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Sprinter 2003 VA Service Manual – PDF DOWNLOAD
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Description
Sprinter 2003 VA Service Manual – PDF DOWNLOAD
FILE DETAILS:
Sprinter 2003 VA Service Manual – PDF DOWNLOAD
Language : English
Pages : 1964
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sprinter 2003 VA Service Manual – PDF DOWNLOAD
VA Service Manual......................................................................................... 0 VA Powertrain............................................................................................. 0 VA Body................................................................................................... 0 VA Transmission........................................................................................... 0 VA Chassis................................................................................................ 64 TABLE OF CONTENTS..................................................................................... 4 1.0 INTRODUCTION...................................................................................... 6 1.1 SYSTEM COVERAGE............................................................................... 6 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE............................................................ 6 2.0 INDENTIFICATION OF SYSTEM......................................................................... 6 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION....................................................... 6 3.1 ABS........................................................................................... 6 3.2 TCS (ASR)..................................................................................... 7 3.3 SYSTEM COMPONENTS............................................................................. 7 3.3.1 ABS AND TCS (ASR) INDICATORS............................................................ 7 3.3.2 CONTROLLER ANTILOCK BRAKE (CAB)......................................................... 7 3.3.3 HYDRAULIC CONTROL UNIT (HCU)............................................................ 7 3.3.4 SWITCHES/SENSORS........................................................................ 7 3.3.5 SELF TESTS.............................................................................. 8 3.4 USING THE DRBIII.............................................................................. 8 3.5 DRBIII ERROR MESSAGES......................................................................... 8 3.5.1 DRBIII DOES NOT POWER UP (BLANK SCREEN)................................................. 8 3.5.2 DISPLAY IS NOT VISIBLE.................................................................. 9 4.0 DISCLAIMERS, SAFETY, WARNINGS..................................................................... 9 4.1 DISCLAIMERS................................................................................... 9 4.2 SAFETY........................................................................................ 9 4.2.1 TECHNICIAN SAFETY INFORMATION........................................................... 9 4.2.2 VEHICLE PREPARATION FOR TESTING......................................................... 9 4.2.3 SERVICING SUB-ASSEMBLIES................................................................ 9 4.2.4 DRBIII SAFETY INFORMATION............................................................... 9 4.3 WARNING....................................................................................... 10 4.3.1 VEHICLE DAMAGE WARNINGS................................................................. 10 4.3.2 ROAD TESTING A COMPLAINT VEHICLE........................................................ 10 4.4 DIAGNOSIS..................................................................................... 10 5.0 REQUIRED TOOLS AND EQUIPMENT...................................................................... 11 6.0 GLOSSARY OF TERMS................................................................................. 11 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................................................. 12 BRAKES (CAB)...................................................................................... 13 BRAKE SWITCH CIRCUIT.......................................................................... 13 CAB CHECK SUM................................................................................. 17 CAB INTERNAL.................................................................................. 19 CAB OPTION.................................................................................... 21 INCORRECT TONE WHEEL.......................................................................... 23 LEFT FRONT INLET SOLENOID..................................................................... 25 LEFT FRONT OUTLET SOLENOID.................................................................... 25 LEFT FRONT, RIGHT REAR INLET SOLENOID......................................................... 25 LEFT FRONT, RIGHT REAR OUTLET SOLENOID........................................................ 25 LEFT REAR INLET SOLENOID...................................................................... 25 LEFT REAR OUTLET SOLENOID..................................................................... 25 RIGHT FRONT INLET SOLENOID.................................................................... 25 RIGHT FRONT OUTLET SOLENOID................................................................... 25 RIGHT FRONT, LEFT REAR INLET SOLENOID......................................................... 25 RIGHT FRONT, LEFT REAR OUTLET SOLENOID........................................................ 25 RIGHT REAR INLET SOLENOID..................................................................... 25 RIGHT REAR OUTLET SOLENOID.................................................................... 25 LEFT FRONT WHEEL SPEED SENSOR CIRCUIT......................................................... 29 LEFT REAR WHEEL SPEED SENSOR CIRCUIT.......................................................... 29 RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT........................................................ 29 RIGHT REAR WHEEL SPEED SENSOR CIRCUIT......................................................... 29 LEFT FRONT WHEEL SPEED SENSOR SIGNAL.......................................................... 32 LEFT REAR WHEEL SPEED SENSOR SIGNAL........................................................... 32 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL......................................................... 32 RIGHT REAR WHEEL SPEED SENSOR SIGNAL.......................................................... 32 NO COMMUNICATION WITH BUS..................................................................... 35 NO COMMUNICATION WITH ECM..................................................................... 38 NO COMMUNICATION WITH IC...................................................................... 40 PUMP MOTOR.................................................................................... 42 RELAY OUTPUT VOLTAGE.......................................................................... 45 SOLENOID RELAY................................................................................ 48 COMMUNICATION..................................................................................... 50 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE................................................... 50 VERIFICATION TESTS................................................................................ 52 VERIFICATION TESTS............................................................................ 52 8.0 COMPONENT LOCATIONS............................................................................... 54 8.1 DLC – INDICATORS.............................................................................. 54 8.2 CAB – WSS..................................................................................... 55 9.0 CONNECTOR PINOUTS................................................................................. 56 BRAKE LAMP SWITCH C1.............................................................................. 56 BRAKE LAMP SWITCH C2 - BLACK...................................................................... 56 CONTROLLER ANTILOCK BRAKE......................................................................... 56 DATA LINK CONNECTOR - BLACK....................................................................... 57 FUSES (FUSE/RELAY BLOCK).......................................................................... 59 TCS SWITCH (ASR) - BLACK.......................................................................... 59 WHEEL SPEED SENSOR-LEFT FRONT..................................................................... 59 WHEEL SPEED SENSOR-LEFT REAR...................................................................... 59 WHEEL SPEED SENSOR-RIGHT FRONT.................................................................... 59 WHEEL SPEED SENSOR-RIGHT REAR..................................................................... 60 10.0 SCHEMATIC DIAGRAMS............................................................................... 62 10.1 BOSCH 5.7 ANTILOCK BRAKE SYSTEM – ABS........................................................ 62 COMMENTS.............................................................................................. 64 VA Service Manual......................................................................................... 0 VA Powertrain............................................................................................. 0 VA Body................................................................................................... 0 VA Chassis................................................................................................ 0 VA Transmission........................................................................................... 66 TABLE OF CONTENTS..................................................................................... 66 1.0 INTRODUCTION...................................................................................... 70 1.1 SYSTEM COVERAGE............................................................................... 70 1.2 SIX -STEP TROUBLESHOOTING PROCEDURE........................................................... 70 2.0 IDENTIFICATION OF SYSTEM.......................................................................... 70 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION....................................................... 70 3.1 GENERAL DESCRIPTION........................................................................... 70 3.2 FUNCTIONAL OPERATION.......................................................................... 70 3.2.1 CONTROLLER MODES OF OPERATION........................................................... 71 3.2.2 MIL ILLUMINATION........................................................................ 71 3.2.3 SOLENOIDS............................................................................... 71 3.2.4 TRANSMISSION COMPONENT DESCRIPTIONS..................................................... 72 3.2.5 TRANSMISSION OPERATION AND SHIFT SCHEDULING............................................. 73 3.2.6 TRANSMISSION ADAPTIVES - INITIALIZE AND STORE........................................... 73 3.3 DIAGNOSTIC TROUBLE CODES...................................................................... 73 3.3.1 ACTIVE (HARD) CODE...................................................................... 73 3.3.2 STORED (INTERMITTENT) CODE.............................................................. 73 3.3.3 TROUBLE CODE ERASURE.................................................................... 74 3.4 USING THE DRBIII.............................................................................. 74 3.5 DRBIII ERROR MESSAGES......................................................................... 74 3.5.1 DRBIII DOES NOT POWER UP (BLANK SCREEN)................................................. 74 3.5.2 DISPLAY IS NOT VISIBLE.................................................................. 74 4.0 DISCLAIMERS, SAFETY, AND WARNINGS................................................................. 74 4.1 DISCLAIMERS................................................................................... 74 4.2 SAFETY........................................................................................ 75 4.2.1 TECHNICIAN SAFETY INFORMATION........................................................... 75 4.2.2 VEHICLE PREPARATION FOR TESTING......................................................... 75 4.2.3 SERVICING SUB-ASSEMBLIES................................................................ 75 4.2.4 DRBIII SAFETY INFORMATION............................................................... 75 4.3 WARNINGS...................................................................................... 76 4.3.1 VEHICLE DAMAGE WARNINGS................................................................. 76 4.3.2 ROAD TESTING A COMPLAINT VEHICLE........................................................ 76 4.4.4 BULLETINS AND RECALLS................................................................... 76 5.0 REQUIRED TOOLS AND EQUIPMENT...................................................................... 77 6.0 GLOSSARY OF TERMS................................................................................. 77 6.1 ACRONYMS...................................................................................... 77 6.2 DEFINITIONS................................................................................... 77 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................................................. 78 COMMUNICATION..................................................................................... 79 *NO RESPONSE FROM SHIFTER ASSEMBLY............................................................ 79 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE................................................. 81 SHIFT LEVER ASSEMBLY.............................................................................. 83 BACKUP LAMP CKT SHORT TO GROUND............................................................... 83 BACKUP LAMP CKT SHORT TO VOLTAGE OR OPEN...................................................... 84 BACKUP LAMP SUPPLY CIRCUIT OPEN............................................................... 85 CAN BUS CIRCUIT............................................................................... 86 INCORRECT CAN MESSAGE FROM ABS................................................................ 87 INTERNAL CONTROLLER........................................................................... 88 LR WHEEL SPIN CAN MESSAGE NOT VALID........................................................... 89 OVER VOLTAGE.................................................................................. 90 RR WHEEL SPIN CAN MESSAGE NOT VALID........................................................... 91 UNDER VOLTAGE................................................................................. 92 TRANSMISSION - NAG1............................................................................... 93 1-2/4-5 SOLENOID CIRCUIT...................................................................... 93 1-2/4-5 SOLENOID CIRCUIT SHORT TO GROUND...................................................... 93 2-3 SOLENOID CIRCUIT.......................................................................... 96 2-3 SOLENOID CIRCUIT SHORT TO GROUND.......................................................... 96 3-4 SOLENOID CIRCUIT.......................................................................... 99 3-4 SOLENOID CIRCUIT SHORT TO GROUND.......................................................... 99 ABS BRAKE MESSAGE............................................................................. 102 ABS CAN MESSAGE INCORRECT..................................................................... 104 ABS CAN MESSAGE MISSING....................................................................... 105 ABS LF SENSOR MESSAGE......................................................................... 107 ABS LR SENSOR MESSAGE......................................................................... 109 ABS RF SENSOR MESSAGE......................................................................... 111 ABS RR SENSOR MESSAGE......................................................................... 113 ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT...................................................... 115 CAN BUS CIRCUIT............................................................................... 117 CAN MESSAGE FROM ECM FROM SLA................................................................. 122 CONTROL MODULE TCM IS NOT CODED............................................................... 124 ENGINE CAN MESSAGE INCORRECT.................................................................. 125 ENGINE CAN MESSAGE MISSING.................................................................... 127 ENGINE OVERSPEED.............................................................................. 129 ENGINE RPM MESSAGE............................................................................ 131 ENGINE TEMP MESSAGE........................................................................... 133 ENGINE TORQUE MESSAGE INCORRECT............................................................... 135 ENGINE TORQUE REDUCTION....................................................................... 137 IC CAN MESSAGE INCORRECT...................................................................... 139 IC/ATC CAN MESSAGE MISSING.................................................................... 141 IMPROPER GEAR................................................................................. 143 IMPROPER RATIO................................................................................ 145 INPUT SENSOR MISMATCH......................................................................... 147 INPUT SENSOR OVERSPEED........................................................................ 149 INTERNAL CONTROLLER........................................................................... 151 INVALID CONTROL MODULE VERSION................................................................ 152 MODULATING PRESSURE SOLENOID CIRCUIT.......................................................... 153 N2 INPUT SPEED SENSOR CIRCUIT................................................................. 156 N3 INPUT SPEED SENSOR CIRCUIT................................................................. 160 SENSOR SUPPLY VOLTAGE......................................................................... 164 SHIFT LEVER POSITION INVALID.................................................................. 166 SHIFT PRESSURE SOLENOID CIRCUIT............................................................... 168 SLA CAN MESSAGE INCORRECT..................................................................... 171 SOLENOID SUPPLY VOLTAGE....................................................................... 172 SOLENOID SUPPLY/WATCHDOG...................................................................... 174 SYSTEM OVERVOLTAGE............................................................................ 176 SYSTEM UNDERVOLTAGE........................................................................... 178 TCC OVER TEMP................................................................................. 180 TCC SOLENOID CIRCUIT.......................................................................... 181 TCC STUCK ON.................................................................................. 184 TRANS TEMP SENSOR - P/N SWITCH CIRCUIT........................................................ 186 TRANS TEMP SENSOR ERRATIC..................................................................... 189 TRANS TEMP SENSOR SHORTED..................................................................... 191 TRANSMISSION SLIPPING......................................................................... 194 VERIFICATION TESTS................................................................................ 196 VERIFICATION TESTS............................................................................ 196 8.0 COMPONENT LOCATIONS............................................................................... 198 8.1 ENGINE CONTROL MODULE......................................................................... 198 8.2 TRANSMISSION CONTROL MODULE................................................................... 198 8.3 TRANSMISSION SOLENOID ASSEMBLY................................................................ 198 9.0 CONNECTOR PINOUTS................................................................................. 200 SHIFTER ASSEMBLY - BLACK.......................................................................... 200 TRANSMISSION CONTROL MODULE C1 - BLACK............................................................ 200 TRANSMISSION CONTROL MODULE C2 - BLACK............................................................ 200 TRANSMISSION RELAY (RELAY BLOCK).................................................................. 202 TRANSMISSION SOLENOID ASSEMBLY - BLACK............................................................ 202 10.0 SCHEMATIC DIAGRAMS............................................................................... 204 11.0 CHARTS AND GRAPHS................................................................................ 206 11.1 5 VOLT SQUARE WAVE – TYPICAL PATTERN......................................................... 206 11.2 TRANSMISSION TEMP SENSOR..................................................................... 207 COMMENTS.............................................................................................. 208 VA Service Manual......................................................................................... 0 VA Body................................................................................................... 0 VA Chassis................................................................................................ 0 VA Transmission........................................................................................... 0 VA Powertrain............................................................................................. 418 TABLE OF CONTENTS..................................................................................... 210 1.0 INTRODUCTION...................................................................................... 216 1.1 SYSTEM COVERAGE............................................................................... 216 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE............................................................ 216 2.0 IDENTIFICATION OF SYSTEM.......................................................................... 216 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION....................................................... 216 3.1 GENERAL DESCRIPTION........................................................................... 216 3.2 FUNCTIONAL OPERATION.......................................................................... 216 3.2.1 ECM ON-BOARD DIAGNOSTICS................................................................ 216 3.2.2 ECM OPERATING MODES..................................................................... 217 3.2.3 MONITORED CIRCUITS...................................................................... 217 3.2.4 SKREEM OVERVIEW......................................................................... 217 3.2.5 SKREEM ON-BOARD DIAGNOSTICS............................................................. 217 3.2.6 SKREEM OPERATION........................................................................ 217 3.3 DIAGNOSTIC TROUBLE CODES...................................................................... 218 3.3.1 HARD CODE............................................................................... 218 3.3.2 INTERMITTENT CODE....................................................................... 218 3.3.3 ECM DIAGNOSTIC TROUBLE CODES............................................................ 218 3.3.4 HANDLING NO TROUBLE CODE PROBLEMS....................................................... 220 3.4 USING THE DRBIII.............................................................................. 221 3.4.1 DRBIII DOES NOT POWER UP................................................................ 221 3.4.2 DISPLAY IS NOT VISIBLE.................................................................. 221 4.0 DISCLAIMERS, SAFETY, WARNINGS..................................................................... 221 4.1 DISCLAIMERS................................................................................... 221 4.2 SAFETY........................................................................................ 221 4.2.1 TECHNICIAN SAFETY INFORMATION........................................................... 221 4.2.2 VEHICLE PREPARATION FOR TESTING......................................................... 221 4.2.3 SERVICING SUB-ASSEMBLIES................................................................ 221 4.2.4 DRBIII SAFETY INFORMATION............................................................... 222 4.3 WARNINGS AND CAUTIONS......................................................................... 222 4.3.1 ROAD TEST WARNINGS...................................................................... 222 4.3.2 VEHICLE DAMAGE CAUTIONS................................................................. 222 5.0 REQUIRED TOOLS AND EQUIPMENT...................................................................... 222 6.0 GLOSSARY OF TERMS................................................................................. 222 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................................................. 224 DRIVEABILITY - DIESEL............................................................................. 225 P-1105 ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH.................................... 225 P-1105 ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW..................................... 225 P1613-ECM INTERNAL ERROR - LOWER STABILIZATION LIMIT.......................................... 225 P1613-ECM INTERNAL ERROR - UPPER STABILIZATION LIMIT.......................................... 225 P1614-ECM COMMUNICATION #1.................................................................... 225 P1614-ECM COMMUNICATION #2.................................................................... 225 P1614-ECM QUANTITY STOP....................................................................... 225 P1614-ECM RECOVERY ERROR...................................................................... 225 P1614-ECM SHUT OFF MONITORING................................................................. 225 P1617-ECM EEPROM ADAPTION VALUE............................................................... 225 P1617-ECM EEPROM COMMUNICATION................................................................ 225 P1630-IMMOBILIZER - NO ERROR IN ECM EEPROM TEST............................................... 225 P1666-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE........................................... 225 P1666-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY.................................................. 225 P2319-A/D CONVERTER ERROR APP SENSOR GROUND FAILURE........................................... 225 P2319-A/D CONVERTER ERROR INTERNAL FAILURE.................................................... 225 P2319-A/D CONVERTER ERROR VOLTAGE FAILURE..................................................... 225 P2320-CAPACITOR #1 - VOLTAGE ERROR............................................................ 225 P2320-CAPACITOR #2 - VOLTAGE ERROR............................................................ 225 P0100-MASS AIR FLOW SENSOR PLAUSIBILITY #1.................................................... 227 P0100-MASS AIR FLOW SENSOR PLAUSIBILITY #2.................................................... 227 P0100-MASS AIR FLOW SENSOR PLAUSIBILITY #3.................................................... 227 P0100-MASS AIR FLOW SENSOR PLAUSIBILITY #4.................................................... 227 P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH............................................ 227 P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW............................................. 227 P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW..................................... 227 P0105-BOOST PRESSURE SENSOR PLAUSIBILITY...................................................... 233 P0105-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH........................................... 235 P0105-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW............................................ 238 P0105-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW.................................... 241 P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.................................. 244 P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW................................... 247 P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT ENGINE IS COLD TOO LONG.............................. 249 P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.............................. 250 P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW............................... 253 P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE TOO HIGH............................... 255 P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE TOO LOW................................ 258 P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH.................................. 260 P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW................................... 264 P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR LOW........................... 267 P0190-FUEL PRESS SENSOR CIRCUIT PLAUSIBILITY.................................................. 268 P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE............................................ 270 P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP................................................... 270 P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE....................................... 270 P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE........................................ 270 P0202-CYLINDER 2-INJECTOR CIRCUIT CURRENT DECREASE............................................ 270 P0202-CYLINDER 2-INJECTOR CIRCUIT LOAD DROP................................................... 270 P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE....................................... 270 P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT LOW SIDE........................................ 270 P0203-CYLINDER 3-INJECTOR CIRCUIT CURRENT DECREASE............................................ 270 P0203-CYLINDER 3-INJECTOR CIRCUIT LOAD DROP................................................... 270 P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE....................................... 270 P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT LOW SIDE........................................ 270 P0204-CYLINDER 4-INJECTOR CIRCUIT CURRENT DECREASE............................................ 270 P0204-CYLINDER 4-INJECTOR CIRCUIT LOAD DROP................................................... 270 P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE....................................... 270 P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT LOW SIDE........................................ 270 P0205-CYLINDER 5-INJECTOR CIRCUIT CURRENT DECREASE............................................ 270 P0205-CYLINDER 5-INJECTOR CIRCUIT LOAD DROP................................................... 270 P0205-CYLINDER 5-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE....................................... 270 P0205-CYLINDER 5-INJECTOR CIRCUIT OVERCURRENT LOW SIDE........................................ 270 P0500-VEHICLE SPEED SENSOR - PLAUSIBILITY #1.................................................. 277 P0500-VEHICLE SPEED SENSOR - PLAUSIBILITY #2.................................................. 277 P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH................................................. 277 P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH............................................ 277 P0600-CAN DATA BUS - BUS FAILURE.............................................................. 279 P0600-CAN DATA BUS - HARDWARE FAULT........................................................... 279 P0600-CAN DATA BUS - TRANSMISSION ERROR #1.................................................... 279 P0600-CAN DATA BUS - TRANSMISSION ERROR #2.................................................... 279 P0703-BRAKE SWITCH SIGNAL CIRCUITS INCORRECT CAN MESSAGE...................................... 284 P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY #1............................................ 284 P0703-BRAKE SWITCH SIGNAL PLAUSIBILITY #2..................................................... 284 P1187-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICKING........................................ 286 P1187-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED......................................... 286 P1187-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED......................................... 286 P1187-FUEL RAIL PRESSURE MALFUNCTION POSITIVE DEVIATION AT ENGINE SPEED TO HIGH............... 286 P1187-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT OFF............................... 286 P1187-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW......................................... 286 P1187-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN............................................ 286 P1188-FUEL SHUTDOWN SOLENOID CIRCUIT OPEN..................................................... 291 P1188-FUEL SHUTDOWN SOLENOID CIRCUIT SHORTED TO GROUND OR B+.................................. 291 P1190-FUEL PRESSURE SOLENOID CIRCUIT OPEN CIRCUIT............................................. 294 P1190-FUEL PRESSURE SOLENOID CIRCUIT PLAUSIBILITY............................................. 294 P1190-FUEL PRESSURE SOLENOID CIRCUIT SHORTED TO GROUND OR B+.................................. 294 P1663-FUEL PRESSURE SOLENOID SIGNAL VOLTAGE TOO HIGH.......................................... 294 P1663-FUEL PRESSURE SOLENOID SIGNAL VOLTAGE TOO LOW........................................... 294 P1192-ENGINE OIL SENSOR WATER CONTAMINATION................................................... 298 P1192-ENGINE OIL SENSOR OIL LEVEL PLAUSIBILITY................................................ 298 P1192-ENGINE OIL SENSOR OIL QUALITY PLAUSIBILITY.............................................. 298 P1192-ENGINE OIL SENSOR CIRCUIT OPEN OR SHORTED TO GROUND..................................... 299 P1192-ENGINE OIL SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW........................................ 299 P1192-ENGINE OIL SENSOR SYNCHRONIZATION ERROR #1.............................................. 299 P1192-ENGINE OIL SENSOR SYNCHRONIZATION ERROR #2.............................................. 299 P1192-ENGINE OIL SENSOR TIMING ERROR.......................................................... 299 P1221-CAN MESSAGE - ABS MESSAGE ERROR......................................................... 303 P1221-CAN MESSAGE - TCM MESSAGE ERROR......................................................... 305 P1222-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY #1......................................... 307 P1222-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY #2......................................... 307 P1222-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY #3......................................... 307 P1222-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH................................. 307 P1222-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW.................................. 307 P1222-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH OR LOW.......................... 307 P1234-ACC PEDAL POSITION SENSOR 2 CIRCUIT PLAUSIBILITY 1 AND 2................................ 307 P1234-ACC PEDAL POSITION SENSOR 2 CKT SIGNAL VOLTAGE TOO HIGH................................. 307 P1234-ACC PEDAL POSITION SENSOR 2 CKT SIGNAL VOLTAGE TOO LOW.................................. 307 P1234-ACC PEDAL POSITION SENSOR 2 CKT SUPPLY VOLTAGE TOO HIGH OR LOW.......................... 307 P1330-STARTER RELAY CIRCUIT OPEN CIRCUIT...................................................... 313 P1330-STARTER RELAY CIRCUIT SHORT CIRCUIT..................................................... 313 P1335-CKP SENSOR CIRCUIT DYNAMIC PLAUSIBILITY................................................. 316 P1335-CKP SENSOR CIRCUIT PLAUSIBILITY #1...................................................... 316 P1335-CKP SENSOR CIRCUIT PLAUSIBILITY #2...................................................... 316 P1354-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSIBILITY.............................. 319 P1354-CMP/CKP POSITION SENSOR CIRCUIT - CMP/CKP SYNC FAILURE.................................. 322 P1354-CMP/CKP POSITION SENSOR CIRCUIT - CORRECTION FOR MAIN INJECTION DELAYED................. 322 P1354-CMP/CKP POSITION SENSOR CIRCUIT - FUEL SHUT-OFF ACTIVATED............................... 322 P1354-CMP/CKP POSITION SENSOR CIRCUIT - DYNAMIC PLAUSIBILITY.................................. 325 P1354-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO HIGH............................. 325 P1403-EGR SOLENOID CIRCUIT IMPROPER FLOW...................................................... 330 P1403-EGR SOLENOID CIRCUIT NEGATIVE DEVIATION................................................. 330 P1403-EGR SOLENOID CIRCUIT POSITIVE DEVIATION................................................. 330 P1403-EGR SOLENOID CIRCUIT OPEN CIRCUIT....................................................... 332 P1403-EGR SOLENOID CIRCUIT SHORT CIRCUIT...................................................... 335 P1470-BOOST PRESSURE SOLENOID CIRCUIT - PLAUSIBILITY.......................................... 337 P1470-BOOST PRESSURE SOLENOID CIRCUIT NEGATIVE DEVIATION...................................... 337 P1470-BOOST PRESSURE SOLENOID CIRCUIT POSITIVE DEVIATION...................................... 337 P1470-BOOST PRESSURE SOLENOID CIRCUIT OPEN CIRCUIT............................................ 340 P1470-BOOST PRESSURE SOLENOID CIRCUIT SHORT CIRCUIT........................................... 343 P1481-GLOW PLUG FAILURE - CYLINDER #1......................................................... 345 P1481-GLOW PLUG FAILURE - CYLINDER #2......................................................... 