostic Information and Procedures...................................................................................................... 808 Diagnostic Starting Point - Engine Controls............................................................................................ 808 Scan Tool Output Controls - Engine Controls - 3.6L (LY7)............................................................................... 808 Scan Tool Data List - Engine Controls - 3.6L (LY7)..................................................................................... 810 Scan Tool Data Definitions - Engine Controls - 3.6L (LY7).............................................................................. 816 Fuel Pump Electrical Circuit Diagnosis................................................................................................. 822 Fuel System Diagnosis.................................................................................................................. 824 Fuel Injector Solenoid Coil Test....................................................................................................... 825 Fuel Injector Balance Test with Special Tool........................................................................................... 826 Fuel Injector Balance Test with Tech 2................................................................................................. 828 Fuel Tank Leak Test.................................................................................................................... 829 Alcohol/Contaminants-in-Fuel Diagnosis (w/o Special Tool).............................................................................. 830 Alcohol/Contaminants-in-Fuel Diagnosis (w/ Special Tool)............................................................................... 831 Repair Instructions........................................................................................................................ 832 Fuel Pressure Relief (With J 34730-1A)................................................................................................. 832 Fuel Pressure Relief (Without J 34730-1A).............................................................................................. 833 Fuel Pressure Gage Installation and Removal............................................................................................ 833 Metal Collar Quick Connect Fitting Service............................................................................................. 834 Plastic Collar Quick Connect Fitting Service........................................................................................... 836 Fuel Feed Pipe Replacement............................................................................................................. 839 Fuel Injector and Fuel Rail Replacement................................................................................................ 843 Fuel Tank Draining..................................................................................................................... 845 Filler Tube Replacement................................................................................................................ 848 Fuel Tank Replacement (FWD)............................................................................................................ 850 Fuel Tank Replacement (AWD)............................................................................................................ 853 Fuel Tank Pressure Sensor Replacement.................................................................................................. 855 Primary Fuel Tank Module Replacement................................................................................................... 856 Secondary Fuel Tank Module Replacement................................................................................................. 858 Primary Fuel Level Sensor Replacement.................................................................................................. 860 Fuel Level Sensor Replacement - Secondary.............................................................................................. 860 Fuel Tank Filler Vent Hose Replacement................................................................................................. 861 Fuel System Cleaning................................................................................................................... 862 Specifications............................................................................................................................. 862 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 862 Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...................................................................... 862 Special Tools and Equipment................................................................................................................ 863 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 863 Ignition System................................................................................................................................ 865 General Description........................................................................................................................ 865 Electronic Ignition (EI) System Description............................................................................................ 865 Diagnostic Information and Procedures...................................................................................................... 866 Electronic Ignition (EI) System Diagnosis.............................................................................................. 866 Repair Instructions........................................................................................................................ 867 Ignition Coil Replacement - Bank 1..................................................................................................... 867 Ignition Coil Replacement - Bank 2..................................................................................................... 868 Spark Plug Replacement................................................................................................................. 869 Spark Plug Inspection.................................................................................................................. 870 Specifications............................................................................................................................. 872 Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...................................................................... 872 Ignition System Specifications......................................................................................................... 872 Special Tools and Equipment................................................................................................................ 872 Special Tools - Engine Controls - 3.6L (LY7)........................................................................................... 872 Starting System................................................................................................................................ 873 General Description........................................................................................................................ 873 Starting System Description and Operation.............................................................................................. 873 Schematic and Routing Diagram.............................................................................................................. 873 Starting and Charging Schematics....................................................................................................... 873 Engine Electrical Connector End Views.................................................................................................. 876 Component Location......................................................................................................................... 877 Engine Electrical Component Views...................................................................................................... 877 Diagnostic Information and Procedures...................................................................................................... 880 Diagnostic Starting Point - Engine Electrical.......................................................................................... 880 Scan Tool Output Controls - Engine Electrical.......................................................................................... 880 Scan Tool Data List - Engine Electrical................................................................................................ 880 Scan Tool Data Definitions - Engine Electrical......................................................................................... 882 DTC P0615.............................................................................................................................. 882 DTC P0616.............................................................................................................................. 884 DTC P0617.............................................................................................................................. 885 Symptoms - Engine Electrical........................................................................................................... 886 Starter Solenoid Does Not Click........................................................................................................ 886 Starter Solenoid Clicks, Engine Does Not Crank......................................................................................... 888 Engine Cranks Slowly................................................................................................................... 888 Starter Motor Noise Diagnosis.......................................................................................................... 889 Repair Instructions........................................................................................................................ 890 Starter Motor Replacement.............................................................................................................. 890 Starter Removal........................................................................................................................ 891 Starter Installation................................................................................................................... 892 Specifications............................................................................................................................. 893 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 893 Fastener Tightening Specifications - Engine Electrical................................................................................. 893 Special Tools and Equipment................................................................................................................ 893 Special Tools - Engine Electrical...................................................................................................... 893 Charging System................................................................................................................................ 894 Precautions................................................................................................................................ 894 Battery Disconnect Caution............................................................................................................. 894 Batteries Produce Explosive Gases Caution.............................................................................................. 894 General Description........................................................................................................................ 895 Battery Description and Operation...................................................................................................... 895 Charging System Description and Operation.............................................................................................. 896 Electrical Power Management Description and Operation.................................................................................. 899 Schematic and Routing Diagram.............................................................................................................. 899 Starting and Charging Schematics....................................................................................................... 899 Engine Electrical Connector End Views.................................................................................................. 902 Component Location......................................................................................................................... 903 Engine Electrical Component Views...................................................................................................... 903 Diagnostic Information and Procedures...................................................................................................... 906 Diagnostic Starting Point - Engine Electrical.......................................................................................... 906 Scan Tool Output Controls - Engine Electrical.......................................................................................... 906 Scan Tool Data List - Engine Electrical................................................................................................ 906 Scan Tool Data Definitions - Engine Electrical......................................................................................... 908 DTC B1325.............................................................................................................................. 908 DTC B1405.............................................................................................................................. 910 DTC B1424.............................................................................................................................. 911 DTC B1516.............................................................................................................................. 912 DTC B1517.............................................................................................................................. 913 DTC B1527.............................................................................................................................. 915 DTC P0621.............................................................................................................................. 915 DTC P0622.............................................................................................................................. 916 DTC P0625.............................................................................................................................. 917 DTC P0626.............................................................................................................................. 919 DTC C0899.............................................................................................................................. 920 DTC C0900.............................................................................................................................. 920 Symptoms - Engine Electrical........................................................................................................... 921 Charging System Test................................................................................................................... 922 Battery Charging....................................................................................................................... 925 Battery Common Causes of Failure....................................................................................................... 926 Jump Starting in Case of Emergency..................................................................................................... 927 Charge Indicator Always On............................................................................................................. 928 Charge Indicator Inoperative........................................................................................................... 929 Generator Noise Diagnosis.............................................................................................................. 929 Engine Cranks Slowly................................................................................................................... 931 Battery Inspection/Test................................................................................................................ 931 Battery Electrical Drain/Parasitic Load Test........................................................................................... 934 Repair Instructions........................................................................................................................ 936 Battery Negative Cable Disconnection and Connection.................................................................................... 936 Battery Current Sensor Replacement..................................................................................................... 938 Battery Negative Cable Replacement..................................................................................................... 939 Battery Positive Cable Replacement..................................................................................................... 941 Battery Replacement.................................................................................................................... 943 Battery Tray Replacement............................................................................................................... 945 Battery Box Replacement................................................................................................................ 945 Generator Replacement.................................................................................................................. 947 Specifications............................................................................................................................. 948 Fastener Tightening Specifications - Engine Electrical................................................................................. 948 Battery Usage.......................................................................................................................... 949 Generator Usage........................................................................................................................ 949 Special Tools and Equipment................................................................................................................ 949 Special Tools - Engine Electrical...................................................................................................... 949 Exhaust System................................................................................................................................. 950 Precautions................................................................................................................................ 950 Exhaust Service Caution................................................................................................................ 950 Hot Exhaust System Caution............................................................................................................. 950 Three-Way Catalytic Converter Damage Notice............................................................................................ 950 General Description........................................................................................................................ 951 Exhaust System Description............................................................................................................. 951 Diagnostic Information and Procedures...................................................................................................... 953 Diagnostic Starting Point - Engine Exhaust............................................................................................. 953 Symptoms - Engine Exhaust.............................................................................................................. 953 Restricted Exhaust..................................................................................................................... 954 Exhaust Leakage........................................................................................................................ 956 Exhaust Noise.......................................................................................................................... 956 Repair Instructions........................................................................................................................ 957 Exhaust Manifold Replacement - Left Side............................................................................................... 957 Exhaust Manifold Replacement - Right Side.............................................................................................. 958 Exhaust Flexible Pipe Replacement...................................................................................................... 959 Catalytic Converter Replacement - Left Side............................................................................................ 961 Catalytic Converter Replacement - Right Side........................................................................................... 963 Muffler Replacement.................................................................................................................... 965 Catalytic Converter Heat Shield Replacement............................................................................................ 966 Exhaust Heat Shield Replacement - Dash Panel........................................................................................... 967 Exhaust Manifold Heat Shield Replacement............................................................................................... 968 Exhaust Manifold Heat Shield Replacement - Right Side.................................................................................. 969 Exhaust Manifold Heat Shield Replacement - Left Side................................................................................... 970 Exhaust Manifold Removal - Left Side................................................................................................... 971 Exhaust Manifold Removal - Right Side.................................................................................................. 972 Exhaust Manifold Cleaning and Inspection - Left Side................................................................................... 975 Exhaust Manifold Cleaning and Inspection - Right Side.................................................................................. 976 Exhaust Manifold Installation - Left Side.............................................................................................. 977 Exhaust Manifold Installation - Right Side............................................................................................. 978 Specifications............................................................................................................................. 982 Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7).................................................................... 982 Fastener Tightening Specifications - Engine Exhaust.................................................................................... 982 Special Tools and Equipment................................................................................................................ 982 Tools and Equipment.................................................................................................................... 982 Special Tools - Engine Exhaust......................................................................................................... 982 Suspention......................................................................................................................................... 983 Suspension General Diagnosis................................................................................................................... 985 Diagnostic Information and Procedures...................................................................................................... 985 Diagnostic Starting Point - Suspension General Diagnosis............................................................................... 985 Symptoms - Suspension General Diagnosis................................................................................................ 985 Ride Diagnosis......................................................................................................................... 985 Vehicle Leads/Pulls.................................................................................................................... 986 Body Leans or Sways in Corners......................................................................................................... 987 Suspension Bottoms..................................................................................................................... 987 Torque Steer........................................................................................................................... 988 Memory Steer........................................................................................................................... 989 Noise Diagnosis - Front Suspension..................................................................................................... 989 Noise Diagnosis - Rear Suspension...................................................................................................... 991 Wheel Bearings Diagnosis............................................................................................................... 992 Suspension Strut and Shock Absorber Testing - On Vehicle............................................................................... 993 Ball Joint Inspection.................................................................................................................. 994 Trim Height Inspection................................................................................................................. 994 Specifications............................................................................................................................. 996 Trim Height Specifications............................................................................................................. 996 Special Tools and Equipment................................................................................................................ 998 Special Tools - Suspension General Diagnosis........................................................................................... 998 Front Suspension............................................................................................................................... 999 General Description........................................................................................................................ 999 General Description.................................................................................................................... 999 Caster Description..................................................................................................................... 999 Camber Description.....................................................................................................................1000 Toe Description........................................................................................................................1000 Setback Description....................................................................................................................1000 Thrust Angles Description..............................................................................................................1000 Lead/Pull Description..................................................................................................................1001 Torque Steer Description...............................................................................................................1001 Memory Steer Description...............................................................................................................1001 Wander Description.....................................................................................................................1001 Scrub Radius Description...............................................................................................................1001 Diagnostic Information and Procedures......................................................................................................1002 Vibration Analysis - Hub and/or Axle Input.............................................................................................1002 Repair Instructions........................................................................................................................1005 Stabilizer Shaft Link Replacement......................................................................................................1005 Stabilizer Shaft Insulator Replacement.................................................................................................1006 Stabilizer Shaft Replacement...........................................................................................................1007 Lower Ball Joint Replacement...........................................................................................................1008 Front Wheel Bearing and Hub Replacement................................................................................................1009 Wheel Stud Replacement.................................................................................................................1012 Hub/Axle Flange and Wheel Stud Runout Inspection.......................................................................................1013 Lower Control Arm Replacement..........................................................................................................1014 Front Lower Control Arm Bushing Replacement (Rear Bushing).............................................................................1016 Strut Assembly Replacement.............................................................................................................1016 Suspension Strut Disposal..............................................................................................................1018 Strut, Strut Component and/or Spring Replacement.......................................................................................1019 Steering Knuckle Replacement...........................................................................................................1021 Measuring Wheel Alignment..............................................................................................................1023 Front Caster Adjustment................................................................................................................1024 Front Camber Adjustment................................................................................................................1024 Front Toe Adjustment...................................................................................................................1025 Specifications.............................................................................................................................1026 Fastener Tightening Specifications - Front Suspension..................................................................................1026 Fastener Tightening Specifications - Wheel Alignment...................................................................................1026 Wheel Alignment Specifications.........................................................................................................1026 Special Tools and Equipment................................................................................................................1027 Special Tools - Front Suspension.......................................................................................................1027 Rear Suspension................................................................................................................................1028 General Description........................................................................................................................1028 General Description....................................................................................................................1028 Camber Description.....................................................................................................................1028 Toe Description........................................................................................................................1028 Setback Description....................................................................................................................1029 Thrust Angles Description..............................................................................................................1029 Lead/Pull Description..................................................................................................................1029 Scrub Radius Description...............................................................................................................1029 Diagnostic Information and Procedures......................................................................................................1030 Vibration Analysis - Hub and/or Axle Input.............................................................................................1030 Repair Instructions........................................................................................................................1032 Measuring Wheel Alignment..............................................................................................................1032 Hub/Axle Flange and Wheel Stud Runout Inspection.......................................................................................1033 Stabilizer Shaft Link Replacement......................................................................................................1034 Stabilizer Shaft Insulator Replacement.................................................................................................1036 Stabilizer Shaft Replacement...........................................................................................................1037 Rear Wheel Bearing and Hub Replacement.................................................................................................1038 Wheel Stud Replacement.................................................................................................................1040 Rear Axle Upper Control Arm Replacement................................................................................................1041 Rear Axle Lower Control Arm Replacement................................................................................................1042 Shock Absorber Replacement.............................................................................................................1044 Shock Absorber Disposal................................................................................................................1045 Coil Spring Replacement................................................................................................................1046 Coil Spring Insulators Replacement.....................................................................................................1048 Trailing Arm Replacement...............................................................................................................1049 Trailing Arm Bracket Replacement.......................................................................................................1050 Adjustment Link Replacement............................................................................................................1051 Spring Jounce Bumper Replacement.......................................................................................................1052 Knuckle Replacement....................................................................................................................1053 Support Replacement (AWD Vehicles).....................................................................................................1056 Support Replacement (FWD Vehicles).....................................................................................................1059 Rear Camber Adjustment.................................................................................................................1062 Rear Toe Adjustment....................................................................................................................1062 Specifications.............................................................................................................................1063 Fastener Tightening Specifications - Rear Suspension...................................................................................1063 Fastener Tightening Specifications - Wheel Alignment...................................................................................1063 Wheel Alignment Specifications.........................................................................................................1063 Special Tools and Equipment................................................................................................................1064 Special Tools - Rear Suspension........................................................................................................1064 Wheels and Tires...............................................................................................................................1065 General Description........................................................................................................................1065 General Description....................................................................................................................1065 Tread Wear Indicators Description......................................................................................................1065 Metric Wheel Nuts and Bolts Description................................................................................................1065 Tire Inflation Description.............................................................................................................1065 All Seasons Tires Description..........................................................................................................1066 