345 P1481-GLOW PLUG FAILURE - CYLINDER #3......................................................... 345 P1481-GLOW PLUG FAILURE - CYLINDER #4......................................................... 345 P1481-GLOW PLUG FAILURE - CYLINDER #5......................................................... 345 P1482-GLOW PLUG MODULE - COMMUNICATION FAULT.................................................. 347 P1482-GLOW PLUG MODULE - INCORRECT RECEPTION MESSAGE.......................................... 347 P1482-GLOW PLUG MODULE - SHORT CIRCUIT........................................................ 347 P1482-GLOW PLUG MODULE - EXCESS CURRENT....................................................... 349 P1482-GLOW PLUG MODULE - INCORRECT DIAGNOSTIC SEQUENCE........................................ 349 P1482-GLOW PLUG MODULE - INTERNAL FAULT....................................................... 349 P1520-S/C - CAN MESSAGE PLAUSIBILITY.......................................................... 351 P1520-S/C - NEGATIVE ACCELERATION DEVIATION................................................... 351 P1520-S/C - NEGATIVE ACCELERATION DEVIATION................................................... 351 P1520-S/C - POSITIVE ACCELERATION DEVIATION................................................... 351 P1520-S/C - SWITCH SIGNAL OUT OF RANGE........................................................ 351 P1520-S/C - SWITCH SIGNAL PLAUSIBILITY........................................................ 351 P1610-ENGINE CONTROL RELAY SHUTS OFF TOO EARLY................................................ 355 P1610-ENGINE CONTROL RELAY SHUTS OFF TOO LATE................................................. 357 P1611-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH......................................... 360 P1611-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW.......................................... 363 P1612-IGNITION VOLTAGE - VOLTAGE ERROR........................................................ 367 P1615-ECM INTERNAL ERROR - SUPPLY VOLTAGE IS TOO HIGH......................................... 368 P1615-ECM VOLTAGE SUPPLY IS TOO LOW........................................................... 368 P1617- ECM CODEWORD IS INCORRECT OR MISSING................................................... 370 P1617- ECM VERSION NUMBER MISSING............................................................. 370 P1630-IMMOBILIZER MESSAGE MISSING............................................................. 371 P1661-CAPACITOR #1 CALCULATED VOLTAGE IS INCORRECT............................................ 373 P1661-CAPACITOR #1 READOUT TOO LARGE.......................................................... 373 P1661-CAPACITOR #1 READOUT TOO SMALL.......................................................... 373 P1661-CAPACITOR 1 VOLTAGE TOO HIGH............................................................ 373 P1661-CAPACITOR 1 VOLTAGE TOO LOW............................................................. 373 P1681-ACM CIRCUIT FAULT....................................................................... 375 P2006-LOW FUEL PRESSURE SENSOR SIGNAL VOLTAGE TOO HI.......................................... 377 P2006-LOW SIDE FUEL PRESSURE SENSOR - SIGNAL VOLTAGE IS TOO LOW............................... 381 P2007-FUEL DELIVERY - MINIMUM PRESSURE NOT REACHED............................................ 383 P2007-FUEL DELIVERY PLAUSIBILITY.............................................................. 383 P2007-FUEL DELIVERY- FUEL FILTER RESTRICTION.................................................. 383 P2007-FUEL DELIVERY- PRESSURE TOO LOW......................................................... 383 P2008-FUEL PRESSURE - MEASUREMENT IS TOO HIGH................................................. 383 P2008-FUEL PRESSURE - MEASUREMENT IS TOO LOW.................................................. 383 P2009-WATER LEVEL SENSOR - WATER IN FUEL...................................................... 384 P2200-INSTRUMENT CLUSTER - CAN ERROR.......................................................... 387 P2200-INSTRUMENT CLUSTER - GLOW LAMP FAULT.................................................... 387 P2203-TORQUE REDUCTION MESSAGE FROM ABS - CAN PLAUSIBILITY.................................... 389 P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGE ERROR....................................... 389 P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGES MISSING.................................... 389 P2203-TORQUE REDUCTION MESSAGE FROM ABS - NO COMMUNIOCATION................................... 389 P2203-TORQUE REDUCTION MESSAGE FROM ABS - PLAUSIBILITY #1..................................... 389 P2203-TORQUE REDUCTION MESSAGE FROM ABS PLAUSIBILITY #2....................................... 389 P2204-TORQUE REDUCTION MESSAGE FROM TCM - CAN PLAUSIBILITY.................................... 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - ENGINE STOP......................................... 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - MESSAGE ERROR....................................... 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - MESSAGES MISSING.................................... 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - PLAUSIBILITY........................................ 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - TCM DTC #1.......................................... 391 P2204-TORQUE REDUCTION MESSAGE FROM TCM - TCM DTC #2.......................................... 391 P2306-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH......................................... 393 P2306-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW.......................................... 396 *CHECKING THE POWER AND GROUNDS............................................................... 399 *ENGINE CRANKS BUT WILL NOT START............................................................. 404 *ENGINE WILL NOT CRANK........................................................................ 407 VERIFICATION TESTS................................................................................ 411 VERIFICATION TESTS............................................................................ 411 8.0 COMPONENT LOCATIONS............................................................................... 414 8.1 CONTROL MODULES............................................................................... 414 8.2 CONTROLS AND SOLENOIDS........................................................................ 414 8.3 SENSORS....................................................................................... 415 8.4 SWITCHES...................................................................................... 416 9.0 CONNECTOR PINOUTS................................................................................. 418 ACCELERATOR PEDAL POSITION SENSOR - BLACK......................................................... 418 AIRBAG CONTROL MODULE - YELLOW.................................................................... 418 BOOST PRESSURE SENSOR - BLACK..................................................................... 418 BOOST PRESSURE SOLENOID - BLACK................................................................... 418 CAMSHAFT POSITION SENSOR - BLACK.................................................................. 419 CENTRAL TIMER MODULE C1 - PINK.................................................................... 419 CRANKSHAFT POSITION SENSOR - BLACK................................................................ 419 DATA LINK CONNECTOR - BLACK....................................................................... 419 EGR VALVE - BLACK................................................................................. 420 ENGINE CONTROL MODULE C1 - BLACK.................................................................. 420 ENGINE CONTROL MODULE C2 - BLACK.................................................................. 420 ENGINE CONTROL MODULE C3 - BLACK.................................................................. 421 ENGINE CONTROL MODULE C4 - BLACK.................................................................. 421 ENGINE CONTROL MODULE C5 - GRAY................................................................... 422 ENGINE COOLANT TEMPERATURE SENSOR - BLACK......................................................... 422 ENGINE OIL SENSOR - BLACK......................................................................... 422 FUEL INJECTOR NO. 1 - BLACK....................................................................... 422 FUEL INJECTOR NO. 2 - BLACK....................................................................... 423 FUEL INJECTOR NO. 3 - BLACK....................................................................... 423 FUEL INJECTOR NO. 4 - BLACK....................................................................... 423 FUEL INJECTOR NO. 5 - BLACK....................................................................... 423 FUEL PRESSURE SENSOR - BLACK...................................................................... 424 FUEL PRESSURE SOLENOID............................................................................ 424 FUEL SHUTDOWN SOLENOID............................................................................ 424 FUEL TEMPERATURE SENSOR........................................................................... 424 ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)........................................................... 426 STARTER MOTOR RELAY (FUSE/RELAY BLOCK)............................................................ 428 GLOW PLUG CONTROL MODULE C1 - BLACK............................................................... 428 GLOW PLUG CONTROL MODULE C2 - BLACK............................................................... 428 INSTRUMENT CLUSTER C1............................................................................. 428 INTAKE AIR TEMPERATURE SENSOR - BLACK............................................................. 429 LOW FUEL PRESSURE SENSOR - BLACK.................................................................. 429 MASS AIR FLOW SENSOR - BLACK...................................................................... 429 SPEED CONTROL SWITCH.............................................................................. 429 10.0 SCHEMATIC DIAGRAMS............................................................................... 430 10.1 ENGINE CONTROL MODULE........................................................................ 430 10.2 ENGINE CONTROL MODULE........................................................................ 431 11.0 CHARTS AND GRAPHS................................................................................ 432 VA Service Manual......................................................................................... 0 VA Powertrain............................................................................................. 0 VA Chassis................................................................................................ 0 VA Transmission........................................................................................... 0 VA Body................................................................................................... 434 TABLE OF CONTENTS..................................................................................... 434 1.0 INTRODUCTION...................................................................................... 442 1.1 SYSTEM COVERAGE............................................................................... 442 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE............................................................ 442 2.0 IDENTIFICATION OF SYSTEM.......................................................................... 442 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION....................................................... 442 3.1 AIRBAG SYSTEM................................................................................. 442 3.1.1 DRIVER AIRBAG........................................................................... 443 3.1.2 CLOCKSPRING............................................................................. 444 3.1.3 PASSENGER AIRBAG........................................................................ 444 3.1.4 SEAT BELT TENSIONERS.................................................................... 444 3.1.5 SPECIAL TOOLS........................................................................... 444 3.1.6 DIAGNOSTIC TROUBLE CODES................................................................ 445 3.1.6.1 ACTIVE CODES.......................................................................... 445 3.1.6.2 STORED CODES.......................................................................... 445 3.2 COMMUNICATION................................................................................. 445 3.2.1 COMMUNICATION K-LINES................................................................... 445 3.2.2 CAN BUS................................................................................. 446 3.3 HEATING & A/C SYSTEM.......................................................................... 446 3.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC)..................................................... 446 3.3.1.1 SYSTEM CONTROLS....................................................................... 446 3.3.1.2 SYSTEM DIAGNOSTICS.................................................................... 446 3.3.2 CABIN HEATER MODULE (CHM) & HEATER BOOSTER MODULE (HBM)................................. 448 3.3.2.1 SYSTEM DESCRIPTION.................................................................... 448 3.3.2.2 VENTING THE HEATER'S EXHAUST.......................................................... 449 3.3.2.3 SYSTEM DIAGNOSTICS.................................................................... 449 3.4 INSTRUMENT CLUSTER............................................................................ 450 3.5 POWER DOOR LOCKS/RKE.......................................................................... 450 3.5.1. CENTRAL LOCKING........................................................................ 450 3.5.2 REMOTE KEYLESS ENTRY (RKE).............................................................. 450 3.5.3 AUTO DOOR LOCKS......................................................................... 451 3.5.4 ACCIDENT RESPONSE....................................................................... 451 3.6 VEHICLE THEFT SECURITY SYSTEM (VTSS).......................................................... 451 3.7 USING THE DRBIII.............................................................................. 452 3.8 DRBIII ERROR MESSAGES......................................................................... 452 3.9 DRBIII DOES NOT POWER UP (BLANK SCREEN)....................................................... 452 3.10 DISPLAY IS NOT VISIBLE....................................................................... 452 4.0 DISCLAIMERS, SAFETY, WARNINGS..................................................................... 452 4.1 DISCLAIMERS................................................................................... 452 4.2 SAFETY........................................................................................ 452 4.2.1 TECHNICIAN SAFETY INFORMATION........................................................... 452 4.2.2 VEHICLE PREPARATION FOR TESTING......................................................... 453 4.2.3 SERVICING SUB-ASSEMBLIES................................................................ 453 4.2.4 DRBIII SAFETY INFORMATION............................................................... 453 4.3 WARNINGS...................................................................................... 453 4.3.1 VEHICLE DAMAGE WARNINGS................................................................. 453 4.3.2 ROAD TESTING A COMPLAINT VEHICLE........................................................ 453 5.0 REQUIRED TOOLS AND EQUIPMENT...................................................................... 454 6.0 GLOSSARY OF TERMS................................................................................. 454 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................................................. 456 AIRBAG............................................................................................ 457 AIRBAG WARNING INDICATOR - DRIVER HIGH........................................................ 457 AIRBAG WARNING INDICATOR - DRIVER LOW......................................................... 460 DRIVER SEAT BELT TENSIONER - INCORRECT FEEDBACK............................................... 463 DRIVER SQUIB 1 - INCORRECT FEEDBACK........................................................... 463 INTERNAL 1.................................................................................... 463 INTERNAL 2.................................................................................... 463 INTERNAL 3.................................................................................... 463 PASSENGER SEAT BELT TENSIONER - INCORRECT FEEDBACK............................................ 463 PASSENGER SQUIB 1 - INCORRECT FEEDBACK........................................................ 463 STORED ENERGY FIRING 1........................................................................ 463 STORED ENERGY FIRING 2........................................................................ 463 DRIVER SEAT BELT TENSIONER CIRCUIT OPEN....................................................... 465 DRIVER SEAT BELT TENSIONER CIRCUIT SHORT...................................................... 467 DRIVER SEAT BELT TENSIONER SHORT TO BATTERY................................................... 469 DRIVER SEAT BELT TENSIONER SHORT TO GROUND.................................................... 472 DRIVER SQUIB 1 CIRCUIT OPEN................................................................... 474 DRIVER SQUIB 1 CIRCUIT SHORT.................................................................. 477 DRIVER SQUIB 1 SHORT TO BATTERY............................................................... 480 DRIVER SQUIB 1 SHORT TO GROUND................................................................ 483 LOSS OF IGNITION RUN - START.................................................................. 486 PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN.................................................... 488 PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT................................................... 490 PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY................................................ 492 PASSENGER SEAT BELT TENSIONER SHORT TO GROUND................................................. 495 PASSENGER SQUIB 1 CIRCUIT OPEN................................................................ 497 PASSENGER SQUIB 1 CIRCUIT SHORT............................................................... 500 PASSENGER SQUIB 1 SHORT TO BATTERY............................................................ 503 PASSENGER SQUIB 1 SHORT TO GROUND............................................................. 506 *AIRBAG WARNING INDICATOR FLASHING............................................................ 509 CABIN HEATER...................................................................................... 510 A. HEATER PRE-TEST............................................................................ 510 CIRC PUMP CONTROL OPEN........................................................................ 513 CIRC PUMP CONTROL SHORTED..................................................................... 515 COMBUST FAN SHORTED........................................................................... 517 COMBUST FAN SPEED INCORRECT................................................................... 517 COMBUSTION FAN OPEN........................................................................... 517 CONTROL UNIT FAULTY........................................................................... 518 DOSING PUMP OPEN.............................................................................. 519 DOSING PUMP SHORTED........................................................................... 522 FAN STAGE 1 RELAY CONTROL OPEN................................................................ 524 FAN STAGE 1 RELAY CONTROL SHORTED............................................................. 526 FLAME DETECT PRIOR TO COMBUST................................................................. 528 FLAME OUT..................................................................................... 529 NO START...................................................................................... 529 FLAME SENSOR OPEN............................................................................. 532 FLAME SENSOR SHORTED.......................................................................... 532 GLOW PIN OPEN................................................................................. 532 GLOW PIN SHORTED.............................................................................. 532 HEATER IN LOCKOUT MODE........................................................................ 534 HEATER OVERHEATED............................................................................. 534 SUCCESSIVE OVERHEATING........................................................................ 534 OVER VOLTAGE.................................................................................. 537 OVERHEATING SENSOR OPEN....................................................................... 538 OVERHEATING SENSOR SHORTED.................................................................... 538 TEMP SENSOR OPEN.............................................................................. 539 TEMP SENSOR SHORTED........................................................................... 539 UNDER VOLTAGE................................................................................. 540 COMMUNICATION..................................................................................... 543 *NO RESPONSE FROM AIRBAG CONTROL MODULE....................................................... 543 *NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL............................................... 545 *NO RESPONSE FROM CABIN HEATER MODULE......................................................... 547 *NO RESPONSE FROM CENTRAL TIMER MODULE........................................................ 549 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE................................................... 551 *NO RESPONSE FROM ENGINE CONTROL MODULE....................................................... 553 *NO RESPONSE FROM HEATER BOOSTER MODULE....................................................... 555 *NO RESPONSE FROM INSTRUMENT CLUSTER.......................................................... 557 *NO RESPONSE FROM SECURITY SYSTEM MODULE...................................................... 559 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE.............................................. 561 *NO RESPONSE FROM SHIFTER ASSEMBLY............................................................ 563 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE................................................. 565 HEATING & A/C..................................................................................... 567 A/C COMPRESSOR CONTROL HIGH OR OPEN (ACTIVE).................................................. 567 A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED).................................................. 569 A/C COMPRESSOR CONTROL SHORTED LOW (STORED)................................................... 569 AIR OUTLET TEMP SENSOR HIGH OR OPEN (STORED).................................................. 569 AIR OUTLET TEMP SENSOR SHORTED LOW (STORED)................................................... 569 AUX FAN RELAY CONTROL HIGH OR OPEN (STORED)................................................... 569 AUX FAN RELAY CONTROL SHORTED LOW (STORED).................................................... 569 BLOWER STAGE 1 HIGH OR OPEN (STORED).......................................................... 569 BLOWER STAGE 1 SHORTED LOW (STORED)........................................................... 569 CABIN HEATER CONTROL HIGH OR OPEN (STORED).................................................... 569 CABIN HEATER CONTROL SHORTED LOW (STORED)..................................................... 569 CIRC PUMP CONTROL HIGH OR OPEN (STORED)....................................................... 569 CIRC PUMP CONTROL SHORTED LOW (STORED)........................................................ 569 EVAP TEMP SENSOR HIGH OR OPEN (STORED)........................................................ 569 EVAP TEMP SENSOR SHORTED LOW (STORED)......................................................... 569 NO COMMUNICATION BUS (STORED)................................................................. 569 NO COMMUNICATION WITH ECM (STORED)............................................................ 569 NO COMMUNICATION WITH IC (STORED)............................................................. 569 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (STORED)............................................. 569 RECIRC AIR SOLENOID CONTROL SHORTED LOW (STORED).............................................. 569 REFRIG PRESS SENSOR HIGH OR OPEN (STORED)..................................................... 569 REFRIG PRESS SENSOR SHORTED LOW (STORED)...................................................... 569 WATER CYCLE VALVE CONTROL HIGH OR OPEN (STORED)............................................... 569 WATER CYCLE VALVE CONTROL SHORTED LOW (STORED)................................................ 569 A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE)................................................... 571 AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE).................................................. 573 AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE)................................................... 575 ATC FUNCTION TEST COOL FAILURE................................................................ 577 ATC FUNCTION TEST FAILURE..................................................................... 577 ATC FUNCTION TEST HEAT FAILURE................................................................ 577 AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE)................................................... 579 AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE).................................................... 581 BLOWER STAGE 1 HIGH OR OPEN (ACTIVE).......................................................... 583 BLOWER STAGE 1 SHORTED LOW (ACTIVE)........................................................... 585 CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE).................................................... 587 CABIN HEATER CONTROL SHORTED LOW (ACTIVE)..................................................... 589 CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE)....................................................... 591 CIRC PUMP CONTROL SHORTED LOW (ACTIVE)........................................................ 593 EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE)........................................................ 595 EVAP TEMP SENSOR SHORTED LOW (ACTIVE)......................................................... 597 NO COMMUNICATION BUS (ACTIVE)................................................................. 599 NO COMMUNICATION WITH ECM (ACTIVE)............................................................ 602 NO COMMUNICATION WITH IC (ACTIVE)............................................................. 604 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE)............................................. 606 RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE).............................................. 608 REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE)..................................................... 610 REFRIG PRESS SENSOR SHORTED LOW (ACTIVE)...................................................... 612 WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE)............................................... 614 WATER CYCLE VALVE CONTROL SHORTED LOW (ACTIVE)................................................ 616 INSTRUMENT CLUSTER................................................................................ 618 AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY..................................................... 618 AMBIENT TEMP SENSOR SHORT TO GROUND........................................................... 620 FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY....................................................... 621 FUEL LEVEL SENSOR SHORT TO GROUND............................................................. 623 INSTRUMENT CLUSTER INTERNAL FAILURE B1043..................................................... 624 INSTRUMENT CLUSTER INTERNAL FAILURE B1053..................................................... 625 INSTRUMENT CLUSTER OVERVOLTAGE................................................................ 626 NO CAN COMMUNICATION WITH ABS................................................................. 627 NO CAN COMMUNICATION WITH ECM................................................................. 629 NO CAN COMMUNICATION WITH TCM................................................................. 631 PREGLOW INDICATOR LAMP FAILURE................................................................ 633 SRS INDICATOR LAMP FAILURE.................................................................... 634 POWER DOOR LOCKS/RKE.............................................................................. 635 DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND..................................... 635 PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND.................................. 637 REPLACE CONTROL MODULE........................................................................ 639 RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM................................................... 640 RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM................................................ 642 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM.................................................. 644 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM............................................... 645 THE ACM HAS UNLOCKED THE DOORS................................................................ 647 UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2....................................................... 648 *RKE INOPERATIVE.............................................................................. 649 *RKE POOR RANGE............................................................................... 650 VEHICLE THEFT/SECURITY............................................................................ 651 DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND........................................... 651 DRIVER CYLINDER UNLOCK SWITCH CIRCUIT SHORT TO GROUND......................................... 653 FRONT DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND................................................ 655 INTERNAL ERROR - SSM.......................................................................... 657 TOWING INCLINATION SENSOR BEYOND LIMITS....................................................... 657 TOWING INCLINATION SENSOR VALUE IS INVALID.................................................... 657 TOWING INCLINATION SENSOR VALUE IS MISSING.................................................... 657 INTRUSION SENSOR 1 CIRCUIT OPEN/SHORT TO GROUND............................................... 659 INTRUSION SENSOR 1 GROUND CIRCUIT OPEN........................................................ 661 INTRUSION SENSOR 2 CIRCUIT OPEN/SHORT TO GROUND............................................... 662 INTRUSION SENSOR 2 GROUND CIRCUIT OPEN........................................................ 664 INTRUSION SENSOR 3 CIRCUIT OPEN/SHORT TO GROUND............................................... 665 INTRUSION SENSOR 3 GROUND CIRCUIT OPEN........................................................ 667 REAR OR SLIDING DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND...................................... 668 RKE INTERFACE CIRCUIT FAILURE - SSM........................................................... 670 SECURITY SYSTEM INTERFACE FAILURE - SSM....................................................... 672 SIREN CIRCUIT OPEN/SHORTED TO GROUND.......................................................... 674 SIREN INTERNAL FAILURE........................................................................ 676 SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND.................................................. 677 VERIFICATION TESTS................................................................................ 678 VERIFICATION TESTS............................................................................ 678 8.0 COMPONENT LOCATIONS............................................................................... 682 8.1 AIRBAG SYSTEM................................................................................. 682 8.2 AIRBAG CONTROL MODULE......................................................................... 682 8.3 DRIVER AIRBAG SQUIB........................................................................... 682 8.4 CLOCKSPRING .................................................................................. 683 8.5 SEAT BELT TENSIONER........................................................................... 683 8.6 HEATING & A/C................................................................................. 683 8.6.1 AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM COMPONENTS................................... 683 8.6.2 CABIN HEATER & HEATER BOOSTER SYSTEM COMPONENTS......................................... 684 8.6.3 AUTO TEMP CONTROL, CABIN HEATER, & HEATER BOOSTER FUSES & RELAYS........................ 684 8.6.4 EVAP TEMP SENSOR & AIR OUTLET TEMP SENSOR............................................... 684 8.7 INSTRUMENT CLUSTER............................................................................ 685 8.7.1 AMBIENT TEMPERATURE SENSOR.............................................................. 685 8.8 POWER DOOR LOCKS/RKE.......................................................................... 685 8.8.1 CENTRAL TIMER MODULE.................................................................... 685 8.8.2 SENTRY KEY REMOTE ENTRY MODULE.......................................................... 686 8.8.3 DOOR LOCK MOTOR/AJAR SWITCH............................................................. 686 8.8.4 CONTACT PLATES.......................................................................... 686 8.8.5 DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS.................................................. 687 8.9 VEHICLE THEFT SECURITY SYSTEM................................................................. 687 8.9.1 SECURITY SYSTEM MODULE.................................................................. 687 8.9.2 INTRUSION SENSORS....................................................................... 687 8.9.3 SWITCHES................................................................................ 688 8.9.4 SIREN................................................................................... 688 9.0 CONNECTOR PINOUTS................................................................................. 690 AIR OUTLET TEMPERATURE SENSOR..................................................................... 690 AIRBAG CONTROL MODULE - YELLOW.................................................................... 690 AIRBAG SQUIB-DRIVER............................................................................... 690 AIRBAG SQUIB-PASSENGER - YELLOW................................................................... 690 AMBIENT TEMPERATURE SENSOR........................................................................ 691 AUXILIARY HEATER SWITCH........................................................................... 691 BLOWER MOTOR RESISTOR BLOCK....................................................................... 691 BLOWER MOTOR-FRONT - BLACK........................................................................ 691 C200 - BLACK (DASH SIDE).......................................................................... 692 C200 - BLACK (MAIN BODY SIDE)..................................................................... 692 C205 - YELLOW (DASH SIDE)......................................................................... 692 C205 - YELLOW (MAIN BODY SIDE).................................................................... 693 C219 - (MAIN BODY SIDE)........................................................................... 693 C219 - BLACK (CABIN SIDE)......................................................................... 693 CENTRAL TIMER MODULE C1 - PINK.................................................................... 693 CENTRAL TIMER MODULE C2 - LT.GREEN................................................................ 694 CIRCULATION PUMP (CABIN HEATER MODULE)............................................................ 694 CIRCULATION PUMP (REST SYSTEM).................................................................... 694 CLOCKSPRING C2.................................................................................... 694 CONTROLLER ANTILOCK BRAKE......................................................................... 695 CYLINDER LOCK SWITCH-DRIVER....................................................................... 695 DATA LINK CONNECTOR - BLACK....................................................................... 695 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C1.................................................... 695 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C2.................................................... 696 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C1.............................................. 696 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C2.............................................. 696 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C1................................................. 696 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C2................................................. 696 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C1...................................................... 697 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C2...................................................... 697 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C1............................................. 697 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C2............................................. 