P-Metric Sized Tires Description.......................................................................................................1066 Replacement Wheels Description.........................................................................................................1067 Steel Wheel Repair Description.........................................................................................................1067 Diagnostic Information and Procedures......................................................................................................1068 Component Rotational Speed Calculation.................................................................................................1068 Tire Diagnosis - Irregular or Premature Wear...........................................................................................1071 Tire Diagnosis - Waddle Complaint......................................................................................................1072 Tire and Wheel Inspection..............................................................................................................1073 Tire and Wheel Assembly Runout Measurement - On-Vehicle................................................................................1074 Tire and Wheel Assembly Runout Measurement - Off Vehicle...............................................................................1075 Wheel Mounting Surface Check...........................................................................................................1078 Radial Tire Lead/Pull Correction.......................................................................................................1079 Vibration Analysis - Tire and Wheel....................................................................................................1080 Tire and Wheel Assembly Isolation Test.................................................................................................1083 Repair Instructions........................................................................................................................1084 Tire and Wheel Removal and Installation................................................................................................1084 Tire and Wheel Assembly Balancing - Off Vehicle........................................................................................1086 Tire and Wheel Assembly Balancing - On- Vehicle........................................................................................1089 Tire Rotation..........................................................................................................................1090 Tire Mounting and Dismounting..........................................................................................................1090 Tire Repair............................................................................................................................1091 Tire-to-Wheel Match-Mounting (Vectoring)...............................................................................................1095 Tire and Wheel Assembly-to-Hub/Axle Flange Match-Mounting..............................................................................1096 Specifications.............................................................................................................................1097 Fastener Tightening Specifications - Tires and Wheels..................................................................................1097 Tire and Wheel Runout Specifications...................................................................................................1097 Special Tools and Equipment................................................................................................................1097 Special Tools - Tires and Wheels.......................................................................................................1097 Driveline / Axle...................................................................................................................................1099 Drive Shaft....................................................................................................................................1101 General Description........................................................................................................................1101 Wheel Drive Shafts Description and Operation...........................................................................................1101 Component Location.........................................................................................................................1102 Wheel Drive Shafts Disassembled Views..................................................................................................1102 Diagnostic Information and Procedures......................................................................................................1103 Diagnostic Starting Point - Wheel Drive Shafts.........................................................................................1103 Symptoms - Wheel Drive Shafts..........................................................................................................1103 Click Noise In Turns...................................................................................................................1103 Clunk When Accelerating from Coast.....................................................................................................1103 Clunk Noise When Accelerating During Turns.............................................................................................1104 Shudder or Vibration During Acceleration...............................................................................................1104 Vibration Analysis - Driveline.........................................................................................................1104 Vibration Analysis - Hub and/or Axle Input.............................................................................................1108 Repair Instructions........................................................................................................................1110 Front Wheel Drive Shaft Replacement (AWD)..............................................................................................1110 Front Wheel Drive Shaft Replacement (FWD)..............................................................................................1112 Intermediate Shaft Replacement.........................................................................................................1114 Rear Wheel Drive Shaft Replacement.....................................................................................................1115 Front Wheel Drive Shaft Inner Joint and Seal Replacement...............................................................................1118 Front Wheel Drive Shaft Outer Joint and Seal Replacement...............................................................................1120 Rear Wheel Drive Shaft Inner Joint and Seal Replacement................................................................................1123 Rear Wheel Drive Shaft Outer Joint and Seal Replacement................................................................................1125 Specifications.............................................................................................................................1128 Fastener Tightening Specifications - Wheel Drive Shafts................................................................................1128 Special Tools and Equipment................................................................................................................1128 Special Tools - Wheel Drive Shafts.....................................................................................................1129 Differential...................................................................................................................................1130 General Description........................................................................................................................1130 Rear Drive Axle Description and Operation..............................................................................................1130 All-Wheel Drive Description and Operation..............................................................................................1130 Diagnostic Information and Procedures......................................................................................................1131 Diagnostic Starting Point - Rear Drive Axle............................................................................................1131 Scan Tool Output Controls - Rear Drive Axle............................................................................................1131 Scan Tool Data List - Rear Drive Axle..................................................................................................1131 Scan Tool Data Definitions - Rear Drive Axle...........................................................................................1131 DTC C0393..............................................................................................................................1132 DTC C0394..............................................................................................................................1133 DTC C0550..............................................................................................................................1134 DTC C0558..............................................................................................................................1134 DTC C0561..............................................................................................................................1135 Symptoms - Rear Drive Axle.............................................................................................................1136 All-Wheel Drive (AWD) Disabled Indicator Always On.....................................................................................1136 Service All-Wheel Drive Indicator Always On............................................................................................1137 Noisy in Drive.........................................................................................................................1138 Noisy When Coasting....................................................................................................................1139 Intermittent Noise.....................................................................................................................1139 Constant Noise.........................................................................................................................1140 Noisy on Turns.........................................................................................................................1140 Rear Axle Lubricant Leak Diagnosis.....................................................................................................1141 Repair Instructions........................................................................................................................1141 Rear Axle Lubricant Level Inspection...................................................................................................1141 Rear Axle Lubricant Replacement........................................................................................................1142 Rear Wheel Drive Module Clutch Housing Replacement.....................................................................................1143 Differential Carrier Assembly Mount Replacement........................................................................................1144 Differential Carrier Cover and Seal Replacement - Left Side............................................................................1145 Rear Axle Shaft Seal Replacement - Left Side...........................................................................................1145 Rear Axle Shaft Seal Replacement - Right Side..........................................................................................1147 Drive Pinion Flange/Yoke and/or Oil Seal Replacement...................................................................................1148 Differential Replacement...............................................................................................................1149 Differential Housing Support Bushing Replacement (Front)...............................................................................1151 Differential Housing Support Bushing Replacement (Rear)................................................................................1151 Rear Differential Clutch Control Module Replacement....................................................................................1154 Rear Differential Clutch Control Module Calibration....................................................................................1155 Rear Differential Clutch Control Module Programming and Setup..........................................................................1155 Specifications.............................................................................................................................1155 Fastener Tightening Specifications - Rear Drive Axle...................................................................................1155 Rear Axle Specifications...............................................................................................................1155 Sealers, Adhesives, and Lubricants.....................................................................................................1155 Special Tools and Equipment................................................................................................................1156 Special Tools - Rear Drive Axle........................................................................................................1156 Transfer.......................................................................................................................................1157 General Description........................................................................................................................1157 Transfer Case Description and Operation................................................................................................1157 Schematic and Routing Diagram..............................................................................................................1157 All-Wheel Drive Schematics.............................................................................................................1157 Transfer Case Control Connector End Views..............................................................................................1159 Component Location.........................................................................................................................1160 Transfer Case Control Component Views..................................................................................................1160 Transfer Case Disassembled View........................................................................................................1161 Diagnostic Information and Procedures......................................................................................................1162 Diagnostic Starting Point - Transfer Case..............................................................................................1162 Symptoms - Transfer Case...............................................................................................................1162 Noisy in Drive.........................................................................................................................1162 Noisy When Coasting....................................................................................................................1163 Intermittent Noise.....................................................................................................................1163 Constant Noise.........................................................................................................................1164 Transfer Case Leak Diagnosis...........................................................................................................1164 Repair Instructions........................................................................................................................1165 Transfer Case Fluid Replacement........................................................................................................1165 Transfer Case Assembly Replacement.....................................................................................................1165 Transfer Case Disassemble..............................................................................................................1167 Transfer Case Cleaning and Inspection..................................................................................................1173 Rear Output Drive Housing Cleaning and Inspection......................................................................................1174 Input Shaft Seal Replacement - Right...................................................................................................1175 Input Shaft Seal Replacement - Left....................................................................................................1176 Front Drive Axle Inner Shaft Seal Replacement..........................................................................................1177 Input Shaft and Rear Output Drive Shaft Cleaning and Inspection........................................................................1178 Transfer Case Assemble.................................................................................................................1179 Specifications.............................................................................................................................1186 Fastener Tightening Specifications - Transfer Case - Getrag 760........................................................................1186 Sealers, Adhesives, and Lubricants.....................................................................................................1186 Approximate Fluid Capacities...........................................................................................................1186 Special Tools and Equipment................................................................................................................1186 Special Tools - Transfer Case - Getrag 760.............................................................................................1186 Propeller Shafts...............................................................................................................................1188 General Description........................................................................................................................1188 Propeller Shaft Description and Operation..............................................................................................1188 Diagnostic Information and Procedures......................................................................................................1189 Component Rotational Speed Calculation.................................................................................................1189 Diagnostic Starting Point - Propeller Shaft............................................................................................1192 Symptoms - Propeller Shaft.............................................................................................................1192 Roughness or Vibration.................................................................................................................1192 Ping, Snap, or Click Noise.............................................................................................................1193 Knock or Clunk Noise...................................................................................................................1193 Scraping Noise.........................................................................................................................1193 Squeak Noise...........................................................................................................................1193 Shudder on Acceleration at Low Speed...................................................................................................1193 Vibration Analysis - Driveline.........................................................................................................1193 Transfer Case Output Flange Runout Measurement.........................................................................................1197 Propeller Shaft Runout Measurement.....................................................................................................1197 Torque Tube Input Flange Runout Measurement............................................................................................1200 Pinion Flange Runout Measurement.......................................................................................................1200 Differential Pinion Input Shaft Runout Measurement.....................................................................................1202 Driveline Working Angles Measurement...................................................................................................1203 Repair Instructions........................................................................................................................1206 Driveline System Balance Adjustment (Using EVA)........................................................................................1206 Driveline System Balance Adjustment (Without EVA)......................................................................................1209 Driveline Working Angles Adjustment....................................................................................................1211 Propeller Shaft Phasing Inspection.....................................................................................................1212 Propeller Shaft Phasing Correction.....................................................................................................1212 Propeller Shaft Replacement............................................................................................................1213 Specifications.............................................................................................................................1215 Fastener Tightening Specifications - Propeller Shaft...................................................................................1215 Sealers, Adhesives, and Lubricants.....................................................................................................1215 Propeller Shaft Runout Specifications..................................................................................................1215 Driveline Runout Specifications........................................................................................................1215 Brakes.............................................................................................................................................1217 Brake Control System and Diagnosis.............................................................................................................1220 General Description........................................................................................................................1220 Hydraulic Brake System Description and Operation.......................................................................................1220 Brake Assist System Description and Operation..........................................................................................1220 Brake Warning System Description and Operation.........................................................................................1220 Schematic and Routing Diagram..............................................................................................................1221 Hydraulic Brake Schematics.............................................................................................................1222 Hydraulic Brake Connector End Views....................................................................................................1223 Hydraulic Brake Pipe Routing - Master Cylinder to ABS..................................................................................1224 Component Location.........................................................................................................................1225 Hydraulic Brake Component Views........................................................................................................1225 Diagnostic Information and Procedures......................................................................................................1227 Diagnostic Starting Point - Hydraulic Brakes...........................................................................................1227 Scan Tool Data List - Hydraulic Brakes.................................................................................................1227 Scan Tool Data Definitions - Hydraulic Brakes..........................................................................................1227 DTC C0267..............................................................................................................................1227 Symptoms - Hydraulic Brakes............................................................................................................1228 Brake Warning Indicator Malfunction....................................................................................................1229 Brake Pulsation........................................................................................................................1230 Brake System Noise.....................................................................................................................1230 Braking Action Uneven - Pulls to One Side..............................................................................................1231 Braking Action Uneven - Front to Rear..................................................................................................1232 Brake Pedal Excessive Travel...........................................................................................................1232 Brake Pedal Excessive Effort...........................................................................................................1233 Brakes Drag............................................................................................................................1233 Brake System Slow Release..............................................................................................................1234 Brake Fluid Loss.......................................................................................................................1235 Hydraulic Brake System Diagnosis.......................................................................................................1235 Brake Assist System Diagnosis..........................................................................................................1239 Brake System Vehicle Road Test.........................................................................................................1241 Brake Pedal Travel Measurement and Inspection..........................................................................................1242 Brake System Vacuum Source Test........................................................................................................1242 Brake System External Leak Inspection..................................................................................................1243 Brake System Internal Leak Test........................................................................................................1243 Hydraulic Brake Component Operation Visual Inspection..................................................................................1244 Repair Instructions........................................................................................................................1245 Master Cylinder Reservoir Filling......................................................................................................1245 Hydraulic Brake System Bleeding (Pressure).............................................................................................1245 Hydraulic Brake System Bleeding (Manual)...............................................................................................1247 Hydraulic Brake System Flushing........................................................................................................1248 Brake Pedal Assembly Replacement.......................................................................................................1249 Brake Pedal Pushrod Inspection.........................................................................................................1252 Brake Pedal Position Sensor Replacement................................................................................................1253 Brake Pedal Position Sensor Calibration................................................................................................1254 Stop Lamp Switch Adjustment............................................................................................................1254 Stop Lamp Switch Replacement...........................................................................................................1255 Front Brake Hose Replacement...........................................................................................................1255 Rear Brake Hose Replacement............................................................................................................1257 Brake Pipe Replacement.................................................................................................................1259 Brake Pipe and Hose Inspection.........................................................................................................1262 Master Cylinder Fluid Level Sensor Replacement.........................................................................................1263 Master Cylinder Reservoir Replacement..................................................................................................1264 Master Cylinder Replacement............................................................................................................1265 Master Cylinder Bench Bleeding.........................................................................................................1267 Vacuum Brake Booster Check Valve and/or Hose Replacement...............................................................................1268 Vacuum Brake Booster Replacement.......................................................................................................1269 Specifications.............................................................................................................................1271 Fastener Tightening Specifications - Hydraulic Brakes..................................................................................1271 Fastener Tightening Specifications - Lighting..........................................................................................1271 Brake Component Specifications.........................................................................................................1272 Brake System Specifications............................................................................................................1272 Special Tools and Equipment................................................................................................................1272 Special Tools - Hydraulic Brakes.......................................................................................................1272 Front Brakes...................................................................................................................................1273 Precautions................................................................................................................................1273 Brake Dust Caution.....................................................................................................................1273 Brake Fluid Irritant Caution...........................................................................................................1273 General Description........................................................................................................................1273 Disc Brake System Description and Operation............................................................................................1273 Diagnostic Information and Procedures......................................................................................................1274 Diagnostic Starting Point - Disc Brakes................................................................................................1274 Disc Brake System Diagnosis............................................................................................................1274 Brake Rotor Thickness Measurement......................................................................................................1280 Brake Rotor Thickness Variation Measurement............................................................................................1280 Brake Rotor Assembled Lateral Runout Measurement.......................................................................................1281 Repair Instructions........................................................................................................................1283 Front Disc Brake Pads Replacement......................................................................................................1283 Brake Pad Inspection...................................................................................................................1285 Brake Pad and Rotor Burnishing.........................................................................................................1285 Front Brake Caliper Replacement........................................................................................................1286 Brake Caliper Inspection...............................................................................................................1288 Front Disc Brake Hardware Replacement..................................................................................................1289 Front Disc Brake Mounting and Hardware Inspection......................................................................................1291 Front Brake Caliper Bracket Replacement................................................................................................1292 Front Brake Rotor Replacement..........................................................................................................1293 Brake Rotor Surface and Wear Inspection................................................................................................1294 Brake Rotor/Drum Balance Inspection....................................................................................................1295 Front Brake Shield Replacement.........................................................................................................1296 Brake Rotor Assembled Lateral Runout Correction........................................................................................1296 Brake Rotor Assembled Lateral Runout Correction - Indexing.............................................................................1297 Brake Rotor Assembled Lateral Runout Correction - Correction Plates....................................................................1298 Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe.....................................................................1299 Brake Rotor Refinishing................................................................................................................1300 Specifications.............................................................................................................................1301 Fastener Tightening Specifications - Disc Brakes.......................................................................................1301 Disc Brake Component Specifications....................................................................................................1301 Special Tools and Equipment................................................................................................................1302 Special Tools - Disc Brakes............................................................................................................1302 Rear Brakes....................................................................................................................................1303 Precautions................................................................................................................................1303 Brake Dust Caution.....................................................................................................................1303 Brake Fluid Irritant Caution...........................................................................................................1303 General Description........................................................................................................................1303 Disc Brake System Description and Operation............................................................................................1303 Diagnostic Information and Procedures......................................................................................................1304 Diagnostic Starting Point - Disc Brakes................................................................................................1304 Disc Brake System Diagnosis............................................................................................................1304 Brake Rotor Thickness Measurement......................................................................................................1310 Brake Rotor Thickness Variation Measurement............................................................................................1310 Brake Rotor Assembled Lateral Runout Measurement.......................................................................................1311 Repair Instructions........................................................................................................................1313 Brake Pad and Rotor Burnishing.........................................................................................................1313 Rear Disc Brake Pads