697 DOSING PUMP....................................................................................... 697 ENGINE CONTROL MODULE C2 - BLACK.................................................................. 698 ENGINE CONTROL MODULE C3 - BLACK.................................................................. 698 EVAPORATOR TEMPERATURE SENSOR..................................................................... 698 FUEL LEVEL SENSOR................................................................................. 699 FUSE BLOCK NO. 1 C2............................................................................... 699 FUSES (FUSE BLOCK NO. 1).......................................................................... 701 FUSES (FUSE BLOCK NO. 2).......................................................................... 701 FUSES (FUSE BLOCK NO. 3).......................................................................... 702 FUSES (FUSE/RELAY BLOCK).......................................................................... 702 HOOD AJAR SWITCH - BLACK.......................................................................... 703 INSTRUMENT CLUSTER C1............................................................................. 703 INSTRUMENT CLUSTER C2 - WHITE..................................................................... 703 INTRUSION SENSOR NO. 1 - BLACK.................................................................... 704 INTRUSION SENSOR NO. 2 - BLACK.................................................................... 704 INTRUSION SENSOR NO. 3 - BLACK.................................................................... 704 MASTER DOOR LOCK SWITCH........................................................................... 704 PANIC ALARM SWITCH - BLACK........................................................................ 704 RECIRCULATED AIR SOLENOID VALVE................................................................... 705 REFRIGERANT PRESSURE SENSOR....................................................................... 705 A/C AUXILIARY FAN RELAY (IN RELAY BLOCK).......................................................... 707 A/C AUXILIARY FAN................................................................................. 707 CIRCULATION PUMP RELAY (RELAY BLOCK).............................................................. 707 D(+) RELAY NO. 1 (RELAY BLOCK).................................................................... 707 FAN STAGE 1 RELAY (RELAY BLOCK)................................................................... 707 HORN RELAY - (RELAY BLOCK)........................................................................ 707 TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT (RELAY BLOCK)............................................. 707 TURN SIGNAL/ANTI-THEFT ALARM RELAY-RIGHT (RELAY BLOCK)............................................ 708 REMOTE KEYLESS ENTRY ANTENNA...................................................................... 709 SEAT BELT TENSIONER-DRIVER - YELLOW............................................................... 709 SEAT BELT TENSIONER-PASSENGER - YELLOW............................................................ 709 SECURITY SYSTEM MODULE C1 - BROWN................................................................. 710 SECURITY SYSTEM MODULE C2 - LT.GREEN.............................................................. 710 SENTRY KEY REMOTE ENTRY MODULE (SKREEM)........................................................... 710 SHIFTER ASSEMBLY - BLACK.......................................................................... 711 SIREN - BLACK..................................................................................... 711 TOWING/INTRUSION SENSOR ON/OFF SWITCH............................................................. 711 TRANSMISSION CONTROL MODULE C1 - BLACK............................................................ 711 TRANSMISSION CONTROL MODULE C2 - BLACK............................................................ 712 WATER CYCLE VALVE................................................................................. 712 WINDOW DEFOGGER-LEFT REAR......................................................................... 712 WINDOW DEFOGGER-RIGHT REAR........................................................................ 712 10.0 SCHEMATIC DIAGRAMS............................................................................... 714 10.1 AIRBAG SYSTEM................................................................................ 714 10.2 COMMUNICATION................................................................................ 715 10.2.1 COMMUNICATION K-LINES.................................................................. 715 10.2.2 CAN BUS NETWORK........................................................................ 716 10.3 HEATING & A/C................................................................................ 717 10.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC).................................................... 717 10.3.2 CABIN HEATER MODULE (CHM).............................................................. 718 10.3.3 HEATER BOOSTER MODULE (HBM)............................................................ 719 10.4 INSTRUMENT CLUSTER........................................................................... 720 10.5 POWER DOOR LOCKS/RKE......................................................................... 721 10.5.1 FRONT DOORS............................................................................ 721 10.5.2 SLIDING AND REAR DOORS................................................................. 722 10.5.3 SWITCH AND MISCELLANEOUS CIRCUITS...................................................... 723 10.6 VEHICLE THEFT SECURITY SYSTEM................................................................ 724 11.0 CHARTS AND GRAPHS................................................................................ 726 11.1 EVAP TEMP SENSOR RESISTANCE TO TEMPERATURE SPECIFICATIONS.................................... 726 11.2 AIR OUTLET TEMP SENSOR RESISTANCE TO TEMPERATURE SPECIFICATIONS.............................. 726 VA Powertrain............................................................................................. 0 VA Body................................................................................................... 0 VA Chassis................................................................................................ 0 VA Transmission........................................................................................... 0 VA Service Manual......................................................................................... 730 FOREWORD.............................................................................................. 0 GROUP TAB LOCATOR..................................................................................... 730 in-INTRODUCTION....................................................................................... 732 VEHICLE IDENTIFICATION NUMBER..................................................................... 732 DESCRIPTION................................................................................... 732 INTERNATIONAL SYMBOLS............................................................................. 733 DESCRIPTION................................................................................... 733 FASTENER IDENTIFICATION........................................................................... 733 DESCRIPTION................................................................................... 733 FASTENER USAGE.................................................................................... 736 DESCRIPTION - FASTENER USAGE.................................................................. 736 THREADED HOLE REPAIR.............................................................................. 736 DESCRIPTION - THREADED HOLE REPAIR............................................................ 736 METRIC SYSTEM..................................................................................... 736 DESCRIPTION................................................................................... 736 TORQUE REFERENCES................................................................................. 738 DESCRIPTION................................................................................... 738 0-LUBRICATION & MAINTENANCE........................................................................... 740 FLUID TYPES....................................................................................... 740 DESCRIPTION................................................................................... 740 DESCRIPTION - FUEL REQUIREMENTS - DIESEL ENGINE........................................... 740 DESCRIPTION........................................................................... 740 DESCRIPTION - ENGINE COOLANT.............................................................. 740 ETHYLENE-GLYCOL MIXTURES.............................................................. 740 PROPYLENE-GLYCOL MIXTURES............................................................. 741 DESCRIPTION - HOAT COOLANT................................................................ 741 COOLANT PERFORMANCE................................................................... 741 COOLANT SELECTION AND ADDITIVES....................................................... 742 DESCRIPTION - AXLE........................................................................ 742 REAR AXLE............................................................................. 742 DESCRIPTION - BRAKE FLUID................................................................. 742 BRAKE FLUID........................................................................... 742 DESCRIPTION - POWER STEERING FLUID........................................................ 742 POWER STEERING FLUID.................................................................. 742 DESCRIPTION - ENGINE OIL - DIESEL ENGINES................................................. 742 SAE VISCOSITY GRADE................................................................... 742 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - NAG1......................................... 743 FLUID ADDITIVES....................................................................... 743 OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 743 FLUID CAPACITIES.................................................................................. 743 SPECIFICATIONS - FLUID CAPACITIES............................................................. 743 FLUID FILL/CHECK LOCATIONS........................................................................ 743 INSPECTION - FLUID FILL/CHECK LOCATIONS....................................................... 743 PARTS & LUBRICANT RECOMMENDATION.................................................................. 744 STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS........................................ 744 HOISTING.......................................................................................... 744 STANDARD PROCEDURE - HOISTING................................................................. 744 FLOOR JACK................................................................................ 744 HOIST..................................................................................... 744 JUMP STARTING..................................................................................... 745 STANDARD PROCEDURE - JUMP STARTING............................................................ 745 TO JUMP START A DISABLED VEHICLE:......................................................... 745 DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 745 TOWING............................................................................................ 745 STANDARD PROCEDURE - TOWING................................................................... 745 If the Engine is Damaged.................................................................. 746 If the Transmission is Damaged............................................................ 746 If the Front Axle is Damaged.............................................................. 746 If the Rear Axle is Damaged............................................................... 746 SAFETY PRECAUTIONS........................................................................ 746 GROUND CLEARANCE.......................................................................... 746 RAMP ANGLE................................................................................ 746 TOWING WHEN KEYS ARE NOT AVAILABLE........................................................ 746 MAINTENANCE SCHEDULES............................................................................. 746 DESCRIPTION................................................................................... 746 MAINTENANCE - WITHOUT ASSYST MAINTENANCE COMPUTER......................................... 746 MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER............................................ 747 REGULAR CHECK-UPS......................................................................... 747 SPECIAL MAINTENANCE REQUIREMENTS.......................................................... 747 ENGINE OIL CHANGE AND FILTER REPLACEMENT.................................................. 747 SCOPE OF WORK FOR MAINTENANCE SERVICE..................................................... 747 ADDITIONAL MAINTENANCE WORK............................................................... 748 ADDITIONAL MAINTENANCE WORK AFTER YEARS................................................... 748 INTERNATIONAL SYMBOLS............................................................................. 748 DESCRIPTION................................................................................... 748 2-SUSPENSION.......................................................................................... 750 FRONT............................................................................................. 750 FRONT......................................................................................... 751 SPECIFICATIONS - TORQUE CHART............................................................. 751 SPECIAL TOOLS............................................................................. 751 FRONT SUSPENSION...................................................................... 751 BUSHINGS...................................................................................... 752 REMOVAL................................................................................... 752 INSTALLATION.............................................................................. 752 HUB / BEARING................................................................................. 753 DIAGNOSIS AND TESTING -................................................................... 753 REMOVAL................................................................................... 753 INSTALLATION.............................................................................. 754 KNUCKLE....................................................................................... 754 REMOVAL................................................................................... 754 INSTALLATION.............................................................................. 754 LOWER BALL JOINT.............................................................................. 755 REMOVAL................................................................................... 755 INSTALLATION.............................................................................. 755 LOWER CONTROL ARM............................................................................. 755 REMOVAL................................................................................... 755 INSTALLATION.............................................................................. 755 SPRING........................................................................................ 756 REMOVAL................................................................................... 756 INSTALLATION.............................................................................. 757 SPRING CLAMP PLATES........................................................................... 757 REMOVAL................................................................................... 757 INSTALLATION.............................................................................. 757 SPRING STOP PLATES............................................................................ 758 REMOVAL................................................................................... 758 INSTALLATION.............................................................................. 758 STABILIZER BAR................................................................................ 758 DESCRIPTION............................................................................... 758 OPERATION................................................................................. 758 REMOVAL................................................................................... 758 INSTALLATION.............................................................................. 758 STABILIZER LINK............................................................................... 758 REMOVAL................................................................................... 758 INSTALLATION.............................................................................. 758 STRUT......................................................................................... 759 REMOVAL................................................................................... 759 INSTALLATION.............................................................................. 759 REAR.............................................................................................. 760 REAR.......................................................................................... 760 DESCRIPTION............................................................................... 760 DIAGNOSIS AND TESTING - SPRING AND SHOCK.................................................. 760 SPECIFICATIONS - TORQUE CHART............................................................. 761 SHOCK......................................................................................... 762 DIAGNOSIS AND TESTING - SHOCK............................................................. 762 REMOVAL................................................................................... 762 INSTALLATION.............................................................................. 762 SPRING........................................................................................ 763 DESCRIPTION............................................................................... 763 OPERATION................................................................................. 763 REMOVAL................................................................................... 763 REMOVAL - (SRW)....................................................................... 763 REMOVAL - (DRW)....................................................................... 763 INSTALLATION.............................................................................. 763 INSTALLATION - (SRW).................................................................. 763 INSTALLATION - (DRW).................................................................. 764 SPRING SHACKLE................................................................................ 764 REMOVAL................................................................................... 764 INSTALLATION.............................................................................. 764 STABILIZER BAR................................................................................ 764 REMOVAL................................................................................... 764 INSTALLATION.............................................................................. 764 STABILIZER LINK............................................................................... 765 REMOVAL................................................................................... 765 INSTALLATION.............................................................................. 765 WHEEL ALIGNMENT................................................................................... 766 WHEEL ALIGNMENT............................................................................... 766 DESCRIPTION............................................................................... 766 DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION.......................................... 766 STANDARD PROCEDURE - TOE ADJUSTMENT....................................................... 768 SPECIFICATIONS............................................................................ 768 3-DIFFERENTIAL & DRIVELINE............................................................................ 770 PROPELLER SHAFT................................................................................... 770 PROPELLER SHAFT............................................................................... 770 DIAGNOSIS AND TESTING..................................................................... 770 PROPELLER SHAFT VIBRATION............................................................. 770 PROPELLER SHAFT BALANCE............................................................... 771 PROPELLER SHAFT RUNOUT................................................................ 772 STANDARD PROCEDURE........................................................................ 772 PROPELLER SHAFT ANGLE................................................................. 772 TWO/THREE-PIECE PROPELLER SHAFT....................................................... 773 SPECIFICATIONS............................................................................ 774 SPECIAL TOOLS............................................................................. 774 PROPELLER SHAFT............................................................................... 775 REMOVAL................................................................................... 775 INSTALLATION.............................................................................. 775 CENTER BEARING................................................................................ 777 REMOVAL................................................................................... 777 INSTALLATION.............................................................................. 778 REAR AXLE......................................................................................... 779 REAR AXLE..................................................................................... 779 DESCRIPTION............................................................................... 779 OPERATION................................................................................. 779 DIAGNOSIS AND TESTING..................................................................... 779 GEAR NOISE............................................................................ 779 BEARING NOISE......................................................................... 779 LOW SPEED KNOCK....................................................................... 780 VIBRATION............................................................................. 780 DRIVELINE SNAP........................................................................ 780 STANDARD PROCEDURE - DRAIN AND FILL....................................................... 780 REMOVAL................................................................................... 780 INSTALLATION.............................................................................. 781 SPECIFICATIONS............................................................................ 782 SPECIAL TOOLS............................................................................. 783 AXLE SHAFTS................................................................................... 784 REMOVAL................................................................................... 784 INSTALLATION.............................................................................. 784 AXLE BEARINGS/SEALS........................................................................... 786 REMOVAL................................................................................... 786 INSTALLATION.............................................................................. 786 AXLE SHAFTS - DUAL REAR WHEELS................................................................ 788 REMOVAL................................................................................... 788 INSTALLATION.............................................................................. 788 AXLE HUB BEARINGS/SEALS....................................................................... 789 REMOVAL................................................................................... 789 INSTALLATION.............................................................................. 789 PINION SEAL................................................................................... 791 REMOVAL................................................................................... 791 INSTALLATION.............................................................................. 791 5-BRAKES.............................................................................................. 794 BRAKES - BASE..................................................................................... 794 BRAKES - BASE................................................................................. 795 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM................................................. 795 PRELIMINARY BRAKE CHECK............................................................... 795 ROAD TESTING.......................................................................... 796 BRAKE NOISES.......................................................................... 797 STANDARD PROCEDURE........................................................................ 797 STANDARD PROCEDURE - MANUAL BLEEDING.................................................. 797 STANDARD PROCEDURE - PRESSURE BLEEDING................................................ 798 HYDRAULIC/MECHANICAL.......................................................................... 798 SPECIFICATIONS............................................................................ 798 SPECIFICATIONS - TORQUE CHART......................................................... 798 BASE BRAKE............................................................................ 799 SPECIAL TOOLS............................................................................. 800 BRAKES................................................................................ 800 BRAKE LINES................................................................................... 801 STANDARD PROCEDURE........................................................................ 801 STANDARD PROCEDURE - ISO FLARING...................................................... 801 STANDARD PROCEDURE - DOUBLE INVERTED FLARING.......................................... 801 BRAKE PADS/SHOES.............................................................................. 802 REMOVAL................................................................................... 802 REMOVAL - FRONT (SRW)................................................................. 802 REMOVAL - FRONT (DRW)................................................................. 802 REMOVAL - REAR (16” WHEELS) (SRW)..................................................... 802 REMOVAL - REAR (15” WHEELS) (SRW)..................................................... 802 REMOVAL - REAR (DRW).................................................................. 803 INSTALLATION.............................................................................. 803 INSTALLATION - FRONT (SRW)............................................................ 803 INSTALLATION - FRONT (DRW)............................................................ 804 INSTALLATION - REAR (16” WHEELS) (SRW)................................................ 804 INSTALLATION - REAR (16” WHEELS) (SRW)................................................ 804 INSTALLATION - REAR (DRW)............................................................. 804 DISC BRAKE CALIPERS........................................................................... 804 REMOVAL................................................................................... 804 REMOVAL - FRONT (SRW)................................................................. 804 REMOVAL - FRONT (DRW)................................................................. 805 REMOVAL - REAR (SRW).................................................................. 805 REMOVAL - REAR (DRW).................................................................. 805 INSTALLATION.............................................................................. 805 INSTALLATION - FRONT (SRW)............................................................ 805 INSTALLATION - FRONT (DRW)............................................................ 806 INSTALLATION - REAR (SRW)............................................................. 806 INSTALLATION - REAR (DRW)............................................................. 806 DISC BRAKE CALIPER ADAPTER.................................................................... 806 REMOVAL................................................................................... 806 REMOVAL - FRONT....................................................................... 806 REMOVAL - REAR........................................................................ 806 INSTALLATION.............................................................................. 807 INSTALLATION - FRONT.................................................................. 807 INSTALLATION - REAR................................................................... 807 FLUID......................................................................................... 807 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................... 807 STANDARD PROCEDURE - BRAKE FLUID LEVEL.................................................... 807 SPECIFICATIONS............................................................................ 807 BRAKE FLUID........................................................................... 807 FLUID RESERVOIR............................................................................... 808 REMOVAL................................................................................... 808 INSTALLATION.............................................................................. 808 ALB LEVER..................................................................................... 808 REMOVAL................................................................................... 808 INSTALLATION.............................................................................. 808 ALB CONTROLLER................................................................................ 808 REMOVAL................................................................................... 808 INSTALLATION.............................................................................. 808 ADJUSTMENTS............................................................................... 809 ADJUSTMENT............................................................................ 809 MASTER CYLINDER............................................................................... 809 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 809 POWER BOOSTER VACUUM TEST............................................................. 810 POWER BOOSTER CHECK VALVE TEST........................................................ 810 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 810 REMOVAL................................................................................... 810 INSTALLATION.............................................................................. 811 PEDAL......................................................................................... 811 REMOVAL................................................................................... 811 INSTALLATION.............................................................................. 812 POWER BRAKE BOOSTER........................................................................... 812 DESCRIPTION............................................................................... 812 OPERATION................................................................................. 812 REMOVAL................................................................................... 812 INSTALLATION.............................................................................. 812 ROTORS........................................................................................ 812 REMOVAL................................................................................... 812 REMOVAL - FRONT (SRW)................................................................. 812 REMOVAL - REAR (SRW).................................................................. 813 REMOVAL - FRONT (DRW)................................................................. 813 REMOVAL - REAR (DRW).................................................................. 813 INSTALLATION.............................................................................. 814 INSTALLATION - FRONT (SRW)............................................................ 814 INSTALLATION - REAR (SRW)............................................................. 814 INSTALLATION - FRONT (DRW)............................................................ 814 INSTALLATION - REAR (DRW)............................................................. 814 SUPPORT PLATE................................................................................. 815 REMOVAL - REAR............................................................................ 815 INSTALLATION - REAR....................................................................... 815 PARKING BRAKE................................................................................. 815 SPECIFICATIONS............................................................................ 815 TORQUE CHART.......................................................................... 815 SPECIAL TOOLS............................................................................. 816 PARK BRAKE............................................................................ 816 CABLE TENSIONER............................................................................... 816 REMOVAL................................................................................... 816 INSTALLATION.............................................................................. 816 CABLES........................................................................................ 817 REMOVAL................................................................................... 817 REMOVAL - FRONT....................................................................... 817 REMOVAL - REAR........................................................................ 817 INSTALLATION.............................................................................. 817 INSTALLATION - FRONT.................................................................. 817 INSTALLATION - REAR................................................................... 818 ADJUSTMENTS............................................................................... 818 ADJUSTMENT - PARKING BRAKE CABLES..................................................... 818 LEVER......................................................................................... 819 REMOVAL................................................................................... 819 INSTALLATION.............................................................................. 819 SHOES......................................................................................... 819 REMOVAL................................................................................... 819 REMOVAL - (SRW)....................................................................... 819 REMOVAL - (DRW)....................................................................... 819 CLEANING - REAR DRUM IN HAT BRAKE......................................................... 820 INSTALLATION.............................................................................. 820 INSTALLATION - (SRW).................................................................. 820 INSTALLATION - (DRW).................................................................. 820 ADJUSTMENTS............................................................................... 820 ADJUSTMENT............................................................................ 820 BRAKES - ABS...................................................................................... 822 BRAKES - ABS.................................................................................. 822 SPECIFICATIONS - TORQUE CHART............................................................. 822 ELECTRICAL.................................................................................... 822 DESCRIPTION............................................................................... 822 OPERATION................................................................................. 822 FRONT WHEEL SPEED SENSOR...................................................................... 823 REMOVAL................................................................................... 823 INSTALLATION.............................................................................. 823 REAR WHEEL SPEED SENSOR....................................................................... 823 REMOVAL................................................................................... 823 INSTALLATION.............................................................................. 824 TONE WHEEL.................................................................................... 824 REMOVAL................................................................................... 824 INSTALLATION.............................................................................. 824 HCU (HYDRAULIC CONTROL UNIT).................................................................. 824 DESCRIPTION............................................................................... 824 REMOVAL................................................................................... 824 INSTALLATION.............................................................................. 825 7-COOLING............................................................................................. 826 COOLING........................................................................................... 826 OPERATION—COOLING SYSTEM...................................................................... 826 DIAGNOSIS AND TESTING......................................................................... 826 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS................................................ 826 ENGINE COOLING SYSTEM OVERHEATING..................................................... 826 DIAGNOSIS AND TESTING - COOLING SYSTEM.................................................... 827 ACCESSORY DRIVE................................................................................... 830 BELT TENSIONERS............................................................................... 830 DESCRIPTION............................................................................... 830 OPERATION................................................................................. 830 DRIVE BELTS................................................................................... 830 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT.............................................. 830 VISUAL DIAGNOSIS...................................................................... 830 NOISE DIAGNOSIS....................................................................... 831 REMOVAL................................................................................... 833 INSTALLATION.............................................................................. 833 ENGINE............................................................................................ 834 COOLANT....................................................................................... 834 DESCRIPTION............................................................................... 834 DIAGNOSIS AND TESTING - COOLING SYSTEM LEAKS.............................................. 835 ULTRAVIOLET LIGHT METHOD.............................................................. 835 PRESSURE TESTER METHOD................................................................ 835 INTERNAL LEAKAGE INSPECTION........................................................... 836 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER..................................... 836 STANDARD PROCEDURE........................................................................ 836 STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................ 836 STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................... 837 STANDARD PROCEDURE - REFILLING COOLING SYSTEM......................................... 837 COOLANT LEVEL SENSOR.......................................................................... 838 REMOVAL................................................................................... 838 INSTALLATION.............................................................................. 838 RADIATOR FAN.................................................................................. 838 REMOVAL................................................................................... 838 INSTALLATION.............................................................................. 838 ENGINE BLOCK HEATER........................................................................... 839 REMOVAL................................................................................... 839 INSTALLATION.............................................................................. 839 ENGINE COOLANT TEMP SENSOR.................................................................... 839 DESCRIPTION............................................................................... 839 REMOVAL................................................................................... 839 INSTALLATION.............................................................................. 840 ENGINE COOLANT THERMOSTAT..................................................................... 840 REMOVAL................................................................................... 840 INSTALLATION.............................................................................. 841 FAN DRIVE VISCOUS CLUTCH...................................................................... 841 REMOVAL................................................................................... 841 INSTALLATION.............................................................................. 841 RADIATOR...................................................................................... 841 REMOVAL................................................................................... 841 INSTALLATION.............................................................................. 842 RADIATOR PRESSURE CAP......................................................................... 843 DESCRIPTION............................................................................... 843 OPERATION................................................................................. 843 DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP............................................. 844 WATER PUMP.................................................................................... 844 REMOVAL................................................................................... 844 INSTALLATION.............................................................................. 845 8a-AUDIO/VIDEO........................................................................................ 846 AUDIO............................................................................................. 846 SPECIAL TOOLS................................................................................. 846 AUDIO..................................................................................... 846 ANTENNA BODY & CABLE.............................................................................. 846 REMOVAL....................................................................................... 846 INSTALLATION.................................................................................. 846 INSTRUMENT PANEL ANTENNA CABLE.................................................................... 846 REMOVAL....................................................................................... 846 INSTALLATION.................................................................................. 847 RADIO............................................................................................. 847 REMOVAL....................................................................................... 847 INSTALLATION.................................................................................. 847 SPEAKER........................................................................................... 847 REMOVAL....................................................................................... 847 INSTALLATION.................................................................................. 847 8b-CHIME/BUZZER....................................................................................... 848 CHIME/BUZZER...................................................................................... 848 DESCRIPTION................................................................................... 848 OPERATION..................................................................................... 848 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM.................................................. 849 8e-ELECTRONIC CONTROL MODULES......................................................................... 850 CENTRAL TIMER MODULE.............................................................................. 850 DESCRIPTION................................................................................... 850 OPERATION..................................................................................... 851 DIAGNOSIS AND TESTING - CENTRAL TIMER MODULE.................................................. 851 REMOVAL....................................................................................... 851 INSTALLATION.................................................................................. 851 CONTROLLER ANTILOCK BRAKE......................................................................... 852 DESCRIPTION................................................................................... 852 REMOVAL....................................................................................... 852 INSTALLATION.................................................................................. 852 ENGINE CONTROL MODULE............................................................................. 852 DESCRIPTION................................................................................... 852 REMOVAL....................................................................................... 853 INSTALLATION.................................................................................. 853 TRANSMISSION CONTROL MODULE....................................................................... 854 DESCRIPTION................................................................................... 854 OPERATION..................................................................................... 854 TCM SIGNALS............................................................................... 855 BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)................................................. 855 SHIFT SCHEDULES........................................................................... 855 DOWNSHIFT SAFETY.......................................................................... 856 ADAPTATION................................................................................ 856 CONTROLLER MODES OF OPERATION............................................................. 857 STANDARD PROCEDURE - TCM ADAPTATION........................................................... 857 8f-ENGINE SYSTEMS..................................................................................... 858 BATTERY SYSTEM.................................................................................... 858 BATTERY SYSTEM................................................................................ 858 DESCRIPTION............................................................................... 858 OPERATION................................................................................. 859 DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................... 859 MICRO 420 BATTERY TESTER.............................................................. 859 ABNORMAL BATTERY DISCHARGING.......................................................... 862 CLEANING.................................................................................. 862 INSPECTION................................................................................ 863 SPECIAL TOOLS............................................................................. 863 BATTERY SYSTEM SPECIAL TOOLS.......................................................... 863 BATTERY....................................................................................... 863 DESCRIPTION............................................................................... 863 OPERATION................................................................................. 864 DIAGNOSIS AND TESTING - BATTERY........................................................... 864 MICRO 420 BATTERY TESTER.............................................................. 864 STANDARD PROCEDURE........................................................................ 865 STANDARD PROCEDURE - BATTERY CHARGING................................................. 865 CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 866 CHARGING TIME REQUIRED............................................................ 866 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 867 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 867 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 868 BATTERY TESTING................................................................... 868 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL............................... 869 REMOVAL................................................................................... 869 UNDER HOOD BATTERY REMOVAL............................................................ 869 AUXILIARY BATTERY REMOVAL............................................................. 870 INSTALLATION.............................................................................. 870 UNDER HOOD BATTERY INSTALLATION....................................................... 870 AUXILIARY BATTERY INSTALLATION........................................................ 870 BATTERY HOLDDOWN.............................................................................. 871 DESCRIPTION............................................................................... 871 REMOVAL................................................................................... 871 INSTALLATION.............................................................................. 871 BATTERY CABLES................................................................................ 871 DESCRIPTION............................................................................... 871 OPERATION................................................................................. 871 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 871 REMOVAL................................................................................... 873 INSTALLATION.............................................................................. 873 BATTERY TRAY.................................................................................. 873 DESCRIPTION............................................................................... 873 OPERATION................................................................................. 873 REMOVAL................................................................................... 873 INSTALLATION.............................................................................. 873 CHARGING SYSTEM................................................................................... 874 CHARGING SYSTEM............................................................................... 874 SPECIFICATIONS............................................................................ 874 TORQUE – 2.7L DIESEL.................................................................. 874 SPECIAL TOOLS............................................................................. 874 GENERATOR..................................................................................... 875 DESCRIPTION............................................................................... 875 OPERATION................................................................................. 875 REMOVAL................................................................................... 875 INSTALLATION.............................................................................. 875 GENERATOR DECOUPLER PULLEY.................................................................... 876 DESCRIPTION............................................................................... 876 OPERATION................................................................................. 876 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 876 REMOVAL................................................................................... 877 INSTALLATION.............................................................................. 878 VOLTAGE REGULATOR............................................................................. 880 DESCRIPTION............................................................................... 880 STARTING SYSTEM................................................................................... 881 STARTING SYSTEM............................................................................... 881 DESCRIPTION............................................................................... 881 OPERATION................................................................................. 881 DIAGNOSIS AND TESTING - STARTING SYSTEM................................................... 882 INSPECTION............................................................................ 883 TESTING............................................................................... 883 SPECIFICATIONS............................................................................ 886 TORQUE - STARTER - DIESEL............................................................. 886 SPECIFICATIONS - STARTER MOTOR - DIESEL............................................... 886 STARTER MOTOR................................................................................. 886 DIAGNOSIS AND TESTING - STARTER MOTOR..................................................... 886 REMOVAL................................................................................... 887 INSTALLATION.............................................................................. 888 STARTER MOTOR RELAY........................................................................... 888 DESCRIPTION............................................................................... 888 REMOVAL................................................................................... 888 INSTALLATION.............................................................................. 889 8g-HEATED SYSTEMS..................................................................................... 890 HEATED SEATS...................................................................................... 890 DESCRIPTION................................................................................... 890 OPERATION..................................................................................... 891 DIAGNOSIS AND TESTING - HEATED SEATS.......................................................... 891 DRIVER HEATED SEAT SWITCH......................................................................... 891 DESCRIPTION................................................................................... 891 OPERATION..................................................................................... 891 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH............................................. 891 REMOVAL....................................................................................... 892 INSTALLATION.................................................................................. 892 HEATED SEAT ELEMENT............................................................................... 892 DESCRIPTION................................................................................... 892 OPERATION..................................................................................... 892 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT................................................... 892 HEATED SEAT RELAY................................................................................. 893 DESCRIPTION................................................................................... 893 OPERATION..................................................................................... 893 DIAGNOSIS AND TESTING - HEATED SEAT RELAY..................................................... 893 REMOVAL....................................................................................... 893 INSTALLATION.................................................................................. 893 HEATED SEAT SENSOR................................................................................ 893 DESCRIPTION................................................................................... 893 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR.................................................... 893 PASSENGER HEATED SEAT SWITCH...................................................................... 894 DESCRIPTION................................................................................... 894 OPERATION..................................................................................... 894 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH.......................................... 894 REMOVAL....................................................................................... 894 INSTALLATION.................................................................................. 894 8h-HORN............................................................................................... 896 HORN.............................................................................................. 896 REMOVAL....................................................................................... 896 INSTALLATION.................................................................................. 896 HORN SWITCH....................................................................................... 896 REMOVAL....................................................................................... 896 INSTALLATION.................................................................................. 896 8i-IGNITION CONTROL................................................................................... 898 IGNITION CONTROL.................................................................................. 898 SPECIAL TOOLS................................................................................. 898 GLOW PLUG......................................................................................... 898 REMOVAL....................................................................................... 898 INSTALLATION.................................................................................. 898 GLOW PLUG RELAY................................................................................... 899 DESCRIPTION................................................................................... 899 OPERATION..................................................................................... 899 DIAGNOSIS AND TESTING - GLOW PLUG RELAYS...................................................... 899 8j-INSTRUMENT CLUSTER................................................................................. 900 INSTRUMENT CLUSTER................................................................................ 901 DESCRIPTION................................................................................... 901 OPERATION..................................................................................... 904 INPUT AND OUTPUT CIRCUITS................................................................. 905 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER.................................................... 906 REMOVAL....................................................................................... 906 INSTALLATION.................................................................................. 908 ABS INDICATOR..................................................................................... 908 DESCRIPTION................................................................................... 908 OPERATION..................................................................................... 908 AIRBAG INDICATOR.................................................................................. 909 DESCRIPTION................................................................................... 909 OPERATION..................................................................................... 909 AMBIENT TEMPERATURE INDICATOR..................................................................... 910 DESCRIPTION................................................................................... 910 OPERATION..................................................................................... 910 BRAKE/PARK BRAKE INDICATOR........................................................................ 910 DESCRIPTION................................................................................... 910 OPERATION..................................................................................... 911 BRAKE WEAR INDICATOR.............................................................................. 911 DESCRIPTION................................................................................... 911 OPERATION..................................................................................... 911 CHARGING INDICATOR................................................................................ 912 DESCRIPTION................................................................................... 912 OPERATION..................................................................................... 912 CLOCK............................................................................................. 912 DESCRIPTION................................................................................... 912 OPERATION..................................................................................... 913 COOLANT LOW INDICATOR............................................................................. 913 DESCRIPTION................................................................................... 913 OPERATION..................................................................................... 913 ENGINE TEMPERATURE GAUGE.......................................................................... 914 DESCRIPTION................................................................................... 914 OPERATION..................................................................................... 914 FUEL FILTER CLOGGED INDICATOR..................................................................... 914 DESCRIPTION................................................................................... 914 OPERATION..................................................................................... 914 FUEL GAUGE........................................................................................ 915 DESCRIPTION................................................................................... 915 OPERATION..................................................................................... 915 GEAR SELECTOR INDICATOR........................................................................... 916 DESCRIPTION................................................................................... 916 OPERATION..................................................................................... 916 HIGH BEAM INDICATOR............................................................................... 916 DESCRIPTION................................................................................... 916 OPERATION..................................................................................... 916 LOW FUEL INDICATOR................................................................................ 917 DESCRIPTION................................................................................... 917 OPERATION..................................................................................... 917 LOW OIL LEVEL INDICATOR........................................................................... 917 DESCRIPTION................................................................................... 917 OPERATION..................................................................................... 917 MAINTENANCE INDICATOR............................................................................. 918 DESCRIPTION................................................................................... 918 OPERATION..................................................................................... 918 MALFUNCTION INDICATOR LAMP (MIL).................................................................. 919 DESCRIPTION................................................................................... 919 OPERATION..................................................................................... 919 MULTI-FUNCTION INDICATOR.......................................................................... 919 DESCRIPTION................................................................................... 919 OPERATION..................................................................................... 920 ODOMETER.......................................................................................... 920 DESCRIPTION................................................................................... 920 OPERATION..................................................................................... 921 SEATBELT INDICATOR................................................................................ 921 DESCRIPTION................................................................................... 921 OPERATION..................................................................................... 921 SPEEDOMETER....................................................................................... 922 DESCRIPTION................................................................................... 922 OPERATION..................................................................................... 922 TACHOMETER........................................................................................ 922 DESCRIPTION................................................................................... 922 OPERATION..................................................................................... 923 TRACTION CONTROL INDICATOR........................................................................ 923 DESCRIPTION................................................................................... 923 OPERATION..................................................................................... 923 TRACTION CONTROL MALFUNCTION INDICATOR............................................................ 924 DESCRIPTION................................................................................... 924 OPERATION..................................................................................... 924 TURN SIGNAL INDICATOR............................................................................. 924 DESCRIPTION................................................................................... 924 OPERATION..................................................................................... 924 WAIT-TO-START INDICATOR........................................................................... 925 DESCRIPTION................................................................................... 925 OPERATION..................................................................................... 925 WASHER FLUID INDICATOR............................................................................ 926 DESCRIPTION................................................................................... 926 OPERATION..................................................................................... 926 WATER-IN-FUEL INDICATOR........................................................................... 926 DESCRIPTION................................................................................... 926 OPERATION..................................................................................... 927 8l-LAMPS.............................................................................................. 928 LAMPS/LIGHTING - EXTERIOR......................................................................... 928 LAMPS/LIGHTING - EXTERIOR..................................................................... 929 DESCRIPTION............................................................................... 929 OPERATION................................................................................. 930 SPECIFICATIONS - LAMPS/LIGHTING - EXTERIOR................................................ 932 BACKUP LAMP BULB.............................................................................. 932 REMOVAL................................................................................... 932 INSTALLATION.............................................................................. 933 BRAKE LAMP SWITCH............................................................................. 933 REMOVAL0 - 2 VA (Continued)........................................................... 933 INSTALLATION.............................................................................. 933 BRAKE/PARK LAMP BULB.......................................................................... 934 REMOVAL................................................................................... 934 INSTALLATION.............................................................................. 934 CENTER HIGH MOUNTED STOP LAMP BULB............................................................ 934 REMOVAL................................................................................... 934 INSTALLATION.............................................................................. 934 CENTER HIGH MOUNTED STOP LAMP UN.............................................................. 935 REMOVAL................................................................................... 935 INSTALLATION.............................................................................. 935 CLEARANCE LAMP BULB........................................................................... 935 REMOVAL................................................................................... 935 INSTALLATION.............................................................................. 935 CLEARANCE LAMP UNIT........................................................................... 935 REMOVAL................................................................................... 935 INSTALLATION.............................................................................. 936 DAYTIME RUNNING LAMP RELAY.................................................................... 936 REMOVAL................................................................................... 936 INSTALLATION.............................................................................. 936 FOG LAMP BULB................................................................................. 937 REMOVAL................................................................................... 937 INSTALLATION.............................................................................. 937 FOG LAMP RELAY................................................................................ 937 REMOVAL................................................................................... 937 INSTALLATION.............................................................................. 938 FOG LAMP SWITCH............................................................................... 938 REMOVAL................................................................................... 938 INSTALLATION.............................................................................. 939 FRONT LAMP UNIT............................................................................... 939 REMOVAL................................................................................... 939 INSTALLATION.............................................................................. 939 ADJUSTMENTS............................................................................... 939 ADJUSTMENT - FRONT LAMP UNIT.......................................................... 939 VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT................................. 939 FRONT LAMP UNIT ALIGNMENT......................................................... 940 FRONT POSITION LAMP BULB...................................................................... 941 REMOVAL................................................................................... 941 INSTALLATION.............................................................................. 941 FRONT TURN/PARK/SIDE MARKER LAMP BULB......................................................... 941 REMOVAL................................................................................... 941 INSTALLATION.............................................................................. 942 HEADLAMP LEVELING MOTOR....................................................................... 942 REMOVAL................................................................................... 942 INSTALLATION.............................................................................. 943 HEADLAMP LEVELING SWITCH...................................................................... 943 REMOVAL................................................................................... 943 INSTALLATION.............................................................................. 944 HIGH BEAM HEADLAMP BULB....................................................................... 944 REMOVAL................................................................................... 944 INSTALLATION.............................................................................. 944 LICENSE PLATE LAMP BULB....................................................................... 944 REMOVAL................................................................................... 944 INSTALLATION.............................................................................. 945 LICENSE PLATE LAMP UNIT....................................................................... 945 REMOVAL................................................................................... 945 INSTALLATION.............................................................................. 945 LOW BEAM HEADLAMP BULB........................................................................ 945 REMOVAL................................................................................... 945 INSTALLATION.............................................................................. 946 MULTI-FUNCTION SWITCH......................................................................... 946 REMOVAL................................................................................... 946 INSTALLATION.............................................................................. 947 PARK BRAKE SWITCH............................................................................. 947 REMOVAL................................................................................... 947 INSTALLATION.............................................................................. 947 REAR SIDE MARKER LAMP BULB.................................................................... 948 REMOVAL................................................................................... 948 INSTALLATION.............................................................................. 