Replacement.......................................................................................................1313 Brake Pad Inspection...................................................................................................................1315 Rear Brake Caliper Replacement.........................................................................................................1316 Brake Caliper Inspection...............................................................................................................1318 Rear Disc Brake Hardware Replacement...................................................................................................1319 Rear Disc Brake Mounting and Hardware Inspection.......................................................................................1320 Rear Brake Caliper Bracket Replacement.................................................................................................1322 Rear Brake Rotor Replacement...........................................................................................................1323 Brake Rotor Surface and Wear Inspection................................................................................................1324 Brake Rotor/Drum Balance Inspection....................................................................................................1325 Rear Disc Brake Backing Plate Replacement..............................................................................................1326 Brake Rotor Assembled Lateral Runout Correction........................................................................................1326 Brake Rotor Assembled Lateral Runout Correction - Indexing.............................................................................1327 Brake Rotor Assembled Lateral Runout Correction - Correction Plates....................................................................1328 Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe.....................................................................1329 Brake Rotor Refinishing................................................................................................................1330 Specifications.............................................................................................................................1331 Fastener Tightening Specifications - Disc Brakes.......................................................................................1331 Disc Brake Component Specifications....................................................................................................1331 Special Tools and Equipment................................................................................................................1332 Special Tools - Disc Brakes............................................................................................................1332 Parking Brake..................................................................................................................................1333 General Description........................................................................................................................1333 Park Brake System Description and Operation............................................................................................1333 Diagnostic Information and Procedures......................................................................................................1334 Diagnostic Starting Point - Park Brake.................................................................................................1334 DTC B0005..............................................................................................................................1334 Symptoms - Park Brake..................................................................................................................1335 Park Brake Will Not Hold or Release....................................................................................................1335 Park Brake System Diagnosis............................................................................................................1336 Repair Instructions........................................................................................................................1338 Park Brake Adjustment..................................................................................................................1338 Park Brake Shoe Replacement............................................................................................................1340 Park Brake Lever Assembly Replacement..................................................................................................1341 Park Brake Warning Lamp Switch Replacement.............................................................................................1343 Parking Brake Front Cable Replacement..................................................................................................1343 Parking Brake Rear Cable Replacement...................................................................................................1344 Parking Brake Actuator Replacement.....................................................................................................1348 Park Brake Hardware Inspection.........................................................................................................1349 Specifications.............................................................................................................................1350 Fastener Tightening Specifications - Park Brake........................................................................................1350 Special Tools and Equipment................................................................................................................1350 Special Tools - Park Brake.............................................................................................................1350 ABS............................................................................................................................................1351 Precautions................................................................................................................................1351 ABS Component Handling Caution.........................................................................................................1351 General Description........................................................................................................................1351 ABS Description and Operation..........................................................................................................1351 Schematic and Routing Diagram..............................................................................................................1354 Antilock Brake System Schematic Icons..................................................................................................1354 Antilock Brake System Schematics.......................................................................................................1354 Antilock Brake System Connector End Views..............................................................................................1358 Component Location.........................................................................................................................1362 Antilock Brake System Component Views..................................................................................................1362 Diagnostic Information and Procedures......................................................................................................1367 Diagnostic Starting Point - Antilock Brake System......................................................................................1367 Scan Tool Output Controls - Antilock Brake System......................................................................................1367 Scan Tool Data List - Antilock Brake System............................................................................................1367 Scan Tool Data Definitions - Antilock Brake System.....................................................................................1368 Diagnostic Test Drive..................................................................................................................1369 Initialization Sequence................................................................................................................1369 DTC C0035-C0050........................................................................................................................1370 DTC C0110..............................................................................................................................1372 DTC C0131..............................................................................................................................1374 DTC C0161..............................................................................................................................1375 DTC C0186..............................................................................................................................1376 DTC C0196..............................................................................................................................1378 DTC C0201..............................................................................................................................1380 DTC C0252..............................................................................................................................1381 DTC C0280..............................................................................................................................1382 DTC C0292..............................................................................................................................1383 DTC C0460..............................................................................................................................1384 DTC C0550..............................................................................................................................1385 DTC C0551..............................................................................................................................1386 DTC C0561..............................................................................................................................1386 DTC C0899..............................................................................................................................1387 DTC C0900..............................................................................................................................1388 Symptoms - Antilock Brake System.......................................................................................................1388 ABS Active Indicator Always On.........................................................................................................1389 ABS Active Indicator Inoperative.......................................................................................................1390 Traction Control Indicator Always On...................................................................................................1392 Traction Control Indicator Inoperative.................................................................................................1394 Repair Instructions........................................................................................................................1396 Antilock Brake System Automated Bleed Procedure........................................................................................1396 Steering Angle Sensor Centering........................................................................................................1397 Electronic Brake Control Module Replacement............................................................................................1397 Electronic Brake Control Module Programming and Setup..................................................................................1398 Brake Pressure Modulator Valve Replacement.............................................................................................1399 Brake Pressure Modulator Valve Bracket Replacement.....................................................................................1401 Front Wheel Speed Sensor Replacement...................................................................................................1402 Rear Wheel Speed Sensor Replacement....................................................................................................1403 Electronic Traction Control Switch Replacement.........................................................................................1404 Vehicle Yaw Sensor Replacement.........................................................................................................1405 Specifications.............................................................................................................................1405 Fastener Tightening Specifications - Antilock Brake System.............................................................................1405 Transmission / Transaxle...........................................................................................................................1407 Automatic Transmission.........................................................................................................................1411 General Description........................................................................................................................1411 Transmission General Description.......................................................................................................1411 Transmission General Information.......................................................................................................1412 Definitions and Abbreviations..........................................................................................................1412 Automatic Transmission Shift Lock Control Description and Operation....................................................................1414 Transmission Component and System Description..........................................................................................1414 Transmission Adaptive Functions........................................................................................................1414 Transmission Oil Life Monitor..........................................................................................................1414 Transmission Indicators and Messages...................................................................................................1415 Electronic Component Description.......................................................................................................1415 Park - Engine Running..................................................................................................................1419 Reverse................................................................................................................................1422 Reverse Inhibit........................................................................................................................1425 Neutral - Engine Running...............................................................................................................1428 Drive and M Range - First Gear.........................................................................................................1431 M Range - First Gear, Engine Braking...................................................................................................1434 Drive and M Range - Second Gear........................................................................................................1437 Drive and M Range - Third Gear.........................................................................................................1440 Drive Range - Fourth Gear..............................................................................................................1443 Drive Range Fifth Gear - Torque Converter Clutch Released..............................................................................1446 Drive Range Fifth Gear - Torque Converter Clutch Applied...............................................................................1449 Drive Range - Emergency Fifth Gear.....................................................................................................1452 Schematic and Routing Diagram..............................................................................................................1454 Automatic Transmission Schematic Icons.................................................................................................1454 Automatic Transmission Controls Schematics.............................................................................................1454 Shift Lock Control Schematics..........................................................................................................1458 Automatic Transmission Inline Harness Connector End View...............................................................................1459 Automatic Transmission Internal Connector End Views....................................................................................1460 Automatic Transmission Related Connector End Views.....................................................................................1463 Shift Lock Control Connector End Views.................................................................................................1466 Component Location.........................................................................................................................1467 Automatic Transmission Electronic Component Views......................................................................................1467 Shift Lock Control Component Views.....................................................................................................1468 Disassembled Views.....................................................................................................................1469 Bearing, Race, Thrust Washer and Seal Locations........................................................................................1490 Fluid Passages.........................................................................................................................1492 Diagnostic Information and Procedures......................................................................................................1513 Diagnostic Starting Point - Automatic Transmission.....................................................................................1513 Diagnostic Starting Point - Automatic Transmission Shift Lock Control..................................................................1513 Scan Tool Output Controls - Automatic Transaxle - AF33-5...............................................................................1514 Scan Tool Output Controls - Shift Lock Control.........................................................................................1518 Scan Tool Data List - Automatic Transaxle - AF33-5.....................................................................................1519 Scan Tool Data List - Shift Lock Control...............................................................................................1520 Scan Tool Data Definitions - Automatic Transaxle - AF33-5..............................................................................1521 Scan Tool Data Definitions - Shift Lock Control........................................................................................1523 Diagnostic Trouble Code (DTC) Type Definitions.........................................................................................1524 Diagnostic Trouble Code (DTC) List/Type................................................................................................1524 DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637..........................................................................1526 DTC P0562 or P0563.....................................................................................................................1527 DTC P0601, P0602, P0603, or P0604......................................................................................................1528 DTC P0706-P0708........................................................................................................................1529 DTC P0711, P0712, or P0713.............................................................................................................1530 DTC P0717 or P0722.....................................................................................................................1532 DTC P0730..............................................................................................................................1533 DTC P0731..............................................................................................................................1535 DTC P0732..............................................................................................................................1537 DTC P0733..............................................................................................................................1539 DTC P0734..............................................................................................................................1541 DTC P0735..............................................................................................................................1543 DTC P0736..............................................................................................................................1545 DTC P0741..............................................................................................................................1546 DTC P0742..............................................................................................................................1548 DTC P0762..............................................................................................................................1549 DTC P081A or P081B.....................................................................................................................1551 DTC P0851 or P0852.....................................................................................................................1552 DTC P0897..............................................................................................................................1553 DTC P0962, P0963, P0966, P0967, P0970, or P0971........................................................................................1554 DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986............................................................1556 DTC P1719..............................................................................................................................1557 DTC P2534..............................................................................................................................1559 DTC P2536..............................................................................................................................1560 DTC B2705..............................................................................................................................1561 DTC P280A..............................................................................................................................1563 Symptoms - Automatic Transmission......................................................................................................1564 Symptoms - Automatic Transmission Shift Lock Control...................................................................................1565 Transmission Adaptive Learn and Transmission Neutral Learn.............................................................................1565 Road Test..............................................................................................................................1567 Torque Converter Diagnosis.............................................................................................................1567 Flexplate/Torque Converter Vibration Test..............................................................................................1569 Stall Speed Test.......................................................................................................................1569 Engagement Delay Test..................................................................................................................1570 Noise and Vibration Analysis...........................................................................................................1571 Clutch Plate Diagnosis.................................................................................................................1571 Engine Coolant/Water in Transmission...................................................................................................1572 Fluid Leak Diagnosis...................................................................................................................1572 Case Porosity Repair...................................................................................................................1575 Transmission Fluid Cooler Flushing and Flow Test.......................................................................................1575 Transmission Overheats.................................................................................................................1580 No Forward and Reverse.................................................................................................................1581 Slips in Drive or No Drive.............................................................................................................1582 Slips in Reverse or No Reverse.........................................................................................................1583 Engagement Time From Park or Neutral to Drive is Not Within Specifications.............................................................1584 Engagement Time From Park or Neutral to Reverse is Not Within Specifications...........................................................1584 Engine Stalls During Reverse or Drive Engagement.......................................................................................1585 Slips on Acceleration..................................................................................................................1585 Harsh Feel at Light Acceleration or Deceleration Without Causing an Upshift or Downshift...............................................1586 No 1-2 Upshift.........................................................................................................................1587 No 2-3 Upshift.........................................................................................................................1587 No 3-4 Upshift.........................................................................................................................1588 No 4-5 Upshift.........................................................................................................................1588 No 5-4 Downshift.......................................................................................................................1589 No 4-3 Downshift.......................................................................................................................1589 No 3-2 Downshift.......................................................................................................................1590 No 2-1 Downshift.......................................................................................................................1590 Torque Converter Clutch Stuck On or Off................................................................................................1591 No Engine Braking in Fourth Gear.......................................................................................................1591 No Engine Braking in Third Gear........................................................................................................1592 No Engine Braking in Second Gear.......................................................................................................1592 No Response to Movement of Shift Lever.................................................................................................1593 Transmission Attempts to Move but Appears Locked Up....................................................................................1593 Vibration at Idle......................................................................................................................1593 Vibration While Driving................................................................................................................1593 Hum or Rattle Noise at Idle............................................................................................................1594 Whine/Growl Noise That Changes with Vehicle Speed......................................................................................1594 Automatic Transmission Fluid Leaks.....................................................................................................1594 Harsh Park or Neutral to Drive Engagement..............................................................................................1596 Harsh Park or Neutral to Reverse Engagement............................................................................................1597 Harsh Upshift..........................................................................................................................1598 Harsh Shift on Coastdown...............................................................................................................1599 Harsh Forced Downshift.................................................................................................................1600 Shift Lever Does Not Move with Brake Pedal Depressed...................................................................................1602 Shift Lever Can Be Moved without Brake Pedal Depressed.................................................................................1603 Repair Instructions........................................................................................................................1604 Transmission Fluid Check...............................................................................................................1604 Line Pressure Check....................................................................................................................1605 Transaxle Fluid Replacement............................................................................................................1607 Transmission Control Lever Knob Replacement............................................................................................1608 Automatic Transmission Control Indicator Replacement...................................................................................1609 Transmission Control Boot Replacement..................................................................................................1610 Shift Control Replacement..............................................................................................................1611 Shift Lock Solenoid/Switch Assembly Replacement........................................................................................1612 Transmission Control Bracket Replacement...............................................................................................1613 Shift Control Cable Replacement........................................................................................................1613 Shift Control Cable Adjustment.........................................................................................................1615 Shift Control Cable Bracket Replacement................................................................................................1616 Automatic Transmission Range Selector Lever Replacement................................................................................1617 Transmission Control Module Replacement................................................................................................1618 Transmission Control Module Programming and Setup......................................................................................1620 Transaxle Brace Replacement............................................................................................................1620 Transmission Mount Inspection..........................................................................................................1621 Transmission Front Mount Replacement...................................................................................................1621 Transmission Rear Mount Replacement (Getrag 760 Transfer Case).........................................................................1622 Transmission Mount Replacement - Left Side.............................................................................................1623 Transmission Rear Mount Bracket Replacement (AWD)......................................................................................1624 Transmission Rear Mount Bracket Replacement (FWD)......................................................................................1625 Transmission Mount Bracket Replacement - Left Side.....................................................................................1625 Fluid Level Indicator Replacement......................................................................................................1626 Input Speed Sensor Replacement.........................................................................................................1627 Output Speed Sensor Replacement........................................................................................................1628 Control Valve Body Cover Replacement...................................................................................................1629 Automatic Transmission Wiring Harness Replacement......................................................................................1630 Control Valve Body Replacement.........................................................................................................1632 Oil Cooler Line Replacement............................................................................................................1635 Fluid Cooler Pipe Seal Replacement.....................................................................................................1636 Drive Axle Shaft Seal Replacement (Left)...............................................................................................1638 Drive Axle Shaft Seal Replacement (Right)..............................................................................................1639 Transaxle Replacement..................................................................................................................1640 Torque Converter Assembly Removal......................................................................................................1642 Holding Fixture Installation...........................................................................................................1642 Transmission Fluid Draining............................................................................................................1643 Input and Output Speed Sensor Removal..................................................................................................1644 Transmission Control Module Removal....................................................................................................1644 Control Valve Body Cover Removal.......................................................................................................1644 Wiring Harness Removal.................................................................................................................1645 Control Valve Body Assembly Removal....................................................................................................1646 Fluid Pump Assembly Removal............................................................................................................1647 Second Coast, Second Clutch Hub and Second Clutch Sprag Assembly Removal...............................................................1647 Torque Converter Housing Removal.......................................................................................................1647 Front Differential Assembly Removal....................................................................................................1648 Fluid Filter Removal...................................................................................................................1648 Transmission Fluid Baffle Removal......................................................................................................1648 Third Gear Band Apply Tube Removal.....................................................................................................1649 Manual Shift Detent Lever and Park Pawl Removal........................................................................................1649 Front Differential Transfer Drive Gear Assembly Removal................................................................................1652 Third Gear Band Servo Piston Pin Measurement...........................................................................................1652 4-5 Clutch Assembly Removal............................................................................................................1653 Third Gear Band Assembly Removal.......................................................................................................1653 1-2-Reverse Carrier Gear Assembly Removal..............................................................................................1654 Third Gear Band Servo Piston Assembly Removal..........................................................................................1654 Case Cover and 1-2 Reverse Clutch Assembly Removal.....................................................................................1655 Forward and Direct Clutch Assembly Removal.............................................................................................1656 Rear Internal Gear and Front Carrier Removal...........................................................................................1656 Front Internal Gear and Low and Reverse Clutch Assembly Removal........................................................................1659 Low and Reverse Clutch Piston Removal..................................................................................................1660 Output Gear Assembly