948 REAR TURN LAMP BULB........................................................................... 948 REMOVAL................................................................................... 948 INSTALLATION.............................................................................. 949 REPEATER LAMP BULB............................................................................ 949 REMOVAL................................................................................... 949 INSTALLATION.............................................................................. 949 REPEATER LAMP UNIT............................................................................ 949 REMOVAL................................................................................... 949 INSTALLATION.............................................................................. 950 TAIL LAMP UNIT................................................................................ 950 REMOVAL................................................................................... 950 INSTALLATION.............................................................................. 950 TURN SIGNAL RELAY............................................................................. 951 REMOVAL................................................................................... 951 INSTALLATION.............................................................................. 951 LAMPS/LIGHTING - INTERIOR......................................................................... 952 LAMPS/LIGHTING - INTERIOR..................................................................... 952 DESCRIPTION............................................................................... 952 OPERATION................................................................................. 953 INTERIOR LIGHTING CIRCUIT............................................................. 953 EXTERIOR LIGHTING CIRCUIT............................................................. 953 SPECIFICATIONS - INTERIOR LIGHTING........................................................ 953 ASH RECEIVER/CIGAR LIGHTER LAMP UNIT.......................................................... 954 REMOVAL................................................................................... 954 INSTALLATION.............................................................................. 954 CARGO/DOME LAMP BULB.......................................................................... 954 REMOVAL................................................................................... 954 INSTALLATION.............................................................................. 954 CARGO/DOME LAMP UNIT.......................................................................... 955 REMOVAL................................................................................... 955 INSTALLATION.............................................................................. 955 CARGO LAMP SWITCH............................................................................. 955 REMOVAL................................................................................... 955 REMOVAL - INSTRUMENT PANEL............................................................ 955 REMOVAL - BULKHEAD.................................................................... 955 REMOVAL - REAR PILLAR................................................................. 955 INSTALLATION.............................................................................. 956 INSTALLATION - INSTRUMENT PANEL....................................................... 956 INSTALLATION - BULKHEAD............................................................... 956 INSTALLATION - REAR PILLAR............................................................ 956 DOME/READING LAMP BULB........................................................................ 956 REMOVAL................................................................................... 956 INSTALLATION.............................................................................. 956 DOME/READING LAMP UNIT........................................................................ 957 REMOVAL................................................................................... 957 INSTALLATION.............................................................................. 957 DOME LAMP/INTRUSION SENSOR BULB............................................................... 957 REMOVAL................................................................................... 957 INSTALLATION.............................................................................. 957 DOME LAMP/INTRUSION SENSOR.................................................................... 958 REMOVAL................................................................................... 958 INSTALLATION.............................................................................. 958 DOOR JAMB SWITCH.............................................................................. 958 REMOVAL................................................................................... 958 INSTALLATION.............................................................................. 958 ENTRY/EXIT LAMP BULB.......................................................................... 958 REMOVAL................................................................................... 958 INSTALLATION.............................................................................. 959 ENTRY/EXIT LAMP UNIT.......................................................................... 959 REMOVAL................................................................................... 959 INSTALLATION.............................................................................. 959 TIME DELAY RELAY.............................................................................. 959 REMOVAL................................................................................... 959 INSTALLATION.............................................................................. 960 8n-POWER SYSTEMS...................................................................................... 962 POWER LOCKS....................................................................................... 962 POWER LOCKS................................................................................... 962 DESCRIPTION............................................................................... 962 CENTRAL LOCKING....................................................................... 962 REMOTE KEYLESS ENTRY.................................................................. 962 AUTO DOOR LOCKS....................................................................... 962 ACCIDENT RESPONSE..................................................................... 962 DOOR LOCK MOTOR............................................................................... 962 REMOVAL................................................................................... 962 INSTALLATION.............................................................................. 962 REMOTE KEYLESS ENTRY TRANSMITTER.............................................................. 963 DESCRIPTION............................................................................... 963 MASTER LOCK SWITCH............................................................................ 963 DESCRIPTION............................................................................... 963 DIAGNOSIS AND TESTING - MASTER LOCK SWITCH................................................ 963 REMOVAL................................................................................... 963 INSTALLATION.............................................................................. 963 POWER MIRRORS..................................................................................... 964 POWER MIRRORS................................................................................. 964 DESCRIPTION............................................................................... 964 POWER MIRROR SWITCH........................................................................... 964 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH............................................... 964 REMOVAL................................................................................... 964 INSTALLATION.............................................................................. 965 POWER WINDOWS..................................................................................... 966 POWER WINDOWS................................................................................. 966 DESCRIPTION............................................................................... 966 OPERATION................................................................................. 966 WINDOW SWITCH......................................................................... 966 WINDOW MOTOR.......................................................................... 966 WINDOW MOTOR.................................................................................. 966 REMOVAL................................................................................... 966 POWER WINDOW SWITCH........................................................................... 966 DIAGNOSIS AND TESTING - POWER WINDOW SWITCH............................................... 966 REMOVAL................................................................................... 967 INSTALLATION.............................................................................. 967 8o-RESTRAINTS......................................................................................... 968 RESTRAINTS........................................................................................ 969 DESCRIPTION................................................................................... 969 ACTIVE RESTRAINTS......................................................................... 970 PASSIVE RESTRAINTS........................................................................ 970 OPERATION..................................................................................... 971 ACTIVE RESTRAINTS......................................................................... 971 PASSIVE RESTRAINTS........................................................................ 971 WARNING....................................................................................... 972 WARNINGS - RESTRAINT SYSTEM............................................................... 972 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM......................................... 972 STANDARD PROCEDURE............................................................................ 973 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 973 SUPPLEMENTAL RESTRAINT STORAGE........................................................ 973 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 973 CLEANUP PROCEDURE..................................................................... 973 STANDARD PROCEDURE - VERIFICATION TEST.................................................... 974 AIRBAG CONTROL MODULE............................................................................. 975 DESCRIPTION................................................................................... 975 OPERATION..................................................................................... 976 REMOVAL....................................................................................... 977 INSTALLATION.................................................................................. 978 CLOCKSPRING....................................................................................... 979 DESCRIPTION................................................................................... 979 OPERATION..................................................................................... 980 STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 980 REMOVAL....................................................................................... 981 INSTALLATION.................................................................................. 982 DRIVER AIRBAG..................................................................................... 983 DESCRIPTION................................................................................... 983 OPERATION..................................................................................... 984 REMOVAL....................................................................................... 984 INSTALLATION.................................................................................. 985 FRONT SEAT BELT & RETRACTOR....................................................................... 986 REMOVAL....................................................................................... 986 INSTALLATION.................................................................................. 988 FRONT SEAT BELT BUCKLE............................................................................ 989 REMOVAL....................................................................................... 989 INSTALLATION.................................................................................. 990 PASSENGER AIRBAG.................................................................................. 990 DESCRIPTION................................................................................... 990 OPERATION..................................................................................... 991 REMOVAL....................................................................................... 991 INSTALLATION.................................................................................. 993 PASSENGER AIRBAG BRACKET.......................................................................... 994 REMOVAL....................................................................................... 994 INSTALLATION.................................................................................. 994 REAR SEAT BELT & RETRACTOR........................................................................ 994 REMOVAL....................................................................................... 994 INSTALLATION.................................................................................. 996 REAR SEAT BELT BUCKLE............................................................................. 996 REMOVAL....................................................................................... 996 REMOVAL - INBOARD......................................................................... 996 REMOVAL - OUTBOARD........................................................................ 997 INSTALLATION.................................................................................. 997 INSTALLATION - INBOARD.................................................................... 997 INSTALLATION - OUTBOARD................................................................... 998 SEAT BELT SWITCH.................................................................................. 998 DESCRIPTION................................................................................... 998 OPERATION..................................................................................... 998 SEAT BELT TENSIONER............................................................................... 998 DESCRIPTION................................................................................... 998 OPERATION..................................................................................... 999 SEAT BELT TURNING LOOP ADJUSTER...................................................................1000 REMOVAL.......................................................................................1000 INSTALLATION..................................................................................1001 8p-SPEED CONTROL......................................................................................1002 SPEED CONTROL.....................................................................................1002 DESCRIPTION...................................................................................1002 OPERATION.....................................................................................1002 SPECIFICATIONS................................................................................1003 TORQUE....................................................................................1003 CABLE.............................................................................................1004 DESCRIPTION...................................................................................1004 SERVO.............................................................................................1004 DESCRIPTION...................................................................................1004 SWITCH............................................................................................1004 REMOVAL.......................................................................................1004 INSTALLATION..................................................................................1004 8q-VEHICLE THEFT SECURITY.............................................................................1006 VEHICLE THEFT SECURITY............................................................................1006 DESCRIPTION...................................................................................1006 OPERATION.....................................................................................1006 DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY................................................1006 INTRUSION SENSOR..................................................................................1007 REMOVAL.......................................................................................1007 INSTALLATION..................................................................................1007 SECURITY SYSTEM MODULE............................................................................1007 REMOVAL.......................................................................................1007 INSTALLATION..................................................................................1007 SENTRY KEY REMOTE ENTRY MODULE....................................................................1007 DESCRIPTION...................................................................................1007 SENTRY KEY IMMOBILIZER....................................................................1008 REMOTE KEYLESS ENTRY (RKE)................................................................1008 OPERATION.....................................................................................1008 SENTRY KEY IMMOBILIZER....................................................................1008 REMOTE KEYLESS ENTRY......................................................................1008 REMOVAL.......................................................................................1008 SENTRY KEY REMOTE ENTRY MODULE............................................................1008 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING...........................................1009 INSTALLATION..................................................................................1009 SENTRY KEY REMOTE ENTRY MODULE............................................................1009 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING...........................................1009 SIREN.............................................................................................1009 REMOVAL.......................................................................................1009 INSTALLATION..................................................................................1009 TRANSPONDER KEY...................................................................................1010 DESCRIPTION...................................................................................1010 OPERATION.....................................................................................1010 8r-WIPERS/WASHERS.....................................................................................1012 WIPERS/WASHERS....................................................................................1012 DESCRIPTION...................................................................................1012 OPERATING MODES...........................................................................1014 OPERATION.....................................................................................1014 DIAGNOSIS AND TESTING - WIPER & WASHER SYSTEM.................................................1016 CLEANING - WIPER & WASHER SYSTEM..............................................................1016 WIPER SYSTEM..............................................................................1016 WASHER SYSTEM.............................................................................1016 INSPECTION - WIPER & WASHER SYSTEM............................................................1017 WIPER SYSTEM..............................................................................1017 WASHER SYSTEM.............................................................................1017 CHECK VALVE.......................................................................................1018 DESCRIPTION...................................................................................1018 OPERATION.....................................................................................1018 REMOVAL.......................................................................................1018 INSTALLATION..................................................................................1018 WASHER FLUID LEVEL SWITCH.........................................................................1018 DESCRIPTION...................................................................................1018 OPERATION.....................................................................................1019 WASHER HOSES/TUBES................................................................................1019 DESCRIPTION...................................................................................1019 OPERATION.....................................................................................1020 WASHER NOZZLE.....................................................................................1020 DESCRIPTION...................................................................................1020 OPERATION.....................................................................................1020 REMOVAL.......................................................................................1020 INSTALLATION..................................................................................1020 WASHER PUMP/MOTOR.................................................................................1020 DESCRIPTION...................................................................................1020 OPERATION.....................................................................................1021 REMOVAL.......................................................................................1021 INSTALLATION..................................................................................1021 WASHER RESERVOIR..................................................................................1022 DESCRIPTION...................................................................................1022 OPERATION.....................................................................................1022 REMOVAL.......................................................................................1022 INSTALLATION..................................................................................1023 WIPER ARM.........................................................................................1024 DESCRIPTION...................................................................................1024 OPERATION.....................................................................................1025 REMOVAL.......................................................................................1025 INSTALLATION..................................................................................1025 WIPER BLADE.......................................................................................1026 DESCRIPTION...................................................................................1026 OPERATION.....................................................................................1026 REMOVAL.......................................................................................1027 INSTALLATION..................................................................................1027 WIPER LINKAGE.....................................................................................1028 DESCRIPTION...................................................................................1028 OPERATION.....................................................................................1028 REMOVAL.......................................................................................1028 INSTALLATION..................................................................................1029 WIPER MOTOR.......................................................................................1030 DESCRIPTION...................................................................................1030 OPERATION.....................................................................................1030 REMOVAL.......................................................................................1030 INSTALLATION..................................................................................1030 WIPER RELAY.......................................................................................1031 DESCRIPTION...................................................................................1031 OPERATION.....................................................................................1032 REMOVAL.......................................................................................1033 INSTALLATION..................................................................................1033 8w-WIRING.............................................................................................1034 8W-01 WIRING DIAGRAM INFORMATION..................................................................1036 WIRING DIAGRAM INFORMATION....................................................................1036 DESCRIPTION...............................................................................1036 DESCRIPTION - HOW TO USE WIRING DIAGRAMS..............................................1036 SYMBOLS...........................................................................1036 TERMINOLOGY.......................................................................1040 DESCRIPTION - CIRCUIT INFORMATION.....................................................1040 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION..................................1040 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................1040 IDENTIFICATION....................................................................1040 LOCATIONS.........................................................................1041 WARNING...................................................................................1041 WARNINGS - GENERAL....................................................................1041 DIAGNOSIS AND TESTING - WIRING HARNESS....................................................1041 TROUBLESHOOTING TOOLS.................................................................1041 INTERMITTENT AND POOR CONNECTIONS.....................................................1042 TROUBLESHOOTING WIRING PROBLEMS.......................................................1042 STANDARD PROCEDURE........................................................................1042 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES..................1042 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL.....................................1042 STANDARD PROCEDURE - TESTING FOR CONTINUITY...........................................1043 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND....................................1043 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS....1043 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP.......................................1043 CONNECTOR.....................................................................................1043 REMOVAL...................................................................................1043 INSTALLATION..............................................................................1044 DIODE.........................................................................................1044 REMOVAL...................................................................................1044 INSTALLATION..............................................................................1044 TERMINAL......................................................................................1044 REMOVAL...................................................................................1044 INSTALLATION..............................................................................1045 WIRE..........................................................................................1045 STANDARD PROCEDURE - WIRE SPLICING........................................................1045 8W-02 COMPONENT INDEX.............................................................................1046 8W-10 POWER DISTRIBUTION..........................................................................1048 8W-11 FUSE BLOCK..................................................................................1082 8W-15 GROUND DISTRIBUTION.........................................................................1122 8W-18 BUS COMMUNICATIONS..........................................................................1150 8W-20 CHARGING SYSTEM.............................................................................1156 8W-21 STARTING SYSTEM.............................................................................1162 8W-30 FUEL/IGNITION SYSTEM........................................................................1164 8W-31 TRANSMISSION CONTROL SYSTEM.................................................................1182 8W-33 VEHICLE SPEED CONTROL.......................................................................1192 8W-35 ANTILOCK BRAKES.............................................................................1196 8W-39 VEHICLE THEFT SECURITY SYSTEM...............................................................1204 8W-40 INSTRUMENT CLUSTER..........................................................................1218 8W-41 HORN/CIGAR LIGHTER..........................................................................1226 8W-42 AIR CONDITIONER/HEATER......................................................................1230 8W-43 AIRBAG SYSTEM...............................................................................1254 8W-44 INTERIOR LIGHTING...........................................................................1258 8W-45 CENTRAL TIMER MODULE........................................................................1270 8W-47 AUDIO SYSTEM................................................................................1278 8W-48 REAR WINDOW DEFOGGER........................................................................1284 8W-50 FRONT LIGHTING..............................................................................1290 8W-51 REAR LIGHTING...............................................................................1306 8W-52 TURN SIGNALS................................................................................1316 8W-53 WIPERS......................................................................................1322 8W-54 TRAILER TOW.................................................................................1326 8W-55 NAVIGATION/TELECOMMUNICATIONS...............................................................1330 8W-60 POWER WINDOWS...............................................................................1334 8W-61 POWER DOOR LOCKS............................................................................1338 8W-62 POWER MIRRORS...............................................................................1346 8W-63 POWER SEATS.................................................................................1350 8W-70 SPLICE INFORMATION..........................................................................1354 8W-80 CONNECTOR PIN-OUTS..........................................................................1356 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................1424 CONNECTOR/GROUND/SPLICE LOCATION..............................................................1424 DESCRIPTION...............................................................................1424 8W-97 POWER DISTRIBUTION..........................................................................1462 POWER DISTRIBUTION............................................................................1462 DESCRIPTION...............................................................................1462 OPERATION.................................................................................1462 CIGAR LIGHTER OUTLET..........................................................................1462 DESCRIPTION...............................................................................1462 OPERATION.................................................................................1463 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..............................................1463 REMOVAL...................................................................................1463 CIRCUIT BREAKER...............................................................................1463 DESCRIPTION...............................................................................1463 OPERATION.................................................................................1463 DIAGNOSIS AND TESTING - CIRCUIT BREAKER...................................................1463 FUSE BLOCK #1.................................................................................1463 DESCRIPTION...............................................................................1463 OPERATION.................................................................................1463 REMOVAL...................................................................................1464 INSTALLATION..............................................................................1464 FUSE BLOCK #2.................................................................................1464 DESCRIPTION...............................................................................1464 OPERATION.................................................................................1464 POWER DISTRIBUTION CENTER.....................................................................1464 DESCRIPTION...............................................................................1464 OPERATION.................................................................................1464 POWER OUTLET..................................................................................1464 DESCRIPTION...............................................................................1464 OPERATION.................................................................................1465 DIAGNOSIS AND TESTING - POWER OUTLET......................................................1465 REMOVAL...................................................................................1465 INSTALLATION..............................................................................1465 RELAY.........................................................................................1465 DESCRIPTION...............................................................................1465 OPERATION.................................................................................1466 DIAGNOSIS AND TESTING - RELAY.............................................................1466 DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST............................................1466 REMOVAL...................................................................................1466 INSTALLATION..............................................................................1466 9-ENGINE..............................................................................................1468 ENGINE............................................................................................1469 DESCRIPTION...................................................................................1469 STANDARD PROCEDURE............................................................................1470 STANDARD PROCEDURE - COMPRESSION TESTING ENGINE...........................................1470 STANDARD PROCEDURE - CYLINDER LEAK DOWN TEST..............................................1470 INSPECTING............................................................................1470 STANDARD PROCEDURE - DETERMINING CYLINDER PRESSURE LOSS...................................1471 REMOVAL.......................................................................................1471 REMOVAL - ENGINE COVER....................................................................1471 REMOVAL...................................................................................1471 INSTALLATION..................................................................................1474 INSTALLATION - ENGINE COVER...............................................................1474 INSTALLATION..............................................................................1474 SPECIFICATIONS - TORQUE SPECIFICATIONS........................................................1475 SPECIAL TOOLS.................................................................................1481 AIR CLEANER ELEMENT...............................................................................1487 REMOVAL.......................................................................................1487 INSTALLATION..................................................................................1487 AIR CLEANER HOUSING...............................................................................1487 REMOVAL.......................................................................................1487 INSTALLATION..................................................................................1487 CYLINDER