Removal...........................................................................................................1660 Transmission Cooler Line Seals Removal.................................................................................................1661 Transmission Case Inspection...........................................................................................................1662 Transmission Cooler Line Seals Installation............................................................................................1663 Rotational Torque Measurement..........................................................................................................1663 Front Differential Bearing Race and Selective Shim Removal.............................................................................1664 Front Differential Bearing Race and Selective Shim Installation........................................................................1665 Manual Shift Shaft Seal and Bearing Removal............................................................................................1666 Manual Shift Shaft Seal and Bearing Installation.......................................................................................1666 Front Wheel Drive Shaft Oil Seal Removal...............................................................................................1667 Front Wheel Drive Shaft Oil Seal Installation..........................................................................................1667 Front Differential Carrier Seal Removal................................................................................................1667 Front Differential Carrier Seal Installation...........................................................................................1667 4-5 Clutch Drum Assembly Disassemble...................................................................................................1668 4-5 Clutch Drum Assembly Assemble......................................................................................................1670 4-5 Clutch Piston Travel Measurement...................................................................................................1672 Output Gear Assembly Installation......................................................................................................1672 Low and Reverse Clutch Piston Installation.............................................................................................1673 Front Internal Gear and Overrun Clutch Disassemble.....................................................................................1674 Front Internal Gear Cleaning and Inspection............................................................................................1674 Front Internal Gear and Overrun Clutch Assemble........................................................................................1675 Front Internal Gear and Low and Reverse Clutch Installation............................................................................1675 Low and Reverse Clutch Piston Travel Measurement.......................................................................................1676 Rear Internal Gear and Front Carrier Installation......................................................................................1677 Forward and Direct Clutch Assembly Disassemble.........................................................................................1678 Forward and Direct Clutch Assembly Assemble............................................................................................1681 Direct Clutch Piston Travel Check......................................................................................................1684 Forward Clutch Piston Travel Check.....................................................................................................1685 Forward and Direct Clutch Assembly Installation........................................................................................1685 Case Cover Assembly Disassemble........................................................................................................1687 1-2 Reverse Clutch Disassemble.........................................................................................................1688 Case Cover Cleaning and Inspection.....................................................................................................1689 1-2 Reverse Clutch Assemble............................................................................................................1689 Case Cover Assembly Assemble...........................................................................................................1691 1-2-Reverse Clutch Piston Travel Measurement...........................................................................................1692 Forward and Direct Clutch End Play Measurement.........................................................................................1693 Transmission Case Cover and 1-2 Reverse Clutch Assembly Installation...................................................................1694 Third Gear Band Servo Piston Disassemble...............................................................................................1695 Third Gear Band Servo Piston Assemble..................................................................................................1695 Third Gear Band Servo Piston Installation..............................................................................................1696 1-2-Reverse Carrier Gear Assembly Installation.........................................................................................1697 Third Gear Band Assembly Installation..................................................................................................1697 4-5 Clutch Assembly Installation.......................................................................................................1698 Front Differential Transfer Drive Gear Assembly Installation...........................................................................1698 Manual Shift Detent Lever and Park Pawl Installation...................................................................................1700 Third Gear Band Apply Tube Installation................................................................................................1702 Transmission Fluid Baffle Installation.................................................................................................1703 Fluid Filter Installation..............................................................................................................1703 Front Differential Assembly Cleaning and Inspection....................................................................................1704 Front Differential Assembly Installation...............................................................................................1704 Torque Converter Housing Cleaning and Inspection.......................................................................................1704 Torque Converter Housing Installation..................................................................................................1706 Second Coast Clutch Disassemble........................................................................................................1707 Second Clutch Disassemble..............................................................................................................1708 Transmission Fluid Pump Disassemble....................................................................................................1709 Fluid Pump Cleaning and Inspection.....................................................................................................1711 Transmission Fluid Pump Assemble.......................................................................................................1711 Second Clutch Assemble.................................................................................................................1713 Second Coast Clutch Assemble...........................................................................................................1714 Second Clutch Piston Travel Measurement................................................................................................1715 Second Coast Clutch Piston Travel Measurement..........................................................................................1716 Second Coast, Second Clutch Hub and Second Clutch Sprag Disassemble....................................................................1717 Second Coast, Second Clutch Hub and Second Clutch Sprag Assemble.......................................................................1717 Fluid Pump Installation................................................................................................................1718 Control Valve Body Assembly Disassemble................................................................................................1720 Middle Control Valve Body Disassemble..................................................................................................1723 Middle Control Valve Body Assemble.....................................................................................................1725 Control Valve Rear Body Disassemble....................................................................................................1727 Control Valve Rear Body Assemble.......................................................................................................1730 No. 2 Rear Control Valve Body Disassemble..............................................................................................1733 No. 2 Rear Control Valve Body Assemble.................................................................................................1734 Control Valve Front Body Disassemble...................................................................................................1735 Control Valve Front Body Assemble......................................................................................................1737 Control Valve Body Assembly Assemble...................................................................................................1738 Control Valve Body Assembly Installation...............................................................................................1743 Wiring Harness Installation............................................................................................................1744 Control Valve Body Cover Installation..................................................................................................1745 Transmission Control Module Installation...............................................................................................1746 Input and Output Speed Sensor Installation.............................................................................................1747 Drain Plug Installation................................................................................................................1747 Holding Fixture Removal................................................................................................................1748 Torque Converter Assembly Installation.................................................................................................1748 Specifications.............................................................................................................................1749 Fastener Tightening Specifications - Automatic Transaxle - AF33-5......................................................................1749 Transmission Fluid Temperature Sensor Specifications...................................................................................1751 Transmission General Specifications....................................................................................................1752 Fluid Capacity Specifications..........................................................................................................1752 Shim Size Specifications...............................................................................................................1752 Transmission Clearance Specifications..................................................................................................1753 Race and Bearing Specifications........................................................................................................1755 Range Reference........................................................................................................................1756 Shift Solenoid Valve State and Gear Ratio..............................................................................................1757 Shift Speed............................................................................................................................1757 Line Pressure..........................................................................................................................1757 Component Resistance...................................................................................................................1758 Third Gear Band Servo Piston Pin Selection.............................................................................................1758 Sealers, Adhesives, and Lubricants.....................................................................................................1759 Special Tools and Equipment................................................................................................................1759 Special Tools - Automatic Transaxle - AF33- 5..........................................................................................1759 Steering...........................................................................................................................................1763 Steering Wheel and Column......................................................................................................................1764 General Description........................................................................................................................1764 Steering Wheel and Column Description and Operation....................................................................................1764 Electronic Park Lock Description and Operation.........................................................................................1764 Component Location.........................................................................................................................1765 Steering Column Disassembled View......................................................................................................1765 Diagnostic Information and Procedures......................................................................................................1766 Symptoms - Steering Wheel and Column...................................................................................................1766 Noise in Steering Column...............................................................................................................1766 Looseness in Steering Column...........................................................................................................1767 Ignition Key Cannot Be Removed from the Ignition Lock Cylinder.........................................................................1767 Ignition Key Cannot Turn or Sticks in Any Position.....................................................................................1768 Ignition Can/Cannot Be Turned Off with Transmission in Any Gear........................................................................1768 Repair Instructions........................................................................................................................1770 Intermediate Steering Shaft Replacement................................................................................................1770 Steering Column Accident Damage Inspection.............................................................................................1771 Steering Column Trim Covers Replacement................................................................................................1772 Multifunction Turn Signal Switch Housing Replacement...................................................................................1773 Turn Signal Multifunction Switch Replacement...........................................................................................1774 Steering Wheel Replacement.............................................................................................................1775 Steering Column Replacement............................................................................................................1776 Steering Wheel Position Sensor Replacement.............................................................................................1778 Ignition Lock Cylinder Case Replacement................................................................................................1779 Ignition Lock Cylinder Replacement.....................................................................................................1780 Ignition and Start Switch Replacement..................................................................................................1781 Specifications.............................................................................................................................1782 Fastener Tightening Specifications - Wiring Systems and Power Management...............................................................1782 Fastener Tightening Specifications - Steering Wheel and Column - Tilt..................................................................1782 Special Tools and Equipment................................................................................................................1782 Special Tools - Steering Wheel and Column - Tilt.......................................................................................1782 Power Assisted Steering System.................................................................................................................1783 General Description........................................................................................................................1783 Power Steering System Description and Operation........................................................................................1783 Diagnostic Information and Procedures......................................................................................................1783 Diagnostic Starting Point - Power Steering System......................................................................................1783 Symptoms - Power Steering System.......................................................................................................1783 Power Steering System Test.............................................................................................................1784 Power Steering Fluid Leaks.............................................................................................................1787 Rattle, Clunk, or Shudder Noise from the Power Steering System.........................................................................1788 Whine or Growl Noise from the Power Steering System....................................................................................1789 Poor Return of Steering Wheel..........................................................................................................1789 Steering Effort Too Easy in One or Both Directions.....................................................................................1791 Steering Effort Hard in One or Both Directions.........................................................................................1791 Repair Instructions........................................................................................................................1792 Power Steering System Bleeding.........................................................................................................1792 Checking and Adding Power Steering Fluid...............................................................................................1792 Power Steering System Flushing.........................................................................................................1792 Remote Power Steering Fluid Reservoir Replacement......................................................................................1793 Power Steering Pump Pulley Replacement.................................................................................................1795 Power Steering Pump Replacement........................................................................................................1796 Rack and Pinion Outer Tie Rod End Replacement..........................................................................................1798 Power Steering Cooler Pipe/Hose Replacement............................................................................................1799 Power Steering Fluid Reservoir Outlet Hose Replacement.................................................................................1800 Power Steering Pump Inlet Pipe Replacement.............................................................................................1802 Power Steering Gear Inlet Pipe/Hose Replacement........................................................................................1803 Steering Gear Replacement..............................................................................................................1804 Steering Gear Boot Replacement - Off Vehicle...........................................................................................1806 Steering Gear Inner Tie Rod Replacement - Off Vehicle..................................................................................1808 Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle...............................................................1809 Specifications.............................................................................................................................1810 Fastener Tightening Specifications - Power Steering System.............................................................................1810 Power Steering Pump Specifications.....................................................................................................1810 Special Tools and Equipment................................................................................................................1811 Special Tools - Power Steering System..................................................................................................1811 HVAC...............................................................................................................................................1813 Heating, Ventilation and Air Conditioning......................................................................................................1815 General Description........................................................................................................................1815 Air Delivery Description and Operation.................................................................................................1815 Air Temperature Description and Operation..............................................................................................1817 Schematic and Routing Diagram..............................................................................................................1820 HVAC Schematics........................................................................................................................1820 HVAC Connector End Views...............................................................................................................1826 Component Location.........................................................................................................................1834 HVAC Component Views...................................................................................................................1834 Diagnostic Information and Procedures......................................................................................................1838 Diagnostic Starting Point - Heating, Ventilation and Air Conditioning..................................................................1838 Scan Tool Output Controls - HVAC - Automatic...........................................................................................1838 Scan Tool Data List - HVAC - Automatic.................................................................................................1839 Scan Tool Data Definitions - HVAC - Automatic..........................................................................................1840 DTC B0158..............................................................................................................................1841 DTC B0228, B0413, B0423, B0433, B3779 or B3782.........................................................................................1842 DTC B3933..............................................................................................................................1846 DTC P0532 or P0533.....................................................................................................................1847 DTC P0645, P0646, or P0647.............................................................................................................1849 Symptoms - HVAC Systems - Automatic....................................................................................................1850 Odor Diagnosis.........................................................................................................................1851 Air Conditioning Compressor Malfunction................................................................................................1852 Blower Motor Malfunction...............................................................................................................1854 Auxiliary Blower Motor Malfunction.....................................................................................................1856 Upper or Lower Duct Air Temperature Sensor Malfunction.................................................................................1858 Heating Performance Diagnostic.........................................................................................................1858 Defrosting Insufficient................................................................................................................1860 Noise Diagnosis - Auxiliary Blower Motor...............................................................................................1861 Noise Diagnosis - Blower Motor.........................................................................................................1862 Noise Diagnosis - Air Conditioning (A/C) System........................................................................................1863 Noise Diagnosis - HVAC Module..........................................................................................................1865 Too Hot in Vehicle.....................................................................................................................1866 Too Cold in Vehicle....................................................................................................................1867 Too Hot in Vehicle - Auxiliary.........................................................................................................1869 Too Cold in Vehicle - Auxiliary........................................................................................................1871 Air Delivery Improper..................................................................................................................1873 Air Delivery Improper - Auxiliary......................................................................................................1875 Air Recirculation Malfunction..........................................................................................................1877 Inside Air Temperature Sensor Malfunction..............................................................................................1878 Sun Load Sensor Malfunction............................................................................................................1879 Afterblow Enabling.....................................................................................................................1880 Actuator Recalibration.................................................................................................................1880 Leak Testing...........................................................................................................................1881 Air Conditioning (A/C) System Performance Test (w/ C69)................................................................................1882 Air Conditioning (A/C) System Performance Test (w/o C69)...............................................................................1886 Air Conditioning (A/C) Diagnostics - Pressure Zone A...................................................................................1889 Air Conditioning (A/C) Diagnostics - Pressure Zone B...................................................................................1892 Air Conditioning (A/C) Diagnostics - Pressure Zone C...................................................................................1894 Air Conditioning (A/C) Diagnostics - Pressure Zone D...................................................................................1896 Repair Instructions........................................................................................................................1898 Odor Correction........................................................................................................................1898 Refrigerant Recovery and Recharging....................................................................................................1899 Compressor Oil Balancing...............................................................................................................1900 Compressor Hose Assembly Replacement...................................................................................................1901 Compressor Replacement.................................................................................................................1902 Compressor Clutch Assembly Replacement.................................................................................................1903 Compressor Pressure Relief Valve Replacement...........................................................................................1906 Sealing Washer Replacement.............................................................................................................1907 O-Ring Replacement.....................................................................................................................1908 Liquid Line Replacement................................................................................................................1909 Evaporator Outlet Hose Replacement.....................................................................................................1912 Air Conditioning Refrigerant Service Valve Core Replacement............................................................................1913 Receiver Dehydrator Replacement........................................................................................................1914 Thermal Expansion Valve Replacement....................................................................................................1915 Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement.........................................................................1917 Air Conditioning (A/C) Refrigerant Low Temperature Sensor Replacement..................................................................1918 Condenser Replacement..................................................................................................................1918 Air Conditioning (A/C) Evaporator Case Assembly Replacement............................................................................1921 Blower Case Assembly Replacement.......................................................................................................1923 HVAC Module Assembly Replacement.......................................................................................................1925 HVAC Control Module Programming and Setup..............................................................................................1929 Evaporator Core Replacement............................................................................................................1929 Heater Inlet Hose Replacement (w/o C69)................................................................................................1931 Heater Inlet Hose Replacement (w/ C69).................................................................................................1932 Heater Outlet Hose Replacement (w/o C69)...............................................................................................1933 Heater Outlet Hose Replacement (w/C69).................................................................................................1935 Passenger Compartment Air Filter Housing Replacement...................................................................................1936 Passenger Compartment Air Filter Replacement...........................................................................................1938 Air Inlet Assembly Replacement.........................................................................................................1940 Blower Motor Control Module Replacement................................................................................................1941 Blower Control Module Programming and Setup............................................................................................1941 Blower Motor Replacement...............................................................................................................1941 Instrument Panel Outer Air Outlet Replacement - Left Side..............................................................................1942 Instrument Panel Center Air Outlet Replacement.........................................................................................1943 Instrument Panel Outer Air Outlet Replacement - Right Side.............................................................................1944 Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side...................................................................1945 Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side..................................................................1946 Floor Air Outlet Replacement - Center..................................................................................................1947 Rear Floor Air Outlet Replacement......................................................................................................1947 Center Air Outlet Duct Replacement.....................................................................................................1948 Windshield Defroster Duct Replacement..................................................................................................1948 Side Window Defogger Outlet Duct Replacement - Left Side...............................................................................1949 Side Window Defogger Outlet Duct Replacement - Right Side..............................................................................1949 Defroster Air Outlet Replacement.......................................................................................................1950 Air Temperature Door Replacement.......................................................................................................1951 Defroster Door Replacement.............................................................................................................1953 Panel Air Door Replacement.............................................................................................................1955 Heater Core Replacement................................................................................................................1957 Air Temperature Door Replacement - Auxiliary...........................................................................................1958 Auxiliary Heater Pipe Replacement......................................................................................................1959 Auxiliary Blower Control Module Replacement............................................................................................1960 Auxiliary Blower Motor Replacement.....................................................................................................1961 Auxiliary Air Distributor Lower Duct Replacement.......................................................................................1962 Auxiliary Air Distributor Duct Replacement - Upper.....................................................................................1963 Auxiliary Heater Core Replacement......................................................................................................1964 Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement..............................................................1965 Auxiliary HVAC Module Replacement......................................................................................................1966 Auxiliary Heating, Ventilation, and Air Conditioning Control Module Programming and Setup..............................................1967 Auxiliary Air Conditioning Evaporator Core Replacement.................................................................................1967 Auxiliary Air Conditioning Evaporator Tube Replacement.................................................................................1969 Auxiliary Heater and Air Conditioning Pipe Repair......................................................................................1970 HVAC Control Assembly Replacement......................................................................................................1972 Auxiliary Heater and Air Conditioning Control Replacement..............................................................................1973 Recirculation Actuator Replacement.....................................................................................................1974 Mode Actuator Replacement..............................................................................................................1974 Air Temperature Actuator Replacement...................................................................................................1975 Auxiliary Air Temperature Actuator Replacement.........................................................................................1976 Auxiliary Mode Actuator Replacement....................................................................................................1977 Air Temperature Sensor Replacement - Upper.............................................................................................1978 Air Temperature Sensor Replacement - Lower.............................................................................................1979 Inside Air Temperature Sensor Assembly Replacement.....................................................................................1980 Specifications.............................................................................................................................1981 Fastener Tightening Specifications - Heating, Ventilation and Air Conditioning.........................................................1981 Fastener Tightening Specifications - HVAC - Automatic..................................................................................1982 Refrigerant System Capacities..........................................................................................................1982 Sensor Resistance Table (Volts to Temp to Resistance)..................................................................................1982 Special Tools and Equipment................................................................................................................1983 Special Tools - Heating, Ventilation and Air Conditioning..............................................................................1983 Special Tools - HVAC - Automatic.......................................................................................................1984 Restraints.........................................................................................................................................1985 Seat Belts.....................................................................................................................................1987 Precautions................................................................................................................................1987 Seat Belt Service Precautions..........................................................................................................1987 General Description........................................................................................................................1987 Seat Belt System Description and Operation.............................................................................................1987 Schematic and Routing Diagram..............................................................................................................1988 Seat Belt Schematics...................................................................................................................1989 Seat Belt Connector End Views..........................................................................................................1990 Component Location.........................................................................................................................1991 Seat Belt Component Views..............................................................................................................1991 Diagnostic Information and Procedures......................................................................................................1993 Diagnostic Starting Point - Seat Belts.................................................................................................1993 Scan Tool Data List - Seat Belts.......................................................................................................1993 Scan Tool Data Definitions - Seat Belts................................................................................................1993 Operational and Functional Checks......................................................................................................1993 Symptoms - Seat Belts..................................................................................................................1994 Seat Belt Does Not Retract.............................................................................................................1994 Seat Belt Indicator Circuit Malfunction - Driver.......................................................................................1994 Seat Belt Indicator Circuit Malfunction - Passenger....................................................................................1995 Repair Instructions........................................................................................................................1997 Repairs and Inspections Required After a Collision.....................................................................................1997 Front Seat Belt Buckle Replacement.....................................................................................................1998 Rear Seat Center Belt Buckle Replacement...............................................................................................1999 Seat Belt Buckle Replacement - No. 2 Rear..............................................................................................2000 Front Seat Belt Replacement (Quick Connect)............................................................................................2001 Rear Seat Belt Replacement.............................................................................................................2002 Seat Belt Replacement - Center Rear....................................................................................................2003 Seat Belt Height Adjuster Replacement - Front..........................................................................................2004 Seat Belt Retractor Anchor Plate Replacement...........................................................................................2005 Seat Belt Retractor Replacement - No. 2 Rear...........................................................................................2006 Guide Replacement - Rear Seat Shoulder Belt............................................................................................2007 Seat Belt Retractor Pretensioner Replacement - Front...................................................................................2008 Pretensioner Handling and Scrapping....................................................................................................2009 Specifications.............................................................................................................................2012 Fastener Tightening Specifications - Seat Belts........................................................................................2012 Air Bag System.................................................................................................................................2013 Precautions................................................................................................................................2013 SIR Caution............................................................................................................................2013 SIR Deployed Inflator Modules are Hot Caution..........................................................................................2013 SIR Inflatable Module Deployment Outside Vehicle Caution...............................................................................2013 SIR Inflator Module Disposal Caution...................................................................................................2013 SIR Inflator Module Handling and Storage Caution.......................................................................................2013 SIR Special Tool Caution...............................................................................................................2013 General Description........................................................................................................................2014 SIR System Description and Operation...................................................................................................2014 Schematic and Routing Diagram..............................................................................................................2017 SIR Schematic Icons....................................................................................................................2017 SIR Schematics.........................................................................................................................2018 SIR Connector End Views................................................................................................................2022 Component Location.........................................................................................................................2028 SIR Identification Views...............................................................................................................2028 SIR Component Views....................................................................................................................2029 Diagnostic Information and Procedures......................................................................................................2034 Diagnostic Starting Point - SIR........................................................................................................2034 Scan Tool Data List - SIR..............................................................................................................2035 Scan Tool Data Definitions - SIR.......................................................................................................2036 DTC B0012 or B0013.....................................................................................................................2036 DTC B0014-B0045........................................................................................................................2038 DTC B0052 or B0053.....................................................................................................................2041 DTC B0055..............................................................................................................................2042 DTC B0056..............................................................................................................................2043 DTC B0057..............................................................................................................................2044 DTC B0058..............................................................................................................................2045 DTC B0073..............................................................................................................................2046 DTC B0081..............................................................................................................................2047 DTC B0083 or B0084.....................................................................................................................2049 DTC B0085 or B0086.....................................................................................................................2051 DTC B0090..............................................................................................................................2052 DTC B1001 (SDM)........................................................................................................................2054 DTC B1019..............................................................................................................................2055 DTC B1370..............................................................................................................................2056 Symptoms - SIR.........................................................................................................................2058 Passenger Presence System Rezeroing....................................................................................................2058 Air Bag Indicator Circuit Malfunction..................................................................................................2059 Passenger Presence System Indicator Circuit Malfunction................................................................................2060 Repairs and Inspections Required After a Collision.....................................................................................2061 Repair Instructions........................................................................................................................2062 SIR Disabling and Enabling.............................................................................................................2062 Inflatable Restraint Front End Sensor Replacement......................................................................................2064 Inflatable Restraint Side Impact Sensor Replacement....................................................................................2065 Inflatable Restraint Vehicle Rollover Sensor Replacement...............................................................................2066 Inflatable Restraint Vehicle Rollover Sensor Programming and Setup.....................................................................2066 Inflatable Restraint Sensing and Diagnostic Module Replacement.........................................................................2067 Inflatable Restraint Sensing and Diagnostic Module Programming and Setup...............................................................2068 Inflatable Restraint Steering Wheel Module Replacement.................................................................................2069 Inflatable Restraint Steering Wheel Module Coil Replacement............................................................................2070 Inflatable Restraint Steering Wheel Module Coil Centering..............................................................................2071 Inflatable Restraint Instrument Panel Module Replacement...............................................................................2072 Inflatable Restraint Passenger Presence System Replacement - Front.....................................................................2074 Passenger Presence System Programming and Setup........................................................................................2075 Instrument Panel Inflatable Restraint Module Indicator Replacement.....................................................................2075 Inflatable Restraint Roof Rail Module Replacement - Front..............................................................................2076 Inflator Module Handling and Scrapping.................................................................................................2077 SIR/SRS Wiring Repairs.................................................................................................................2091 Connector Repairs......................................................................................................................2094 Connector Position Assurance Locks.....................................................................................................2097 Terminal Position Assurance Locks......................................................................................................2097 Specifications.............................................................................................................................2098 Fastener Tightening Specifications - SIR...............................................................................................2098 Special Tools and Equipment................................................................................................................2098 Special Tools - SIR....................................................................................................................2098 Body, Cab and Accessories..........................................................................................................................2099 Wiring Systems.................................................................................................................................2109 General Description........................................................................................................................2109 Electrical Center Identification Views.................................................................................................2109 Circuit Protection - Fuses.............................................................................................................2114 Circuit Protection - Circuit Breakers..................................................................................................2114 Circuit Protection - Fusible Links.....................................................................................................2115 Electrical Symbols.....................................................................................................................2115 Schematic and Routing Diagram..............................................................................................................2123 Power and Grounding Schematic Icons....................................................................................................2123 Power Distribution Schematics..........................................................................................................2123 Power Moding Schematics................................................................................................................2139 Ignition Lock Schematics...............................................................................................................2141 Ground Distribution Schematics.........................................................................................................2142 Trailer Connector/Provision Schematics.................................................................................................2151 Harness Routing Views..................................................................................................................2153 Power and Grounding Connector End Views................................................................................................2166 Splice Pack Connector End Views........................................................................................................2167 Inline Harness Connector End Views.....................................................................................................2167 Component Location.........................................................................................................................2220 Utility/Van Zoning.....................................................................................................................2220 Master Electrical Component List.......................................................................................................2221 Power and Grounding Component Views....................................................................................................2235 Diagnostic Information and Procedures......................................................................................................2245 Diagnostic Starting Point - Wiring Systems and Power Management........................................................................2245 Scan Tool Data Definitions - Wiring Systems and Power Management.......................................................................2245 Scan Tool Data List - Wiring Systems and Power Management..............................................................................2246 DTC B1370..............................................................................................................................2246 DTC B1380..............................................................................................................................2249 DTC B1428..............................................................................................................................2252 DTC B1433..............................................................................................................................2253 DTC B1441..............................................................................................................................2255 DTC B1475..............................................................................................................................2258 Symptoms - Wiring Systems..............................................................................................................2259 General Electrical Diagnosis...........................................................................................................2259 Checking Aftermarket Accessories.......................................................................................................2259 Circuit Testing........................................................................................................................2259 Using Connector Test Adapters..........................................................................................................2260 Probing Electrical Connectors..........................................................................................................2260 Troubleshooting with a Digital Multimeter..............................................................................................2262 Troubleshooting with a Test Lamp.......................................................................................................2262 Using Fused Jumper Wires...............................................................................................................2262 Measuring Voltage......................................................................................................................2263 Measuring Voltage Drop.................................................................................................................2263 Measuring Frequency....................................................................................................................2263 Testing for Continuity.................................................................................................................2263 Testing for Short to Ground............................................................................................................2264 Testing for a Short to Voltage.........................................................................................................2264 Testing for Intermittent Conditions and Poor Connections...............................................................................2264 Inducing Intermittent Fault Conditions.................................................................................................2266 Testing for Electrical Intermittents...................................................................................................2268 Scan Tool Snapshot Procedure...........................................................................................................2268 Repair Instructions........................................................................................................................2269 Wiring Repairs.........................................................................................................................2269 Repairing Damaged Wire Insulation......................................................................................................2269 Flat Wire Repairs......................................................................................................................2269 GMLAN Wiring Repairs...................................................................................................................2269 High Temperature Wiring Repairs........................................................................................................2272 Splicing Copper Wire Using Splice Clips................................................................................................2274 Splicing Copper Wire Using Splice Sleeves..............................................................................................2276 Splicing Twisted or Shielded Cable.....................................................................................................2277 Splicing Inline Harness Diodes.........................................................................................................2278 Connector Repairs......................................................................................................................2279 Connector Position Assurance Locks.....................................................................................................2282 Terminal Position Assurance Locks......................................................................................................2282 AFL/EPC Connectors.....................................................................................................................2282 Bosch Connectors (BSK).................................................................................................................2284 Bosch Connectors (0.64)................................................................................................................2285 Bosch Connectors (2.8 JPT).............................................................................................................2286 Bosch Connectors (ECM).................................................................................................................2287 Delphi Connectors (Weather Pack).......................................................................................................2288 Delphi Connectors (Push To Seat).......................................................................................................2289 Delphi Connectors (Pull To Seat).......................................................................................................2290 Delphi Connectors (Micro-Pack 100W)....................................................................................................2291 Delphi Connectors (Micro.64)...........................................................................................................2294 Delphi Connectors (12-Way).............................................................................................................2298 FCI Connectors.........................................................................................................................2300 JST Connectors.........................................................................................................................2301 Kostal Connectors......................................................................................................................2302 Molex Connectors.......................................................................................................................2304 Sumitomo Connectors....................................................................................................................2306 Tyco/AMP Connectors (CM 42-Way)........................................................................................................2308 Tyco/AMP Connectors (Sensor)...........................................................................................................2309 Tyco/AMP Connectors (0.25 Cap).........................................................................................................2310 Tyco/AMP Connectors (43-Way)...........................................................................................................2311 Tyco/AMP Connectors (Door Module)......................................................................................................2312 Yazaki Connectors (2-Way)..............................................................................................................2314 Yazaki Connectors (16-Way).............................................................................................................2314 Repairing Connector Terminals..........................................................................................................2316 Relay Replacement (Within an Electrical Center)........................................................................................2316 Relay Replacement (Attached to Wire Harness)...........................................................................................2317 Underhood Electrical Center or Junction Block Replacement..............................................................................2318 Instrument Panel Electrical Center or Junction Block Replacement.......................................................................2319 Specifications.............................................................................................................................2320 Fastener Tightening Specifications - Wiring Systems and Power Management...............................................................2320 Special Tools and Equipment................................................................................................................2320 Special Tools - Wiring Systems and Power Management....................................................................................2320 Lighting Systems...............................................................................................................................2322 Precautions................................................................................................................................2322 Halogen Bulb Caution...................................................................................................................2322 General Description........................................................................................................................2322 Exterior Lighting Systems Description and Operation....................................................................................2322 Interior Lighting Systems Description and Operation....................................................................................2324 Schematic and Routing Diagram..............................................................................................................2324 Headlights/Daytime Running Lights (DRL) Schematics.....................................................................................2325 Fog Lights Schematics..................................................................................................................2326 Exterior Lights Schematics.............................................................................................................2327 Interior Lights Schematics.............................................................................................................2334 Interior Lights Dimming Schematics.....................................................................................................2335 Lighting Systems Connector End Views...................................................................................................2336 Component Location.........................................................................................................................2347 Lighting Systems Component Views.......................................................................................................2347 Diagnostic Information and Procedures......................................................................................................2353 Diagnostic Starting Point - Lighting Systems...........................................................................................2353 Scan Tool Output Controls - Lighting...................................................................................................2353 Scan Tool Data List - Lighting.........................................................................................................2354 Scan Tool Data Definitions - Lighting..................................................................................................2354 DTC B257A..............................................................................................................................2356 DTC B2530..............................................................................................................................2357 DTC B2545..............................................................................................................................2358 DTC B2575..............................................................................................................................2359 DTC B2580..............................................................................................................................2361 DTC B2585..............................................................................................................................2362 DTC B2600..............................................................................................................................2363 DTC B2610..............................................................................................................................2365 DTC B2615..............................................................................................................................2366 DTC B2645..............................................................................................................................2367 DTC B2652..............................................................................................................................2368 DTC B3445..............................................................................................................................2370 DTC B3600..............................................................................................................................2371 DTC B3867..............................................................................................................................2372 DTC B3884..............................................................................................................................2374 DTC C0277 or DTC C0890.................................................................................................................2375 DTC C0297..............................................................................................................................2376 DTC P0572..............................................................................................................................2378 DTC P0573..............................................................................................................................2379 Symptoms - Lighting Systems............................................................................................................2380 Backup Lamps Malfunction...............................................................................................................2381 Courtesy Lamps Always On...............................................................................................................2382 Courtesy Lamps Inoperative.............................................................................................................2383 Daytime Running Lamps (DRL) Inoperative................................................................................................2385 Fog Lamps Always On....................................................................................................................2386 Fog Lamps Inoperative..................................................................................................................2387 Hazard Lamps Inoperative...............................................................................................................2389 Headlamp Low or High Beams Always On...................................................................................................2390 Headlamps Inoperative - High Beams.....................................................................................................2392 Headlamps Inoperative - Low Beams......................................................................................................2393 Low and High Beams Headlamps Inoperative...............................................................................................2395 Headlamps Flash to Pass Inoperative....................................................................................................2396 Interior Backlighting Does Not Dim.....................................................................................................2397 Interior Backlighting Inoperative......................................................................................................2398 Park Lamps Always On...................................................................................................................2399 Park Lamps Inoperative.................................................................................................................2400 Reading Lamp(s) Inoperative............................................................................................................2401 Stop Lamps Always On...................................................................................................................2402 Stop Lamps Inoperative.................................................................................................................2404 Turn Signal Lamps and/or Indicators Always On or Flashing..............................................................................2405 Turn Signal Lamps and/or Indicators Inoperative........................................................................................2406 Repair Instructions........................................................................................................................2408 Fog Lamp Switch Replacement............................................................................................................2408 Hazard Warning Switch Replacement......................................................................................................2409 Instrument Panel Dimmer Switch Replacement.............................................................................................2410 Ambient Light Sensor Replacement.......................................................................................................2411 Daytime Running Lamps (DRL) Resistor Replacement.......................................................................................2412 Reading Lamp Bulb Replacement (Without CF5)............................................................................................2413 Reading Lamp Bulb Replacement (With