HEAD.....................................................................................1488 STANDARD PROCEDURE............................................................................1488 STANDARD PROCEDURE - CYLINDER HEAD BOLT INSPECTION........................................1488 STANDARD PROCEDURE - MEASURE CYLINDER HEAD SURFACE........................................1488 REMOVAL.......................................................................................1489 REMOVAL - CYLINDER HEAD...................................................................1489 REMOVAL - CYLINDER HEAD FRONT COVER.......................................................1490 REMOVAL - CYLINDER HEAD GUIDE RAIL........................................................1491 INSTALLATION..................................................................................1492 INSTALLATION - CYLINDER HEAD..............................................................1492 CYLINDER HEAD BOLT TORQUE SEQUENCE....................................................1492 INSTALLATION - CYLINDER HEAD FRONT COVER..................................................1493 INSTALLATION - CYLINDER HEAD GUIDE RAIL...................................................1493 CAMSHAFT(S).......................................................................................1494 STANDARD PROCEDURE - CHECKING CAMSHAFT POSITION...............................................1494 REMOVAL.......................................................................................1495 INSTALLATION..................................................................................1496 CYLINDER HEAD COVER(S)............................................................................1497 REMOVAL.......................................................................................1497 INSTALLATION..................................................................................1497 VALVE SPRINGS.....................................................................................1498 REMOVAL.......................................................................................1498 REMOVAL - VALVE SPRINGS...................................................................1498 REMOVAL - VALVES..........................................................................1498 INSTALLATION..................................................................................1499 INSTALLATION - VALVE SPRINGS..............................................................1499 INSTALLATION - VALVES.....................................................................1500 ENGINE BLOCK......................................................................................1501 STANDARD PROCEDURE............................................................................1501 STANDARD PROCEDURE - REPLACING ENGINE CORE AND OIL GALLERY PLUGS..........................1501 STANDARD PROCEDURE - MEASURING CYLINDER BORES.............................................1501 CRANKSHAFT........................................................................................1502 STANDARD PROCEDURE - MEASURE CRANKSHAFT AND BLOCK JOURNALS....................................1502 ASSIGN CRANKSHAFT BEARING SHELLS..........................................................1502 REMOVAL.......................................................................................1502 INSTALLATION..................................................................................1503 CRANKSHAFT OIL SEAL - REAR........................................................................1504 REMOVAL.......................................................................................1504 INSTALLATION..................................................................................1504 CRANKSHAFT OIL SEAL - FRONT.......................................................................1505 REMOVAL.......................................................................................1505 INSTALLATION..................................................................................1505 FLYWHEEL..........................................................................................1506 REMOVAL.......................................................................................1506 INSTALLATION..................................................................................1506 INSTALLATION..............................................................................1506 INSTALLATION..............................................................................1506 PISTON & CONNECTING ROD...........................................................................1507 DESCRIPTION...................................................................................1507 STANDARD PROCEDURE............................................................................1507 STANDARD PROCEDURE - CHECKING AND REPAIRING CONNECTING RODS...............................1507 CONNECTING ROD SPECIFICATIONS.........................................................1509 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION..........................................1509 REMOVAL.......................................................................................1509 INSTALLATION..................................................................................1510 PISTON RINGS......................................................................................1513 STANDARD PROCEDURE - PISTON RING FITTING......................................................1513 VIBRATION DAMPER..................................................................................1514 REMOVAL.......................................................................................1514 INSTALLATION..................................................................................1515 VACUUM PUMP.......................................................................................1515 DESCRIPTION...................................................................................1515 OPERATION.....................................................................................1515 REMOVAL.......................................................................................1515 INSTALLATION..................................................................................1516 LEFT MOUNT........................................................................................1516 REMOVAL.......................................................................................1516 INSTALLATION..................................................................................1516 RIGHT MOUNT.......................................................................................1516 REMOVAL.......................................................................................1516 INSTALLATION..................................................................................1516 OIL...............................................................................................1517 REMOVAL - OIL SEPARATOR.......................................................................1517 INSTALLATION - OIL SEPARATOR..................................................................1517 OIL COOLER & LINES................................................................................1517 REMOVAL.......................................................................................1517 INSTALLATION..................................................................................1517 OIL FILTER........................................................................................1518 REMOVAL.......................................................................................1518 INSTALLATION..................................................................................1518 OIL JET...........................................................................................1518 DESCRIPTION...................................................................................1518 REMOVAL.......................................................................................1518 INSTALLATION..................................................................................1518 OIL PAN...........................................................................................1519 REMOVAL.......................................................................................1519 INSTALLATION..................................................................................1519 OIL PUMP..........................................................................................1520 REMOVAL.......................................................................................1520 REMOVAL...................................................................................1520 REMOVAL- OIL PUMP CHAIN...................................................................1520 INSTALLATION..................................................................................1521 INSTALLATION..............................................................................1521 INSTALLATION - OIL PUMP CHAIN.............................................................1521 OIL TEMPERATURE SENSOR............................................................................1523 DESCRIPTION...................................................................................1523 OPERATION.....................................................................................1523 REMOVAL.......................................................................................1524 INSTALLATION..................................................................................1524 INTAKE MANIFOLD...................................................................................1524 REMOVAL.......................................................................................1524 INSTALLATION..................................................................................1525 EXHAUST MANIFOLD..................................................................................1526 REMOVAL.......................................................................................1526 INSTALLATION..................................................................................1526 TIMING CHAIN COVER................................................................................1526 REMOVAL.......................................................................................1526 INSTALLATION..................................................................................1527 TIMING BELT/CHAIN AND SPROCKETS...................................................................1528 REMOVAL.......................................................................................1528 REMOVAL - TENSIONING AND SLIDE RAILS......................................................1528 REMOVAL - INTERMEDIATE GEAR...............................................................1528 REMOVAL - TIMING CHAIN TENSIONING RAIL....................................................1530 REMOVAL - TIMING CHAIN....................................................................1530 INSTALLATION..................................................................................1533 INSTALLATION - TENSIONING AND SLIDE RAIL..................................................1533 INSTALLATION - INTERMEDIATE GEAR..........................................................1533 INSTALLATION - TIMING CHAIN TENSIONING RAIL...............................................1533 ADJUSTMENTS...................................................................................1534 INSTALLATION - TIMING CHAIN...............................................................1534 TIMING CHAIN TENSIONER............................................................................1537 REMOVAL.......................................................................................1537 INSTALLATION..................................................................................1538 11-EXHAUST SYSTEM.....................................................................................1540 EXHAUST SYSTEM....................................................................................1540 DESCRIPTION - 2.7L DIESEL.....................................................................1540 DIAGNOSIS AND TESTING - DIESEL ENGINE.........................................................1541 CATALYTIC CONVERTER...............................................................................1542 REMOVAL.......................................................................................1542 INSTALLATION..................................................................................1542 EXHAUST PIPE......................................................................................1542 REMOVAL.......................................................................................1542 INSTALLATION..................................................................................1542 TAILPIPE..........................................................................................1542 REMOVAL.......................................................................................1542 INSTALLATION..................................................................................1542 TURBOCHARGER SYSTEM...............................................................................1542 DESCRIPTION...................................................................................1542 OPERATION.....................................................................................1543 CHARGE AIR COOLER AND PLUMBING....................................................................1543 DESCRIPTION...................................................................................1543 OPERATION.....................................................................................1543 DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS......................................1543 REMOVAL.......................................................................................1544 CLEANING......................................................................................1544 INSPECTION....................................................................................1544 INSTALLATION..................................................................................1544 TURBOCHARGER......................................................................................1545 DESCRIPTION...................................................................................1545 OPERATION.....................................................................................1545 REMOVAL.......................................................................................1546 REMOVAL...................................................................................1546 REMOVAL - VACUUM TRANSDUCER...............................................................1546 INSTALLATION..................................................................................1547 INSTALLATION..............................................................................1547 INSTALLATION - VACUUM TRANSDUCER..........................................................1547 13-FRAME & BUMPERS....................................................................................1548 BUMPERS...........................................................................................1548 SPECIFICATIONS - TORQUE.......................................................................1548 FRONT BUMPER - STEPS..............................................................................1549 REMOVAL.......................................................................................1549 INSTALLATION..................................................................................1549 FRONT FASCIA......................................................................................1549 REMOVAL.......................................................................................1549 INSTALLATION..................................................................................1549 REAR BUMPER - STEP................................................................................1550 REMOVAL.......................................................................................1550 INSTALLATION..................................................................................1550 REAR FASCIA.......................................................................................1550 REMOVAL.......................................................................................1550 INSTALLATION..................................................................................1550 FRAME.............................................................................................1551 SPECIFICATIONS................................................................................1551 SPECIFICATIONS - FRAME DIMENSIONS.........................................................1551 VEHICLE PREPARATION...................................................................1551 SPECIFICATIONS - TORQUE...................................................................1553 ENGINE CRADLE CROSSMEMBER.........................................................................1553 REMOVAL.......................................................................................1553 INSTALLATION..................................................................................1555 REAR CROSSMEMBER - TRANSMISSION...................................................................1556 REMOVAL.......................................................................................1556 INSTALLATION..................................................................................1556 TRAILER HITCH.....................................................................................1556 REMOVAL.......................................................................................1556 INSTALLATION..................................................................................1557 14-FUEL SYSTEM........................................................................................1558 FUEL SYSTEM.......................................................................................1558 WARNING.......................................................................................1558 WARNING - HIGH FUEL SYSTEM PRESSURE.......................................................1558 WARNING...................................................................................1558 DIAGNOSIS AND TESTING.........................................................................1558 DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES..........................................1558 DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM................................................1559 STANDARD PROCEDURE............................................................................1559 STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS.....................................1559 STANDARD PROCEDURE - DISCONNECTING AND CONNECTING FUEL LINES..............................1559 STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER.....................................1559 STANDARD PROCEDURE - LOW PRESSURE FUEL PUMP TEST..........................................1560 FUEL DELIVERY.....................................................................................1561 FUEL DELIVERY.................................................................................1561 SPECIFICATIONS............................................................................1561 TORQUE................................................................................1561 SPECIAL TOOLS.............................................................................1562 FUEL SYSTEM...........................................................................1562 FUEL DRAIN TUBES..............................................................................1562 DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS..........................................1562 LOW-PRESSURE LINES0 - 4 VA (Continued)............................................1562 HIGH-PRESSURE LINES...................................................................1562 FUEL FILTER...................................................................................1562 DESCRIPTION...............................................................................1562 OPERATION.................................................................................1562 REMOVAL...................................................................................1562 INSTALLATION..............................................................................1563 FUEL LINES....................................................................................1563 REMOVAL - HIGH PRESSURE LINES.............................................................1563 INSTALLATION - HIGH PRESSURE LINES........................................................1564 FUEL PUMP.....................................................................................1564 DESCRIPTION...............................................................................1564 DESCRIPTION - HIGH PRESSURE PUMP......................................................1564 DESCRIPTION - LOW PRESSURE PUMP.......................................................1564 OPERATION.................................................................................1564 OPERATION.............................................................................1564 LOW PRESSURE SIDE.................................................................1564 HIGH PRESSURE SIDE................................................................1565 OPERATION - LOW PRESSURE PUMP.........................................................1565 REMOVAL...................................................................................1565 REMOVAL - HIGH PRESSURE PUMP..........................................................1565 REMOVAL - LOW PRESSURE PUMP...........................................................1566 INSTALLATION..............................................................................1567 INSTALLATION - HIGH PRESSURE PUMP.....................................................1567 INSTALLATION - LOW PRESSURE PUMP......................................................1568 FUEL RAIL.....................................................................................1568 DESCRIPTION...............................................................................1568 OPERATION.................................................................................1568 REMOVAL...................................................................................1568 INSTALLATION..............................................................................1568 FUEL TANK.....................................................................................1569 DESCRIPTION...............................................................................1569 REMOVAL...................................................................................1569 INSTALLATION..............................................................................1570 FUEL TANK MODULE..............................................................................1570 DESCRIPTION...............................................................................1570 REMOVAL...................................................................................1570 INSTALLATION..............................................................................1571 FUEL LEVEL SENDING UNIT / SENSOR..............................................................1572 DESCRIPTION...............................................................................1572 REMOVAL...................................................................................1572 INSTALLATION..............................................................................1572 HI PRESSURE FUEL SHUTOFF SOL..................................................................1573 DESCRIPTION...............................................................................1573 OPERATION.................................................................................1573 WATER IN FUEL SENSOR..........................................................................1573 DESCRIPTION...............................................................................1573 OPERATION.................................................................................1573 FUEL INJECTION....................................................................................1574 ACCELERATOR PEDAL POSITION SENSOR.............................................................1574 DESCRIPTION...............................................................................1574 BOOST PRESSURE SENSOR.........................................................................1574 DESCRIPTION...............................................................................1574 OPERATION.................................................................................1575 DIAGNOSIS AND TESTING - BOOST PRESSURE SENSOR.............................................1575 REMOVAL...................................................................................1575 INSTALLATION..............................................................................1575 CAMSHAFT POSITION SENSOR......................................................................1576 DESCRIPTION...............................................................................1576 OPERATION.................................................................................1576 REMOVAL...................................................................................1576 INSTALLATION..............................................................................1576 CRANKSHAFT POSITION SENSOR....................................................................1577 DESCRIPTION...............................................................................1577 OPERATION.................................................................................1577 REMOVAL...................................................................................1577 INSTALLATION..............................................................................1577 FUEL INJECTOR.................................................................................1577 DESCRIPTION...............................................................................1577 FUEL INJECTOR.........................................................................1577 OPERATION.................................................................................1577 Injector closed (with high pressure applied)..........................................1578 Injector opens (start of injection)...................................................1578 Injector opens fully..................................................................1579 Injector closes (end of injection)....................................................1579 STANDARD PROCEDURE........................................................................1579 STANDARD PROCEDURE - INJECTOR CLASSIFICATION..........................................1579 INJECTOR CLASSIFICATION PROCEDURE.................................................1579 STANDARD PROCEDURE - CLEANING FUEL INJECTORS..........................................1579 REMOVAL...................................................................................1580 INSTALLATION..............................................................................1580 FUEL PRESSURE SENSOR..........................................................................1582 DESCRIPTION...............................................................................1582 DESCRIPTION...........................................................................1582 DESCRIPTION...........................................................................1582 OPERATION.................................................................................1582 OPERATION.............................................................................1582 OPERATION.............................................................................1582 REMOVAL...................................................................................1583 REMOVAL...............................................................................1583 REMOVAL...............................................................................1583 INSTALLATION..............................................................................1583 INSTALLATION..........................................................................1583 INSTALLATION..........................................................................1584 FUEL PRESSURE SOLENOID........................................................................1584 DESCRIPTION...............................................................................1584 OPERATION.................................................................................1584 REMOVAL...................................................................................1585 INSTALLATION..............................................................................1585 FUEL TEMPERATURE SENSOR.......................................................................1586 DESCRIPTION...............................................................................1586 OPERATION.................................................................................1586 REMOVAL...................................................................................1586 INSTALLATION..............................................................................1586 INLET AIR TEMPERATURE SENSOR..................................................................1586 DESCRIPTION...............................................................................1586 OPERATION.................................................................................1586 REMOVAL...................................................................................1587 INSTALLATION..............................................................................1587 MANIFOLD AIR FLOW (MAF) SENSOR................................................................1587 DESCRIPTION...............................................................................1587 OPERATION.................................................................................1587 REMOVAL...................................................................................1588 INSTALLATION..............................................................................1588 19-STEERING...........................................................................................1590 STEERING..........................................................................................1590 DESCRIPTION...................................................................................1590 OPERATION.....................................................................................1590 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM.................................................1591 COLUMN............................................................................................1594 COLUMN........................................................................................1594 SPECIFICATIONS - TORQUE CHART.............................................................1594 INTERMEDIATE SHAFT............................................................................1594 REMOVAL...................................................................................1594 INSTALLATION..............................................................................1594 KEY/LOCK CYLINDER.............................................................................1595 REMOVAL...................................................................................1595 INSTALLATION..............................................................................1596 STEERING WHEEL................................................................................1596 REMOVAL...................................................................................1596 INSTALLATION..............................................................................1596 GEAR..............................................................................................1597 GEAR..........................................................................................1597 DESCRIPTION...............................................................................1597 REMOVAL...................................................................................1597 INSTALLATION..............................................................................1597 SPECIFICATIONS - TORQUE CHART.............................................................1598 LINKAGE...........................................................................................1599 LINKAGE.......................................................................................1599 DIAGNOSIS AND TESTING - OUTER TIE ROD END.................................................1599 SPECIFICATIONS - TORQUE CHART.............................................................1599 SPECIAL TOOLS.............................................................................1600 FRONT SUSPENSION......................................................................1600 TIE ROD END...................................................................................1600 REMOVAL...................................................................................1600 INSTALLATION..............................................................................1600 PUMP..............................................................................................1601 PUMP..........................................................................................1601 DESCRIPTION...............................................................................1601 OPERATION.................................................................................1601 DIAGNOSIS AND TESTING - PUMP LEAKAGE......................................................1601 STANDARD PROCEDURE........................................................................1601 STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION..........................1601 STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM...................................1602 REMOVAL...................................................................................1602 INSTALLATION..............................................................................1602 SPECIFICATIONS - TORQUE CHART.............................................................1603 FLUID.........................................................................................1603 STANDARD PROCEDURE........................................................................1603 POWER STEERING PUMP FILL AND BLEED PROCEDURE..........................................1603 FLUID COOLER TUBE.............................................................................1603 REMOVAL...................................................................................1603 INSTALLATION..............................................................................1603 HOSES.........................................................................................1604 REMOVAL...................................................................................1604 REMOVAL - PRESSURE HOSE...............................................................1604 REMOVAL - RETURN LINE FROM PUMP TO COOLER TUBE........................................1604 REMOVAL - RETURN HOSE FROM GEAR TO COOLER TUBE........................................1604 INSTALLATION..............................................................................1604 INSTALLATION - PRESSURE HOSE..........................................................1604 INSTALLATION - RETURN LINE FROM PUMP TO COOLER TUBE...................................1604 INSTALLATION - RETURN HOSE FROM GEAR TO COOLER TUBE...................................1604 21-TRANSMISSION.......................................................................................1606 AUTOMATIC TRANSMISSION - NAG1.....................................................................1606 AUTOMATIC TRANSMISSION - NAG1.................................................................1607 DESCRIPTION...............................................................................1607 TRANSMISSION IDENTIFICATION...........................................................1607 TRANSMISSION GEAR RATIOS..............................................................1607 TRANSMISSION HOUSING..................................................................1607 MECHANICAL SECTION....................................................................1608 ELECTROHYDRAULIC CONTROL UNIT.........................................................1608 SHIFT GROUPS..........................................................................1609 OPERATION.................................................................................1609 EMERGENCY RUNNING FUNCTION............................................................1609 CLUTCH APPLICATION....................................................................1609 FIRST GEAR POWERFLOW..................................................................1610 SECOND GEAR POWERFLOW.................................................................1612 THIRD GEAR POWERFLOW..................................................................1614 FOURTH GEAR POWERFLOW.................................................................1616 FIFTH GEAR POWERFLOW..................................................................1618 REVERSE GEAR POWERFLOW................................................................1620 SHIFT GROUPS/ SHIFT SEQUENCE..........................................................1622 DIAGNOSIS AND TESTING.....................................................................1628 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1628 DIAGNOSIS AND TESTING - PRELIMINARY...................................................1628 VEHICLE IS DRIVABLE...............................................................1628 VEHICLE IS DISABLED...............................................................1628 DIAGNOSIS AND TESTING - ROAD TESTING..................................................1628 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1629 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1632 REMOVAL...................................................................................1632 DISASSEMBLY...............................................................................1635 