CF5)...............................................................................................2414 Dome Lamp Replacement (Without DVD)....................................................................................................2415 Dome Lamp Bulb Replacement (Without DVD)...............................................................................................2416 Dome Lamp Bulb Replacement (With DVD)..................................................................................................2417 Headlamp Replacement...................................................................................................................2418 Headlamp Bulb Replacement..............................................................................................................2419 Headlamp Aiming (VOR)..................................................................................................................2420 Front Fog Lamp Replacement.............................................................................................................2422 Front Fog Lamp Bulb Replacement........................................................................................................2423 Front Fog Lamp Cover Replacement.......................................................................................................2423 Fog Lamp Aiming........................................................................................................................2424 Front Side Marker Lamp Bulb Replacement................................................................................................2425 Park/Turn Signal Lamp Bulb Replacement.................................................................................................2425 Cornering Lamp Bulb Replacement........................................................................................................2426 High Mount Stop Lamp Replacement.......................................................................................................2426 Cargo Lamp Replacement.................................................................................................................2427 Cargo Lamp Bulb Replacement............................................................................................................2428 Backup Lamp Bulb Replacement...........................................................................................................2429 Rear License Lamp Replacement..........................................................................................................2429 License Lamp Bulb Replacement..........................................................................................................2430 Tail Lamp Replacement..................................................................................................................2430 Tail Lamp Bulb Replacement.............................................................................................................2431 Specifications.............................................................................................................................2431 Fastener Tightening Specifications - Lighting..........................................................................................2431 Instrumentation / Driver Info. / Horn..........................................................................................................2432 General Description........................................................................................................................2432 Instrument Cluster Description and Operation...........................................................................................2432 Indicator/Warning Message Description and Operation....................................................................................2433 Audible Warnings Description and Operation.............................................................................................2437 Door Ajar Indicator Description and Operation..........................................................................................2437 Horns System Description and Operation.................................................................................................2438 Schematic and Routing Diagram..............................................................................................................2438 Horn Schematic Icons...................................................................................................................2438 Instrument Cluster Schematics..........................................................................................................2438 Driver Information System Schematics...................................................................................................2441 Audible Warnings Schematics............................................................................................................2442 Cigar Lighter/Power Outlet Schematics..................................................................................................2443 Horn Schematics........................................................................................................................2444 Displays and Gages Connector End Views.................................................................................................2445 Horn Connector End Views...............................................................................................................2446 Power Outlet Connector End Views.......................................................................................................2446 Component Location.........................................................................................................................2448 Displays and Gages Component Views.....................................................................................................2448 Horn Component Views...................................................................................................................2449 Power Outlet Component Views...........................................................................................................2451 Diagnostic Information and Procedures......................................................................................................2452 Diagnostic Starting Point - Displays and Gages.........................................................................................2452 Scan Tool Output Controls - Displays and Gages.........................................................................................2452 Scan Tool Output Controls - Horns......................................................................................................2453 Scan Tool Data List - Displays and Gages...............................................................................................2453 Scan Tool Data List - Horns............................................................................................................2457 Scan Tool Data Definitions - Displays and Gages........................................................................................2457 Scan Tool Data Definitions - Horns.....................................................................................................2458 DTC B2750..............................................................................................................................2459 DTC B2965..............................................................................................................................2460 DTC P0461..............................................................................................................................2461 DTC P0462..............................................................................................................................2462 DTC P0463..............................................................................................................................2464 DTC P0464..............................................................................................................................2465 DTC P0520..............................................................................................................................2466 Symptoms - Displays and Gages..........................................................................................................2467 Symptoms - Horns.......................................................................................................................2468 Daytime Running Lamps (DRL) Indicator Inoperative......................................................................................2469 Fog Lamp Indicator Inoperative.........................................................................................................2470 High Beam Indicator Inoperative........................................................................................................2471 Chime Always On........................................................................................................................2472 Chime Inoperative......................................................................................................................2472 Door Ajar Indicator Malfunction........................................................................................................2473 Horns Malfunction......................................................................................................................2474 Engine Coolant Temperature Indicator Always On.........................................................................................2475 Engine Coolant Temperature Gage Inaccurate or Inoperative..............................................................................2476 Engine Oil Pressure Indicator Always On................................................................................................2476 Fuel Gage Inaccurate or Inoperative....................................................................................................2477 Instrument Cluster Gages Inoperative...................................................................................................2477 Odometer Trip/Reset Switch Inoperative.................................................................................................2478 Rear Hatch/Gate Ajar Indicator Always On...............................................................................................2479 Rear Hatch/Gate Ajar Indicator Inoperative.............................................................................................2480 Speedometer and/or Odometer Inaccurate or Inoperative..................................................................................2481 Tachometer Inaccurate or Inoperative...................................................................................................2481 Turn Signal Lamps and/or Indicators Always On or Flashing..............................................................................2482 Turn Signal Lamps and/or Indicators Inoperative........................................................................................2483 Repair Instructions........................................................................................................................2485 Instrument Panel Insulator Panel Replacement - Right Side..............................................................................2485 Instrument Panel Insulator Panel Replacement - Left Side...............................................................................2486 Instrument Panel Lower Brace Bezel Replacement.........................................................................................2487 Knee Bolster Replacement...............................................................................................................2488 Driver Knee Bolster Reinforcement Replacement..........................................................................................2489 Instrument Panel Accessory Trim Plate Replacement......................................................................................2490 Instrument Panel Outer Trim Cover Replacement..........................................................................................2491 Instrument Panel Lower Trim Panel Replacement - Right Side.............................................................................2492 Instrument Panel Upper Trim Panel Replacement..........................................................................................2493 Instrument Panel Lower Trim Panel Replacement - Left Side..............................................................................2494 Instrument Panel Cluster Trim Plate Bezel Replacement..................................................................................2495 Instrument Panel Lower Center Trim Panel Replacement...................................................................................2496 Instrument Panel Compartment Door Latch Replacement....................................................................................2497 Instrument Panel Compartment Door Replacement..........................................................................................2498 Instrument Panel Compartment Replacement...............................................................................................2499 Instrument Panel Compartment Door Lock Striker Replacement.............................................................................2500 Instrument Panel Compartment Door Dampener Replacement.................................................................................2501 Ambient Air Temperature Sensor Replacement.............................................................................................2502 Driver Information Display Switch Replacement..........................................................................................2503 Instrument Cluster Replacement.........................................................................................................2504 Instrument Cluster Programming and Setup...............................................................................................2504 Instrument Panel Cluster Trim Plate Cover Replacement..................................................................................2505 Instrument Panel Retainer Replacement..................................................................................................2506 Instrument Panel Tie Bar Replacement...................................................................................................2507 Horn Replacement.......................................................................................................................2509 Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement.............................................................2509 Specifications.............................................................................................................................2510 Fastener Tightening Specifications - Instrument Panel and Console Trim.................................................................2510 Fastener Tightening Specifications - Displays and Gages................................................................................2511 Fastener Tightening Specifications - Horns.............................................................................................2511 Fastener Tightening Specifications - Power Outlets.....................................................................................2511 Fuel Level Specifications..............................................................................................................2511 Special Tools and Equipment................................................................................................................2511 Special Tools - Power Outlets..........................................................................................................2511 Wipers / Washers...............................................................................................................................2512 General Description........................................................................................................................2512 Wiper/Washer System Description and Operation..........................................................................................2512 Schematic and Routing Diagram..............................................................................................................2512 Wiper/Washer Schematics................................................................................................................2512 Wiper/Washer Connector End Views.......................................................................................................2515 Component Location.........................................................................................................................2517 Wiper/Washer Component Views...........................................................................................................2517 Diagnostic Information and Procedures......................................................................................................2520 Diagnostic Starting Point - Wipers and Washers.........................................................................................2520 Scan Tool Output Controls - Wipers/Washer Systems......................................................................................2520 Scan Tool Data List - Wipers/Washer Systems............................................................................................2520 Scan Tool Data Definitions - Wipers/Washer Systems.....................................................................................2520 DTC B3715..............................................................................................................................2521 DTC B3873..............................................................................................................................2522 DTC B3875..............................................................................................................................2523 DTC B3922..............................................................................................................................2525 Symptoms - Wipers and Washers..........................................................................................................2527 Windshield Wiper System Malfunction (Front)............................................................................................2527 Windshield Wiper System Malfunction (Rear).............................................................................................2530 Washer Malfunction (Front).............................................................................................................2532 Washer Malfunction (Rear)..............................................................................................................2534 Repair Instructions........................................................................................................................2535 Wipers/Washer Switch Replacement.......................................................................................................2535 Windshield Washer Nozzle Replacement...................................................................................................2536 Rear Window Washer Nozzle Replacement..................................................................................................2537 Windshield Washer Hose Replacement.....................................................................................................2537 Washer Solvent Container Replacement...................................................................................................2538 Washer Pump Filter Grommet Replacement.................................................................................................2539 Washer Pump Replacement................................................................................................................2539 Wiper Arm Replacement..................................................................................................................2540 Rear Window Wiper Arm Replacement......................................................................................................2541 Wiper Arm Blade Replacement............................................................................................................2542 Rear Window Wiper Blade Replacement....................................................................................................2542 Wiper Blade Element Replacement........................................................................................................2543 Rear Window Wiper Blade Element Replacement............................................................................................2543 Blade Element Cleaning.................................................................................................................2544 Wiper Motor Module Replacement.........................................................................................................2544 Wiper Motor Module Grommet Replacement.................................................................................................2545 Wiper Motor Replacement................................................................................................................2546 Liftgate Wiper Motor Replacement.......................................................................................................2547 Rear Washer Hose Replacement...........................................................................................................2547 Specifications.............................................................................................................................2548 Fastener Tightening Specifications - Wipers/Washer Systems.............................................................................2548 Glass / Windows / Mirrors......................................................................................................................2549 Precautions................................................................................................................................2549 Cracked Window Caution.................................................................................................................2549 Defroster Outlet Caution...............................................................................................................2549 Safety Glasses Caution.................................................................................................................2549 Safety Glasses and Compressed Air Caution..............................................................................................2549 Window Retention Caution...............................................................................................................2549 Window Edge Damage Notice..............................................................................................................2549 General Description........................................................................................................................2550 Full-Cut Method Description............................................................................................................2550 Adhesive Service Kit Description.......................................................................................................2550 Stationary Window Description..........................................................................................................2550 Power Windows Description and Operation................................................................................................2550 Rear Window Defogger Description and Operation.........................................................................................2551 Outside Mirror Description and Operation...............................................................................................2552 Automatic Day-Night Mirror Description and Operation...................................................................................2552 Compass Calibration and Magnetic Variance..............................................................................................2553 Schematic and Routing Diagram..............................................................................................................2553 Moveable Window Schematics.............................................................................................................2554 Defogger Schematics....................................................................................................................2555 Inside Rearview Mirror Schematics......................................................................................................2556 Outside Rearview Mirror Schematics.....................................................................................................2557 Window Systems Connector End Views.....................................................................................................2558 Mirror Connector End Views.............................................................................................................2561 Component Location.........................................................................................................................2564 Window Systems Component Views.........................................................................................................2564 Mirror Component Views.................................................................................................................2570 Diagnostic Information and Procedures......................................................................................................2574 Diagnostic Starting Point - Fixed and Moveable Windows.................................................................................2574 Scan Tool Output Controls - Fixed and Moveable Windows.................................................................................2574 Scan Tool Data List - Fixed and Moveable Windows.......................................................................................2574 Scan Tool Data Definitions - Fixed and Moveable Windows................................................................................2574 DTC B0285 or B0286.....................................................................................................................2574 Symptoms - Fixed and Moveable Windows..................................................................................................2576 Power Windows Inoperative - All........................................................................................................2577 Rear Window Defogger Inoperative.......................................................................................................2580 Automatic Day-Night Mirrors Inoperative................................................................................................2582 Power Mirrors Inoperative..............................................................................................................2583 Mirror Compass Display Inoperative or Inaccurate.......................................................................................2584 Mirrors - Temperature Displays SC or OC................................................................................................2585 Air/Wind Noise.........................................................................................................................2586 Exterior Windnoise.....................................................................................................................2587 Interior Windnoise.....................................................................................................................2587 Waterleak Test Preparation.............................................................................................................2587 Dust Leaks.............................................................................................................................2589 Water Hose Test........................................................................................................................2589 Air Hose Test..........................................................................................................................2589 Tracing Powder or Chalk Test...........................................................................................................2590 Air Pressure Test......................................................................................................................2590 Soap Suds or Bubble Test...............................................................................................................2590 Repair Instructions........................................................................................................................2590 Rearview Mirror Replacement............................................................................................................2590 Inside Rearview Mirror Programming and Setup...........................................................................................2591 Rearview Mirror Support Installation...................................................................................................2591 Windshield Replacement.................................................................................................................2592 Windshield Glass Cleaning..............................................................................................................2593 Adhesive Installation of Stationary Windows (Windshield)...............................................................................2594 Front Side Door Window Replacement.....................................................................................................2599 Rear Side Door Window Replacement......................................................................................................2600 Quarter Window Replacement.............................................................................................................2602 Adhesive Installation of Encapsulated Stationary Windows...............................................................................2604 Liftgate Window Replacement............................................................................................................2606 Adhesive Installation of Stationary Windows (Liftgate).................................................................................2607 Stationary Window Reveal Molding Repair................................................................................................2610 Front Side Door Window Switch Replacement..............................................................................................2612 Rear Side Door Window Switch Replacement...............................................................................................2613 Front Side Door Window Regulator Replacement...........................................................................................2614 Front Side Door Window Regulator Motor Replacement.....................................................................................2615 Rear Side Door Window Regulator Replacement............................................................................................2615 Rear Side Door Window Regulator Motor Replacement......................................................................................2616 Power Mirror Switch Replacement........................................................................................................2617 Mirror Replacement.....................................................................................................................2618 Outside Rearview Mirror Glass Replacement..............................................................................................2618 Body Waterleak Repair..................................................................................................................2619 Stationary Window Waterleak Repair.....................................................................................................2620 Specifications.............................................................................................................................2620 Fastener Tightening Specifications - Fixed and Moveable Windows........................................................................2620 Fastener Tightening Specifications - Mirrors...........................................................................................2620 Special Tools and Equipment................................................................................................................2621 Special Tools - Air/Wind Noise.........................................................................................................2621 Special Tools - Fixed and Moveable Windows.............................................................................................2621 Security and Locks.............................................................................................................................2622 General Description........................................................................................................................2622 Power Door Locks Description and Operation.............................................................................................2622 Rear Hatch/Gate Description and Operation..............................................................................................2623 Keyless Entry System Description and Operation.........................................................................................2623 Content Theft Deterrent (CTD) Description and Operation................................................................................2625 Key and Lock Cylinder Coding...........................................................................................................2626 Schematic and Routing Diagram..............................................................................................................2627 Door Lock/Indicator Schematics.........................................................................................................2627 Release Systems Schematics.............................................................................................................2630 Remote Function Schematics.............................................................................................................2631 Theft Deterrent System Schematics......................................................................................................2632 Vehicle Access Connector End Views.....................................................................................................2634 Remote Function Connector End Views....................................................................................................2637 Component Location.........................................................................................................................2638 Vehicle Access Component Views.........................................................................................................2638 Remote Function Component Views........................................................................................................2644 Diagnostic Information and Procedures......................................................................................................2645 Diagnostic Starting Point - Vehicle Access.............................................................................................2645 Diagnostic Starting Point - Remote Functions...........................................................................................2645 Diagnostic Starting Point - Theft Deterrent............................................................................................2645 Scan Tool Output Controls - Vehicle Access.............................................................................................2645 Scan Tool Output Controls - Remote Functions...........................................................................................2645 Scan Tool Data List - Vehicle Access...................................................................................................2646 Scan Tool Data List - Remote Functions.................................................................................................2646 Scan Tool Data List - Theft Deterrent..................................................................................................2647 Scan Tool Data Definitions - Vehicle Access............................................................................................2648 Scan Tool Data Definitions - Remote Functions..........................................................................................2648 Scan Tool Data Definitions - Theft Deterrent...........................................................................................2649 DTC B2495..............................................................................................................................2649 DTC B3105..............................................................................................................................2650 DTC B3109..............................................................................................................................2651 DTC B3110..............................................................................................................................2652 DTC B3111..............................................................................................................................2652 DTC B3112..............................................................................................................................2653 DTC B3125, B3130, or B3135.............................................................................................................2654 DTC B3140, B3145, B3150, or B3155......................................................................................................2655 DTC B3265..............................................................................................................................2657 Symptoms - Vehicle Access..............................................................................................................2658 Symptoms - Remote Functions............................................................................................................2659 Symptoms - Theft Deterrent.............................................................................................................2659 Liftgate Release Inoperative...........................................................................................................2660 Power Door Locks Inoperative...........................................................................................................2662 Keyless Entry System Inoperative.......................................................................................................2665 Remote Vehicle Start Inoperative.......................................................................................................2666 Content Theft Deterrent Malfunction....................................................................................................2667 Security Indicator Malfunction.........................................................................................................2667 Repair Instructions........................................................................................................................2668 Opening the Liftgate without Electrical Power..........................................................................................2668 Front Side Door Lock Cylinder Replacement..............................................................................................2669 Front Side Door Latch Replacement......................................................................................................2669 Rear Side Door Latch Replacement.......................................................................................................2671 Liftgate Latch Replacement.............................................................................................................2674 Front Side Door Lock Striker Adjustment................................................................................................2675 Front Side Door Lock Striker Replacement...............................................................................................2676 Rear Side Door Lock Striker Adjustment.................................................................................................2677 Rear Side Door Lock Striker Replacement................................................................................................2678 Liftgate Lock Striker Adjustment.......................................................................................................2679 Liftgate Lock Striker Replacement......................................................................................................2680 Power Door Lock Switch Replacement.....................................................................................................2681 Transmitter Battery Replacement........................................................................................................2682 Transmitter Programming................................................................................................................2683 Remote Control Door Lock Receiver Replacement..........................................................................................2683 Remote Control Door Lock Receiver Antenna Replacement..................................................................................2684 Remote Control Door Lock Receiver Programming and Setup................................................................................2684 Theft Deterrent Module Replacement.....................................................................................................2685 Theft Deterrent Control Module Programming and Setup...................................................................................2685 Specifications.............................................................................................................................2686 Fastener Tightening Specifications - Vehicle Access....................................................................................2686 Seats..........................................................................................................................................2687 General Description........................................................................................................................2687 Manual Seats Description...............................................................................................................2687 Power Seats System Description and Operation...........................................................................................2687 Heated Seats Description and Operation.................................................................................................2688 Schematic and Routing Diagram..............................................................................................................2688 Driver Seat Schematics.................................................................................................................2689 Heated/Cooled Seat Schematics..........................................................................................................2690 Power Seat Connector End Views.........................................................................................................2691 Heated/Cooled Seat Connector End Views.................................................................................................2692 Component Location.........................................................................................................................2695 Power Seat Component Views.............................................................................................................2695 Heated/Cooled Seat Component Views.....................................................................................................2696 Diagnostic Information and Procedures......................................................................................................2698 Diagnostic Starting Point - Seats......................................................................................................2698 Scan Tool Data List - Seat Heating and Cooling.........................................................................................2698 Scan Tool Data Definitions - Seat Heating and Cooling..................................................................................2698 DTC B1395..............................................................................................................................2699 DTC B1925 or B2170.....................................................................................................................2700 DTC B2345..............................................................................................................................2702 DTC B2425 or B2430.....................................................................................................................2704 DTC B2508 or B2509.....................................................................................................................2707 Symptoms - Seats.......................................................................................................................2708 Symptoms - Seats.......................................................................................................................2709 Symptoms - Seat Heating and Cooling....................................................................................................2709 Power Seat Inoperative.................................................................................................................2710 Seat - Hard to Move Forward and Rearward...............................................................................................2711 Seat - Manual Adjuster Does Not Lock...................................................................................................2711 Seat - Manual Adjuster Does Not Unlock.................................................................................................2711 Seat - Manual Adjuster Locks Between Lock Positions....................................................................................2711 Seats - Adjuster Track Locks Ahead of Other Track......................................................................................2712 Heated Seat Inoperative................................................................................................................2712 Repair Instructions........................................................................................................................2713 Front Seat Adjuster Switch Knob Replacement............................................................................................2713 Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)......................................................................2714 Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)......................................................................2715 Front Seat Recliner Mechanism Replacement..............................................................................................2716 Driver Seat Recliner Handle and Passenger Seat Recliner Handle Replacement.............................................................2717 Driver Seat Recliner Actuator Cable and Passenger Seat Recliner Actuator Cable Replacement (Fold Flat).................................2718 Power Seat Switch Replacement..........................................................................................................2719 Front Seat Cushion Outer Trim Panel Replacement (Non Fold Flat)........................................................................2720 Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)............................................................................2721 Front Seat Cushion Inner Trim Panel Replacement (Non Fold Flat)........................................................................2722 Front Seat Cushion Inner Trim Panel Replacement (Fold Flat)............................................................................2723 Front Seat Replacement - Bucket........................................................................................................2724 Front Seat Cushion Cover and Pad Replacement...........................................................................................2726 Front Seat Adjuster Replacement........................................................................................................2727 Front Seat Adjuster Replacement (2-way Manual).........................................................................................2728 Front Seat Back Panel Replacement (Fold Flat)..........................................................................................2729 Front Seat Head Restraint Replacement..................................................................................................2730 Front Seat Head Restraint Guide Replacement (Non Fold Flat)............................................................................2730 Front Seat Head Restraint Guide Replacement (Fold Flat)................................................................................2731 Front Seat Cushion Frame Replacement...................................................................................................2732 Front Seat Back Cushion Cover and Cushion Pad Replacement (Non Fold Flat)..............................................................2733 Front Seat Back Cushion Cover and Cushion Pad Replacement (Fold Flat)..................................................................2734 Front Seat Lumbar Support Replacement..................................................................................................2735 Lumbar Support Knob Replacement........................................................................................................2736 Lumbar Support Actuator Replacement....................................................................................................2737 Front Seat Back Frame Replacement (Non- Fold Flat).....................................................................................2738 Front Seat Back Frame Replacement (Fold Flat)..........................................................................................2741 Front Seat Heater Control Module Replacement...........................................................................................2742 Heated Seat Control Module Programming and Setup.......................................................................................2742 Driver Seat Back Cushion Heater and Passenger Seat Back Cushion Heater Replacement (Non Fold Flat).....................................2743 Driver Seat Back Cushion Heater and Passenger Seat Back Cushion Heater Replacement (Fold Flat).........................................2744 Driver Seat Cushion Heater and Passenger Seat Cushion Heater Replacement...............................................................2745 Rear Seat Armrest Replacement..........................................................................................................2746 Rear Seat Shoulder Belt Opening Bezel Replacement......................................................................................2747 Rear Seat Strut Replacement............................................................................................................2748 Rear Seat Head Restraint Replacement (Inner)...........................................................................................2749 Rear Seat Head Restraint Replacement (Outer)...........................................................................................2750 Rear Seat Head Restraint Guide Replacement (Inner).....................................................................................2751 Rear Seat Head Restraint Guide Replacement (Outer).....................................................................................2752 Rear Seat Recliner Handle Replacement (Rear No. 1).....................................................................................2753 Rear Seat Back Recliner Cover Replacement (Inner)......................................................................................2754 Rear Seat Back Recliner Cover Replacement (Outer)......................................................................................2755 Rear Seat Front Riser Finish Cover Replacement.........................................................................................2756 Rear Seat Latch Replacement............................................................................................................2757 Rear Seat Replacement..................................................................................................................2758 Rear Seat Cushion Cover and Pad Replacement............................................................................................2760 Rear Seat Cushion Frame Replacement....................................................................................................2761 Rear Seat Back Cushion Latch Cable Replacement.........................................................................................2762 Rear Seat Back Cushion Cover and Pad Replacement (60% Seat)............................................................................2763 Rear Seat Back Cushion Cover and Pad Replacement (40% Seat)............................................................................2764 Rear Seat Back Filler Panel Replacement................................................................................................2765 Rear Seat Back Cushion Frame Replacement...............................................................................................2766 Rear Seat Number 2 Head Restraint Replacement..........................................................................................2767 Rear Seat Number 2 Head Restraint Guide Replacement....................................................................................2768 Rear Seat Recliner Handle Replacement (Rear No. 2).....................................................................................2769 Rear Seat Number 2 Back Cushion Latch Release Handle Replacement.......................................................................2770 Rear Seat Latch Finish Cover Replacement...............................................................................................2771 Rear Seat Number 2 Back Cushion Panel Replacement......................................................................................2772 Rear Seat Number 2 Cushion Trim Panel Replacement......................................................................................2773 Rear Number 2 Seat Replacement.........................................................................................................2774 Rear Seat Back Cushion Outer Pivot Support Cover Replacement...........................................................................2775 Rear Seat Number 2 Hinge Front Link Replacement........................................................................................2776 Rear Seat Number 2 Cushion Cover and Pad Replacement...................................................................................2777 Rear Seat Number 2 Back Cushion Latch Replacement......................................................................................2778 Rear Seat Number 2 Cushion Frame Replacement...........................................................................................2779 Rear Seat Number 2 Back Cushion Cover and Pad Replacement..............................................................................2780 Rear Seat Recliner Replacement (Rear No. 2)............................................................................................2781 Rear Seat Number 2 Back Cushion Frame Replacement......................................................................................2782 Specifications.............................................................................................................................2783 Fastener Tightening Specifications - Seat Hardware, Trim, and Upholstery...............................................................2783 Fastener Tightening Specifications - Power Seats.......................................................................................2783 Fastener Tightening Specifications - Seat Heating and Cooling..........................................................................2783 Special Tools and Equipment................................................................................................................2783 Special Tools - Seat Hardware, Trim, and Upholstery....................................................................................2783 Interior Trim..................................................................................................................................2784 Repair Instructions........................................................................................................................2784 Eliminating Unwanted Odors in Vehicles.................................................................................................2784 Liftgate Door Sill Plate Replacement...................................................................................................2785 Windshield Upper Garnish Molding Replacement...........................................................................................2786 Center Pillar Lower Garnish Molding Replacement........................................................................................2787 Center Pillar Upper Garnish Molding Replacement........................................................................................2788 Rear Storage Compartment Replacement...................................................................................................2789 Body Rear Corner Garnish Molding Replacement...........................................................................................2790 Child Restraint Tether Anchor Bezel Replacement........................................................................................2791 Lock Pillar Upper Garnish Molding Replacement (Left Side)..............................................................................2792 Lock Pillar Upper Garnish Molding Replacement (Right Side).............................................................................2793 Front Floor Console Armrest Replacement................................................................................................2794 Console Replacement....................................................................................................................2795 Console Rear Trim Plate Replacement....................................................................................................2796 Front Floor Upper Console Trim Plate Replacement.......................................................................................2797 Console Compartment Door Replacement...................................................................................................2798 Front Floor Console Side Trim Panel Replacement - Right Side...........................................................................2799 Front Floor Console Side Trim Panel Replacement - Right Side...........................................................................2800 Front Floor Console Side Trim Panel Replacement - Left Side............................................................................2801 Front Floor Console Side Trim Panel Replacement - Left Side............................................................................2802 Front Carpet Retainer Replacement......................................................................................................2803 Rear Carpet Retainer Replacement.......................................................................................................2804 Floor Panel Carpet Replacement (Front).................................................................................................2805 Floor Panel Carpet Replacement (Rear)..................................................................................................2806 Floor Carpet Drying....................................................................................................................2806 Roof Console Replacement...............................................................................................................2807 Headlining Trim Panel Replacement......................................................................................................2808 Rear Quarter Lower Trim Panel Replacement..............................................................................................2809 Specifications.............................................................................................................................2810 Fastener Tightening Specifications - Instrument Panel and Console Trim.................................................................2810 Fastener Tightening Specifications - Interior Trim and Paneling........................................................................2810 Sun Roof / T-Top / Convertible Top.............................................................................................................2811 General Description........................................................................................................................2811 Sunroof Description and Operation......................................................................................................2811 Schematic and Routing Diagram..............................................................................................................2812 Sunroof Schematics.....................................................................................................................2813 Sunroof Connector End Views............................................................................................................2814 Component Location.........................................................................................................................2816 Sunroof Component Views................................................................................................................2816 Diagnostic Information and Procedures......................................................................................................2817 Diagnostic Starting Point - Roof.......................................................................................................2817 Symptoms - Roof........................................................................................................................2817 Power Sunroof Inoperative..............................................................................................................2818 Power Sunroof Does Not Open to Express Position........................................................................................2821 Power Sunroof Does Not Close...........................................................................................................2822 Repair Instructions........................................................................................................................2824 Sunroof Air Deflector Replacement......................................................................................................2824 Sunroof Housing Front Drain Hose Replacement...........................................................................................2825 Sunroof Housing Rear Drain Hose Replacement............................................................................................2826 Sunroof Drain Inspection and Cleaning..................................................................................................2827 Sunroof Sunshade Replacement...........................................................................................................2828 Sunroof Switch Replacement.............................................................................................................2829 Sunroof Window Height and Opening Fit Adjustment.......................................................................................2830 Sunroof Window Replacement.............................................................................................................2830 Sunroof Control Module Replacement.....................................................................................................2831 Sunroof Control Module Programming and Setup...........................................................................................2832 Sunroof Module Assembly Replacement....................................................................................................2832 Sunroof Motor/Actuator Replacement.....................................................................................................2833 Center Pillar Assist Handle Replacement................................................................................................2834 Coat Hook Replacement..................................................................................................................2835 Sunshade Replacement...................................................................................................................2836 Sunshade Anchor Replacement............................................................................................................2837 Specifications.............................................................................................................................2838 Fastener Tightening Specifications - Interior Trim and Paneling........................................................................2838 Fastener Tightening Specifications - Sunroof...........................................................................................2838 Hood / Fenders / Doors.........................................................................................................................2839 Repair Instructions........................................................................................................................2839 Hood Bumper Replacement................................................................................................................2839 Hood Strut Replacement.................................................................................................................2840 Hood Adjustment........................................................................................................................2841 Hood Hinge Replacement.................................................................................................................2842 Hood Replacement.......................................................................................................................2843 Hood Insulator Replacement.............................................................................................................2844 Hood Latch Release Cable Replacement...................................................................................................2845 Hood Primary Latch Striker Replacement.................................................................................................2846 Hood Primary Latch Replacement.........................................................................................................2847 Hood Secondary Latch Replacement.......................................................................................................2848 Hood Front Seal Replacement............................................................................................................2849 Hood Rear Seal Replacement.............................................................................................................2849 Hood Rear Outer Seal Replacement.......................................................................................................2850 Hood Open Assist Rod Stud Replacement..................................................................................................2851 Air Inlet Grille Panel Replacement.....................................................................................................2852 Front Fender Replacement...............................................................................................................2853 Front Fender Upper Bracket Replacement.................................................................................................2854 Front Fender Insulator Replacement.....................................................................................................2855 Front Side Door Outside Handle Replacement.............................................................................................2856 Rear Side Door Outside Handle Replacement..............................................................................................2857 Door Handle Bezel Replacement..........................................................................................................2858 Upper Extension Trim Panel Replacement (Front Side Door)...............................................................................2859 Front Side Door Trim Panel Replacement.................................................................................................2860 Rear Side Door Trim Panel Replacement..................................................................................................2861 Door Inside Handle Replacement.........................................................................................................2862 Front Side Door Water Deflector Replacement............................................................................................2863 Rear Side Door Water Deflector Replacement.............................................................................................2864 Front Side Door Window Belt Inner Sealing Strip Replacement............................................................................2865 Front Side Door Window Belt Outer Sealing Strip Replacement............................................................................2865 Rear Door Window Belt Inner Sealing Strip Replacement..................................................................................2866 Rear Door Window Belt Outer Sealing Strip Replacement..................................................................................2866 Front Side Door Window Channel Replacement.............................................................................................2867 Front Side Door Window Channel Replacement.............................................................................................2867 Rear Side Door Window Channel Replacement..............................................................................................2868 Rear Side Door Window Channel Replacement..............................................................................................2869 Front Door Opening Weatherstrip Replacement............................................................................................2870 Rear Door Opening Weatherstrip Replacement.............................................................................................2870 Front Side Door Adjustment.............................................................................................................2871 Rear Door Adjustment...................................................................................................................2872 Front Side Door Hinge Replacement......................................................................................................2872 Rear Side Door Hinge Replacement.......................................................................................................2873 Front Side Door Check Link Replacement.................................................................................................2874 Rear Side Door Check Link Replacement..................................................................................................2875 Front Side Door Replacement............................................................................................................2876 Rear Door Replacement..................................................................................................................2877 Liftgate Bumper Replacement............................................................................................................2878 Liftgate Outside Handle Replacement....................................................................................................2879 Liftgate Trim Panel Replacement (Upper)................................................................................................2880 Liftgate Trim Panel Replacement (Lower)................................................................................................2881 Liftgate Weatherstrip Replacement......................................................................................................2882 Liftgate Strut Replacement.............................................................................................................2883 Liftgate Strut Ball Stud Replacement...................................................................................................2884 Liftgate Adjustment....................................................................................................................2885 Liftgate Hinge Replacement.............................................................................................................2886 Liftgate Wedge Replacement (Body Side).................................................................................................2887 Liftgate Wedge Replacement (Liftgate Side).............................................................................................2888 Liftgate Replacement...................................................................................................................2889 Fuel Tank Filler Door Replacement......................................................................................................2890 Specifications.............................................................................................................................2891 Fastener Tightening Specifications - Wipers/Washer Systems.............................................................................2891 Fastener Tightening Specifications - Interior Trim and Paneling........................................................................2891 Fastener Tightening Specifications - Fixed and Moveable Windows........................................................................2891 Fastener Tightening Specifications - Bolted Exterior Body Panels and Closures..........................................................2891 Special Tools and Equipment................................................................................................................2892 Special Tools - Fixed and Moveable Windows.............................................................................................2892 Body Structure.................................................................................................................................2893 Repair Instructions........................................................................................................................2893 Metal Panel Bonding....................................................................................................................2893 General Plastic Repair Instructions....................................................................................................2893 How to Identify Plastic Parts..........................................................................................................2894 Plastic Identification and Refinishing Systems.........................................................................................2895 Front Bumper Fascia Replacement........................................................................................................2897 Front Bumper Fascia Energy Absorber Replacement........................................................................................2898 Front Bumper Impact Bar Replacement....................................................................................................2899 Front Bumper Lower Fascia Grille Replacement...........................................................................................2900 Front Bumper Upper Fascia Grille Replacement...........................................................................................2901 Front Bumper Lower Fascia Replacement..................................................................................................2902 