ASSEMBLY..................................................................................1639 INSTALLATION..............................................................................1646 SCHEMATICS AND DIAGRAMS...................................................................1652 SPECIFICATIONS - NAG1 AUTOMATIC TRANSMISSION..............................................1673 SPECIAL TOOLS - NAG1 AUTOMATIC TRANSMISSION...............................................1674 DRIVING CLUTCHES..............................................................................1677 DESCRIPTION...............................................................................1677 OPERATION.................................................................................1677 DRIVING CLUTCH K1.............................................................................1679 DISASSEMBLY...............................................................................1679 ASSEMBLY..................................................................................1680 DRIVING CLUTCH K2.............................................................................1681 DISASSEMBLY...............................................................................1681 ASSEMBLY..................................................................................1683 DRIVING CLUTCH K3.............................................................................1685 DISASSEMBLY...............................................................................1685 ASSEMBLY..................................................................................1685 ELECTROHYDRAULIC UNIT.........................................................................1687 DESCRIPTION...............................................................................1687 ELECTRICAL CONTROL UNIT...............................................................1687 HYDRAULIC CONTROL UNIT................................................................1687 OPERATION.................................................................................1692 ELECTRICAL CONTROL UNIT...............................................................1692 HYDRAULIC CONTROL UNIT................................................................1693 REMOVAL...................................................................................1697 DISASSEMBLY...............................................................................1697 ASSEMBLY..................................................................................1700 INSTALLATION..............................................................................1705 FLUID AND FILTER..............................................................................1706 DESCRIPTION...............................................................................1706 OPERATION.................................................................................1706 DIAGNOSIS AND TESTING.....................................................................1707 DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL..............................1707 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1707 DIAGNOSIS AND TESTING - FLUID CONTAMINATION...........................................1707 STANDARD PROCEDURE........................................................................1707 STANDARD PROCEDURE - CHECK OIL LEVEL..................................................1707 STANDARD PROCEDURE - TRANSMISSION FILL................................................1708 STANDARD PROCEDURE - FLUID/FILTER SERVICE.............................................1709 FREEWHEELING CLUTCH...........................................................................1710 DESCRIPTION...............................................................................1710 OPERATION.................................................................................1710 DISASSEMBLY...............................................................................1711 ASSEMBLY..................................................................................1712 GEARSHIFT CABLE...............................................................................1714 DIAGNOSIS AND TESTING - GEARSHIFT CABLE...................................................1714 REMOVAL...................................................................................1714 INSTALLATION..............................................................................1714 HOLDING CLUTCHES..............................................................................1716 DESCRIPTION...............................................................................1716 OPERATION.................................................................................1717 HOLDING CLUTCH B1.............................................................................1717 DISASSEMBLY...............................................................................1717 ASSEMBLY..................................................................................1718 HOLDING CLUTCH B2.............................................................................1720 DISASSEMBLY...............................................................................1720 ASSEMBLY..................................................................................1721 INPUT SPEED SENSORS...........................................................................1724 DESCRIPTION...............................................................................1724 OPERATION.................................................................................1724 OIL PUMP......................................................................................1725 DESCRIPTION...............................................................................1725 OPERATION.................................................................................1725 DISASSEMBLY...............................................................................1725 ASSEMBLY..................................................................................1726 OUTPUT SHAFT BEARING..........................................................................1727 REMOVAL...................................................................................1727 INSTALLATION..............................................................................1727 OUTPUT SHAFT SEAL.............................................................................1730 REMOVAL...................................................................................1730 INSTALLATION..............................................................................1730 PARK LOCK CABLE...............................................................................1730 REMOVAL...................................................................................1730 INSTALLATION..............................................................................1731 PISTONS.......................................................................................1733 DESCRIPTION...............................................................................1733 OPERATION.................................................................................1733 PRESSURE..............................................................................1734 PRESSURE ON A CONFINED FLUID..........................................................1734 FORCE MULTIPLICATION..................................................................1734 PISTON TRAVEL.........................................................................1734 PLANETARY GEARTRAIN...........................................................................1735 DESCRIPTION...............................................................................1735 OPERATION.................................................................................1735 DISASSEMBLY...............................................................................1736 ASSEMBLY..................................................................................1736 SHIFT MECHANISM...............................................................................1738 DESCRIPTION...............................................................................1738 OPERATION.................................................................................1738 REMOVAL...................................................................................1739 INSTALLATION..............................................................................1740 SOLENOID......................................................................................1741 DESCRIPTION...............................................................................1741 UPSHIFT/DOWNSHIFT SOLENOID VALVES.....................................................1742 MODULATING PRESSURE CONTROL SOLENOID VALVE............................................1742 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE.....................................1742 SHIFT PRESSURE CONTROL SOLENOID VALVE.................................................1743 OPERATION.................................................................................1743 UPSHIFT/DOWNSHIFT SOLENOID VALVES.....................................................1744 MODULATING PRESSURE CONTROL SOLENOID VALVE............................................1744 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE.....................................1744 SHIFT PRESSURE CONTROL SOLENOID VALVE.................................................1744 TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT.......................................................1744 DESCRIPTION...............................................................................1744 DESCRIPTION - PARK/NEUTRAL CONTACT....................................................1744 DESCRIPTION - TRANSMISSION TEMPERATURE SENSOR.........................................1745 OPERATION.................................................................................1745 OPERATION - PARK/NEUTRAL CONTACT......................................................1745 OPERATION - TRANSMISSION TEMPERATURE SENSOR...........................................1746 TORQUE CONVERTER..............................................................................1746 DESCRIPTION...............................................................................1746 IMPELLER..............................................................................1747 TURBINE...............................................................................1747 STATOR................................................................................1747 TORQUE CONVERTER CLUTCH (TCC).........................................................1748 OPERATION.................................................................................1748 TURBINE...............................................................................1749 STATOR................................................................................1750 TORQUE CONVERTER CLUTCH (TCC).........................................................1751 REMOVAL...................................................................................1751 INSTALLATION..............................................................................1751 TORQUE CONVERTER HUB SEAL.....................................................................1752 REMOVAL...................................................................................1752 INSTALLATION..............................................................................1752 22-TIRES/WHEELS.......................................................................................1754 TIRES/WHEELS......................................................................................1754 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................1754 METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................1755 METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................1755 STANDARD PROCEDURE............................................................................1755 STANDARD PROCEDURE - MATCH MOUNTING.......................................................1755 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE...............................................1756 STANDARD PROCEDURE - TIRE ROTATION........................................................1758 SPECIFICATIONS................................................................................1758 TORQUE CHART..............................................................................1758 TIRES.............................................................................................1759 DESCRIPTION...................................................................................1759 DESCRIPTION - TIRES.......................................................................1759 TIRE IDENTIFICATION...................................................................1759 TIRE CHAINS...........................................................................1759 DESCRIPTION - RADIAL – PLY TIRES..........................................................1759 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEEDS...............................................1759 DESCRIPTION - REPLACEMENT TIRES...........................................................1760 DESCRIPTION - TIRE INFLATION PRESSURES....................................................1760 DIAGNOSIS AND TESTING.........................................................................1761 DIAGNOSIS AND TESTING - PRESSURE GAUGES...................................................1761 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................1761 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................1761 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................1761 DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD.................................................1761 STANDARD PROCEDURE - REPAIRING LEAKS..........................................................1763 CLEANING......................................................................................1763 SPECIFICATIONS................................................................................1763 TIRES.....................................................................................1763 SPARE TIRE CARRIER................................................................................1763 REMOVAL.......................................................................................1763 INSTALLATION..................................................................................1763 WHEELS............................................................................................1764 DESCRIPTION...................................................................................1764 OPERATION.....................................................................................1764 DIAGNOSIS AND TESTING.........................................................................1764 WHEEL INSPECTION..........................................................................1764 STANDARD PROCEDURE............................................................................1764 STANDARD PROCEDURE - WHEEL REPLACEMENT....................................................1764 STANDARD PROCEDURE - DUAL REAR WHEEL INSTALLATION.........................................1765 REMOVAL.......................................................................................1766 INSTALLATION..................................................................................1766 23-BODY...............................................................................................1768 BODY..............................................................................................1768 WARNING.......................................................................................1768 SAFETY PRECAUTIONS AND WARNINGS...........................................................1768 DIAGNOSIS AND TESTING.........................................................................1768 DIAGNOSIS AND TESTING - WATER LEAKS.......................................................1768 VISUAL INSPECTION BEFORE WATER LEAK TESTS.............................................1769 WATER LEAK TESTS......................................................................1769 WATER LEAK DETECTION..................................................................1769 DIAGNOSIS AND TESTING - WIND NOISE........................................................1769 VISUAL INSPECTION BEFORE TESTS........................................................1769 STANDARD PROCEDURE............................................................................1770 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................1770 Rigid Plastics:.......................................................................1770 Semi-Rigid Plastics:..................................................................1770 Flexible Plastics:....................................................................1770 Repair Procedure:.....................................................................1770 Adhesion Promoter/Surface Modifier:...................................................1770 SAFETY PRECAUTION AND WARNINGS........................................................1770 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................1771 PANEL SECTIONING......................................................................1773 PANEL REINFORCEMENT...................................................................1773 VISUAL INSPECTION.....................................................................1774 PANEL SURFACE PREPARATION.............................................................1774 PATCHING PANELS.......................................................................1774 PANEL PATCH FABRICATIONS..............................................................1774 PANEL PATCH INSTALLATION..............................................................1775 PATCHED PANEL SURFACING...............................................................1777 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE................................................1777 SPECIFICATIONS................................................................................1779 DOOR - FRONT......................................................................................1780 CHECK.........................................................................................1780 REMOVAL...................................................................................1780 INSTALLATION..............................................................................1780 DOOR..........................................................................................1781 REMOVAL...................................................................................1781 INSTALLATION..............................................................................1781 ADJUSTMENTS...............................................................................1782 ADJUSTMENT............................................................................1782 DOOR GLASS....................................................................................1782 REMOVAL...................................................................................1782 INSTALLATION..............................................................................1782 EXTERIOR HANDLE...............................................................................1783 REMOVAL...................................................................................1783 INSTALLATION..............................................................................1783 HINGE.........................................................................................1784 REMOVAL...................................................................................1784 INSTALLATION..............................................................................1784 LATCH.........................................................................................1785 REMOVAL...................................................................................1785 INSTALLATION..............................................................................1785 LATCH STRIKER.................................................................................1785 REMOVAL...................................................................................1785 INSTALLATION..............................................................................1785 LOCK CYLINDER.................................................................................1785 REMOVAL...................................................................................1785 INSTALLATION..............................................................................1785 TRIM PANEL....................................................................................1786 REMOVAL...................................................................................1786 INSTALLATION..............................................................................1787 WINDOW REGULATOR - POWER......................................................................1787 REMOVAL...................................................................................1787 INSTALLATION..............................................................................1788 WINDOW REGULATOR - MANUAL.....................................................................1789 REMOVAL...................................................................................1789 INSTALLATION..............................................................................1790 DOORS - REAR......................................................................................1791 CHECK.........................................................................................1791 REMOVAL...................................................................................1791 INSTALLATION..............................................................................1791 DOOR..........................................................................................1792 REMOVAL...................................................................................1792 DISASSEMBLY...............................................................................1793 RIGHT DOOR ...........................................................................1793 LEFT DOOR ............................................................................1794 ASSEMBLY..................................................................................1795 RIGHT DOOR ...........................................................................1795 LEFT DOOR ............................................................................1796 INSTALLATION..............................................................................1797 ADJUSTMENTS...............................................................................1797 ADJUSTMENT............................................................................1797 DOOR GLASS....................................................................................1798 REMOVAL...................................................................................1798 INSTALLATION..............................................................................1798 EXTERIOR HANDLE...............................................................................1799 REMOVAL...................................................................................1799 INSTALLATION..............................................................................1800 HINGE.........................................................................................1801 REMOVAL...................................................................................1801 INSTALLATION..............................................................................1801 INSIDE HANDLE ACTUATOR........................................................................1801 REMOVAL...................................................................................1801 INSTALLATION..............................................................................1801 LATCH.........................................................................................1801 REMOVAL...................................................................................1801 INSTALLATION..............................................................................1802 TRIM PANEL....................................................................................1802 REMOVAL...................................................................................1802 INSTALLATION..............................................................................1802 DOORS - SLIDING...................................................................................1803 EXTERIOR HANDLE...............................................................................1803 REMOVAL...................................................................................1803 INSTALLATION..............................................................................1803 INSIDE HANDLE ACTUATOR........................................................................1804 REMOVAL...................................................................................1804 INSTALLATION..............................................................................1804 UPPER ROLLER ARM..............................................................................1804 REMOVAL...................................................................................1804 INSTALLATION..............................................................................1804 CENTER ROLLER ARM.............................................................................1804 REMOVAL...................................................................................1804 INSTALLATION..............................................................................1805 LOWER ROLLER ARM..............................................................................1805 REMOVAL...................................................................................1805 INSTALLATION..............................................................................1805 CENTER TRACK..................................................................................1805 REMOVAL...................................................................................1805 INSTALLATION..............................................................................1806 LATCH / LOCK CONTROL..........................................................................1806 REMOVAL...................................................................................1806 INSTALLATION..............................................................................1807 REAR LATCH....................................................................................1807 REMOVAL...................................................................................1807 INSTALLATION..............................................................................1807 REAR LATCH STRIKER............................................................................1808 REMOVAL...................................................................................1808 INSTALLATION..............................................................................1808 SLIDING DOOR..................................................................................1808 REMOVAL...................................................................................1808 DISASSEMBLY...............................................................................1809 ASSEMBLY..................................................................................1810 INSTALLATION..............................................................................1811 ADJUSTMENTS...............................................................................1811 ADJUSTMENT............................................................................1811 Gaps and Ridge Adjustment.........................................................1811 Flush Adjustment..................................................................1812 Door Stop Bumper Adjust...........................................................1812 STABILIZER....................................................................................1812 REMOVAL...................................................................................1812 INSTALLATION..............................................................................1812 TRIM PANEL....................................................................................1813 REMOVAL...................................................................................1813 Upper.................................................................................1813 Lower.................................................................................1813 INSTALLATION..............................................................................1813 Upper.................................................................................1813 Lower.................................................................................1813 DOOR GLASS....................................................................................1813 REMOVAL...................................................................................1813 INSTALLATION..............................................................................1813 EXTERIOR..........................................................................................1814 FUEL FILL DOOR................................................................................1814 REMOVAL...................................................................................1814 INSTALLATION..............................................................................1814 GRILLE........................................................................................1814 REMOVAL...................................................................................1814 INSTALLATION..............................................................................1814 LICENSE PLATE BRACKET.........................................................................1814 REMOVAL...................................................................................1814 INSTALLATION..............................................................................1814 RADIATOR CROSSMEMBER..........................................................................1814 REMOVAL...................................................................................1814 INSTALLATION..............................................................................1815 SIDE VIEW MIRROR..............................................................................1815 REMOVAL...................................................................................1815 Driver's Side.........................................................................1815 Passenger Side........................................................................1815 INSTALLATION..............................................................................1815 Driver's Side.........................................................................1815 Passenger Side........................................................................1816 SIDE VIEW MIRROR - GLASS......................................................................1816 REMOVAL...................................................................................1816 INSTALLATION..............................................................................1816 HOOD..............................................................................................1817 HINGE.........................................................................................1817 REMOVAL...................................................................................1817 INSTALLATION..............................................................................1817 HOOD..........................................................................................1817 REMOVAL...................................................................................1817 INSTALLATION..............................................................................1817 ADJUSTMENTS...............................................................................1818 ADJUSTMENT............................................................................1818 LATCH.........................................................................................1818 REMOVAL...................................................................................1818 INSTALLATION..............................................................................1818 LATCH RELEASE CABLE...........................................................................1818 REMOVAL...................................................................................1818 INSTALLATION..............................................................................1818 LATCH RELEASE HANDLE..........................................................................1819 REMOVAL...................................................................................1819 INSTALLATION..............................................................................1819 PROP ROD......................................................................................1819 REMOVAL...................................................................................1819 INSTALLATION..............................................................................1819 SAFETY LATCH..................................................................................1819 REMOVAL...................................................................................1819 INSTALLATION..............................................................................1819 INSTRUMENT PANEL..................................................................................1820 CLUSTER BEZEL.................................................................................1820 REMOVAL...................................................................................1820 INSTALLATION..............................................................................1821 ACCESSORY SWITCH BEZEL........................................................................1821 REMOVAL...................................................................................1821 INSTALLATION..............................................................................1821 INSTRUMENT PANEL CENTER BEZEL.................................................................1822 REMOVAL...................................................................................1822 INSTALLATION..............................................................................1822 ASH RECEIVER..................................................................................1822 REMOVAL...................................................................................1822 INSTALLATION..............................................................................1822 CUP HOLDER....................................................................................1822 REMOVAL...................................................................................1822 INSTALLATION..............................................................................1823 GLOVE BOX.....................................................................................1823 REMOVAL...................................................................................1823 INSTALLATION..............................................................................1823 INSTRUMENT PANEL ASSEMBLY.....................................................................1824 REMOVAL...................................................................................1824 INSTALLATION..............................................................................1828 TOP COVER - CLUSTER...........................................................................1829 REMOVAL...................................................................................1829 INSTALLATION..............................................................................1829 TOP COVER - TRAY..............................................................................1830 REMOVAL...................................................................................1830 INSTALLATION..............................................................................1831 TOP COVER.....................................................................................1831 REMOVAL...................................................................................1831 INSTALLATION..............................................................................1832 STEERING COLUMN OPENING COVER.................................................................1833 REMOVAL...................................................................................1833 INSTALLATION..............................................................................1833 INTERIOR..........................................................................................1834 INTERIOR......................................................................................1834 CAUTION...................................................................................1834 A-PILLAR TRIM.................................................................................1834 REMOVAL...................................................................................1834 INSTALLATION..............................................................................1835 ASSIST HANDLE.................................................................................1835 REMOVAL...................................................................................1835 INSTALLATION..............................................................................1835 B-PILLAR TRIM.................................................................................1835 REMOVAL...................................................................................1835 INSTALLATION..............................................................................1836 BULKHEAD TRIM PANEL...........................................................................1836 REMOVAL...................................................................................1836 INSTALLATION..............................................................................1836 CARPETS AND FLOOR MATS........................................................................1836 REMOVAL...................................................................................1836 Cargo/Passenger Van - Front...........................................................1836 Passenger Van - Rear..................................................................1836 Cargo Van - Rear......................................................................1837 INSTALLATION..............................................................................1837 Cargo/Passenger Van - Front...........................................................1837 Passenger Van - Rear..................................................................1837 Cargo Van - Rear......................................................................1837 COWL TRIM.....................................................................................1837 REMOVAL...................................................................................1837 INSTALLATION..............................................................................1837 D-PILLAR TRIM.................................................................................1837 REMOVAL...................................................................................1837 INSTALLATION..............................................................................1837 HEADLINER.....................................................................................1837 REMOVAL...................................................................................1837 Cab Section...........................................................................1837 Number 2 Section......................................................................1837 Number 3 Section......................................................................1837 Number 4 Section......................................................................1838 INSTALLATION..............................................................................1838 Cab Section...........................................................................1838 Number 2 Section......................................................................1838 Number 3 Section......................................................................1838 Number 4 Section......................................................................1838 QUARTER TRIM PANEL............................................................................1838 REMOVAL...................................................................................1838 Passenger Van.........................................................................1838 Cargo Van.............................................................................1839 INSTALLATION..............................................................................1839 Passenger Van.........................................................................1839 Cargo Van.............................................................................1839 REAR VIEW MIRROR..............................................................................1839 REMOVAL...................................................................................1839 INSTALLATION..............................................................................1839 INSTALLATION..........................................................................1839 INSTALLATION - REAR VIEW MIRROR SUPPORT BRACKET.......................................1839 STEPWELL SCUFF PADS...........................................................................1839 REMOVAL...................................................................................1839 INSTALLATION..............................................................................1840 SUN VISOR.....................................................................................1840 REMOVAL...................................................................................1840 INSTALLATION..............................................................................1840 PAINT.............................................................................................1841 PAINT.........................................................................................1841 SPECIFICATIONS - PAINT CODES..............................................................1841 BASECOAT/CLEARCOAT FINISH.....................................................................1841 DESCRIPTION...............................................................................1841 PAINT TOUCH-UP................................................................................1841 DESCRIPTION...............................................................................1841 STANDARD PROCEDURE - PAINT TOUCH-UP.......................................................1842 FINESSE SANDING/BUFFING & POLISH..............................................................1842 DESCRIPTION...............................................................................1842 SEATS.............................................................................................1843 ARMREST.......................................................................................1843 REMOVAL...................................................................................1843 INSTALLATION..............................................................................1843 HEADREST......................................................................................1843 REMOVAL...................................................................................1843 INSTALLATION..............................................................................1843 SEAT - FRONT..................................................................................1844 REMOVAL...................................................................................1844 INSTALLATION0 - 6 VA (Continued)......................................................1844 SEAT BACK - FRONT.............................................................................1844 REMOVAL...................................................................................1844 INSTALLATION..............................................................................1844 SEAT CUSHION - FRONT..........................................................................1845 REMOVAL...................................................................................1845 INSTALLATION..............................................................................1845 SEAT ADJUSTERS - FRONT........................................................................1845 REMOVAL...................................................................................1845 INSTALLATION..............................................................................1845 SEAT - REAR...................................................................................1846 REMOVAL...................................................................................1846 INSTALLATION..............................................................................1846 REAR SEAT BACK SHIELD.........................................................................1846 REMOVAL...................................................................................1846 INSTALLATION..............................................................................1846 SEAT BACK CUSHION/COVER - REAR................................................................1847 REMOVAL...................................................................................1847 INSTALLATION..............................................................................1847 SEAT CUSHION/COVER - REAR.....................................................................1847 REMOVAL...................................................................................1847 INSTALLATION..............................................................................1847 STATIONARY GLASS..................................................................................1848 BACKLITE - BULKHEAD TRIM PANEL................................................................1848 REMOVAL...................................................................................1848 INSTALLATION..............................................................................1848 QUARTER WINDOW................................................................................1848 REMOVAL...................................................................................1848 INSTALLATION..............................................................................1848 WINDSHIELD....................................................................................1849 WARNING...................................................................................1849 WINDSHIELD SAFETY PRECAUTIONS.........................................................1849 REMOVAL...................................................................................1849 INSTALLATION..............................................................................1850 Windshield Preparation - Installing A Previously Installed Windshield.................1851 Windshield Preparation - Installing A New Windshield..................................1852 Windshield Opening Preparation........................................................1852 Windshield Installation...............................................................1852 WEATHERSTRIP/SEALS................................................................................1854 FRONT DOOR INNER BELT WEATHERSTRIP............................................................1854 REMOVAL...................................................................................1854 INSTALLATION..............................................................................1854 FRONT DOOR OUTER BELT WEATHERSTRIP............................................................1854 REMOVAL...................................................................................1854 INSTALLATION..............................................................................1854 DOOR OPENING SEALS............................................................................1854 REMOVAL...................................................................................1854 INSTALLATION..............................................................................1854 BODY STRUCTURE....................................................................................1855 GAP AND FLUSH.................................................................................1855 SPECIFICATIONS............................................................................1855 OPENING DIMENSIONS............................................................................1857 SPECIFICATIONS............................................................................1857 24-HEATING & AIR CONDITIONING.........................................................................1858 HEATING & AIR CONDITIONING........................................................................1858 DESCRIPTION...................................................................................1858 DESCRIPTION - COOLING SYSTEM REQUIREMENTS.................................................1858 DESCRIPTION - HEATER AND AIR CONDITIONER..................................................1858 OPERATION - HEATER AND AIR CONDITIONER........................................................1859 DIAGNOSIS AND TESTING.........................................................................1860 DIAGNOSIS AND TESTING - FUNCTION TEST.....................................................1860 DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..............................................1860 DIAGNOSIS AND TESTING - HEATER PERFORMANCE................................................1861 MAXIMUM HEATER OUTPUT.................................................................1861 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW................................1861 POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT......................................1861 TEMPERATURE CONTROL...................................................................1861 SPECIFICATIONS................................................................................1862 A/C SYSTEM................................................................................1862 CONTROLS - FRONT..................................................................................1865 A/C COMPRESSOR CLUTCH.........................................................................1865 DESCRIPTION...............................................................................1865 OPERATION.................................................................................1865 STANDARD PROCEDURE........................................................................1866 STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP........................................1866 STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN.......................................1866 REMOVAL...................................................................................1866 INSPECTION - COMPRESSOR CLUTCH/COIL.......................................................1867 INSTALLATION..............................................................................1868 A/C COMPRESSOR CLUTCH COIL....................................................................1869 DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL............................................1869 A/C HEATER CONTROL............................................................................1869 DESCRIPTION...............................................................................1869 OPERATION.................................................................................1869 REMOVAL...................................................................................1869 INSTALLATION..............................................................................1870 A/C PRESSURE TRANSDUCER.......................................................................1870 DESCRIPTION...............................................................................1870 OPERATION.................................................................................1870 DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................1870 REMOVAL...................................................................................1871 INSTALLATION..............................................................................1871 AIR OUTLET TEMPERATURE SENSOR.................................................................1871 DESCRIPTION...............................................................................1871 OPERATION.................................................................................1872 REMOVAL...................................................................................1872 INSTALLATION..............................................................................1872 AMBIENT TEMPERATURE SENSOR....................................................................1872 DESCRIPTION...............................................................................1872 OPERATION.................................................................................1872 REMOVAL...................................................................................1872 INSTALLATION..............................................................................1873 BLOWER MOTOR RESISTOR BLOCK...................................................................1873 DESCRIPTION...............................................................................1873 OPERATION.................................................................................1873 DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR BLOCK.......................................1873 REMOVAL...................................................................................1873 INSTALLATION..............................................................................1874 BLOWER MOTOR SWITCH...........................................................................1874 DESCRIPTION...............................................................................1874 OPERATION.................................................................................1874 DIAGNOSIS AND TESTING - BLOWER MOTOR SWITCH...............................................1874 REMOVAL...................................................................................1874 EVAPORATOR TEMPERATURE SENSOR.................................................................1874 DESCRIPTION...............................................................................1874 OPERATION.................................................................................1875 REMOVAL...................................................................................1875 INSTALLATION..............................................................................1875 IN-CAR TEMPERATURE SENSOR.....................................................................1876 DESCRIPTION...............................................................................1876 OPERATION.................................................................................1876 DIAGNOSIS AND TESTING.....................................................................1876 REMOVAL...................................................................................1876 MODE DOOR CABLES..............................................................................1876 REMOVAL...................................................................................1876 INSTALLATION..............................................................................1876 RECIRCULATION DOOR ACTUATOR...................................................................1877 DESCRIPTION...............................................................................1877 OPERATION.................................................................................1877 REMOVAL...................................................................................1878 INSTALLATION..............................................................................1878 CONTROLS - REAR...................................................................................1879 BLOWER MOTOR SWITCH...........................................................................1879 DESCRIPTION...............................................................................1879 OPERATION.................................................................................1879 DIAGNOSIS AND TESTING.....................................................................1880 REMOVAL...................................................................................1880 INSTALLATION..............................................................................1880 BLOWER MOTOR RELAY............................................................................1880 DESCRIPTION...............................................................................1880 OPERATION.................................................................................1880 DIAGNOSIS AND TESTING.....................................................................1881 REMOVAL...................................................................................1881 INSTALLATION..............................................................................1881 CONTROL MODULE................................................................................1881 DESCRIPTION...............................................................................1881 OPERATION.................................................................................1881 DIAGNOSIS AND TESTING.....................................................................1881 REMOVAL...................................................................................1881 INSTALLATION..............................................................................1882 EVAPORATOR TEMPERATURE SENSOR.................................................................1882 DESCRIPTION...............................................................................1882 OPERATION.................................................................................1883 DIAGNOSIS AND TESTING.....................................................................1883 REMOVAL...................................................................................1883 INSTALLATION..............................................................................1883 SOLENOID VALVE................................................................................1884 DESCRIPTION...............................................................................1884 OPERATION.................................................................................1884 DIAGNOSIS AND TESTING.....................................................................1884 REMOVAL...................................................................................1884 INSTALLATION..............................................................................1885 TEMPERATURE CONTROL...........................................................................1886 DESCRIPTION...............................................................................1886 OPERATION.................................................................................1886 DIAGNOSIS AND TESTING.....................................................................1886 REMOVAL...................................................................................1886 INSTALLATION..............................................................................1886 TEMPERATURE SENSOR............................................................................1887 DESCRIPTION...............................................................................1887 OPERATION.................................................................................1887 DIAGNOSIS AND TESTING.....................................................................1887 REMOVAL...................................................................................1887 INSTALLATION..............................................................................1887 DISTRIBUTION - FRONT..............................................................................1888 AIR FILTER....................................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1888 AIR OUTLETS...................................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1889 BLOWER MOTOR..................................................................................1889 REMOVAL...................................................................................1889 INSTALLATION..............................................................................1890 DEFROSTER DUCTS...............................................................................1890 REMOVAL...................................................................................1890 INSTALLATION..............................................................................1890 FLOOR DISTRIBUTION DUCTS......................................................................1890 REMOVAL...................................................................................1890 INSTALLATION..............................................................................1891 HVAC HOUSING..................................................................................1891 REMOVAL...................................................................................1891 DISASSEMBLY...............................................................................1893 ASSEMBLY..................................................................................1893 INSTALLATION..............................................................................1893 INSTRUMENT PANEL DUCTS........................................................................1894 REMOVAL...................................................................................1894 INSTALLATION..............................................................................1895 DISTRIBUTION - REAR...............................................................................1896 AIR FILTER....................................................................................1896 REMOVAL...................................................................................1896 INSTALLATION..............................................................................1896 BLOWER MOTOR..................................................................................1896 REMOVAL...................................................................................1896 INSTALLATION..............................................................................1897 REAR A/C HOUSING..............................................................................1897 REMOVAL...................................................................................1897 INSTALLATION..............................................................................1898 PLUMBING..........................................................................................1900 PLUMBING......................................................................................1901 DESCRIPTION - REFRIGERANT LINE............................................................1901 OPERATION - REFRIGERANT LINE..............................................................1901 WARNING...................................................................................1901 CAUTION...................................................................................1902 CAUTION...............................................................................1902 REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS.............................................1902 DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS..........................................1903 SYSTEM EMPTY..........................................................................1903 SYSTEM LOW............................................................................1903 STANDARD PROCEDURE........................................................................1903 STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT.............................1903 MANIFOLD GAUGE SET CONNECTIONS....................................................1904 STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................1904 STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE......................................1904 STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE........................................1905 PARTIAL CHARGE METHOD.............................................................1905 SPECIFICATIONS............................................................................1906 CHARGE CAPACITY.......................................................................1906 A/C COMPRESSOR................................................................................1906 DESCRIPTION...............................................................................1906 OPERATION.................................................................................1906 DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................1906 REMOVAL...................................................................................1907 INSTALLATION..............................................................................1908 A/C CONDENSER.................................................................................1909 DESCRIPTION...............................................................................1909 OPERATION.................................................................................1909 REMOVAL...................................................................................1909 INSTALLATION..............................................................................1909 A/C DISCHARGE LINE............................................................................1910 REMOVAL...................................................................................1910 INSTALLATION..............................................................................1911 A/C EVAPORATOR................................................................................1911 DESCRIPTION...............................................................................1911 OPERATION.................................................................................1911 REMOVAL...................................................................................1912 INSTALLATION..............................................................................1912 A/C EXPANSION VALVE...........................................................................1912 DESCRIPTION...............................................................................1912 OPERATION.................................................................................1912 DIAGNOSIS AND TESTING - A/C EXPANSION VALVE...............................................1913 REMOVAL...................................................................................1913 INSTALLATION..............................................................................1913 ELECTRIC COOLANT PUMP.........................................................................1914 DESCRIPTION...............................................................................1914 OPERATION.................................................................................1914 REMOVAL...................................................................................1914 INSTALLATION..............................................................................1914 HEATER CORE...................................................................................1914 DESCRIPTION...............................................................................1914 OPERATION.................................................................................1914 REMOVAL...................................................................................1915 INSTALLATION..............................................................................1915 LIQUID LINE...................................................................................1915 REMOVAL...................................................................................1915 INSTALLATION..............................................................................1916 REAR EVAPORATOR...............................................................................1917 REMOVAL...................................................................................1917 INSTALLATION..............................................................................1918 REAR EXPANSION VALVE..........................................................................1919 REMOVAL...................................................................................1919 INSTALLATION..............................................................................1920 RECEIVER/DRIER................................................................................1921 DESCRIPTION...............................................................................1921 OPERATION.................................................................................1921 REMOVAL...................................................................................1921 INSTALLATION..............................................................................1921 REFRIGERANT...................................................................................1922 DESCRIPTION...............................................................................1922 OPERATION.................................................................................1922 REFRIGERANT OIL...............................................................................1922 DESCRIPTION...............................................................................1922 OPERATION.................................................................................1922 STANDARD PROCEDURE - REFRIGERANT OIL LEVEL................................................1922 SUCTION LINE..................................................................................1923 REMOVAL...................................................................................1923 INSTALLATION..............................................................................1923 WATER VALVE...................................................................................1924 REMOVAL...................................................................................1924 INSTALLATION..............................................................................1924 UNDERBODY LINES...............................................................................1925 REMOVAL...................................................................................1925 INSTALLATION..............................................................................1926 CABIN HEATER......................................................................................1929 CABIN HEATER..................................................................................1929 DESCRIPTION...............................................................................1929 OPERATION.................................................................................1929 DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA.................................1929 EXHAUST TUBE..................................................................................1930 REMOVAL...................................................................................1930 INSTALLATION..............................................................................1930 FUEL DOSING PUMP..............................................................................1931 DESCRIPTION...............................................................................1931 OPERATION.................................................................................1931 REMOVAL...................................................................................1931 INSTALLATION..............................................................................1931 FUEL LINE.....................................................................................1932 STANDARD PROCEDURE - CLEANING.............................................................1932 REMOVAL...................................................................................1932 INSTALLATION..............................................................................1933 HEATER UNIT...................................................................................1934 REMOVAL...................................................................................1934 REMOVAL...............................................................................1934 REMOVAL...............................................................................1934 INSTALLATION..............................................................................1935 INSTALLATION..........................................................................1935 INSTALLATION..........................................................................1935 INLET HOSE....................................................................................1935 REMOVAL...................................................................................1935 INSTALLATION..............................................................................1935 25-EMISSIONS CONTROL..................................................................................1938 EXHAUST GAS RECIRCULATION.........................................................................1938 VALVE.........................................................................................1938 DESCRIPTION...............................................................................1938 OPERATION.................................................................................1938 REMOVAL...................................................................................1939 INSTALLATION..............................................................................1939 INDEX.................................................................................................1940 COMMENTS..............................................................................................1960
DESCRIPTION:
Sprinter 2003 VA Service Manual – PDF DOWNLOAD
FOREWORD:
- The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle.
- Information in this manual is divided into groups. These groups contain description, operation, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. To assist in locating a group title page, use the Group Tab Locator on the following page.
- The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual.
- A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler Corporation with your comments and suggestions.
- Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners.
- When replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
INTRODUCTION:
- The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose the Sprinter Chassis system problems: Bosch 5.7 ABS/TCS (ASR) Braking System.
- The diagnostics in this manual are based on the failure condition or symptom being present at time of diagnosis. Please follow the recommendations below when choosing your diagnostic path.
1. First make sure the DRBII It is communicating with the vehicle system being diagnosed. If the DRBII It displays a ‘‘No Response’’ condition, you must diagnose that first.
2. Read DTC’s (diagnostic trouble codes) with the DRBII It.
3. If no DTC’s are present, identify the customer complaint.
4. Once the DTC or customer complaint is identified locate the matching test in the Table of Contents and begin to diagnose the system. All component location views are in Section 8.0. All connector pinouts are in Section 9.0. All schematics are in Section 10.0. When repairs are required, refer to the appropriate service manual for the proper removal and repair procedure. Diagnostic procedures change every year.
New diagnostic systems may be added; carryover systems maybe enhanced.
READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE DIAGNOSTIC TROUBLE CODE.
- It is recommended that you review the entire manual to become familiar with all new and changed diagnostic procedures. This manual reflects many suggested changes from readers of past issues.
- After using this manual, if you have any comments or recommendations, please fill out the form
G.B 07/04/25