Front Bumper Upper Fascia Replacement..................................................................................................2903 Front Bumper Fascia Support Replacement................................................................................................2904 Front Bumper Fascia Upper Support Replacement..........................................................................................2905 Rear Bumper Lower Fascia Replacement...................................................................................................2906 Rear Bumper Bracket Replacement........................................................................................................2907 Rear Bumper Upper Fascia Replacement...................................................................................................2908 Rear Energy Absorber Replacement.......................................................................................................2909 Rear Bumper Impact Bar Replacement.....................................................................................................2910 Rear Bumper Fascia Reflector Replacement...............................................................................................2911 Tie Bar Replacement....................................................................................................................2912 Front Wheelhouse Replacement...........................................................................................................2913 Front Wheelhouse Extension Replacement.................................................................................................2915 Front Compartment Upper Side Rail Replacement..........................................................................................2917 Front Compartment Front Rail Replacement...............................................................................................2919 Front Compartment Front Side Lower Inner Rail Replacement..............................................................................2920 Front Compartment Front Side Lower Inner Rail Sectioning...............................................................................2922 Underbody Outer Front Side Rail Replacement............................................................................................2924 Underbody Outer Front Side Rail Sectioning.............................................................................................2925 Front Hinge Pillar Body Sectioning.....................................................................................................2927 Roof Outer Panel Replacement...........................................................................................................2929 Front Side Door Outer Panel Replacement................................................................................................2931 Rear Side Door Outer Panel Replacement.................................................................................................2935 Rear Compartment Floor Panel Sectioning................................................................................................2938 Body Rear End Panel Replacement........................................................................................................2940 Center Pillar Sectioning...............................................................................................................2942 Quarter Panel Sectioning...............................................................................................................2944 Rear Rail Replacement..................................................................................................................2946 Rail Replacement - Rear Section........................................................................................................2949 Resistance Spot Welded Full Panel Replacement..........................................................................................2951 MIG Welded Full Panel Replacement......................................................................................................2952 Specifications.............................................................................................................................2954 Fastener Tightening Specifications - Bumpers and Fascias...............................................................................2954 Dimensions - Body......................................................................................................................2954 Structure Identification...............................................................................................................2956 Special Tools and Equipment................................................................................................................2958 Flexible Plastic Part Repair Materials.................................................................................................2958 Rigid Plastic Part Repair Materials....................................................................................................2959 Paint / Coatings...............................................................................................................................2960 General Description........................................................................................................................2960 Basecoat/Clearcoat Paint Systems.......................................................................................................2960 Anti-Corrosion Treatment and Repair....................................................................................................2960 Repair Instructions........................................................................................................................2961 Clearcoat Repair without Repainting....................................................................................................2961 Environmental Fallout (Acid Rain)......................................................................................................2961 Paint Gages............................................................................................................................2962 Clearcoat Thickness....................................................................................................................2962 Rail Dust Damage Repair................................................................................................................2962 Specifications.............................................................................................................................2963 Clearcoat Repair Specifications - 3M Products..........................................................................................2963 Clearcoat Repair Specifications - Meguiar Products.....................................................................................2965 Exterior Body Panels...........................................................................................................................2966 Precautions................................................................................................................................2966 Exterior Trim Emblem Removal Notice....................................................................................................2966 Repair Instructions........................................................................................................................2966 Rocker Panel Molding Replacement.......................................................................................................2966 Rocker Panel Molding Support Replacement...............................................................................................2967 Front Wheelhouse Liner Replacement.....................................................................................................2968 Rear Wheelhouse Liner Panel Replacement................................................................................................2969 Engine Splash Shield Replacement - Left Side...........................................................................................2970 Engine Splash Shield Replacement - Right Side..........................................................................................2971 Luggage Carrier Replacement (Without Sunroof)..........................................................................................2972 Luggage Carrier Replacement (With Sunroof).............................................................................................2975 Front Door Frame Applique Replacement..................................................................................................2976 Rear Door Frame Applique Replacement...................................................................................................2977 Liftgate Center Applique Replacement...................................................................................................2977 Rear Side Door Window Frame Front Applique and Front Channel Replacement...............................................................2978 Rear Side Door Window Frame Rear Applique Replacement..................................................................................2979 Windshield Frame Applique Replacement..................................................................................................2979 Liftgate Emblem and Nameplate Replacement..............................................................................................2980 Specifications.............................................................................................................................2981 Fastener Tightening Specifications - Luggage Rack and Roof Trim........................................................................2981 Fastener Tightening Specifications - Exterior Trim.....................................................................................2981 Fastener Tightening Specifications - Frame and Underbody...............................................................................2981 Special Tools and Equipment................................................................................................................2981 Special Tools - Frame and Underbody....................................................................................................2981 Cellular / Entertainment / Navigation / Audio..................................................................................................2982 General Description........................................................................................................................2982 Radio/Audio System Description and Operation...........................................................................................2982 Navigation System Description and Operation............................................................................................2986 Video Entertainment System Description and Operation...................................................................................2987 Steering Wheel Controls Description and Operation......................................................................................2987 Schematic and Routing Diagram..............................................................................................................2987 Radio/Navigation System Schematics.....................................................................................................2987 Steering Wheel Secondary/Configurable Control Schematics...............................................................................2995 Entertainment/Communication Connector End Views........................................................................................2997 Secondary/Configurable Control Connector End Views.....................................................................................3005 Component Location.........................................................................................................................3006 Entertainment/Communication Component Views............................................................................................3006 Secondary/Configurable Control Component Views.........................................................................................3011 Diagnostic Information and Procedures......................................................................................................3012 Diagnostic Starting Point - Cellular, Entertainment, and Navigation....................................................................3012 Diagnostic Starting Point - Secondary and Configurable Customer Controls...............................................................3012 Scan Tool Output Controls - Cellular, Entertainment, and Navigation....................................................................3012 Scan Tool Data List - Cellular, Entertainment, and Navigation..........................................................................3013 Scan Tool Data List - Secondary and Configurable Customer Controls.....................................................................3014 Scan Tool Data Definitions - Secondary and Configurable Customer Controls..............................................................3014 DTC B0000..............................................................................................................................3014 DTC B1025, B1035, B1045, or B1055......................................................................................................3015 DTC B1259..............................................................................................................................3016 DTC B1287..............................................................................................................................3017 DTC B1288..............................................................................................................................3018 DTC B1289..............................................................................................................................3019 DTC B1529..............................................................................................................................3020 DTC B2462..............................................................................................................................3021 DTC B2474..............................................................................................................................3022 DTC B3622..............................................................................................................................3023 Symptoms - Entertainment...............................................................................................................3023 Symptoms - Secondary and Configurable Customer Controls................................................................................3024 Audio System Troubleshooting Hints.....................................................................................................3024 Video Entertainment System Troubleshooting Hints.......................................................................................3026 Audio Distortion - One or More Speakers................................................................................................3027 Radio Setup............................................................................................................................3027 Digital Radio Receiver Setup...........................................................................................................3027 Audio/Video Disc Player Adapter - Audio or Video Inoperative or Degraded Quality.......................................................3028 Digital Radio Poor or No Reception.....................................................................................................3028 Radio Displays CAL or CAL ERR..........................................................................................................3029 Radio Displays LOC, LOCKED, or CODE....................................................................................................3029 Radio Poor Reception...................................................................................................................3029 Navigation System - Voice Guidance Inoperative or Degraded Quality.....................................................................3030 Navigation System - Voice Recognition Inoperative......................................................................................3030 No Global Positioning System (GPS) Reception...........................................................................................3031 Video Display is Poor or Blank.........................................................................................................3031 Video Entertainment System Inoperative.................................................................................................3032 Video Entertainment System Remote Control Inoperative..................................................................................3032 Video Entertainment System Wireless Headphone Inoperative..............................................................................3033 Steering Wheel Controls Inoperative....................................................................................................3034 Reduced Volume - One or More Speakers..................................................................................................3035 Speaker Replacement Reference..........................................................................................................3035 Speakers Inoperative - One or More.....................................................................................................3036 Repair Instructions........................................................................................................................3037 Compact Disc Care and Cleaning.........................................................................................................3037 Mobile Telephone Microphone Replacement (Without CF5)..................................................................................3038 Mobile Telephone Microphone Replacement (With CF5).....................................................................................3039 Amplifier Replacement..................................................................................................................3040 Audio Amplifier Programming and Setup..................................................................................................3040 Radio Replacement......................................................................................................................3041 Radio Programming and Setup............................................................................................................3041 Digital Radio Receiver Replacement.....................................................................................................3042 Digital Radio Receiver Programming and Setup...........................................................................................3042 Cellular and Navigation Antenna Assembly Replacement...................................................................................3043 Digital Radio Antenna Replacement......................................................................................................3044 Global Positioning System (GPS) Antenna Replacement....................................................................................3045 Digital Radio Antenna Cable Replacement................................................................................................3046 Antenna Cable Replacement..............................................................................................................3047 Video Display Replacement..............................................................................................................3048 Auxiliary Audio/Video Input Control Replacement........................................................................................3049 Rear Seat Audio Control Replacement....................................................................................................3050 Radio Front Side Door Upper Speaker Replacement........................................................................................3051 Radio Front Side Door Speaker Replacement..............................................................................................3052 Radio Rear Speaker Replacement.........................................................................................................3053 Radio Rear Side Door Speaker Replacement...............................................................................................3054 Steering Wheel Control Switch Assembly Replacement.....................................................................................3055 Specifications.............................................................................................................................3056 Fastener Tightening Specifications - Cellular, Entertainment, and Navigation...........................................................3056 Special Tools and Equipment................................................................................................................3056 Special Tools - Cellular, Entertainment, and Navigation................................................................................3056 Control Systems....................................................................................................................................3057 Cruise Control System..........................................................................................................................3059 General Description........................................................................................................................3059 Cruise Control Description and Operation...............................................................................................3059 Schematic and Routing Diagram..............................................................................................................3060 Cruise Control Schematics..............................................................................................................3061 Cruise Control Connector End Views.....................................................................................................3062 Component Location.........................................................................................................................3063 Cruise Control Component Views.........................................................................................................3063 Diagnostic Information and Procedures......................................................................................................3065 Diagnostic Starting Point - Cruise Control.............................................................................................3065 Scan Tool Data List - Cruise Control...................................................................................................3065 Scan Tool Data Definitions (Disengage History) - Cruise Control........................................................................3066 DTC B3794..............................................................................................................................3067 DTC B0835..............................................................................................................................3069 DTC P0571..............................................................................................................................3070 DTC P0575..............................................................................................................................3071 Symptoms - Cruise Control..............................................................................................................3072 Cruise Control Switch Indicator Inoperative............................................................................................3072 Cruise Control Inoperative/Malfunctioning..............................................................................................3073 Repair Instructions........................................................................................................................3074 Cruise Release Switch Adjustment.......................................................................................................3074 Cruise Release Switch Replacement......................................................................................................3075 Data Communications............................................................................................................................3077 General Description........................................................................................................................3077 Body Control System Description and Operation..........................................................................................3077 Data Link Communications Description and Operation.....................................................................................3078 Power Mode Description and Operation...................................................................................................3079 Retained Accessory Power (RAP) Description and Operation...............................................................................3080 Schematic and Routing Diagram..............................................................................................................3080 Data Communication Schematic Icons.....................................................................................................3080 Data Communication Schematics..........................................................................................................3080 Body Control System Schematics.........................................................................................................3083 Data Communication Connector End Views.................................................................................................3088 Component Location.........................................................................................................................3093 Data Communication Component Views.....................................................................................................3093 Diagnostic Information and Procedures......................................................................................................3094 Diagnostic Starting Point - Data Communications........................................................................................3094 DTC B1000..............................................................................................................................3094 DTC B1001..............................................................................................................................3095 DTC B1016..............................................................................................................................3096 DTC U0073..............................................................................................................................3096 DTC U0100-U0299........................................................................................................................3097 DTC U1500..............................................................................................................................3099 DTC U1814..............................................................................................................................3100 DTC U2099..............................................................................................................................3101 DTC U2100..............................................................................................................................3102 DTC U2105-U2199 (Except U2142 and U2143)...............................................................................................3103 DTC U2105-U2199 (U2142 or U2143 only)..................................................................................................3105 Symptoms - Data Communications.........................................................................................................3106 Scan Tool Does Not Power Up............................................................................................................3107 Scan Tool Does Not Communicate with High Speed GMLAN Device............................................................................3108 Scan Tool Does Not Communicate with Low Speed GMLAN Device.............................................................................3110 Illuminated Entry Lamps Inoperative....................................................................................................3111 Power Mode Mismatch....................................................................................................................3112 Retained Accessory Power (RAP) Malfunction.............................................................................................3115 Data Link References...................................................................................................................3116 Repair Instructions........................................................................................................................3117 Body Control Module Replacement........................................................................................................3117 Body Control Module Programming and Setup..............................................................................................3118 Special Tools and Equipment................................................................................................................3119 Special Tools - Wiring Systems and Power Management....................................................................................3119 Immobilizer Control System.....................................................................................................................3120 General Description........................................................................................................................3120 Immobilizer Description and Operation..................................................................................................3120 Schematic and Routing Diagram..............................................................................................................3120 Immobilizer Schematics.................................................................................................................3120 Immobilizer Connector End Views........................................................................................................3122 Component Location.........................................................................................................................3123 Immobilizer Component Views............................................................................................................3123 Diagnostic Information and Procedures......................................................................................................3124 Diagnostic Starting Point - Immobilizer................................................................................................3124 Scan Tool Data List - Immobilizer......................................................................................................3124 Scan Tool Data Definitions - Immobilizer...............................................................................................3125 DTC B3006..............................................................................................................................3126 DTC B3031..............................................................................................................................3127 DTC B3055..............................................................................................................................3128 DTC B3060..............................................................................................................................3129 DTC B3935..............................................................................................................................3130 DTC B3976..............................................................................................................................3131 DTC P0513..............................................................................................................................3131 DTC P0633..............................................................................................................................3132 DTC P1629..............................................................................................................................3133 DTC P1631..............................................................................................................................3134 DTC P1632..............................................................................................................................3135 Repair Instructions........................................................................................................................3136 Programming Immobilizer System Components..............................................................................................3136 Adding Keys............................................................................................................................3136 Replacing Keys.........................................................................................................................3136 Tire Pressure Monitoring System................................................................................................................3138 General Description........................................................................................................................3138 Tire Pressure Monitor Description and Operation........................................................................................3138 Diagnostic Information and Procedures......................................................................................................3139 Diagnostic Starting Point - Tire Pressure Monitoring...................................................................................3139 Diagnostic System Check - Tire Pressure Monitoring.....................................................................................3139 Scan Tool Output Controls - Tire Pressure Monitoring...................................................................................3139 Scan Tool Data List - Tire Pressure Monitoring.........................................................................................3140 Scan Tool Data Definitions - Tire Pressure Monitoring..................................................................................3141 DTC C0750, C0755, C0760, or C0765......................................................................................................3142 DTC C0775..............................................................................................................................3143 Symptoms - Tire Pressure Monitoring....................................................................................................3144 Low Tire Pressure Indicator Always On..................................................................................................3144 Low Tire Pressure Indicator Inoperative................................................................................................3145 Repair Instructions........................................................................................................................3145 Tire Pressure Indicator Sensor Replacement.............................................................................................3145 Tire Pressure Sensor Grommet Replacement...............................................................................................3147 Tire Pressure Sensor Learn.............................................................................................................3148 Specifications.............................................................................................................................3149 Fastener Tightening Specifications - Tire Pressure Monitoring..........................................................................3149 Frame and Frame Accessories........................................................................................................................3151 Body Frame.....................................................................................................................................3152 Diagnostic Information and Procedures......................................................................................................3152 Alignment Checking.....................................................................................................................3152 Repair Instructions........................................................................................................................3152 Drivetrain and Front Suspension Frame Reinforcement Replacement........................................................................3152 Frame Replacement......................................................................................................................3153 Front Frame Cushion or Insulator Replacement...........................................................................................3157 Underbody Inspection...................................................................................................................3158 Specifications.............................................................................................................................3158 Fastener Tightening Specifications - Frame and Underbody...............................................................................3158 Special Tools and Equipment................................................................................................................3158 Special Tools - Frame and Underbody....................................................................................................3158 COPYRIGHT..........................................................................................................................................3159
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